High-load-bearing lightweight mounting structure

Abstract

The application provides a high-load light-weight mounting structure, which is a box-shaped structure composed of two side plates, a supporting plate, a bottom plate, a front connecting plate and a rear connecting plate, wherein the two side plates are arranged in parallel and spaced apart on the left and right sides, the left and right sides of the supporting plate and the front connecting plate are fixedly connected with the front sides of the two side plates, the supporting plate is located below the front side of the front connecting plate, the left and right sides of the bottom plate are fixedly connected with the bottoms of the two side plates, the bottom of the front connecting plate is connected with the bottom plate, and the left and right sides of the rear connecting plate are fixedly connected with the rear sides of the two side plates; a mounting bracket of a silencer is fixedly connected with the supporting plate, the rear bottom of the two side plates is fixedly connected with a suspension beam on a side wall of a locomotive, and the top of the two side plates is fixedly connected with the side wall. The light-weight structure is used to replace the original thick plate full-welding structure, the influence of long and large welds on the structure is eliminated, and large welding deformation caused by welding stress at the welding position of the original mounting seat is avoided.

Description

Technical Field

[0001] This invention relates to the field of railway locomotive technology, and more particularly to a lightweight mounting structure with high load-bearing capacity. Background Technology

[0002] The power of a diesel locomotive comes from a diesel engine, and the muffler's main function is to eliminate the vibration and noise generated by the diesel engine during operation. The muffler is installed above the diesel engine and connects to the pre-installed exhaust port to achieve its vibration reduction and noise reduction function. A diesel locomotive muffler weighs approximately 1.5 tons. The muffler's mounting base is welded to the suspension beam on the locomotive's side wall, and the muffler is bolted to the mounting base via its mounting bracket. The load borne by the muffler mounting base includes not only the weight of the muffler and its mounting bracket but also significant vibration and fatigue loads. Therefore, the muffler mounting base is primarily constructed of thick steel plates and welded to the locomotive's side wall via long weld seams.

[0003] There is a type of muffler mounting base welded to the side wall of a locomotive, such as Figure 1 As shown, three fillet welds with a weld height of 6mm are used to weld the side of the cantilever beam on the side wall. The thickness of each welded part of the muffler mounting base is 6-8mm, and all welded parts are fully welded together.

[0004] The existing muffler mounting base has the following defects:

[0005] 1. To meet the requirements of high load-bearing capacity, fatigue resistance, and vibration resistance, the muffler mounting base is fully welded. Furthermore, the welding between the muffler mounting base and the cantilever beam on the side wall uses a large weld leg and a full weld seam. This long weld seam can cause significant deformation of both the muffler itself and the cantilever beam on the side wall.

[0006] 2. The muffler mounting base is made of thick plate, which is heavy. The structural design does not fully consider how to distribute the alternating stress borne by the muffler mounting base.

[0007] 3. The structure of the muffler mounting base only has the function of vertical adjustment, which cannot meet the needs of on-site muffler installation, which requires both a diesel engine mounting interface and a side wall cantilever beam mounting interface. Summary of the Invention

[0008] To address the aforementioned technical problems, a high-load-bearing, lightweight installation structure is provided. This invention replaces the original thick-plate, fully welded structure with a lightweight structure, eliminating the impact of long welds on the structure and avoiding significant welding deformation caused by welding stress at the weld points of the original mounting base. The thin-plate welded installation structure effectively disperses the high stress brought by high loads, and the load transmission path is clear and smooth. This structure also allows for flexible installation of large-mass equipment; the installed equipment can be adjusted in three directions, avoiding rework caused by mismatched installation interfaces on-site, thereby improving production efficiency.

