Composite damper mounting beam for rail vehicles and method

Abstract

The application discloses a composite material barrier damper mounting beam for a rail vehicle and a method, and belongs to the technical field of rail vehicles, which comprises a composite material mounting beam main body, composite material mounting seats are arranged at both ends of the composite material mounting beam main body, the composite material mounting seat and the composite material mounting beam main body both comprise inner layer structures and outer layer structures, the outer layer structures are coated outside the inner layer structures, the inner layer structures are foam core molds, and the outer layer structures are made of composite materials.

Description

Technical Field

[0001] This invention belongs to the field of rail vehicle technology, specifically relating to a composite material obstacle removal damper installation beam and method for rail vehicles. Background Technology

[0002] The statements herein provide only background information in relation to this invention and do not necessarily constitute prior art.

[0003] The obstacle removal damper mounting beam is a component of the bogie of a rail vehicle, installed at the front of the bogie, and used to mount the obstacle removal damper and its accessories. The strength and reliability of the obstacle removal damper mounting beam are crucial to train operation safety and it is a critical load-bearing component.

[0004] Currently, the mounting beams for obstacle removal dampers used in rail vehicle bogies are mostly metal structures, and the components of the mounting beams are connected by bolts. Due to the heavy weight of the metal structure, the bolt connection method is prone to fatigue fracture in application scenarios, and the overall strength cannot meet the usage requirements, thus affecting the service life and driving safety. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention aims to provide a composite material obstacle removal damper mounting beam and method for rail vehicles. The inner layer structure of the mounting beam uses a foam core mold, and the outer layer structure uses composite materials, which can reduce the overall weight and improve the connection stability.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0007] In a first aspect, the present invention provides a composite material obstacle removal damper mounting beam for rail vehicles, comprising a composite material mounting beam body, wherein composite material mounting seats are provided at both ends of the composite material mounting beam body, and both the composite material mounting seats and the composite material mounting beam body include an inner layer structure and an outer layer structure, wherein the outer layer structure covers the outside of the inner layer structure, the inner layer structure is a foam core mold, and the outer layer structure is made of composite material.

[0008] As a further technical solution, the composite material mounting base and the composite material mounting beam body are integrally formed structures.

[0009] As a further technical solution, the outer layer structure is formed by layering composite prepreg onto the surface of the foam core mold.

[0010] As a further technical solution, the outer layer structure comprises, from the inside out: a carbon fiber unidirectional prepreg layer, a glass fiber mesh layer, and a carbon fiber fabric layer. The carbon fiber unidirectional prepreg layer is laid on the surface of the foam core mold, the glass fiber mesh layer is laid on the surface of the carbon fiber unidirectional prepreg layer, and the carbon fiber fabric layer is laid on the surface of the glass fiber mesh layer.

[0011] As a further technical solution, the composite material mounting base is provided with a barrier damper mounting part, the barrier damper mounting part is provided with bolt holes for connection with the barrier damper, and an additional fiberglass layer is provided at the mounting contact position between the barrier damper mounting part and the barrier damper.

[0012] As a further technical solution, the connection between the composite material mounting base and the main body of the composite material mounting beam is designed with a smooth transition.

[0013] Secondly, the present invention also provides a method for forming the composite material obstacle-removing damper mounting beam as described above, comprising the following steps:

[0014] The foam is processed into a foam core mold, which is used as the inner structure of the mounting beam of the obstacle removal damper;

[0015] A carbon fiber unidirectional prepreg layer is laid on the surface of a foam core mold, a glass fiber mesh layer is laid on the surface of the carbon fiber unidirectional prepreg layer, and a carbon fiber fabric layer is laid on the surface of the glass fiber mesh layer to form an outer layer structure.

[0016] The air bag is wrapped around the surface of the outer structure and then cured at a set temperature.

[0017] As a further technical solution, the carbon fiber unidirectional prepreg layer is laid up in even-number layers, with an intermediate layer in the middle of the carbon fiber unidirectional prepreg layer, and the intermediate layer is laid up and down symmetrically; the layer above the intermediate layer is laid up in a cyclic pattern with the fiber direction [+45° / -45° / 0° / 90°], and the layer below the intermediate layer is laid up in a cyclic pattern with the fiber direction [90° / 0° / -45° / +45°].

[0018] As a further technical solution, the glass fiber mesh layer consists of two layers: two layers of glass fiber mesh are laid on the surface of the carbon fiber unidirectional prepreg layer, and the fiber orientation of both layers of glass fiber mesh is 0°.

