Intelligent motor train unit head carbon fiber material molding construction method

Abstract

The invention discloses an intelligent motor train unit headstock carbon fiber material molding construction method. The method comprises the steps that S1, a headstock glass fiber reinforced plastic shutter is molded; s2, molding the head of the aluminum alloy vehicle body; s3, a vehicle head opening and closing mechanism is connected with a vehicle body; according to the carbon fiber material molding construction method, the two structures made of different materials of the vehicle head shutter mechanism and the aluminum alloy vehicle body area are perfectly combined into a whole, that is, the tight combination synchronous molding construction method is achieved, and the method can meet the requirements for molding construction of the vehicle head shutter mechanism and the vehicle body of multiple railway vehicle motor train units.

Description

Technical Field

[0001] The invention relates to the technical field of intelligent EMU car head molding construction, and in particular to a method for intelligent EMU car head carbon fiber material molding construction. Background Art

[0002] The streamlined body of the front of the railway vehicle EMU includes the front opening and closing mechanism, the body ridges, the arcs on both sides of the body, the streamlines on both sides of the body, and the connection area between the plane and the curved arc. When the front opening and closing mechanism is connected with the streamlines on both sides of the body and the body plane and the weld area is in transition, the weld conflicts with the pits, and there is a large height difference between the streamlined profiles on both sides of the body. In addition, the front opening and closing mechanism is made of fiberglass and needs to be effectively and tightly combined with the aluminum alloy body. However, the cross-section circumference of the front opening and closing mechanism and the front structure is long, the number of welds is concentrated, the heat input during welding is large, the temperature distribution is uneven, and the cooling and heat dissipation of thin and thick plates are uneven, which leads to the depression of larger profiles after welding (the intersection depression of the front opening and closing mechanism section and the body weld is large, and the maximum depression depth can reach 10mm), which forms a height difference with the body section, and there is a large gap between the arc frames on both sides of the body, and there is an obvious misalignment, height difference or connection between the front ridge line and the front opening and closing mechanism position ridge line. As a result, the putty applied cannot form a uniform coating surface, and the size cannot be guaranteed after painting is completed, which affects the overall streamline of the front of the car. After the topcoat is sprayed, the streamline flow field and shaping cannot be perfect and natural, and the overall visual sense cannot be met. The shaping size of the cross-section of the front opening and closing mechanism and the front structure cannot be guaranteed to be consistent, which affects the aerodynamic requirements of the rail passenger car during high-speed driving and reduces the product quality.

[0003] Therefore, the existing putty scraping construction method cannot well meet the high-precision quality requirements of the painting construction of the front shutter mechanism and the body connection area on the surface of the railway passenger car body.

[0004] Therefore, based on the above technical problems, technicians in this field urgently need to develop a method for shaping and constructing carbon fiber materials for the front of an intelligent EMU. Summary of the invention

[0005] The purpose of the present invention is to provide a method for shaping and constructing carbon fiber materials for the front of an intelligent EMU. The carbon fiber material forms a good medium so that the fiberglass structure of the front switch and the aluminum alloy body, two structures of two different materials, are perfectly combined into one. The two are subjected to mutual force and jointly bear the role of external loads. This shaping construction method can meet production needs and meet the technical problem of high-precision requirements for the curved contour of the surface of the rail passenger car body.

[0006] In order to achieve the above object, the present invention provides the following technical solutions:

[0007] A method for shaping and constructing a carbon fiber material for a head of an intelligent EMU of the present invention comprises the following steps:

[0008] S1. Molding of the fiberglass shutter of the front of the train, three-dimensional fixed-point measurement of the front cross section of the front of the train and recording of the measurement data, and manufacturing of the carbon fiber reinforcement layer of the front shutter according to the perimeter dimension of the cross section of the front shutter;

[0009] S2, shaping the front of the aluminum alloy body, measuring the three-dimensional fixed points of the cross-section of the front shutter and recording the measurement data, and making the front carbon fiber reinforcement layer according to the perimeter dimension of the front section;

[0010] S3. The connection between the front opening and closing mechanism and the body uses carbon fiber bonding technology to connect the fiberglass material of the front opening and closing mechanism with the aluminum alloy body.

