Carbon fiber composite antenna beam for rail vehicle and forming method

Abstract

The application discloses a carbon fiber composite material antenna beam for a rail vehicle and a forming method, and belongs to the technical field of rail vehicle antenna beam processing. The application discloses a carbon fiber composite material antenna beam for a rail vehicle and a forming method, and belongs to the technical field of rail vehicle antenna beam processing. The application discloses a carbon fiber composite material antenna beam for a rail vehicle and a forming method, and belongs to the technical field of rail vehicle antenna beam processing. The application discloses a carbon fiber composite material antenna beam for a rail vehicle and a forming method, and belongs to the technical field of rail vehicle antenna beam processing. The application discloses a carbon fiber composite material antenna beam for a rail vehicle and a forming method, and belongs to the technical field of rail vehicle antenna beam processing. The application discloses a carbon fiber composite material antenna beam for a rail vehicle and a forming method, and belongs to the technical field of rail vehicle antenna beam processing. The application discloses a carbon fiber composite material antenna beam for a rail vehicle and a forming method, and belongs to the technical field of rail vehicle antenna beam processing. The application discloses a carbon fiber composite material antenna beam for a rail vehicle and a forming method, and belongs to

Description

Technical Field

[0001] This invention belongs to the field of antenna beam processing technology for rail vehicles, specifically relating to a carbon fiber composite antenna beam for rail vehicles and its molding method. Background Technology

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

[0003] As the design speed of rail vehicles gradually increases, the service environment becomes more complex and variable, and the service quality continues to improve, future high-speed railway equipment will require new materials with better comprehensive performance to break through the technical limitations of traditional materials such as metals. The key is to solve the contradictions between lightweighting and various performance aspects such as strength, stiffness, fatigue, corrosion, noise, and fire resistance, and to find a balanced solution for various technical performances.

[0004] With the increasing number of urban rail vehicles, operating mileage, and passenger volume, the reliability and safety of vehicle components are facing severe challenges. The car body and bogies are the most important load-bearing structures of a vehicle, and accessories are usually connected to them mechanically via bolts. An unreasonable structural design can lead to resonance with the main structure, affecting passenger comfort and potentially causing abnormal stops or even endangering passenger safety and property if fatigue fracture occurs. Take the antenna beam installed at the end of the bogie as an example. As the mounting carrier for the ATP monitoring antenna, it is a crucial load-bearing accessory. Currently, the antenna beam uses a welded carbon steel structure. Due to factors such as track irregularities, wheel defects, and rail gaps, vibrations and impact loads transmitted from the bogie end can cause resonance in the antenna beam. This not only affects stable signal transmission but may also lead to vibration fatigue failure, weld cracking, and frequent malfunctions, with an average service life of only about three years. Furthermore, due to the weight of the metal components, maintenance and replacement are difficult, time-consuming, and labor-intensive. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention aims to provide a carbon fiber composite antenna beam for rail vehicles and a molding method thereof. The antenna beam is made by layering carbon fiber composite materials. Carbon fiber composite materials have high specific stiffness and fatigue resistance, which can improve the service life of the antenna beam.

[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 carbon fiber composite antenna beam for rail vehicles, including a balance tube placed on a base; the base has a mounting plate at its bottom, a seat body fixedly mounted on the top of the mounting plate, and a balance tube fixing tube mounted on the top of the seat body, through which the balance tube passes; both the balance tube and the base are made of carbon fiber composite material laid layer by layer.

[0008] As a further technical solution, the balance tube is a circular tube structure, and the mounting plate is provided with holes for the antenna to pass through.

[0009] As a further technical solution, the mounting plate has connection holes, and connectors are inserted into the connection holes to fix the mounting plate to the body structure of the rail vehicle.

[0010] As a further technical solution, the seat has inclined surfaces on both sides, and the cross-sectional area of ​​the seat increases from top to bottom.

[0011] As a further technical solution, an arc-shaped groove is provided on the top of the seat, and the balance tube fixing tube is placed in the arc-shaped groove.

[0012] As a further technical solution, the balance tube fixing tube, the base body, and the mounting plate are integrated into one structure.

[0013] Secondly, the present invention also provides a method for forming the carbon fiber composite antenna beam as described above, comprising the following steps:

[0014] The balance tube is formed using an autoclave molding process;

[0015] The base is formed using a compression molding and blow molding process;

[0016] Apply glue to the balance tube and the inside of the balance tube fixing tube. Insert the balance tube into the balance tube fixing tube and assemble it. The balance tube and the base are made into a whole by adhesive bonding.

