Preparation method of high-performance electromagnetic shielding aluminum honeycomb square cabin

Abstract

The invention relates to a preparation method of a high-performance electromagnetic shielding aluminum honeycomb square cabin, and belongs to the technical field of communication square cabins, and the preparation method comprises the following steps: S100, cabin body assembly welding: six cabin plates of a cabin body are respectively subjected to assembly welding, after assembly welding is completed, the six cabin plates are firstly subjected to spot welding fixation and then are subjected to overall assembly welding to form the cabin body, and the cabin plates are aluminum honeycomb plates; s200, a cabin door is assembled and welded, specifically, a door plate and a door stand column are subjected to tailor welding to form the cabin door, and the cabin door and a cabin body are assembled; s300, accessories are welded in the cabin body; s400, a heat preservation layer and an inner decoration plate are laid in the cabin body; and S500, finishing coat coating, acceptance check and delivery are carried out. The problems that a traditional shelter is large in weight, small in load ratio, poor in shielding performance, high in cost and the like, and the adhesive layer is aged and cannot be recycled when scrapped can be solved.

Description

Technical Field

[0001] The invention belongs to the technical field of communication shelters, and in particular relates to a method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter. Background Art

[0002] Electromagnetic shielding shelters are usually used in the military, aerospace and scientific research fields to protect important equipment from electromagnetic interference. At present, domestic shelters are divided into skeleton-type shelters, large-plate shelters, and carbon fiber and aramid fiber shelters according to their structures. Specifically, skeleton-type shelters use steel or aluminum alloy as the skeleton, install skin panels, and then coat polyurethane foam. This type of shelter has a large weight, a small load-to-weight ratio, and poor shielding performance, and has been basically eliminated. Large-plate shelters use the entire outer skin and inner skin to first make a whole composite board, and then connect the six composite boards and the inner and outer edges together by bonding or riveting. Due to the high requirements for foaming technology, this structure often has bulging, secondary foaming, aging of the glue layer, rivet shedding, skin delamination, etc. during product use, and there are problems such as leaking, reduced bearing strength, and scrapping and inability to be recycled. Carbon fiber and aramid fiber shelters have high material costs, complex and difficult production processes, and poor versatility. The cost of handling the scrapped cabin is high, so it is difficult to promote their use. With the emergence of microwave weapons and the improvement of electromagnetic interference technology, there are more and more command and control units in the shelters, and the carrying requirements of the shelters are getting higher and higher. Traditional shelters can no longer meet the requirements of modern development. Summary of the invention

[0003] In view of the various shortcomings of the existing technology, a method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter is proposed to solve the problems of traditional shelters such as heavy weight, small load-to-weight ratio, poor shielding performance, aging of the adhesive layer, inability to be recycled after being scrapped, and high cost.

[0004] To achieve the above object, the present invention provides the following technical solutions: A method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter comprises the following steps: S100, cabin body welding: The six cabin panels of the cabin body are welded separately. After the welding is completed, the six cabin panels are first spot welded and fixed and then welded as a whole to form the cabin body. The cabin panels are aluminum honeycomb panels. S200, hatch door assembly welding: weld the door panels and door columns to form the hatch, and assemble the hatch and the cabin; S300, welding accessories inside the cabin; S400, laying insulation layer and interior panels inside the cabin; S500, apply topcoat, acceptance, delivery.

[0005] The technical solution is further configured as follows: the cabin plate is welded into a flat plate structure using aluminum honeycomb panels, side beam profiles are welded around the flat plate structure, and corner pieces are welded at the corners of the flat plate structure.

[0006] The technical solution is further configured that, in step S100, the cabin plate includes a cabin bottom plate, a cabin side plate and a cabin top plate, and the cabin assembly welding includes the following steps: S101, welding the cabin bottom plate; S102, welding the cabin side panels, and after welding, spot welding the cabin side panels and the cabin bottom panel; S103, welding the cabin top plate, and after welding, fix the cabin top plate and cabin side plates by spot welding; S104, integrally welding the cabin bottom plate, cabin side plate and cabin top plate.