[0011] Furthermore, the step S1 is specifically as follows:

[0012] Use 80# sandpaper machine to grind the area of ​​the front fiberglass shutter to be bonded with the carbon fiber cloth, use a soft scraper to scrape the carbon fiber adhesive along the circumference of the front fiberglass shutter with a width of 100mm, and reserve a carbon fiber cloth Z-shaped cross structure with an extension width of 100mm at the docking position between the front fiberglass shutter and the vehicle body.

[0013] Furthermore, the step S1 further includes:

[0014] The carbon fiber reinforcement layer of the front shutter is manufactured with reference to the ridgeline reference origin of the front.

[0015] Furthermore, the step S2 is specifically as follows:

[0016] Use 80# sandpaper machine to grind the area of ​​the front of the vehicle to be bonded with the carbon fiber cloth, use a soft scraper to scrape the carbon fiber adhesive along the circumference of the front of the vehicle with a width of 100mm, and reserve a carbon fiber cloth Z-shaped cross structure with an extension width of 100mm at the docking position between the front of the vehicle and the front fiberglass shutter.

[0017] Furthermore, the step S2 further includes:

[0018] The front carbon fiber reinforcement layer is manufactured with reference to the ridgeline reference origin of the front shutter.

[0019] Furthermore, the step S3 is specifically as follows:

[0020] The front shutter and the front of the vehicle after bonding the carbon fiber reinforcement layer are cross-bonded based on the reference points of three-dimensional fixed-point measurement, and a 20mm gap is reserved as a buffer area for cold and hot effects.

[0021] Furthermore, after the bonded carbon fiber cloth is dried, a thickness gauge is used to measure the thickness of the carbon fiber cloth.

[0022] Furthermore, the method further comprises the following steps:

[0023] Step S4: coating the carbon fiber cloth after bonding.

[0024] Furthermore, the step S4 mainly includes the following steps:

[0025] Step S401, coating polishing, first use a polishing machine to polish around the area where the carbon fiber cloth is bonded to the car body, and the polishing speed is uniform, and the machine and the car body are kept parallel;

[0026] Step S402: Check the coating with a level ruler, grind the high point area of ​​the bonded carbon fiber cloth to make it smooth, and measure the coating thickness with a thickness gauge after grinding, at 20 measurement points on each side, and keep measurement records;

[0027] Step S403, spray the polished carbon fiber cloth area with a mid-coat, and then fine-grind with No. 320 circular sandpaper after drying, and repeatedly spray and polish the mid-coat twice to make the sprayed topcoat smooth and flat.

[0028] In the above technical solution, the method for shaping and constructing the carbon fiber material of the head of an intelligent EMU provided by the present invention has the following beneficial effects:

[0029] The carbon fiber material molding construction method of the present invention realizes the perfect integration of two different material structures, namely the front opening and closing mechanism and the aluminum alloy body area, into one, that is, a method of closely combining synchronous molding construction. This method can be applied to the requirements of molding construction of the front opening and closing mechanism and the body of multiple rail vehicle EMUs.

[0030] The carbon fiber material shaping construction method of the present invention solves the problem that after the original two-material structure is painted, the front ridge line and the front opening and closing position ridge line are obviously misaligned and the front ridge shaping construction cannot be carried out. It can also effectively control the conflict between the body weld and the pit, and the large height difference defect between the shutter area and the front of the car, and solve the problem of poor flatness of the connection area between the shutter area and the front of the car and the plane and the curved arc.

