Driver's cab and rail vehicle based on spider web honeycomb welded sandwich

Abstract

The present application relates to a kind of driver's cab based on spider web honeycomb welding sandwich and railway vehicle, belong to the technical field of railway vehicle, driver's cab includes framework and skin on framework, skin uses sandwich structure, skin and framework are connected using welding method;Sandwich structure includes the core material layer prepared by spider web honeycomb core material, spider web honeycomb core material is set as the cell structure consisting of several cells projecting its surface arranged in matrix, both sides of core material layer are provided with panel layer, panel layer and core material layer are connected using welding method, the present application can solve the technical problems of the prior art, such as the weight of driver's cab, welding amount, deformation, poor sealing and high cost.

Description

Technical Field

[0001] This invention belongs to the field of rail vehicle technology, specifically relating to a driver's cab and rail vehicle based on a spider web honeycomb welded sandwich layer. Background Technology

[0002] In the field of rail vehicles, especially urban rail passenger vehicles, the driver's cab of vehicles in operation generally adopts a plate beam skin with an aluminum alloy frame structure, or a fiberglass or carbon fiber mask with a frame structure. Fiberglass driver's cabs have numerous stainless steel connectors embedded inside the skin mask, combined with a complex internal frame supporting the mask. The connection points with the car body are sealed with a large amount of sealant, resulting in poor sealing performance, poor material environmental friendliness, and non-recyclability. While the plate beam skin with aluminum alloy frame structure can solve the sealing and environmental protection problems, the relatively low rigidity of aluminum plates necessitates numerous stiffening ribs to increase rigidity and support capacity, leading to a heavy cab, extensive welding, significant deformation, and difficulty in controlling deformation. The welded aluminum honeycomb lightweight driver's cab, which has emerged in recent years, effectively solves these problems, but its cost is high, making it suitable for vehicles with speeds above 120 km / h. Summary of the Invention

[0003] In view of the various shortcomings of the existing technology, and in order to solve the above problems, a spider web honeycomb welded sandwich driver's cab and rail vehicle are proposed to solve the technical problems of large driver's cab weight, large amount of welding, large deformation, poor sealing and high cost in the existing technology.

[0004] In a first aspect, the present invention provides a driver's cab based on a spider web honeycomb welded sandwich structure, comprising a frame and a skin located on the frame, wherein the skin adopts a sandwich structure and the skin is connected to the frame by welding.

[0005] The sandwich structure includes a core material layer made of spider web honeycomb core material. The spider web honeycomb core material is configured as a cell structure composed of a number of cells protruding from its surface in a matrix arrangement. Both sides of the core material layer are provided with panel layers, and the panel layers are connected to the core material layer by welding.

[0006] This technical solution is further configured such that several cells protrude from the surface of the spider web honeycomb core material in the same direction.

[0007] The technical solution is further configured such that the cell is a frustum structure, and the cross-section of the frustum structure is hexagonal.

[0008] The technical solution is further configured such that the panel layer includes an inner panel layer and an outer panel layer, and the inner panel layer is connected to the frame by welding.

[0009] The technical solution is further configured such that the inner panel layer is welded to the frame via a transition connector, the transition connector being L-shaped, with one side welded to the inner panel layer and the other side welded to the frame.

[0010] The technical solution is further configured such that the skin is spliced ​​together from multiple skin modules, and the skin module adopts a sandwich structure consisting of a core material layer and a panel layer. The splicing end of the skin module is extruded into a flat structure and a welding bevel is reserved.

[0011] The technical solution is further configured such that the splicing ends of adjacent skin modules are connected to each other, and a backing plate is provided at the docking position. The backing plate is connected to the splicing end by welding.

[0012] The technical solution is further configured such that the edges of the window frame and the lamp frame on the skeleton are provided with open-structure overlapping grooves, the inner panel layer and the overlapping grooves form an overlapping structure and are connected by welding.

[0013] The technical solution is further configured such that the lap groove includes a groove bottom and an inclined sidewall located on one side of the groove bottom, the inner panel layer overlaps with the groove bottom, the inclined sidewall forms a V-shaped bevel with the welding bevel, and the thickness of the flat structure is equal to the depth of the lap groove.

[0014] Secondly, the present invention provides a rail vehicle including the aforementioned driver's cab based on a spider web honeycomb welded sandwich layer.