[0007] The technical solution is further configured such that the cabin bottom plate and the cabin side plate are respectively welded to a right-angle side beam profile, a first connecting edge and a second connecting edge extend from the right-angle side beam profile, a right angle is formed between the first connecting edge and the second connecting edge, a first groove is provided on the right-angle side beam profile, the inner wall and the outer wall of the cabin side plate are respectively welded to the first connecting edge and the first groove, and the outer wall of the cabin bottom plate is welded to the second connecting edge.

[0008] The technical solution is further configured as follows: the cabin top plate and the cabin side plate are respectively welded to the rounded edge beam profile, a third connecting edge and a fourth connecting edge are extended from the rounded edge beam profile, a rounded corner is formed between the third connecting edge and the fourth connecting edge, a third bevel and a fourth bevel are opened on the rounded edge beam profile, the inner wall and the outer wall of the cabin top plate are respectively welded to the third connecting edge and the third bevel, and the inner wall and the outer wall of the cabin side plate are respectively welded to the fourth connecting edge and the fourth bevel.

[0009] The technical solution is further configured such that adjacent aluminum honeycomb panels are respectively welded to the flat-angle side beam profiles, a fifth connecting edge extends from the flat-angle side beam profile, a fifth groove is opened on the flat-angle side beam profile, the fifth connecting edge and the fifth groove are symmetrically arranged around the flat-angle side beam profile, and the inner wall and the outer wall of the aluminum honeycomb panel are respectively welded to the fifth connecting edge and the fifth groove.

[0010] The technical solution is further configured to include, before step S102, assembling welding of cabin partitions, wherein the assembling welding of the cabin partitions is performed simultaneously with the assembling welding of the cabin bottom plate, and after the assembling welding is completed, the cabin partitions and the cabin bottom plate are spot welded.

[0011] The technical solution is further configured as follows: in step S300, the accessories include slide connectors, aluminum-clad iron composite components and / or buried iron components.

[0012] The technical solution is further configured as follows: in step 400, a PET insulation layer is first laid on the bottom plate of the cabin and then the floor is laid, a glass wool insulation layer is first laid on the side plate of the cabin and then the interior trim panel is laid, and a glass wool insulation layer is first laid on the top plate of the cabin and then the aluminum foil is laid.

[0013] The technical solution is further configured such that, in step S500, a fluorocarbon topcoat is coated on the outer surface of the cabin, and an acrylic polyurethane topcoat is coated on the inner surface of the cabin. The beneficial effects of the present invention are: Aluminum honeycomb panels are used as the main material, and auxiliary side beam profiles and corner pieces are welded together to form an integrated pure metal cabin. This has reduced weight and low cost, and meets the cabin load ratio, lifting and transportation strength, sound insulation and noise reduction, and electromagnetic shielding requirements, without aging and degradation problems. The aluminum honeycomb panels can ensure the overall sealing of the cabin, and an insulation layer is laid inside the cabin. The cabin sealing and cabin insulation are designed and constructed separately to ensure the insulation effect of the cabin. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a flowchart of a method for preparing a high-performance electromagnetic shielding aluminum honeycomb cabin in an embodiment of the present invention; Figure 2 Schematic diagram of a high-performance electromagnetic shielding aluminum honeycomb cabin in an embodiment of the present invention; Figure 3 Schematic diagram of a right-angle side beam profile in an embodiment of the present invention; Figure 4 is a schematic diagram of a rounded edge beam profile in an embodiment of the present invention; Figure 5 Schematic diagram of a flat-angle side beam profile in an embodiment of the present invention; Figure 6 is a schematic diagram of a slideway connector in an embodiment of the present invention; Figure 7 is a schematic diagram of an aluminum-clad iron composite assembly in an embodiment of the present invention; Figure 8 is a schematic diagram of an embedded iron assembly in an embodiment of the present invention; Fig. 9 is a schematic diagram of the electromagnetic seal of a hatch in an embodiment of the present invention; Fig.10 is a schematic diagram of a cabin insulation structure according to an embodiment of the present invention; In the attached figure: 100, side beam profile; 101, right-angle side beam profile; 1011, first connecting edge; 1012, second connecting edge; 102, rounded side beam profile; 1021, third connecting edge; 1022, fourth connecting edge; 103, flat-angle side beam profile; 1031, fifth connecting edge; 200, cabin plate; 201, cabin bottom plate; 202, cabin side plate; 203, cabin top plate; 204, aluminum Honeycomb panel; 300, corner piece; 400, hatch; 500, slide connector; 501, slide; 600, aluminum-clad iron composite component; 700, connecting bolt; 800, buried iron component; 900, door frame profile; 110, sealing strip; 120, electromagnetic shielding strip; 130, PET insulation layer; 140, floor; 150, glass wool insulation layer; 160, interior panel; 170, curved skirting board. DETAILED DESCRIPTION