[0019] As a further technical solution, the carbon fiber fabric layer is one layer, which is laid on the surface of the glass fiber mesh layer, and the fiber direction of the carbon fiber fabric layer is 0°.

[0020] The beneficial effects of the present invention are as follows:

[0021] The composite material obstacle removal damper mounting beam of this invention features an inner and outer layer structure for both the main body and the mounting base. The inner layer is a foam core mold, and the outer layer is a composite material laid on the surface of the inner layer. Compared to traditional metal structure obstacle removal damper mounting beams, this significantly reduces the overall weight. Furthermore, unlike metal mounting beams that are connected to the mounting base via bolts, the main body and mounting base are integrally designed and molded using foam and composite materials. This avoids additional connecting components such as bolts, improving the connection stability of the product and the fatigue resistance of the connection between the mounting base and the mounting beam, thereby extending the service life of the obstacle removal damper mounting beam. The integrated molding process also improves the product manufacturing efficiency.

[0022] The composite material obstacle removal damper mounting beam of the present invention uses carbon fiber composite material and glass fiber composite material for the outer layer structure of the mounting beam and adopts a reasonable layup design. While improving the lightweight of the obstacle removal damper mounting beam, it also improves the overall strength and stiffness of the mounting beam. Furthermore, by reasonably arranging the glass fiber layer, the overall impact resistance and wear resistance of the component are improved.

[0023] The composite material obstacle removal damper mounting beam of the present invention has a foam core mold inside the mounting beam. On the one hand, it improves the overall strength and stiffness of the beam. On the other hand, the foam can be used as a core mold for composite material laying during molding, which facilitates the laying work of the mounting beam during molding and improves the laying quality.

[0024] The composite material obstacle removal damper mounting beam of the present invention enhances the wear resistance of the contact area between the obstacle removal damper and the mounting base by providing an additional fiberglass layer. A fiberglass layer is also provided on the outermost layer of the entire mounting beam to improve its overall impact resistance.

[0025] The molding method of the composite material obstacle removal damper mounting beam of the present invention adopts the prepreg bag pressing process technology to prepare the composite material obstacle removal damper mounting beam, which ensures the preparation quality and efficiency and reduces the preparation cost. Attached Figure Description

[0026] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0027] Figure 1 This is a schematic diagram of the mounting beam of the composite material obstacle-clearing damper for rail vehicles according to one or more embodiments of the present invention;

[0028] Figure 2 This is a cross-sectional view of the mounting beam of the composite material obstacle-clearing damper for rail vehicles according to one or more embodiments of the present invention;

[0029] Figure 3 This is an enlarged view of the composite material mounting base according to one or more embodiments of the present invention;

[0030] Figure 4 This is a schematic diagram of the outer layer structure of the composite material obstacle-clearing damper mounting beam for rail vehicles according to one or more embodiments of the present invention;

[0031] Figure 5 This is a simulation result diagram of the installation beam of the composite material obstacle removal damper for rail vehicles according to one or more embodiments of the present invention;

[0032] In the diagram: 1. Composite material mounting base, 2. Composite material mounting beam body, 3. Foam core mold, 4. Obstacle removal damper mounting part, 5. Transition area.

[0033] The distances or dimensions between parts have been exaggerated to show their positions; the diagram is for illustrative purposes only. Detailed Implementation

[0034] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0035] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, unless otherwise expressly indicated by the invention, the singular form is also intended to include the plural form. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0036] For ease of description, the words "up," "down," "left," and "right" appearing in this invention only indicate that they are consistent with the up, down, left, and right directions of the accompanying drawings themselves, and do not limit the structure. They are merely for the purpose of facilitating the description of this invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0037] Terminology Explanation: In this invention, terms such as “installation,” “connection,” “linking,” and “fixing” should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components or the interaction relationship between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0038] In a typical embodiment of the present invention, such as Figure 1 As shown, a composite material obstacle removal damper mounting beam for rail vehicles is proposed, which includes a composite material mounting beam body 2, a composite material mounting seat 1, etc., and the total length of the mounting beam is 2372mm.

[0039] The composite material mounting beam body 2 is in the form of a crossbeam, and composite material mounting seats 1 are provided at both ends of the composite material mounting beam body 2. The composite material mounting seats 1 and the composite material mounting beam body 2 are connected as one unit. The composite material mounting seats 1 are used to install the obstacle removal damper.

[0040] In this embodiment, the composite material mounting base 1 and the composite material mounting beam body 2 are integrally formed structures. Compared with the original metal structure mounting beam, the composite material mounting beam integrally forms the mounting base and the mounting beam body, avoiding the problem of insufficient fatigue strength at the connection of the original structure.