[0009] The technical means employed in this invention are as follows:

[0010] A high-load-bearing, lightweight installation structure is a box-shaped structure composed of two side plates, a support plate, a bottom plate, a front connecting plate, and a rear connecting plate. The two side plates are arranged parallel and spaced apart on the left and right sides. The left and right sides of the support plate and the front connecting plate are fixedly connected to the front sides of the two side plates. The support plate is located below the front side of the front connecting plate. The left and right sides of the bottom plate are fixedly connected to the bottom of the two side plates. The bottom of the front connecting plate is connected to the bottom plate. The left and right sides of the rear connecting plate are fixedly connected to the rear sides of the two side plates. The muffler mounting bracket is fixedly connected to the support plate. The bottom rear sides of the two side plates are fixedly connected to the suspension beam on the locomotive side wall. The tops of the two side plates are fixedly connected to the side wall.

[0011] Furthermore, the left and right sides of the tray, base plate, front connecting plate and rear connecting plate are welded to two side plates, and the bottom of the front connecting plate is welded to the base plate.

[0012] Furthermore, the support plate is fixedly connected to the mounting bracket of the muffler by bolts, the rear bottom of the two side plates is welded to the cantilever beam on the side wall of the locomotive, and the top of the two side plates is welded to the side wall.

[0013] Furthermore, the side plate, support plate, bottom plate, front connecting plate, and rear connecting plate are all hollow structures.

[0014] Furthermore, the side plate is provided with through holes and multiple weight-reducing holes.

[0015] Furthermore, the two side plates have the same structure and are arranged symmetrically; the front edge of the side plate is V-shaped, and the lower rear side of the side plate has an inverted L-shaped opening, which is connected to the suspension beam on the locomotive side wall.

[0016] Furthermore, the support plate is provided with multiple rows of elongated waist holes and a weight-reducing hole in the middle. The weight-reducing hole is arranged between the multiple rows of elongated waist holes, and the multiple rows of waist holes are arranged in parallel and spaced apart. The mounting bracket of the muffler is connected to one of the rows of waist holes by bolts or bolts and adjusting shims.

[0017] Furthermore, the upper surface of the tray has a V-shaped angle with the front of the front connecting plate, and both the tray and the front connecting plate are provided with multiple weight-reducing holes. The top of the front connecting plate has a V-shaped bending structure.

[0018] Furthermore, the rear connecting plate has an arc-shaped structure and is provided with multiple weight-reducing holes.

[0019] Furthermore, the side plate, support plate, bottom plate, front connecting plate, and rear connecting plate are all made of steel plate, the thickness of the support plate is 12-16mm, and the thickness of the side plate, bottom plate, front connecting plate, and rear connecting plate is 4-6mm.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] 1. The muffler mounting base of this invention has an exquisite appearance, with most of the weld seams hidden inside the mounting base; it adopts a hollow box-shaped frame structure (lightweight box-shaped structure) to replace the original thick plate fully welded structure, eliminating the impact of long weld seams on the structure and avoiding internal and external welding deformation of the muffler mounting base; it effectively disperses the high stress brought by high loads, and the remaining area after hollowing out makes the load transmission path clear and smooth.

[0022] 2. The structure of this invention takes into account the flexible installation of large-mass equipment. The installed equipment has a greater range of adjustment in the horizontal, vertical and other three directions, avoiding rework caused by mismatched installation interfaces on site, thereby improving production efficiency.

[0023] Based on the above reasons, this invention can be widely promoted in fields such as locomotives. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of an existing muffler mount and its application.

[0026] Figure 2 This is an isometric view of the muffler mounting base of the present invention.

[0027] Figure 3 This is a cross-sectional view of the muffler mounting base of the present invention.

[0028] Figure 4 This is a schematic diagram showing the connection between the muffler mounting base and the side wall of the present invention.

[0029] Figure 5 This is a schematic diagram of the muffler of the present invention installed on a muffler mounting base on a side wall (the other side wall is not shown).

[0030] Figure 6 This is a schematic diagram of the side plate of the present invention.

[0031] Figure 7 This is a schematic diagram of the structure of the tray of the present invention.

[0032] Figure 8 This is a schematic diagram of the structure of the base plate of the present invention.

[0033] Figure 9 This is a schematic diagram of the front connecting plate of the present invention.

[0034] Figure 10 This is a schematic diagram of the structure of the rear connecting plate of the present invention.