[0015] In order to enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention is clearly and completely described below in conjunction with the accompanying drawings of the present invention. Based on the embodiments in this application, other similar embodiments obtained by ordinary technicians in this field without making creative work should all fall within the scope of protection of this application. In addition, the directional words mentioned in the following embodiments, such as "up", "down", "left", "right", etc., are only reference to the directions of the accompanying drawings. Therefore, the directional words used are used to illustrate rather than limit the invention.

[0016] According to an embodiment of the present invention, a method for preparing a high-performance electromagnetic shielding aluminum honeycomb cabin is provided. Figure 1 and Figure 2 , including the following steps: S100, cabin body welding: The six cabin panels of the cabin body are welded separately. After the welding is completed, the six cabin panels are first spot welded and fixed and then welded as a whole to form the cabin body. The cabin panels are aluminum honeycomb panels. S200, hatch door assembly welding: weld the door panels and door columns to form the hatch, and assemble the hatch and the cabin; S300, welding accessories inside the cabin; S400, laying insulation layer and interior panels inside the cabin; S500, apply topcoat, acceptance, delivery.

[0017] It should be noted that the cabin panel 200 is welded into a flat plate structure using aluminum honeycomb panels, and the side beam profiles 100 are welded around the flat plate structure, and the corner pieces 300 are welded at the corners of the flat plate structure. In other words, the aluminum honeycomb panel is used as the main material, and the auxiliary side beam profiles 100 and the corner pieces 300 are welded together to form an integrated pure metal cabin body, which is light in weight and low in cost, and meets the requirements of cabin load ratio, hoisting and transportation strength, sound insulation and noise reduction, and electromagnetic shielding, and has no aging and degradation problems; the aluminum honeycomb panel can ensure the overall sealing of the cabin body, and the insulation layer is laid inside the cabin body to form an insulation structure inside the cabin. The cabin body sealing and cabin insulation are designed and constructed separately to ensure the insulation effect of the cabin body. In addition, the cabin body adopts an independent insulation design to facilitate cabin maintenance and line maintenance, and avoid problems such as uneven surface, secondary foaming, bulging and delamination of sprayed polyurethane insulation.

[0018] Specifically, aluminum honeycomb panels, as the main material of the cabin, not only improve the overall strength and meet the load-bearing and hoisting requirements, but also improve the thermal insulation performance and the impact resistance of the cabin. For example, a 30mm thick welded aluminum honeycomb panel can withstand a vertical impact load of 340Km / H from a 1Kg aluminum bullet. The thermal conductivity of aluminum honeycomb panels is only 0.7~1.0W / mK, less than 1% of aluminum panels. This material combined with the cabin insulation structure can improve the overall thermal insulation performance of the cabin.