[0017] As a further technical solution, the forming process of the balance tube is as follows: carbon fiber plain weave prepreg layer and carbon fiber unidirectional prepreg layer are laid sequentially from the inside out. The carbon fiber unidirectional prepreg layer is laid with the fiber direction as [±45° / 0° / ±45° / 0° / ±45°]. Among them, the carbon fiber unidirectional prepreg with the fiber direction of 0° is laid in 8 turns, and the carbon fiber unidirectional prepreg and carbon fiber plain weave prepreg with other fiber directions are laid in 1 turn each.

[0018] As a further technical solution, the molding process of the base is as follows: carbon fiber plain weave prepreg layer, carbon fiber unidirectional prepreg layer, carbon fiber plain weave prepreg layer are laid in sequence from the inside out, and 11 layers of carbon fiber unidirectional prepreg layer are laid.

[0019] As a further technical solution, the balancing tube is laid using an autoclave molding process during its forming process; the base is laid using a molding and blowing process during its forming process.

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

[0021] The carbon fiber composite antenna beam of the present invention has a balance tube and a base that are made by layering carbon fiber composite materials. On the one hand, it can make full use of the advantages of high specific stiffness and fatigue resistance of composite materials to fundamentally solve the problems of structural resonance and vibration fatigue cracks. On the other hand, the lightweight composite material antenna beam will also help reduce the operating cost of urban rail vehicles throughout their entire life cycle.

[0022] The carbon fiber composite antenna beam of the present invention uses carbon fiber for the main structure and epoxy resin with flame retardant properties as the resin matrix. The carbon fiber is laid on the mold in a specific layup sequence. Under the premise of ensuring mechanical strength, the product weight is reduced, the vibration and impact resistance is improved, the signal transmission performance is improved, and the whole life cycle parameters are improved, thus achieving the effect of improving product performance and reducing costs.

[0023] The carbon fiber composite antenna beam of the present invention achieves weight reduction through material replacement, which plays an important role in reducing vehicle energy consumption and increasing operating speed. Attached Figure Description

[0024] 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.

[0025] Figure 1 This is a schematic diagram of a carbon fiber composite antenna beam according to one or more embodiments of the present invention;

[0026] Figure 2 This is a schematic diagram of the carbon fiber composite antenna beam and antenna assembly according to one or more embodiments of the present invention;

[0027] Figure 3 This is a schematic diagram of the base according to one or more embodiments of the present invention;

[0028] Figure 4 This is a schematic diagram of the balance tube according to one or more embodiments of the present invention;

[0029] Figure 5 This is a schematic diagram of the base according to one or more embodiments of the present invention;

[0030] Figure 6 This is a process diagram of the autoclave forming process of the present invention;

[0031] Figure 7 This is a process diagram of the compression molding and blow molding process of the present invention;

[0032] In the diagram: 1. Balance tube, 2. Base, 3. Mounting plate, 4. Base body, 5. Balance tube fixing tube, 6. Antenna.

[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 intended to include the plural form as well. 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] 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.

[0037] In a typical embodiment of the present invention, such as Figure 1 As shown, a carbon fiber composite antenna beam for rail vehicles is proposed, which includes a balance tube 1, which is placed on a base 2 and supported by the base 2.

[0038] Among them, the balance tube 1 is a cylindrical structure. Both the balance tube and the base are connected to the rail vehicle body. The balance tube plays a balancing role. The antenna passes through the hole set in the base. The balance tube 1 is made of carbon fiber composite material laid layer by layer.

[0039] The base 2 has a mounting plate 3 at its bottom. The mounting plate 3 can have connection holes. The base 2 can be fixed to the body structure of the rail vehicle through the mounting plate 3. Specifically, the base 2 and the rail vehicle can be connected by inserting bolts or other connecting parts into the connection holes of the mounting plate 3.

[0040] Mounting plate 3 is fixedly mounted on top of base 4, and base 4 is mounted on top of balance tube fixing tube 5. Balance tube 1 passes through balance tube fixing tube 5 to fix and support balance tube 1.

[0041] The mounting plate 3 has holes through which the antenna 6 passes, enabling the installation and positioning of the antenna.

[0042] The base 4 has inclined surfaces on both sides, and the cross-sectional area of ​​the base 4 increases from top to bottom, forming a trapezoidal shape to ensure its structural strength and reliability.

[0043] An arc-shaped groove is provided on the top of the base 4, and the balance tube fixing tube 5 is placed in the arc-shaped groove. The balance tube fixing tube 5, the base 4, and the mounting plate 3 form an integrated structure.

