A method for manufacturing a special-shaped high-mobility electromagnetic shielding vehicle cabin

Abstract

The application discloses a manufacturing method of a special-shaped high-mobility electromagnetic shielding vehicle cabin, and has the characteristics that: (1) a cabin body is manufactured, and a door hole and a hole hole are formed on the cabin body; (2) an aluminum profile door hole frame and a hole hole frame are manufactured; (3) the door hole frame is installed on the door hole, the hole hole frame is installed on the hole hole, and a laser continuous welding process is adopted to connect the aluminum profile door hole frame and the hole hole frame with a steel sheet metal skin of the cabin body through a seamless electric conduction connection of a steel-aluminum composite plate; (4) a door plate and a hole plate are manufactured, and the door plate and the hole plate are installed on the cabin body. The vehicle cabin is manufactured. The application solves the problems of poor process, high labor intensity, electromagnetic shielding leakage and the like existing in a current composite cabin plate splicing forming process, solves the problem that a door hole frame and a hole hole frame cannot be completely attached to a cabin body in the prior art, electromagnetic leakage is caused, and the shielding vehicle cabin can reach a shielding effectiveness of 40 dB in a 100 KHz-10 GHz frequency band.

Description

Technical Field

[0001] This invention relates to the field of electromagnetic shielding vehicle technology, specifically to a method for manufacturing an irregularly shaped, highly mobile electromagnetic shielding vehicle. Background Technology

[0002] The manufacturing method of high-speed vehicle shielded compartments mainly includes the design and preparation process of compartment panel structure, the design and preparation process of compartment assembly structure, and the design and preparation process of door frame opening structure.

[0003] 1. Panel structure design and manufacturing process: The panels generally adopt a sandwich structure, that is, an insulation layer is sandwiched between the inner and outer skins. The inner and outer skins are complete thin metal plates, and the insulation layer is composed of insulation materials (polyurethane foam, honeycomb, etc.) and a reinforcing metal skeleton. The inner and outer skins and the metal skeleton are bonded together with adhesives. There are various molding processes, including hot pressing composite molding, vacuum negative pressure composite molding and vacuum bag pressing composite molding. Vacuum bag pressing composite molding is generally used for irregularly shaped panels.

[0004] 2. Body assembly structure design and manufacturing process: Generally, it adopts the assembly of segmented composite panels, that is, each panel is riveted together by metal connecting profiles. Before riveting, conductive tin foil is used to connect the outer sides of two adjacent panels to achieve electrical continuity between the outer and inner metal skins, forming a complete Faraday cage and achieving the effect of electromagnetic shielding.

[0005] 3. Door frame and orifice structure design and manufacturing process: The door panels and orifices of the carriage, which have opening and closing requirements, are the focus of electromagnetic shielding design. Generally, special profiles for shielding doors and orifices are used. The door frame and orifice frame are seamlessly connected by flame brazing at the 45° joint position. After forming, conductive oxidation surface treatment is carried out to form a structure in which the male and female frames of the shielded carriage interlock. Metal wire mesh gaskets are installed at the interlocking position to achieve electrical conduction between the two.

[0006] The existing technology has the following technical defects:

[0007] (1) The design of the segmented composite panel assembly structure is complex and the processability is poor. The body needs to be disassembled into a lot of irregular composite panels. The manufacturing process of irregular composite panels is complicated. They generally have folded corners and rounded edges. Therefore, only vacuum bag pressing process can be used. The process is difficult to control and is prone to delamination and poor contour dimension accuracy.

[0008] (2) Since the irregular-shaped box body needs to be assembled from many scattered box panels, the cumulative error of the box assembly is large. In addition, the adjacent box panels are connected by metal profiles, resulting in many seams. Although aluminum foil is used for overlapping, it is difficult to solve the problem of electromagnetic leakage caused by too many and too large gaps. Furthermore, the work is labor-intensive and the process is not good.

[0009] (3) For irregularly shaped boxes, the door frame and door panel are also irregularly shaped structures (with features such as folded corners or arcs). The irregularly shaped door frame and the box adopt a male frame and female frame interlocking connection structure. Even with the installation of metal wire mesh pads, it is difficult to achieve a complete fit between the door frame and the box, resulting in electromagnetic leakage problems.

[0010] In summary, existing high-speed vehicle shielded carriages cannot simultaneously meet the performance requirements of shielding, watertightness, and corrosion resistance. Summary of the Invention

[0011] To address the aforementioned problems, this invention provides a method for manufacturing an irregularly shaped, highly mobile electromagnetically shielded carriage.