[0019] In the preparation method of the high performance electromagnetic shielding aluminum honeycomb cabin of this embodiment, please refer to Figures 1 to 10 In step S100, the cabin plate 200 includes a cabin bottom plate 201, a cabin side plate 202 and a cabin top plate 203, and the cabin assembly welding includes the following steps: S101, welding the cabin bottom plate 201; S102, welding the cabin side panels 202, and after welding, fix the cabin side panels 202 and the cabin bottom panel 201 by spot welding; S103, welding the cabin top plate 203, and after welding, fix the cabin top plate 203 and the cabin side plate 202 by spot welding; S104, integrally welding the cabin bottom plate 201, the cabin side plate 202 and the cabin top plate 203.

[0020] It should be noted that the spot welding operation in the previous step can be carried out simultaneously with the assembly welding operation in the latter step to improve production efficiency; the cabin body adopts a process method of first processing the components, then assembling them into modules, and finally welding the whole body, which meets the modular production requirements of the components.

[0021] In addition, the cabin bottom plate 201 is welded into a flat plate structure using aluminum honeycomb panels, and the side beam profile 100 is welded around the flat plate structure, and the corner pieces 300 are welded at the corners of the flat plate structure, and then shaped after welding. The assembly welding process is carried out on a welding platform, and the welding deformation is reduced by tooling clamping to ensure flatness and external dimensions. The welding process of the cabin side panels 202 and the cabin top panel 203 is consistent with that of the cabin bottom plate 201.

[0022] In the preparation method of the high performance electromagnetic shielding aluminum honeycomb cabin of this embodiment, please refer to Figure 1 and Figure 3 The cabin bottom plate 201 and the cabin side plate 202 are respectively welded to the right-angle side beam profile 101, and a first connecting edge 1011 and a second connecting edge 1012 are extended from the right-angle side beam profile 101, and a right angle is formed between the first connecting edge 1011 and the second connecting edge 1012. A first groove is opened on the right-angle side beam profile 101, and the inner wall and outer wall of the cabin side plate 202 are respectively welded to the first connecting edge 1011 and the first groove, and the outer wall of the cabin bottom plate 201 is welded to the second connecting edge 1012.

[0023] It should be noted that aluminum alloy has a low melting point and good fluidity. During welding, the weld may burn through, collapse, or be poorly formed because it cannot support the liquid metal. Therefore, a first connecting edge 1011 and a second connecting edge 1012 are provided to form a weld joint pad structure.

[0024] Specifically, the cabin bottom plate 201 adopts a 40 mm thick welded aluminum honeycomb panel, and at the same time, the cabin bottom plate 201 is provided with drainage holes.

[0025] In the preparation method of the high performance electromagnetic shielding aluminum honeycomb cabin of this embodiment, please refer to Figure 1 and Figure 4 The cabin top plate 203 and the cabin side plate 202 are respectively welded to the rounded edge beam profile 102, and a third connecting edge 1021 and a fourth connecting edge 1022 are extended from the rounded edge beam profile 102, and a rounded corner is formed between the third connecting edge 1021 and the fourth connecting edge 1022. The rounded edge beam profile 102 is provided with a third groove and a fourth groove, and the inner wall and the outer wall of the cabin top plate 203 are respectively welded to the third connecting edge 1021 and the third groove, and the inner wall and the outer wall of the cabin side plate 202 are respectively welded to the fourth connecting edge 1022 and the fourth groove.

[0026] It should be noted that the cabin top plate 203 is designed with chamfered corners and rounded transitions to meet the requirements of railway transportation. The outer wall of the cabin top plate 203 is designed with safety buckles and handrails for personnel to climb to the top. The third connecting edge 1021 and the fourth connecting edge 1022 also serve to form a weld joint pad structure.

[0027] Specifically, the cabin top plate 203 is made of 30mm thick aluminum honeycomb panels, and the rounded corners are directly molded with aluminum honeycomb panels to reduce the number of welds and improve the overall load-bearing capacity. The inner wall of the cabin top plate 203 is welded with an aluminum alloy hanging structure for the installation of pipelines and air-conditioning pipes in the cabin. The cabin side panels 202 are made of 30mm thick aluminum honeycomb panels, which are welded together with the cabin bottom plate 201 and the cabin top plate 203. The corners of the cabin side panels 202 and the cabin top plate 203 are transitioned with rounded edge beam profiles 102 to form an internal and external welding structure. The outer surface weld is polished and smooth, and the inner surface is corner welded.