[0044] The inner diameter of the balance tube fixing tube 5 matches the outer diameter of the balance tube 1. The balance tube fixing tube 5 has a certain length, which is greater than the width of the base. After the balance tube 1 is inserted into the balance tube fixing tube 5, the balance tube and the base are connected.

[0045] The base 2 is made of carbon fiber composite material laid layer by layer.

[0046] In another typical embodiment of the present invention, a method for forming a carbon fiber composite antenna beam for rail vehicles as described above is proposed, which includes the following steps:

[0047] The balance tube is formed using an autoclave molding process;

[0048] The base is formed using a compression molding and blow molding process;

[0049] Connect the balance tube to the base to form a whole.

[0050] The connection process between the balance tube and the base is as follows: apply two-component epoxy adhesive evenly to the balance tube, apply two-component epoxy adhesive evenly to the inside of the balance tube fixing tube of the base, and then insert the balance tube into the inside of the balance tube fixing tube for assembly, forming a whole by adhesive bonding.

[0051] Specifically, the forming process of the balance tube is as follows:

[0052] From the inside out, carbon fiber plain weave prepreg layer and carbon fiber unidirectional prepreg layer are laid in sequence. The carbon fiber unidirectional prepreg layer is laid with the fiber direction as [±45° / 0° / ±45° / 0° / ±45°]. Among them, the carbon fiber unidirectional prepreg with the fiber direction of 0° is laid in 8 turns, and the carbon fiber unidirectional prepreg and carbon fiber plain weave prepreg with other fiber directions are laid in 1 turn each.

[0053] During this molding process, the substrate is laid using an autoclave molding process.

[0054] The specific process of autoclave forming is as follows: laying the blank, making a vacuum bag, vacuum leak detection, putting the workpiece into the can, heating, pressurizing, heat preservation and pressure holding, putting the workpiece into the can, cooling, depressurizing and stopping the machine, and taking the workpiece out of the can.

[0055] Specifically, in this embodiment, T700 3K plain weave prepreg and T700 unidirectional tape prepreg are used, and epoxy resin is used as the resin. In the prepreg preparation stage, epoxy resin and carbon fiber are used in combination.

[0056] Roll the material according to the layup sequence, paying attention to size and position control during cutting and rolling; before winding, wrap one end of the balance tube with masking tape. The purpose of the masking tape is to prevent burrs and other problems from appearing at both ends of the tube during the winding process; divide it into 6 equal parts, and overlap the overlap part of each layer of carbon cloth (carbon fiber prepreg) in 6 even parts, with no air bubbles or wrinkles on the surface. You can use masking tape to mark and remind the roll mandrel. The roll should be flat and free of wrinkles, bulges, etc.

[0057] Wrap the effective end 10mm of the carbon cloth at the demolding end with 0-degree material (0-degree material refers to prepreg with carbon fiber direction of 0°) for 2-3 turns to increase demolding strength. Use 30mm wide OPP tape (wrap from one end of the round tube to the other, generally from left to right) and use an indoor vertical tape wrapping machine (if the OPP tape breaks, it needs to be rewrapped). The OPP tape should be continuous, without any joints in the middle, with uniform tape spacing and tension.

[0058] The molding process is carried out using an autoclave. The molding parameters are: curing temperature 140℃, curing pressure 1.0MPa, curing time 2h, and the layup sequence is shown in the table below.

[0059] Table 1. Balanced Pipe Layup Sequence Table

[0060] 1 3K Plain 1 200 1 0.25 150.5 2 C±45 1 200 1 0.4 151.3 3 C0 1 200 8 1.6 154.5 4 C±45 1 200 1 0.4 155.3 5 C0 1 200 8 1.6 158.5 6 C±45 1 200 1 0.4 159.3

[0061] Specifically, the forming process of the base is as follows: the layering sequence of the bottom support is consistent with that of the round tube, one layer of 3K plain weave prepreg is laid on the outer surface, followed by one layer of ±45 unidirectional tape, eight layers of 0 unidirectional tape, one layer of ±45 unidirectional tape, eight layers of 0 unidirectional tape, and one layer of ±45 unidirectional tape.

[0062] From the inside out, carbon fiber plain weave prepreg layer, carbon fiber unidirectional prepreg layer, and carbon fiber plain weave prepreg layer are laid in sequence, with 11 layers of carbon fiber unidirectional prepreg layer laid.

[0063] In this molding process, the lining is laid using a compression blow molding process.

[0064] The specific process of compression molding is as follows: layer laying, placing air bag in mold, air bag leak detection, mold closing, air bag inflation, mold heating, mold pressurization, heat preservation and pressure holding, cooling, depressurization and shutdown, demolding and finishing.