[0035] In the diagram: 1. Side plate; 2. Support plate; 3. Base plate; 4. Front connecting plate; 5. Rear connecting plate. Detailed Implementation

[0036] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0037] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] 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, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. 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.

[0039] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0040] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0041] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figures. For example, if the device in the figures is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0042] This invention provides a high-load-bearing, lightweight installation structure. It replaces the original thick-plate, fully welded structure with a lightweight box-shaped structure, eliminating the impact of long welds on the structure and avoiding significant welding deformation caused by welding stress at the original mounting base. The thin-plate welded box-shaped structure effectively disperses the high stress brought by high loads, and the load transmission path is clear and smooth. This structure also allows for flexible installation of large-mass equipment, with the installed equipment having three-way adjustment capabilities, allowing the installation position to be adjusted from three directions. This avoids rework caused by mismatched installation interfaces on-site, thereby improving production efficiency.

[0043] like Figure 2 , Figure 3 As shown, the muffler mounting bracket consists of two side plates 1 ( Figure 6 ), pallet 2 ( Figure 7 ), base plate 3 ( Figure 8 ), front connecting plate 4 ( Figure 9 ), rear connecting plate 5 ( Figure 10 The components form a box-shaped structure. Two side plates 1 are arranged parallel to each other on the left and right sides. The left and right sides of the support plate 2 and the front connecting plate 4 are fixedly connected to the front sides of the two side plates 1. The support plate 2 is located below the front side of the front connecting plate 4. The left and right sides of the bottom plate 3 are fixedly connected to the bottom of the two side plates 1. The left and right sides of the rear connecting plate 5 are fixedly connected to the rear sides of the two side plates 1. The muffler mounting bracket is fixedly connected to the support plate 2. The bottom rear sides of the two side plates 1 are fixedly connected to the suspension beam on the locomotive side wall. The top of the two side plates 1 is fixedly connected to the side wall. Specifically, the left and right sides of the support plate 2, the bottom plate 3, the front connecting plate 4, and the rear connecting plate 5 are all welded to the two side plates 1. The bottom of the front connecting plate 4 is welded to the bottom plate 3. The support plate 2 is fixedly connected to the muffler mounting bracket by bolts. The bottom rear sides of the two side plates 1 are welded to the suspension beam on the locomotive side wall. The top of the two side plates 1 is welded to the side wall. The rear end of the support plate 2 is not connected to the front end of the front connecting plate 4, and there is a gap between the upper part of the front connecting plate 4 and the rear connecting plate 5. Similarly, there is a gap between the lower part of the bottom plate 3 and the rear connecting plate 5. In this box-shaped structure, except for the support plate 2 which is made of 12mm thick steel plate, all other components are made of 5mm thick steel plate. The side plates 1, support plate 2, bottom plate 3, front connecting plate 4, and rear connecting plate 5 are all perforated structures.

[0044] Figure 2 , Figure 3 The muffler mounting base shown is an irregularly shaped, hollowed-out box structure welded from the aforementioned five types of plates. Finite element analysis shows that the hollowed-out areas are weight-bearing areas, while the non-weight-bearing areas are load-bearing areas. The load transmitted from the muffler to the muffler mounting base support plate 2 is as follows: Figure 6 As shown, the load-bearing area of ​​the two identical side plates 1 is distributed to the load-bearing areas of the base plate 3 and the front connecting plate 4, and then as... Figure 4The load is then redistributed to the rear connecting plate 5 and the side wall.

[0045] Larger loads are distributed to the side walls through the perforated box structure. Each plate and weld of the perforated box, as well as the weld connecting the perforated box to the side walls, only bears less than 40% of its load-bearing capacity. This successfully avoids the use of thick steel plates and long welds, achieving lightweight design and showcasing the charm of optimized structural design.