[0028] In the preparation method of the high performance electromagnetic shielding aluminum honeycomb cabin of this embodiment, please refer to Figure 1 and Figure 5 , the adjacent aluminum honeycomb panels 204 are welded to the flat-angle side beam profile 103, the flat-angle side beam profile 103 is extended with a fifth connecting edge 1031, the flat-angle side beam profile 103 is provided with a fifth groove, the fifth connecting edge 1031 and the fifth groove are symmetrically arranged around the flat-angle side beam profile 103, and the inner wall and outer wall of the aluminum honeycomb panel 204 are welded to the fifth connecting edge 1031 and the fifth groove, respectively. Among them, the fifth connecting edge 1031 also serves to form a weld joint pad structure.

[0029] In the preparation method of the high performance electromagnetic shielding aluminum honeycomb cabin of this embodiment, please refer to Figure 1 Before step S102, it also includes cabin partition wall assembly welding, and the cabin partition wall assembly welding and cabin bottom plate assembly welding are carried out simultaneously. After the assembly welding is completed, the cabin partition wall and the cabin bottom plate are spot welded.

[0030] In the preparation method of the high performance electromagnetic shielding aluminum honeycomb cabin of this embodiment, please refer to Figure 1 and Fig. 9 In step S200, the hatch 400 is provided with components such as a door lock, a hinge and a limiter, and the surface is sprayed with a topcoat; the welding process is carried out on a welding platform, and the welding deformation is reduced by clamping the tooling to ensure the flatness and the outer dimensions.

[0031] It should be noted that the hatch 400 is composed of 30mm honeycomb board + 20mm PET foam board, which has high strength and light weight. A sealing strip 110 is provided for sealing, and has good thermal insulation and sealing performance; an electromagnetic shielding strip 120 is also provided between the hatch 400 and the door frame profile 900, which has a good electromagnetic shielding effect. Specifically, the sealing strip 110 is filled in the gap between the hatch 400 and the door frame profile 900, and at the same time, electromagnetic shielding strips 120 are provided on both sides of the gap, which can effectively prevent external electromagnetic interference signals and water vapor from entering the cabin through the gap.

[0032] In the preparation method of the high performance electromagnetic shielding aluminum honeycomb cabin of this embodiment, please refer to Figure 1 , Figures 6 to 8 In step S300, the accessories include a slide connector 500, an aluminum-clad iron composite component 600 and / or an embedded iron component 800.

[0033] Specifically, a slide groove connector 500 is welded on the inner surface of the cabin, a first side of the slide groove connector 500 is welded to the inner surface of the cabin, and the other side of the slide groove connector 500 is recessed to form a slide groove 501. It should be noted that the slide groove connector 500 is welded to the inner surface of the cabin, which reduces the number of side beam profiles and makes construction more convenient.

[0034] Specifically, an aluminum-clad iron composite component 600 is welded on the inner surface of the cabin. The outer layer of the aluminum-clad iron composite component 600 is an aluminum alloy profile, and its inner core is a galvanized steel plate, which has the dual characteristics of metal aluminum and iron; at the same time, the aluminum alloy profile and the galvanized steel plate are tightly combined without a gap, so that the aluminum-clad iron composite component 600 is free from rust and separation; the aluminum-clad iron composite component 600 can be connected with connecting bolts 700 for easy assembly.

[0035] Specifically, an embedded iron component 800 is welded on the inner surface of the cabin, and the outer layer of the embedded iron component 800 is an aluminum alloy profile, and the aluminum alloy profile is provided with an inner cavity, and a galvanized steel plate is fixed in the inner cavity; the setting of the embedded iron component 800 can effectively improve the overall rigidity and is used for punching, installing and fixing light-load equipment. For example, the control panel can fix the embedded iron component 800, and the embedded iron component 800 is welded to the inner surface of the cabin, and at the same time, a foam plate is set around the embedded iron component 800.