[0031] The method of the present invention ensures product quality and ensures uniform shaping of the front body of a rail vehicle EMU, thereby better adapting to changes in the surface contours of the ridge lines and streamlined arched areas of the rail vehicle body, thereby making the coating round and smooth after painting; it improves production efficiency, eliminates the need for dimensional adjustment after coating construction, effectively guarantees the production cycle, reduces labor intensity, and simplifies the shaping of the entire EMU front body and makes it easy to operate. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. It is obvious that the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0033] Figure 1 A schematic diagram of a method for molding and constructing carbon fiber materials for the head of an intelligent EMU disclosed in an embodiment of the present invention Figure 1 ;

[0034] Figure 2 A schematic diagram of a method for molding and constructing carbon fiber materials for the head of an intelligent EMU disclosed in an embodiment of the present invention Figure 2 ;

[0035] Figure 3 A schematic flow chart of step S4 in the second set of processes of a method for shaping and constructing carbon fiber materials for the front of an intelligent EMU disclosed in an embodiment of the present invention;

[0036] Figure 4 A front view of a section of the front end of an aluminum alloy head of a method for molding and constructing carbon fiber materials for a head of an intelligent EMU disclosed in an embodiment of the present invention;

[0037] Figure 5 A top view of a front section of an aluminum alloy front end of a method for molding and constructing a carbon fiber material for a front end of an intelligent EMU disclosed in an embodiment of the present invention;

[0038] Figure 6 A front view of a section of a front switch of a method for shaping and constructing carbon fiber materials for a front of an intelligent EMU disclosed in an embodiment of the present invention;

[0039] Figure 7 A top view of a section of a front switch of a method for shaping and constructing carbon fiber materials for a front of an intelligent EMU disclosed in an embodiment of the present invention. DETAILED DESCRIPTION

[0040] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0041] See also Figures 1 to 7 As shown;

[0042] A method for shaping and constructing a carbon fiber material for a head of an intelligent EMU in this embodiment comprises the following steps:

[0043] S1. Molding of the fiberglass shutter of the front of the train, three-dimensional fixed-point measurement of the front cross section of the front of the train and recording of the measurement data, and manufacturing of the carbon fiber reinforcement layer of the front shutter according to the perimeter dimension of the cross section of the front shutter;

[0044] S2, shaping the front of the aluminum alloy body, measuring the three-dimensional fixed points of the cross-section of the front shutter and recording the measurement data, and making the front carbon fiber reinforcement layer according to the perimeter dimension of the front section;

[0045] S3. The connection between the front opening and closing mechanism and the body uses carbon fiber bonding technology to connect the fiberglass material of the front opening and closing mechanism with the aluminum alloy body.

[0046] Specifically, this embodiment discloses a method for shaping and constructing carbon fiber materials for the front of an intelligent EMU, which mainly includes the connection area between the fiberglass material of the front opener and shutter and the aluminum alloy body, wherein when the fiberglass material of the streamlined front opener and shutter of the EMU front is connected to the plane of the body and the weld area is in transition, the conflict between the height difference of the cross sections on both sides and the welds and the pits is controlled.

[0047] Preferably, step S1 of the shaping method of this embodiment is specifically as follows:

[0048] Use 80# sandpaper to grind the area of ​​the front fiberglass shutter to be bonded with the carbon fiber cloth, use a soft scraper to scrape the carbon fiber adhesive along the circumference of the front shutter with a width of 100mm, and reserve a carbon fiber cloth Z-shaped cross structure with an extension width of 100mm at the docking position between the front fiberglass shutter and the car body. If the depression is deep, in order to ensure the strength of the carbon fiber cloth, the carbon fiber adhesive should be scraped several times when filling the pit.

[0049] In this embodiment, step S1 further includes:

[0050] The carbon fiber reinforcement layer of the front shutter is manufactured with reference to the ridgeline reference origin of the front.