[0065] Specifically, in this embodiment, T300 3K plain weave prepreg and T700 unidirectional tape prepreg are used, and epoxy resin is used as the resin. In the prepreg preparation stage, epoxy resin and carbon fiber are used in combination.

[0066] The base is laid out according to the layering design sequence. Each layer of material needs to be firmly attached, as shown in Table 2 below. The lower layer is laid with a layer of T300 3K plain weave prepreg, and then T700 unidirectional tape prepreg is laid layer by layer on top of the T300 3K plain weave prepreg. To facilitate the laying operation, the ±45° T700 unidirectional tape is laid together. The bottom mounting plate 3 is laid out according to the same layering information. After the layers are laid out, the surrounding area is cleaned with a cotton cloth dipped in release agent.

[0067] The molding process uses compression molding with blow molding. The curing temperature is 140℃, the curing pressure is 0.8MPa, and the curing time is 2 hours. Molding is performed after the layup is complete. The pressure, temperature, and time parameters are to ensure that the epoxy resin can flow under these conditions, uniformly filling all parts of the sample and reducing the formation of defects and voids. The layup sequence is shown in the table below.

[0068] Table 2. Base Layer Layup Sequence Table

[0069] 1 T300 3K prepreg 0.2 2 T700 unidirectional belt 0.2 3 T700 unidirectional belt 0.2 4 T700 unidirectional belt 0.2 5 T700 unidirectional belt 0.2 6 T700 unidirectional belt 0.2 7 T700 unidirectional belt 0.2 8 T700 unidirectional belt 0.2 9 T700 unidirectional belt 0.2 10 T700 unidirectional belt 0.2 11 T700 unidirectional belt 0.2 12 T700 unidirectional belt 0.2 13 T300 3K prepreg 0.2

[0070] Using this molding method, the antenna beam is made of carbon fiber composite material. The weight of the replaced antenna beam is 18.5 kg, which is more than 70% lighter than the original antenna beam structure, while overcoming the resonance problem.

[0071] 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 carbon fiber composite antenna beam for rail vehicles, characterized in that, The device includes a balance tube placed on a base; the base has a mounting plate at its bottom, a seat body fixedly mounted on the top of the mounting plate, and a balance tube fixing tube mounted on the top of the seat body, through which the balance tube passes; both the balance tube and the base are made of carbon fiber composite material laid layer by layer. The forming process of the balance tube is as follows: carbon fiber plain weave prepreg layer and carbon fiber unidirectional prepreg layer are laid sequentially from the inside out. The carbon fiber unidirectional prepreg layer is laid with the fiber direction as [±45° / 0° / ±45° / 0° / ±45°]. Among them, the carbon fiber unidirectional prepreg with the fiber direction of 0° is laid in 8 rounds, and the carbon fiber unidirectional prepreg and carbon fiber plain weave prepreg with other fiber directions are laid in 1 round each.

2. The carbon fiber composite antenna beam as described in claim 1, characterized in that, The balance tube is a circular tube structure, and the mounting plate has holes for the antenna to pass through.

3. The carbon fiber composite antenna beam as described in claim 1, characterized in that, The mounting plate has connection holes, and connectors are inserted into the connection holes to fix the mounting plate to the body structure of the rail vehicle.

4. The carbon fiber composite antenna beam as described in claim 1, characterized in that, The seat has inclined surfaces on both sides, and the cross-sectional area of ​​the seat increases from top to bottom.

5. The carbon fiber composite antenna beam as described in claim 1, characterized in that, An arc-shaped groove is provided on the top of the seat, and the balance tube fixing tube is placed in the arc-shaped groove.

6. The carbon fiber composite antenna beam as described in claim 1, characterized in that, The balance tube fixing tube, base, and mounting plate are an integrated structure.

7. The method for forming a carbon fiber composite antenna beam as described in any one of claims 1-6, characterized in that, Includes the following steps: The balance tube is formed using an autoclave molding process; The base is formed using a compression molding and blow molding process; Apply glue to the balance tube and the inside of the balance tube fixing tube. Insert the balance tube into the balance tube fixing tube and assemble it. The balance tube and the base are made into a whole by adhesive bonding.

8. The molding method as described in claim 7, characterized in that, The base is formed by laying carbon fiber plain weave prepreg layer, carbon fiber unidirectional prepreg layer, and carbon fiber plain weave prepreg layer in sequence from the inside out, with 11 layers of carbon fiber unidirectional prepreg layer laid.

9. The molding method as described in claim 7, characterized in that, During the molding process of the balance tube, it is laid using a hot autoclave molding process; during the molding process of the base, it is laid using a molding and blowing process.

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