[0012] The technical solution adopted in this invention is:

[0013] A method for manufacturing an irregularly shaped, highly mobile electromagnetically shielded vehicle, comprising:

[0014] (1) Make the box body and open the door and opening holes on the box body;

[0015] (2) Fabricate aluminum profile door frames and opening frames;

[0016] (3) Install the door frame onto the door hole, install the hole frame onto the hole hole, and use laser continuous welding process to seamlessly connect the aluminum profile door frame and hole frame with the steel sheet metal skin of the box body through steel-aluminum composite plate.

[0017] (4) Make door panels and perforated plates, and install the door panels and perforated plates into the car body; the car body is completed.

[0018] The manufacturing process of the enclosure includes:

[0019] (1.1) Construction of the box frame: The box frame is constructed using a prefabricated independent steel frame;

[0020] (1.2) Body skin fabrication: The body skin is fabricated using thin-walled steel sheet metal;

[0021] (1.3) Connection between skin and frame: The segmented body skin is spot-welded to the body frame from the outside using CO2 gas shielded welding. The edges of all body skin overlap the outer surface of the body frame, leaving gaps for laser welding. The body skin segments spot-welded to the body frame are continuously and fully welded to the body frame from the outside using laser welding. The body skin segments are welded to the body frame from the inside using CO2 gas shielded intermittent welding. After welding, the deformed body skin segments are reshaped and the weld scars are repaired, so that the body forms a closed electrical connection, a complete Ferrari cage.

[0022] Furthermore, in step (1.3), the width of the laser weld is 5.0 to 6.5 mm, and the laser welding power is 1.2 to 1.5 KW.

[0023] Furthermore, in step (2), the door frame and the opening frame are made by an overall bending process of aluminum profiles, and the corners are rounded.

[0024] Furthermore, in step (3), the shape of the steel-aluminum composite panel is adapted to the door frame and the opening frame. When installing the door frame and the opening frame, the steel-aluminum composite panel is first installed on the door hole or the opening hole, and the steel plate layer in the steel-aluminum composite panel is seamlessly connected to the steel sheet metal skin of the box body by using a continuous laser welding process; then the opening frame or the opening frame is installed on the steel-aluminum composite panel, and the aluminum plate layer in the steel-aluminum composite panel is seamlessly connected to the aluminum profile door frame and the opening frame by using a continuous laser welding process.

[0025] Furthermore, the door panel manufacturing process includes:

[0026] (4.1) Door panel skin fabrication: The door panel skin is fabricated using steel sheet metal through laser cutting and bending.

[0027] (4.2) Door panel internal frame fabrication: The door panel internal frame is fabricated using aluminum profiles through welding process;

[0028] (4.3) Door panel frame manufacturing: The door panel frame is manufactured using an integral bending and forming process of aluminum profiles, and the corners of the door panel frame are rounded.

[0029] (4.4) Door panel molding: Foam is filled inside the frame, and then the door panel skin is covered on both sides of the door panel frame through an adhesive coating process. Finally, it is formed by vacuum high temperature bag pressing.

[0030] (4.5) Connection between door panel and door panel frame: Install the door panel frame onto the formed door panel, and then install the accessories to finally form a complete door panel.

[0031] Furthermore, in step (4.4), the vacuum bag pressure is greater than 96 kPa, the vacuum bag temperature is 70 ± 10 °C, and the vacuum bag time is 2 to 4 hours.

[0032] Furthermore, after the vacuum bag is compressed, allow it to cool naturally to room temperature before removing the door panel from the bag.

[0033] The beneficial effects of this invention are:

[0034] 1. This invention abandons the traditional composite panel assembly process and adopts a pre-formed independent steel frame and steel thin-walled sheet metal skin, which are intermittently welded on the inside by carbon dioxide gas shielded welding process, and spot welded on the outside by carbon dioxide gas shielded welding process + continuous laser welding process, finally forming a complete shielded Faraday cage shell. It solves the problems of poor processability, high labor intensity and electromagnetic shielding leakage in the existing composite panel assembly process. This invention can achieve a shielding effectiveness of 40dB in the 100KHz~10GHz frequency band.

[0035] 2. This invention connects the body frame and body skin by intermittent welding with carbon dioxide gas shielded welding on the inner side and spot welding with carbon dioxide gas shielded welding plus continuous laser welding on the outer side, achieving a seamless connection between the body frame and body skin and preventing heat deformation of the body skin during the welding process.

[0036] 3. By using steel-aluminum composite plates as transitional parts for welding dissimilar metal components, this invention achieves seamless connection and continuous electrical conduction between the aluminum profile door frame and orifice frame and the steel body skin, solving the problem of electromagnetic leakage caused by the inability of the door frame and orifice frame to fully fit the body in the prior art.