[0051] Step S1 of this embodiment is to shape the fiberglass shutter of the front of the vehicle. Figure 4 and Figure 5 As shown, the three-dimensional fixed point measurement and value recording are performed through the cross section of the front end of the vehicle, see Figure 6 and Figure 7 As shown, a carbon fiber cloth Z-shaped reinforcement layer is made of carbon fiber material according to the circumference dimension of the section of the shutter. The carbon fiber cloth Z-shaped reinforcement layer refers to the ridgeline reference origin of the front of the vehicle, and the two are tightly fitted and bonded according to the shape of the shutter.

[0052] Preferably, step S2 of this embodiment is specifically as follows:

[0053] Use 80# sandpaper machine to polish the area of ​​the front of the car to be bonded with carbon fiber cloth, use a soft scraper to scrape carbon fiber adhesive along the perimeter of the front of the car with a width of 100mm, and reserve a carbon fiber cloth Z-shaped cross structure with an extension width of 100mm at the docking position between the front of the car and the front fiberglass shutter. If the depression is deep, in order to ensure the strength of the carbon fiber, the carbon fiber adhesive should be scraped several times when filling the pit.

[0054] In this embodiment, step S2 further includes:

[0055] The carbon fiber reinforcement layer of the front of the vehicle is manufactured with reference to the ridgeline reference origin of the front shutter.

[0056] Step S2 of this embodiment is to shape the front of the aluminum alloy vehicle body. Figure 6 and Figure 7 As shown, the three-dimensional fixed point measurement and value recording are performed through the cross section of the front end of the shutter, see Figure 4 and Figure 5 As shown, a carbon fiber cloth Z-shaped reinforcement layer is made of carbon fiber material according to the circumference dimension of the front section. The carbon fiber cloth Z-shaped reinforcement layer is tightly combined with reference to the ridgeline reference origin of the shutter, and is bonded according to the shape of the aluminum alloy front.

[0057] Preferably, step S3 of this embodiment is specifically as follows:

[0058] The front shutter and the front of the car are cross-bonded with the carbon fiber reinforcement layer based on the reference points of three-dimensional fixed-point measurement, and a 20mm gap is reserved as a buffer area for cold and hot effects. The ultimate goal is to perfectly connect the fiberglass material of the front shutter and the aluminum alloy body through carbon fiber bonding technology.

[0059] Secondly, when the carbon fiber cloth is bonded between the shutter and the front of the train, the Z-shaped reinforcement layer of the carbon fiber cloth between the shutter and the front of the train must be compacted to avoid wind resistance when the train is running at high speed later.

[0060] The method for shaping the carbon fiber material of the front of an intelligent EMU in the present embodiment can solve the problem of the perfect integration of the fiberglass material mechanism of the front shutter and the aluminum alloy body into one structure of two different materials. It is closely combined with the method of synchronous shaping construction to solve the problem of obvious misalignment between the front edge line and the front shutter edge line, which makes it impossible to carry out front shaping construction, and can effectively control the transition between the front edge line and the curved surface area, the conflict between the weld and the pit, the large height difference between the front shutter mechanism and the aluminum alloy body profile, and solve the problem of poor flatness of the arc of the front shutter mechanism and the area connecting the body plane and the curved surface arc; ensure that the two structures of different materials are smooth. The carbon fiber material is used as the medium for close integration to ensure the quality of rail vehicle products and the uniform shaping of the head of the rail vehicle EMU after overall painting, so as to better adapt to the changes in the surface contours of the ridges and streamlined arch areas of the rail passenger car body, and then make the topcoat coating round and smooth after spraying. Moreover, the method of shaping and constructing using carbon fiber materials can completely replace the original putty scraping method, improve production efficiency, eliminate the need for dimensional adjustment after coating construction, and effectively ensure the production cycle. An important point is that it reduces the harm to the operator during putty scraping and reduces labor intensity. The method of shaping and constructing using carbon fiber materials simplifies the shaping of the entire EMU head and makes it easy to operate.