[0015] The beneficial effects of this invention are:

[0016] The skin based on spider web honeycomb core material can effectively reduce the arrangement of welding stiffeners, reduce the amount of processing and welding work, and effectively reduce the structural deformation of the driver's cab. Compared with the ordinary plate beam structure, the weight of the skin with sandwich structure is reduced by more than 10%. At the same time, the skin with sandwich structure can be welded to the vehicle body to ensure the airtightness of the vehicle body. The skin is a hollow composite material, which can improve the sound insulation performance of the driver's cab by more than 4dB under the same weight, and the cost is low. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of a driver's cab based on a spiderweb honeycomb welded sandwich structure in an embodiment of the present invention;

[0018] Figure 2 This is a schematic diagram of the skeleton in an embodiment of the present invention;

[0019] Figure 3 This is a schematic diagram of the skin in an embodiment of the present invention;

[0020] Figure 4 This is a schematic diagram of the sandwich structure in an embodiment of the present invention;

[0021] Figure 5 This is a schematic diagram of the core material layer in an embodiment of the present invention;

[0022] Figure 6 This is a schematic diagram of the splicing end in an embodiment of the present invention;

[0023] Figure 7 This is a schematic diagram of the splicing of adjacent sandwich structures in an embodiment of the present invention;

[0024] Figure 8 This is a schematic diagram of the assembly of the inner panel layer and the skeleton in an embodiment of the present invention;

[0025] Figure 9 This is a schematic diagram of the assembly of the inner panel layer and the skeleton in an embodiment of the present invention;

[0026] Figure 10 This is a schematic diagram of the assembly of the inner panel layer and the overlapping groove in an embodiment of the present invention.

[0027] In the attached diagram: 100 - skeleton, 200 - skin, 300 - liner, 400 - transition connector;

[0028] 101-Window frame, 102-Groove bottom, 103-Sloping sidewall;

[0029] 201-Top cover skin module, 202-Left side panel skin module, 203-Right side panel skin module, 204-Front window skin module, 205-Outer panel layer, 206-Core material layer, 207-Inner panel layer, 208-Cell, 209-Splicing end, 210-Welding bevel. Detailed Implementation

[0030] To enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Based on the embodiments in this application, other similar embodiments obtained by those skilled in the art without creative effort should all fall within the scope of protection of this application. Furthermore, directional terms mentioned in the following embodiments, such as "up," "down," "left," and "right," are only for reference to the directions in the accompanying drawings; therefore, the directional terms used are for illustrative purposes and not for limiting the invention.

[0031] According to an embodiment of the present invention, a driver's cab based on a spider web honeycomb welded sandwich layer is provided. Please refer to [link / reference]. Figures 1 to 5 It includes a frame 100 and a skin 200 located on the frame 100. The skin 200 adopts a sandwich structure and is connected to the frame 100 by welding.

[0032] It should be noted that the skin 200 mainly serves as a load-bearing, sealing, noise reduction, glass mounting, and headlight mounting carrier, while the frame 100 mainly serves as the main structural load-bearing, connecting to the vehicle body, and connecting to the underframe.

[0033] Specifically, the sandwich structure includes a core material layer 206 made of a spider web honeycomb core material. The spider web honeycomb core material is configured as a cell structure composed of a number of cells 208 protruding from its surface in a matrix arrangement. Both sides of the core material layer 206 are provided with panel layers, and the panel layers are connected to the core material layer 206 by welding.

[0034] It should be noted that the skin 200 based on spider web honeycomb core material can effectively reduce the arrangement of welding stiffeners, reduce the amount of processing and welding work, and effectively reduce the structural deformation of the driver's cab. Compared with the ordinary plate beam structure, the skin 200 with sandwich structure is more than 10% lighter. At the same time, the skin 200 with sandwich structure can be welded to the vehicle body to ensure the airtightness of the vehicle body. The skin is a hollow composite material, which can improve the sound insulation performance of the driver's cab by more than 4dB under the same weight, and the cost is low.

[0035] Specifically, the core layer 206 and the panel layer are made of metal materials, preferably aluminum alloy.

[0036] In the driver's cab based on the spiderweb honeycomb welded sandwich structure of this embodiment, please refer to... Figures 1 to 5 Several cells 208 protrude from the surface of the spider web honeycomb core material in the same direction.

[0037] In the driver's cab based on the spiderweb honeycomb welded sandwich structure of this embodiment, please refer to... Figures 1 to 5 The cell 208 is configured as a frustum structure, and the cross-section of the frustum structure is hexagonal.

[0038] It should be noted that the spider web honeycomb core material is a plate with a certain thickness. Through material forming, it forms many continuous, matrix-arranged hexagonal honeycomb-shaped frustum structures that protrude a certain height from the surface of the spider web honeycomb core material, which manifests as an equal increase in spatial thickness.

[0039] In the driver's cab based on the spiderweb honeycomb welded sandwich structure of this embodiment, please refer to... Figures 1 to 5 The panel layer includes an inner panel layer 207 and an outer panel layer 205. The contact points between the inner panel layer 207, the core material layer 206, and the outer panel layer 205 are all connected by hard brazing. All contact points should be fully brazed, and there should be no welding defects such as incomplete welds or weak welds. The inner panel layer 207 is connected to the vehicle body chassis, the driver's cab frame 100, and accessories by welding. The inner panel layer 207, as the main sealing element, is fully welded to the vehicle body chassis, the rear curved beam, etc.