[0046] like Figure 6 As shown, the through hole at point b of side plate 1 is a weight-reduction hole and also a process hole, which can be used for the installation of a limiting fixture (existing fixture) during assembly welding. The shape, size, and direction of the weight-reduction areas at points c, d, and e of side plate 1 (weight-reduction holes are set at points c, d, and e) are all reduced in weight based on the finite element calculation results of the muffler mounting base. After secondary finite element calculation, the weight-reduction results meet the application requirements, and the load can be distributed and transmitted to other related plates through the non-weight-reduction areas. The two side plates 1 have the same structure and are arranged symmetrically. In this embodiment, the front edge of side plate 1 can be a V-shaped edge with an included angle greater than 90°, which can be a first edge below the front side and a second edge above the rear side that are bent and connected. The left and right sides of the support plate 2 are welded to the inner side of the two side plates 1 near the first edge, and the left and right sides of the front connecting plate 4 are welded to the inner side of the two side plates 1 near the second edge. The bottom of the front connecting plate 4 extends downward to be welded to the upper surface of the base plate 3. The lower rear side of side plate 1 has an inverted L-shaped opening, which is welded to the suspension beam on the locomotive side wall.

[0047] like Figure 7 As shown, the support plate 2 has three rows of elongated slotted holes and one weight-reducing hole. The three rows of slotted holes are arranged in parallel and at equal intervals, or they can form two parallel rows of slotted holes. The weight-reducing hole is located in the middle of the two rows of slotted holes. The three rows of slotted holes and the weight-reducing hole are located in the middle of the support plate 2. The length direction of the slotted holes is used for longitudinal installation adjustment (the bolts can be moved longitudinally within the slotted holes), and the three rows of slotted holes are used for lateral installation adjustment (the silencer can be connected to the two slots in one row on both sides of each mounting bracket with two bolts, depending on the installation requirements). Vertical installation adjustment is achieved by adding adjusting shims to the upper surface of the support plate 2. The upper surface of the support plate 2 and the front of the front connecting plate 4 can form a V-shaped angle greater than 90°.

[0048] like Figure 8 As shown, the base plate 3 has two weight-reduction holes. These two weight-reduction holes can be oblong holes and arranged vertically.

[0049] like Figure 9 As shown, the front connecting plate 4 has two weight-reducing holes. These two weight-reducing holes are arranged in parallel and spaced apart, and they can be oblong holes. The top of the front connecting plate 4 has a V-shaped bend structure with an angle greater than 90°.

[0050] like Figure 10 As shown, the rear connecting plate 5 has six weight-reducing holes arranged in parallel at intervals. The rear connecting plate 5 can have an arc-shaped structure.

[0051] like Figure 3 As shown, the support plate 2, base plate 3, and front connecting plate 4 form a triangular structure, which improves the stability of the muffler mounting base. The front connecting plate 4 extends further and connects to the side wall beam, and the base plate 3 extends further and connects to the cantilever beam on the side wall. Combined with the two side plates 1, the load borne by the support plate 2 is distributed by this structure and evenly transferred to the side wall. In this invention, each plate and each weld is evenly loaded. While avoiding the use of thick plates, weight-reducing holes are opened for lightweight design, retaining the load-bearing material and avoiding the use of long welds, ensuring the high load-bearing capacity of the entire structure.

[0052] like Figure 2 As shown, the two side plates 1 and the support plate 2 are first placed on the limiting fixture for welding. Then, the bottom plate 3, the front connecting plate 4 and the already welded structure are welded together. All the above welds are inside the box body. Finally, the connecting plate 5 is sealed after welding, and the weld is placed on the outside of the box structure at point a.

[0053] Install limiting fixtures on the process holes at point b on both side plates 1 to keep the side plates 1 and the support plate 2 parallel after welding, and make the outer contours of the side plates 1 basically overlap after welding. This can control the outer dimensions of the hollow box shape and ensure its balance when transmitting load.

[0054] By welding in the above order, the weld seams can be arranged inside the hollow box shape, making it look beautiful.

[0055] Applications of muffler mounting brackets on locomotives, such as Figure 5 The four muffler mounting brackets, arranged in a rectangle with two horizontally and two vertically, together support the muffler.