[0061] Preferably, after the bonded carbon fiber cloth of this embodiment is dried, a thickness gauge is used to measure the thickness of the carbon fiber cloth.

[0062] As an extended implementation method, the method of this embodiment further includes the following steps:

[0063] Step S4: coating the carbon fiber cloth after bonding.

[0064] Preferably, step S4 mainly includes the following steps:

[0065] Step S401, coating polishing, first use a polishing machine to polish around the area where the carbon fiber cloth is bonded to the car body, and the polishing speed is uniform, and the machine and the car body are kept parallel;

[0066] Step S402: Check the coating with a level ruler, grind the high point area of ​​the bonded carbon fiber cloth to make it smooth, and measure the coating thickness with a thickness gauge after grinding, at 20 measurement points on each side, and keep measurement records;

[0067] Step S403, spray the polished carbon fiber cloth area with a mid-coat, and then fine-grind with No. 320 circular sandpaper after drying, and repeatedly spray and polish the mid-coat twice to make the sprayed topcoat smooth and flat.

[0068] In the above technical solution, the method for shaping and constructing the carbon fiber material of the head of an intelligent EMU provided by the present invention has the following beneficial effects:

[0069] The carbon fiber material molding construction method of the present invention realizes the perfect integration of two different material structures, namely the front opening and closing mechanism and the aluminum alloy body area, into one, that is, a method of closely combining synchronous molding construction. This method can be applied to the requirements of molding construction of the front opening and closing mechanism and the body of multiple rail vehicle EMUs.

[0070] The carbon fiber material shaping construction method of the present invention solves the problem that after the original two-material structure is painted, the front ridge line and the front opening and closing position ridge line are obviously misaligned and the front ridge shaping construction cannot be carried out. It can also effectively control the conflict between the body weld and the pit, and the large height difference defect between the shutter area and the front of the car, and solve the problem of poor flatness of the connection area between the shutter area and the front of the car and the plane and the curved arc.

[0071] The method of the present invention ensures product quality and ensures uniform shaping of the front body of a rail vehicle EMU, thereby better adapting to changes in the surface contours of the ridge lines and streamlined arched areas of the rail vehicle body, thereby making the coating round and smooth after painting; it improves production efficiency, eliminates the need for dimensional adjustment after coating construction, effectively guarantees the production cycle, reduces labor intensity, and simplifies the shaping of the entire EMU front body and makes it easy to operate.

[0072] The method of shaping the area of ​​the connection between the switch and the front of the EMU rail vehicle of the present invention fills the gap in the synchronous shaping process technology of the two-material structure of the streamlined body of the new domestic EMU, and can be widely used in products such as the "Fuxing" high-speed EMU related projects, intelligent high-speed EMU projects, and 400-kilometer EMU projects. The benefits that can be obtained by the present invention include economic benefits, reduced recovery benefits of defective products, and reduced man-hour savings: from the perspective of economic benefits, a large amount of material and labor costs are saved, specifically: the total amount of material used is reduced by 10%-15%, and the manpower reduces the construction operation time and the later repair construction time by 20%-40%. At the same time, the product quality is improved. After spraying the topcoat, it is glossy, flat, and defect-free, and the glossiness is greater than 80%.

[0073] Economic benefits obtained = (original price of a single product - current price of a single product) × monthly sales volume × 12 months = (10-8.5) × 100 × 12 = 18 million / year; The recovery benefits from reducing defective products = (monthly number of defective products before improvement - monthly number of defective products after improvement) × unit price of each product × 12 months = (15-5) × 5.5 × 12 = 6.6 million / year; The benefits saved from reducing working hours = monthly saved working hours × hourly wages × 12 months = (20X280) × 50 × 12 = 3.36 million / year.