[0040] In engineering applications, the inner panel layer 207, the core material layer 206, and the outer panel layer 205 are first brazed into a sandwich structure, and then molded into a part blank. The part blank is then processed at the edges to form a skin module. The skin modules are then welded together to form the skin 200 of the entire driver's cab. Finally, it is connected to the frame 100 of the driver's cab to form an integral driver's cab.

[0041] In this embodiment, the inner panel layer 207, the core material layer 206, and the outer panel layer 205 are respectively 1.5mm thick 6A02 aluminum plate, 1mm thick 6A02 aluminum plate, and 1.5mm thick 6A02 aluminum plate. After brazing, the total thickness is 7mm, forming a spider web honeycomb structure welded aluminum alloy sandwich panel with a surface density of 10.8kg / m². The weight of each square meter of material is equivalent to the weight of a 4mm aluminum plate. By changing the spatial structure of the material, the bending strength of the material is increased without changing the weight.

[0042] According to the measurement methods specified in GB / T1456-2005 "Test Method for Bending Performance of Sandwich Structures", the bending strength of the welded aluminum alloy sandwich panel with a spider web honeycomb structure was tested. Simultaneously, aluminum plate 4mm-5083 (with the same weight and sample size as the welded aluminum alloy sandwich panel with a spider web honeycomb structure) was measured under the same test method, and a comparative test was conducted with the welded aluminum alloy sandwich panel with a spider web honeycomb structure. The test results are shown in Table 1.

[0043] Table 1:

[0044]

[0045] Comparison of test results shows that the spider web honeycomb structure welded aluminum alloy sandwich panel can effectively improve the rigidity of the driver's cab when used as the skin. The bending strength of the spider web honeycomb structure welded aluminum alloy sandwich panel is 2-3 times that of aluminum plates of the same weight.

[0046] In the driver's cab based on the spiderweb honeycomb welded sandwich structure of this embodiment, please refer to... Figures 1 to 7 The skin 200 is composed of multiple skin modules spliced ​​together. The skin module adopts a sandwich structure consisting of a core material layer 206 and a panel layer. The splicing end 209 of the skin module is extruded into a flat structure and a welding bevel 210 is reserved.

[0047] It should be noted that, considering the curved contour dimensions of the driver's cab, the curved surface of the skin 200 can be designed in blocks. The principle of block design is to further divide the large module into smaller modules, which can fully utilize the linkage between processes, reduce process conflicts, form assembly line production, and improve work efficiency in process setting. In this embodiment, the skin module includes the upper top cover skin module 201, the left side panel skin module 202, the right side panel skin module 203, and the front window skin module 204. Under this block design premise, the number of welds should be minimized and the block plate width should be increased. Combined with the size of the raw material plate, the skin modules are then combined, which allows for group welding and effectively improves production efficiency. According to the type of the skin module, considering the contour shape of different parts, a grid method is used to unfold it into a planar drawing. The material is processed and cut according to the unfolded planar drawing. The cut plate is placed in a forming mold and the required contour is formed by pressure forming. The corresponding positions are set on the forming mold. During the forming process, the corresponding mating positions are flattened at the same time. The flattened structure is as follows. Figure 6 As shown.

[0048] In the driver's cab based on the spiderweb honeycomb welded sandwich structure of this embodiment, please refer to... Figures 1 to 7 The splicing ends of adjacent skin modules are connected to each other, and a backing plate 300 is provided at the docking position. The backing plate 300 is connected to the splicing end by welding.

[0049] Specifically, the skin 200 is a relatively high-strength spatial structural material. The frame 100 can be fabricated as an independent unit, minimizing the arrangement of stiffeners and ribs, primarily using a main load-bearing frame structure, and reducing or eliminating the use of plate-beam stiffener structures. To ensure the positioning and accuracy of the frame 100, welding fixtures are used during the welding of the frame 100. These welding fixtures also serve as the assembly fixtures for the skin 200 and frame 100. After welding, the frame 100 is not disassembled from the fixture; the skin 200 can be assembled on the same fixture.

[0050] The formed skin 200 and frame 100 are mainly welded together using three methods:

[0051] The first type is where the skin 200 and the frame 100 can fit together well. In this case, the inner panel layer 207 is directly welded to the frame 100, such as... Figure 8 As shown.

[0052] The second type is where the skin 200 and the frame 100 do not fit together. In this case, a transition connector 400 can be added for welding. Figure 9 As shown. The transition connector 400 is L-shaped, with one side welded to the inner panel layer 207 and the other side welded to the frame 100.