[0036] In the preparation method of the high performance electromagnetic shielding aluminum honeycomb cabin of this embodiment, please refer to Figure 1 and Fig.10In step 400, a PET insulation layer 130 is first laid on the cabin bottom plate 201 and then a floor 140 is laid, a glass wool insulation layer 150 is first laid on the cabin side plate 202 and then an interior panel 160 is laid, an arc-shaped skirting board 170 is provided at the junction of the interior panel 160 and the floor 140, and a glass wool insulation layer is first laid on the cabin top plate 203 and then an aluminum foil is laid.

[0037] It should be noted that the interior trim panel 160 provides a comfortable working environment for personnel, and the material of the interior trim panel 160 should be environmentally friendly. Specifically, the interior trim panel 160 is a 10mm thick aluminum honeycomb panel, the surface is sprayed with H06-1012H epoxy primer, and the topcoat is sprayed with ice gray fluorocarbon paint. The floor 140 is a 1.5mm thick aluminum plate, and the PET insulation layer 130 and the floor 140 are bonded to form a sandwich structure. A 3mm thick floor cloth is laid on the top of the floor 140, and the periphery is sealed with glue, and the arc-shaped skirting board 170 is glued and riveted with the cabin side panel 202 and the floor 140 to meet the internal watertight requirements. The arc-shaped skirting board 170 is made of a 1.5mm thick stainless steel plate bent and brushed on the surface. The cabin roof 203 is coated with aluminum foil, which can not only play a protective role, but also play a certain electromagnetic shielding role.

[0038] In the preparation method of the high performance electromagnetic shielding aluminum honeycomb cabin of this embodiment, please refer to Figure 1 In step S500, a fluorocarbon topcoat is applied on the outer surface of the cabin, and an acrylic polyurethane topcoat is applied on the inner surface of the cabin.

[0039] In addition, a hanging ring and a U-shaped fixing groove are provided on the outer surface of the cabin side panel, the cabin ladder is connected to the hanging ring through a hook, and the ladder frame of the cabin ladder is embedded in the U-shaped fixing groove, and a fixing bolt threadedly connected to the side wall of the U-shaped fixing groove is provided, and the end of the fixing bolt is against the ladder frame of the cabin ladder.

[0040] It should be noted that the boarding ladder includes a ladder frame, non-slip pedals and hooks, and is made of aluminum alloy with the characteristics of light weight; it is fixed to the outer surface of the cabin side panel by hooks, hanging rings and U-shaped fixing grooves; when in use, screw the fixing bolts, lift it upwards, and the hook is detached from the hanging ring and can be quickly taken out for use; when not in use, the hook is hung on the hanging ring, the ladder frame is embedded in the U-shaped fixing groove, and it can be quickly fixed by screwing the fixing bolts.

[0041] In summary, the cabin is composed of aluminum honeycomb panels, corner pieces, and side beam profiles through tooling positioning welding, and the welding deformation is corrected by plastic shaping. After the weld is completed, the main welds are 100% visually inspected and penetrated for flaw detection. After the cabin is inspected and qualified, the cabin door is assembled and the cabin is insulated. The interior and exterior surfaces of the cabin are sprayed with primer, and wiring, interior decoration, and assembly and debugging of functional parts such as air conditioners, lights, and ventilation fans are carried out. Shielding sheaths and shielding magnetic rings are used at the cable wall connection positions. Waveguide windows and stainless steel wire mesh are added to the air conditioning outlets, fan outlets and other openings to play an electromagnetic shielding role. Finally, the topcoat is sprayed, and hardware accessories such as locks and hinges are installed on the cabin door.

[0042] The cabin body is made of aluminum honeycomb panels, corner pieces, side beam profiles, etc., which are connected into an integral pure metal structure by fusion welding. The welds are long, numerous, and the heat-affected zone is large, making it difficult to control the deformation of the workpiece. Excessive welding deformation will cause the cabin body's external dimensions to be out of tolerance, and the interface dimensional accuracy cannot be guaranteed. The quality of the welded joint will directly affect the overall strength. Therefore, it is necessary to effectively control the welding deformation and the quality of the welded joint during the welding process.