[0037] Instruction manual illustrations

[0038] Figure 1 This is a flowchart illustrating the manufacturing process of the compartment body for this invention.

[0039] Figure 2 This is a flowchart illustrating the door panel manufacturing process of the present invention. Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below in conjunction with the accompanying drawings and a preferred embodiment.

[0041] This embodiment provides a method for manufacturing an irregularly shaped, highly mobile electromagnetically shielded vehicle, including the following steps:

[0042] (1) Make the box body and open the door and opening holes on the box body;

[0043] See Figure 1 The manufacturing process of the box body includes:

[0044] (1.1) Construction of the box frame: The prefabricated independent steel frame is welded together to form the box frame, which is adapted to the shape of the box;

[0045] (1.2) Body skin fabrication: The body skin is made of thin-walled steel sheet metal and is divided into several pieces according to the shape of the car body;

[0046] (1.3) Connection between skin and frame: This refers to covering the body frame with body skin; specifically including:

[0047] (1.3.1) The segmented body skin is spot-welded to the body frame from the outside using carbon dioxide gas shielded welding. The edges of all body skin overlap the outer surface of the body frame, leaving laser welding gaps.

[0048] (1.3.2) Laser welding process is used to continuously weld each piece of the body skin that is spot-welded to the body frame from the outside to the body frame. On the inside of the car body, carbon dioxide gas shielded intermittent welding process is used to weld the body skin to the body frame for reinforcement.

[0049] (1.3.3) After welding, the deformed body skin is shaped and the weld scars are repaired to make the car body a closed electrical connection, a complete Ferrari cage.

[0050] The laser continuous welding process parameters are shown in Table 1 below.

[0051] Table 1

[0052]

[0053] (2) Fabricate aluminum profile door frames and opening frames;

[0054] The irregular door frame and opening frame skeleton is made of aluminum profile through an integral bending process, with rounded transitions at the four corners to avoid stress concentration problems at traditional 90° corners; in order to adapt to the shape of the carriage and ensure aesthetic appearance, the door frame and opening frame are designed with folded corners in the middle; the door frame and opening frame made using the above method have good forming precision, high processing efficiency, high overall strength, excellent shielding performance, and beautiful appearance.

[0055] (3) Install the door frame and opening frame onto the doorway, and use laser continuous welding technology to seamlessly connect the aluminum profile door frame and opening frame to the steel sheet metal skin of the enclosure through a steel-aluminum composite plate; specifically including:

[0056] (3.1) Fabricate a steel-aluminum composite panel frame A that matches the shape of the door frame;

[0057] (3.2) Fabricate a steel-aluminum composite frame B that matches the shape of the orifice frame;

[0058] (3.3) When installing the door frame, first place the steel-aluminum composite panel frame A onto the door hole, and use laser continuous welding process to make the steel plate layer in the steel-aluminum composite panel seamlessly connected with the steel sheet metal skin of the box body; then install the door frame onto the steel-aluminum composite panel frame A, and use laser continuous welding process to make the aluminum plate layer in the steel-aluminum composite panel seamlessly connected with the aluminum profile door frame.

[0059] (3.4) When installing the orifice frame, first place the steel-aluminum composite plate frame B onto the orifice, and use laser continuous welding process to make the steel plate layer in the steel-aluminum composite plate seamlessly connected with the steel sheet metal skin of the box body; then install the orifice frame onto the steel-aluminum composite plate frame B, and use laser continuous welding process to make the aluminum plate layer in the steel-aluminum composite plate seamlessly connected with the aluminum profile orifice frame.

[0060] The laser continuous welding process parameters are shown in Table 2 below.

[0061] Table 2

[0062]

[0063] (4) Fabricate the door panels and perforated plates, and install the door panels and perforated plates into the compartment. The shielded compartment is now complete.

[0064] See Figure 2 The door panel manufacturing process includes:

[0065] (4.1) Door panel skin fabrication: The door panel skin is fabricated using steel sheet metal through laser cutting and bending.

[0066] (4.2) Door panel internal frame fabrication: The door panel internal frame is fabricated using aluminum profiles through welding process;

[0067] (4.3) Door panel foam production: Use polyurethane foam board or honeycomb board cut into insulation boards that fit the shape of the door panel;

[0068] (4.4) Door panel frame manufacturing: The door panel frame is manufactured using an integral bending process with aluminum profiles, and the corners of the door panel frame are rounded.