[0041] The composite material mounting base 1 is a base for mounting the obstacle removal damper. It is set higher than the composite material mounting beam body 2. In a preferred embodiment, the connection between the composite material mounting base 1 and the composite material mounting beam body 2 is smoothly transitioned. That is, a transition fillet is set at the connection between the part of the composite material mounting base 1 that is higher than the composite material mounting beam body 2 and the composite material mounting beam body 2. The increase of the fillet in the transition area further reduces the stress concentration effect in the connection area and improves its fatigue strength.

[0042] The composite material mounting base 1 is provided with a barrier damper mounting part 4, which is the installation position of the barrier damper. The barrier damper mounting part 4 is provided with bolt holes, and the barrier damper is connected by bolts. Since the barrier damper is made of metal and the mounting beam is made of composite material, in order to increase the friction between the composite material and the metal and increase the wear resistance of the mounting part, an additional fiberglass layer is provided at the mounting contact position between the barrier damper mounting part 4 and the barrier damper.

[0043] In a further embodiment, both the composite material mounting base 1 and the composite material mounting beam body 2 include an inner layer structure and an outer layer structure. The outer layer structure covers the outside of the inner layer structure. The inner layer structure is a foam core mold 3, and the outer layer structure is made of composite material.

[0044] In this embodiment, the foam core mold 3 is made of high-density rigid PM I foam.

[0045] The outer layer structure of the foam core mold is formed by layering composite prepreg onto the surface of the foam core mold 3;

[0046] Specifically, the outer structure, from the inside out, includes: a carbon fiber unidirectional prepreg layer, a glass fiber mesh layer, and a carbon fiber fabric layer. The carbon fiber unidirectional prepreg layer is laid on the surface of the foam core mold 3, the glass fiber mesh layer is laid on the surface of the carbon fiber unidirectional prepreg layer, and the carbon fiber fabric layer is laid on the surface of the glass fiber mesh layer.

[0047] This solution, based on high-strength carbon fiber composites and glass fiber composites, fully leverages the advantages of integrated composite design and molding, and innovatively redesigns the original metal obstacle removal damper mounting beam. By using composite materials to integrally mold the obstacle removal damper mounting base and the main body of the mounting beam, the fatigue resistance at the connection point is improved, and the overall strength and stiffness of the mounting beam are enhanced.

[0048] The mounting beam of this invention has a significant lightweight effect, a simple and reliable structure, high rigidity and strength, and high molding efficiency. It is suitable for railway vehicle bogies and can meet the needs of lightweighting key components of railway vehicles and future market development, thus possessing certain market application value.

[0049] In another typical embodiment of the present invention, a molding method for the composite material obstacle-clearing damper mounting beam for rail vehicles as described above is proposed. This method employs a prepreg bag pressing process, where foam is machined into a core mold shape. Composite prepreg is then laid onto the surface of the foam core mold according to a layup scheme. An air bag is then placed over the entire product surface, and the product is cured at 130°C. The foam core mold does not require demolding after product curing, thereby increasing the overall stiffness of the composite material obstacle-clearing damper mounting beam.

[0050] Specifically, the molding method includes the following steps:

[0051] The foam is machined into a foam core mold, which is used as the inner structure of the obstacle removal damper mounting beam.

[0052] A carbon fiber unidirectional prepreg layer is laid on the surface of a foam core mold, a glass fiber mesh layer is laid on the surface of the carbon fiber unidirectional prepreg layer, and a carbon fiber fabric layer is laid on the surface of the glass fiber mesh layer to form an outer layer structure.

[0053] The air bag is wrapped around the surface of the outer structure and then cured at a set temperature.

[0054] The carbon fiber unidirectional prepreg layer is laid in an even number of layers, and an intermediate layer is set in the middle of the carbon fiber unidirectional prepreg layer. The layers are laid symmetrically upward and downward with the intermediate layer as the center, which can minimize the interlayer stress at different angles.

[0055] In this embodiment, the carbon fiber unidirectional prepreg layer is laid up in 26 layers. The middle layer consists of two layers laid at ±45° of the fiber direction. The middle layer is laid up symmetrically above and below. The upper part of the middle layer is laid up in a cyclic pattern with the fiber direction [+45° / -45° / 0° / 90°], and the lower part of the middle layer is laid up in a cyclic pattern with the fiber direction [90° / 0° / -45° / +45°].

[0056] In this embodiment, the carbon fiber unidirectional prepreg layer is laid up using 200g T300 grade carbon fiber unidirectional prepreg, with the fiber direction being (+45° / -45° / 0° / 90° / +45°).