[0074] The above description is only by way of illustration of certain exemplary embodiments of the present invention. It is undoubted that those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A method for shaping and constructing carbon fiber materials for the head of an intelligent EMU, characterized in that: The method comprises the following steps: S1. Molding of the fiberglass shutter of the front of the train, three-dimensional fixed-point measurement of the front cross section of the front of the train and recording of the measurement data, and manufacturing of the carbon fiber reinforcement layer of the front shutter according to the perimeter dimension of the cross section of the front shutter; S2, shaping the front of the aluminum alloy body, measuring the three-dimensional fixed points of the cross-section of the front shutter and recording the measurement data, and making the front carbon fiber reinforcement layer according to the perimeter dimension of the front section; S3. The connection between the front opening and closing mechanism and the body uses carbon fiber bonding technology to connect the fiberglass material of the front opening and closing mechanism with the aluminum alloy body.

2. The method for shaping and constructing carbon fiber materials for the head of an intelligent EMU according to claim 1, characterized in that: The step S1 is specifically as follows: Use 80# sandpaper machine to grind the area of ​​the front fiberglass shutter to be bonded with the carbon fiber cloth, use a soft scraper to scrape the carbon fiber adhesive along the circumference of the front fiberglass shutter with a width of 100mm, and reserve a carbon fiber cloth Z-shaped cross structure with an extension width of 100mm at the docking position between the front fiberglass shutter and the vehicle body.

3. The method for shaping and constructing carbon fiber materials for the head of an intelligent EMU according to claim 2, characterized in that: The step S1 further comprises: The carbon fiber reinforcement layer of the front shutter is manufactured with reference to the ridgeline reference origin of the front.

4. The method for shaping and constructing carbon fiber materials for the head of an intelligent EMU according to claim 1, characterized in that: The step S2 is specifically as follows: Use 80# sandpaper machine to grind the area of ​​the front of the vehicle to be bonded with the carbon fiber cloth, use a soft scraper to scrape the carbon fiber adhesive along the circumference of the front of the vehicle with a width of 100mm, and reserve a carbon fiber cloth Z-shaped cross structure with an extension width of 100mm at the docking position between the front of the vehicle and the front fiberglass shutter.

5. The method for shaping and constructing carbon fiber materials for the head of an intelligent EMU according to claim 4, characterized in that: The step S2 further comprises: The front carbon fiber reinforcement layer is manufactured with reference to the ridgeline reference origin of the front shutter.

6. The method for shaping and constructing carbon fiber materials for the front of an intelligent motor vehicle according to claim 1, characterized in that: The step S3 is specifically as follows: The front shutter and the front of the vehicle after bonding the carbon fiber reinforcement layer are cross-bonded based on the reference points of three-dimensional fixed-point measurement, and a 20mm gap is reserved as a buffer area for cold and hot effects.

7. The method for shaping and constructing carbon fiber materials for the front of an intelligent motor vehicle according to claim 1, characterized in that: After the bonded carbon fiber cloth is dried, a thickness gauge is used to measure the thickness of the carbon fiber cloth.

8. The method for shaping and constructing carbon fiber materials for the front of an intelligent motor vehicle according to claim 7, characterized in that: The method further comprises the following steps: Step S4: coating the carbon fiber cloth after bonding.

9. The method for shaping and constructing carbon fiber materials for the front of an intelligent motor vehicle according to claim 8, characterized in that: The step S4 mainly includes the following steps: Step S401, coating polishing, first use a polishing machine to polish around the area where the carbon fiber cloth is bonded to the car body, and the polishing speed is uniform, and the machine and the car body are kept parallel; Step S402: Check the coating with a level ruler, grind the high point area of ​​the bonded carbon fiber cloth to make it smooth, and measure the coating thickness with a thickness gauge after grinding, at 20 measurement points on each side, and keep measurement records; Step S403, spray the polished carbon fiber cloth area with a mid-coat, and then fine-grind with No. 320 circular sandpaper after drying, and repeatedly spray and polish the mid-coat twice to make the sprayed topcoat smooth and flat.

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