[0056] The protected points of this invention are: 1) a technical solution that utilizes a hollow box-shaped structure to achieve lightweighting, distribute large loads, and reduce welding deformation. 2) a technical solution where the weight-reducing holes and process holes are shared in side plate 1. 3) a technical solution for a support plate that can be adjusted in three directions to install equipment. 4) the process sequence for assembling and welding the hollow box-shaped frame structure.

[0057] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A lightweight installation structure with high load-bearing capacity, characterized in that, The structure is a box-shaped structure consisting of two side plates (1), a support plate (2), a bottom plate (3), a front connecting plate (4), and a rear connecting plate (5). The two side plates (1) are arranged parallel to each other on the left and right sides. The left and right sides of the support plate (2) and the front connecting plate (4) are fixedly connected to the front sides of the two side plates (1). The support plate (2) is located below the front side of the front connecting plate (4). The left and right sides of the bottom plate (3) are fixedly connected to the bottom of the two side plates (1). The bottom of the front connecting plate (4) is connected to the bottom plate (3). The left and right sides of the rear connecting plate (5) are fixedly connected to the rear sides of the two side plates (1); the mounting bracket of the muffler is fixedly connected to the support plate (2); the bottom of the rear side of the two side plates (1) is fixedly connected to the suspension beam on the side wall of the locomotive; the top of the two side plates (1) is fixedly connected to the side wall; the rear end of the support plate (2) has a gap with the front end of the front connecting plate (4) and is not connected; the upper part of the front connecting plate (4) and the rear connecting plate (5) has an opening and is not connected; the bottom plate (3) and the lower part of the rear connecting plate (5) have an opening and are not connected. The side plate (1), support plate (2), bottom plate (3), front connecting plate (4) and rear connecting plate (5) are all hollow structures; The two side plates (1) have the same structure and are arranged symmetrically; the front side of the side plate (1) is V-shaped, and the lower rear side of the side plate (1) has an inverted L-shaped opening, which is connected to the suspension beam on the side wall of the locomotive. The upper surface of the tray (2) and the front of the front connecting plate (4) have a V-shaped angle. Both the tray (2) and the front connecting plate (4) are provided with multiple weight-reducing holes. The top of the front connecting plate (4) has a V-shaped bending structure.

2. The high load-bearing lightweight installation structure according to claim 1, characterized in that, The left and right sides of the pallet (2), the bottom plate (3), the front connecting plate (4) and the rear connecting plate (5) are welded to the two side plates (1), and the bottom of the front connecting plate (4) is welded to the bottom plate (3).

3. The high load-bearing lightweight installation structure according to claim 1, characterized in that, The support plate (2) is fixedly connected to the mounting bracket of the muffler by bolts. The bottom rear side of the two side plates (1) is welded to the suspension beam on the side wall of the locomotive, and the top of the two side plates (1) is welded to the side wall.

4. The high load-bearing lightweight installation structure according to claim 1, characterized in that, The side plate (1) is provided with through holes and multiple weight-reducing holes.

5. The high load-bearing lightweight installation structure according to claim 1, characterized in that, The tray (2) is provided with multiple rows of elongated waist holes and a weight-reducing hole in the middle. The weight-reducing hole is arranged between the multiple rows of elongated waist holes. The multiple rows of waist holes are arranged in parallel and spaced apart. The mounting bracket of the muffler is connected to one of the rows of waist holes by bolts or bolts and adjusting pads.

6. The high load-bearing lightweight installation structure according to claim 1, characterized in that, The rear connecting plate (5) has an arc-shaped structure and multiple weight-reducing holes are provided on the rear connecting plate (5).

7. The high load-bearing lightweight installation structure according to claim 1, characterized in that, The side plate (1), support plate (2), bottom plate (3), front connecting plate (4) and rear connecting plate (5) are all made of steel plate. The thickness of the support plate (2) is 12~16mm, and the thickness of the side plate (1), bottom plate (3), front connecting plate (4) and rear connecting plate (5) is 4~6mm.

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