[0057] / -45° / 0° / 90° / +45° / -45° / 0° / 90° / ±45° / 90° / 0° / -45°

[0058] The ply pattern is as follows: (+45° / 90° / 0° / -45° / +45° / 90° / 0° / -45° / +45°). In this ply pattern, two layers are set in the middle ±45° as intermediate layers, and the intermediate layers are plyed symmetrically on the top and bottom sides.

[0059] The fiberglass mesh layer consists of two layers: two 400g layers of fiberglass mesh are laid on the surface of the carbon fiber unidirectional prepreg layer to improve its wear resistance and impact resistance.

[0060] The fiber orientation of both layers of fiberglass mesh is 0°.

[0061] The carbon fiber fabric layer consists of one layer, which is a 200g T300 grade 3K carbon fiber fabric layer laid on the surface of the glass fiber mesh layer for exterior decoration.

[0062] The fiber orientation of the carbon fiber fabric layer is 0°.

[0063] In a preferred embodiment, since the obstacle removal damper is made of metal and the mounting beam is made of composite material, in order to increase the wear resistance of the mounting part, an additional fiberglass layer is provided at the mounting contact position between the obstacle removal damper mounting part of the composite material mounting seat of the composite material obstacle removal damper mounting beam and the obstacle removal damper.

[0064] like Figure 5 The figure shown is a simulation result diagram of the composite material obstacle removal damper mounting beam of the present invention. The results show that the maximum strain occurs in the transition area 5 between the composite material mounting base 1 and the main body of the composite material mounting beam. The maximum micro-strain is 1243, which is much smaller than the allowable micro-strain of 4000 for composite materials. This indicates that the solution of the present invention solves the problem of insufficient fatigue strength at the connection of the original structure.

[0065] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A composite material obstacle-clearing damper mounting beam for rail vehicles, characterized in that, The system includes a composite material mounting beam body, with composite material mounting seats at both ends. Both the composite material mounting seats and the composite material mounting beam body include an inner layer structure and an outer layer structure, with the outer layer structure covering the outer layer structure. The inner layer structure is a foam core mold, and the outer layer structure is made of composite material. The composite material mounting seats and the composite material mounting beam body are integrally molded. The outer layer structure is formed by layering composite material prepreg onto the surface of the foam core mold. From the inside out, the outer layer structure includes: a carbon fiber unidirectional prepreg layer, a glass fiber mesh layer, and a carbon fiber fabric layer. The carbon fiber unidirectional prepreg layer is laid on the surface of the foam core mold, the glass fiber mesh layer is laid on the surface of the carbon fiber unidirectional prepreg layer, and the carbon fiber fabric layer is laid on the surface of the glass fiber mesh layer. The foam core mold is made of high-density rigid PMI foam, and the foam core mold does not need to be demolded after the product has cured. The composite material mounting base is provided with a barrier damper mounting part, which has bolt holes for connection with the barrier damper. An additional glass fiber layer is provided at the mounting contact position between the barrier damper mounting part and the barrier damper. The carbon fiber unidirectional prepreg layer is laid in even-numbered layers, with an intermediate layer in the middle of the carbon fiber unidirectional prepreg layer, and the intermediate layer is laid symmetrically upward and downward. The layer above the intermediate layer is laid in a cyclic pattern with the fiber direction [+45° / -45° / 0° / 90°], and the layer below the intermediate layer is laid in a cyclic pattern with the fiber direction [90° / 0° / -45° / +45°]. The glass fiber mesh layer consists of two layers, with two layers of glass fiber mesh laid on the surface of the carbon fiber unidirectional prepreg layer, and the fiber orientation of both layers of glass fiber mesh is 0°; the carbon fiber fabric layer consists of one layer, with one layer of carbon fiber fabric laid on the surface of the glass fiber mesh layer, and the fiber orientation of the carbon fiber fabric layer is 0°.

2. The composite material obstacle removal damper mounting beam as described in claim 1, characterized in that, The connection between the composite material mounting base and the main body of the composite material mounting beam is designed with a smooth transition.

3. The method for forming the composite material obstacle-clearing damper mounting beam as described in any one of claims 1-2, characterized in that, Includes the following steps: The foam is processed into a foam core mold, which is used as the inner structure of the mounting beam of the obstacle removal damper; A carbon fiber unidirectional prepreg layer is laid on the surface of a foam core mold, a glass fiber mesh layer is laid on the surface of the carbon fiber unidirectional prepreg layer, and a carbon fiber fabric layer is laid on the surface of the glass fiber mesh layer to form an outer layer structure. The air bag is wrapped around the surface of the outer structure and then cured at a set temperature.

Images