[0069] (4.5) Door panel forming: Insulation board is filled inside the frame, and then the door panel skin is bonded to both sides of the door panel frame by adhesive application. High-strength epoxy adhesive EPLY-2 is used for adhesive application. After 1.2 hours of adhesive application, the composite door panel is put into a vacuum bag and formed by vacuum high temperature bag pressing. The bag pressing pressure is 96KPa and the temperature is 80℃. After bag pressing for 2 hours, the door panel is taken out and cooled to room temperature. The bag is removed and the panel is repaired.

[0070] (4.5) Connection between door panel and door panel frame: Install the door panel frame onto the formed door panel, and then install the accessories to finally form a complete door panel.

[0071] The manufacturing process for perforated plates is the same as that for door panels.

[0072] The highly mobile electromagnetically shielded carriage manufactured using the above process can simultaneously meet the performance requirements of shielding, watertightness, and corrosion resistance. The shielding effect reaches over 40dB in the electromagnetic wave frequency range of 100KHz to 10GHz.

[0073] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications are also within the protection scope of the present invention.

Claims

1. A method for manufacturing an irregularly shaped, highly mobile electromagnetically shielded carriage, characterized in that, include: (1) Construct the compartment and make door openings and door openings on the compartment; (2) Fabricate aluminum profile door frames and opening frames; (3) Install the door frame onto the door and the orifice frame onto the orifice. Use laser continuous welding process to seamlessly connect the aluminum profile door frame and orifice frame with the steel sheet metal skin of the box body through the steel-aluminum composite plate. (4) Make door panels and perforated plates, install the door panels and perforated plates into the car body, and the car body is completed; The manufacturing process of the box body includes: (1.1) Construction of the box frame: The box frame is constructed using a prefabricated independent steel frame; (1.2) Body skin fabrication: The body skin is fabricated using thin-walled steel sheet metal; (1.3) Connection between skin and frame: The segmented body skin is spot-welded to the body frame from the outside using carbon dioxide gas shielded welding. The edges of all body skin overlap the outer surface of the body frame, leaving gaps for laser welding. The body skin segments spot-welded to the body frame are continuously and fully welded to the body frame from the outside using laser welding. The body skin segments are welded to the body frame from the inside using carbon dioxide gas shielded intermittent welding. After welding, the deformed body skin segments are reshaped and the weld scars are repaired. Finally, the body forms a closed electrical connection, a complete Ferrari cage.

2. The manufacturing method according to claim 1, characterized in that, In step (1.3), the width of the laser weld is 5.0 to 6.5 mm, and the laser welding power is 1.2 to 1.5 KW.

3. The manufacturing method according to claim 1, characterized in that, In step (2), the door frame and the opening frame are made by the overall bending process of aluminum profiles, and the corners are rounded.

4. The manufacturing method according to claim 1, characterized in that, In step (3), the shape of the steel-aluminum composite panel is adapted to the door frame and the opening frame. When installing the door frame and the opening frame, the steel-aluminum composite panel is first installed on the door opening and the opening, and the steel plate layer in the steel-aluminum composite panel is seamlessly connected to the steel sheet metal skin of the box body by using laser continuous welding process; then the door frame and the opening frame are installed on the steel-aluminum composite panel, and the aluminum plate layer in the steel-aluminum composite panel is seamlessly connected to the aluminum profile door frame and the opening frame by using laser continuous welding process.

5. The manufacturing method according to claim 1, characterized in that, The door panel manufacturing process includes: (4.1) Door panel skin fabrication: The door panel skin is fabricated using steel sheet metal through laser cutting and bending. (4.2) Door panel internal frame fabrication: The door panel internal frame is fabricated using aluminum profiles through welding process; (4.3) Door panel frame manufacturing: The door panel frame is manufactured using an integral bending and forming process of aluminum profiles, and the corners of the door panel frame are rounded. (4.4) Door panel forming: The core material is filled into the frame, and then the door panel skin is covered on both sides of the door panel frame by the glue coating process. Finally, it is formed by vacuum high temperature bag pressing. (4.5) Connection between door panel and door panel frame: Install the door panel frame onto the formed door panel, and then install the accessories to finally form a complete door panel.

6. The manufacturing method according to claim 5, characterized in that, In step (4.4), the vacuum bag pressure is greater than 96 kPa, the vacuum bag temperature is 70 ± 10 °C, and the vacuum bag time is 2 to 4 hours.

7. The manufacturing method according to claim 5, characterized in that, After vacuum sealing, allow the bag to cool naturally to room temperature before removing the door panel.

8. The manufacturing method according to claim 5, characterized in that, In step (4.4), high-strength epoxy adhesive is used for coating.

9. The manufacturing method according to claim 5, characterized in that, In step (4.5), the accessories include shielded windows, hinges, handles, shielding wire mesh, and sealing rubber strips.

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