[0053] The third type involves welding the skin 200 to the window frame 101 and the lamp frame on the frame 100, such as... Figure 10 As shown, the edges of the window frame 101 and the lamp frame are provided with open-structure overlapping grooves. The inner panel layer 207 forms an overlapping structure with the overlapping grooves and is connected by welding.

[0054] Specifically, the lap groove includes a groove bottom 102 and an inclined sidewall 103 located on one side of the groove bottom 102. The inner panel layer 207 overlaps with the groove bottom 102. The inclined sidewall 103 and the welding bevel 210 form a V-shaped bevel. The thickness of the flat structure is equal to the depth of the lap groove.

[0055] In other words, the skin 200 and the frame 100 are manufactured as independent units, which allows for the layout of production workstations and facilitates personnel organization. The advantage of modularity is that it enables proficiency through practice and rapid accumulation of experience, which can greatly improve production efficiency and product quality.

[0056] It should be noted that by modifying the macroscopic structure of the spiderweb honeycomb core material, it possesses excellent properties such as low density, high rigidity, weldability, three-dimensional molding capability, and pure metal material. The process is simple, has good processability, and low cost, and is mainly used in driver's cabs of rail vehicles with speeds below 120 km / h (primarily for urban rail transit, such as subways). This invention solves the environmental protection problem of traditional fiberglass structure driver's cabs. The overall structure is made of aluminum alloy with no non-metallic materials, and it can be recycled after its service life, resulting in good environmental performance. This invention also solves the airtightness problem of traditional fiberglass structure driver's cabs. Fiberglass driver's cabs can only be fixed to the frame with bolts and sealant, which can lead to aging and poor airtightness. The driver's cab of this invention is an integral welded structure, allowing welding to the car body, frame, etc., and sealing through welding, effectively improving the airtightness of the driver's cab. This invention can be molded to meet the aesthetic requirements of the driver's cab mask, solving the problems of high cost and large rebound deformation of traditional plate beam structures and fiberglass mask molds.

[0057] According to an embodiment of the present invention, a rail vehicle is provided, including the aforementioned driver's cab based on a spider web honeycomb welded sandwich layer.

[0058] The present invention has been described in detail above. The above description is only a preferred embodiment of the present invention and should not be construed as limiting the scope of the present invention. All equivalent changes and modifications made in accordance with the scope of this application should still fall within the scope of the present invention.

Claims

1. A driver's cab based on a spiderweb honeycomb welded sandwich structure, characterized in that, It includes a skeleton and a skin located on the skeleton, the skin adopts a sandwich structure, and the skin is connected to the skeleton by welding; The sandwich structure includes a core material layer made of a spider web honeycomb core material. The spider web honeycomb core material is configured as a cell structure composed of a number of cells protruding from its surface in a matrix arrangement. The number of cells protruding from the surface of the spider web honeycomb core material are in the same direction. The cell is configured as a frustum structure with a hexagonal cross-section. Both sides of the core material layer are provided with a panel layer, and the panel layer is connected to the core material layer by welding. The skin is composed of multiple skin modules spliced ​​together. The skin module adopts a sandwich structure consisting of a core material layer and a panel layer. The splicing ends of the skin modules are extruded into a flat structure and have reserved welding bevels.

2. The driver's cab based on a spiderweb honeycomb welded sandwich structure according to claim 1, characterized in that, The panel layer includes an inner panel layer and an outer panel layer, and the inner panel layer is connected to the frame by welding.

3. The driver's cab based on a spiderweb honeycomb welded sandwich structure according to claim 2, characterized in that, The inner panel layer is welded to the frame via a transition connector. The transition connector is L-shaped, with one side welded to the inner panel layer and the other side welded to the frame.

4. The driver's cab based on a spiderweb honeycomb welded sandwich structure according to claim 1, characterized in that, The splicing ends of adjacent skin modules are connected to each other, and a backing plate is provided at the docking position. The backing plate is connected to the splicing end by welding.

5. The driver's cab based on a spiderweb honeycomb welded sandwich structure according to claim 2, characterized in that, The edges of the window frames and lamp frames on the frame are provided with open-structure overlapping grooves. The inner panel layer forms an overlapping structure with the overlapping grooves and is connected by welding.

6. The driver's cab based on a spiderweb honeycomb welded sandwich structure according to claim 5, characterized in that, The lap groove includes a groove bottom and an inclined sidewall located on one side of the groove bottom. The inner panel layer overlaps with the groove bottom. The inclined sidewall and the welding bevel form a V-shaped bevel. The thickness of the flat structure is equal to the depth of the lap groove.

7. A rail vehicle, characterized in that, The driver's cab based on the spider web honeycomb welded sandwich structure as described in any one of claims 1-6.

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