[0043] First, technological measures to control cabin welding deformation After analyzing the structure of the cabin, the inventors believe that the main factors affecting the welding deformation are: (1) the control of the cabin component assembly welding process; (2) the control of the internal stress of the cabin after welding. The specific measures are as follows: (1) The cabin assembly welding adopts external pressure and internal top type fixtures to adjust the shape before welding, clamp during welding, use special fixtures to press and fix after spot welding, and weld symmetrically after confirming the size. After the welding heat of the workpiece is dissipated, the clamping fixture is released to control the welding deformation within a low range, and the workpiece is reshaped after welding to ensure the flatness and straightness of the product; (2) When welding the deck, add 3mm of welding allowance to the overall dimensions. When welding, follow the welding operation instructions to reduce welding deformation.

[0044] (3) The welding parameters should be as high current and fast as possible to reduce the welding heat input.

[0045] (4) For weld-bearing parts, hammering and surface sandblasting can be used to release internal stress.

[0046] Second, process measures to control the quality of welded joints 1. Try to reduce the number of welds when designing the structure.

[0047] The cabin panels are welded with wide aluminum honeycomb panels as much as possible to reduce the number of welds. The cabin side beam profiles are made of integral aluminum profiles to reduce the number of welds and improve product consistency.

[0048] 2. Reasonable design of weld joint structure.

[0049] Aluminum alloy has a low melting point and good fluidity. During welding, the weld will burn through, collapse, or form poorly because it cannot support the liquid metal. Therefore, the weld joint structure adopts a design with a pad.

[0050] 3. Welding process control (1) Before welding construction, it is necessary to make welding test pieces to verify the welding process parameters.

[0051] (2) During the welding process, the workpiece can be flipped by the tooling to avoid overhead welding, horizontal welding and vertical welding as much as possible. Vertical downward welding is prohibited.

[0052] (3) Panasonic TIG welding machine and German REM MIG welding machine were used. The welding wire was ER5356 welding wire produced by SAFRA. The shielding gas was 99.999% argon.

[0053] (4) The temperature and humidity in the welding workshop are strictly controlled, with temperature ≥10ºC and humidity ≤60%.

[0054] The high-performance electromagnetic shielding aluminum honeycomb cabin prepared by the above method has the following properties: 1. High strength and light weight: Compared with the traditional large-plate shelter, the overall weight is reduced by about 15-20%. The average surface density of the traditional large-plate shelter is about 35Kg / ㎡, and the average surface density of this application does not exceed 25Kg / ㎡; according to the load requirements, the aluminum honeycomb panel of corresponding strength is selected to achieve full-load lifting.

[0055] The tensile strength of high-performance welded aluminum honeycomb panels can reach 6Mpa, and the tensile strength of polyurethane foam sandwich panels is about 0.4Mpa; the compressive strength of high-performance welded aluminum honeycomb panels can reach 4.5Mpa, and the compressive strength of polyurethane foam sandwich panels is about 0.8Mpa.

[0056] 2. Good sealing and shielding properties: Traditional large-plate square cabins generally adopt adhesive riveting structures, and water leakage and seepage often occur during use. The joints on the outer surface of this application are all fully welded and subjected to penetrant testing. Relying on welding to ensure watertightness is also a common method for watertight requirements of rail vehicles; the six cabin surfaces of traditional large-plate square cabins are connected by rivets, and gaps are easily present between surfaces, resulting in poor electromagnetic shielding. This application adopts welded aluminum honeycomb panels, side beam profiles and corner pieces to be welded into a whole, and there is no gap between surfaces. The cabin door adopts a structure that combines sealing strips and electromagnetic shielding strips. The air-conditioning vents are added with waveguide windows, and shielding sheaths and shielding magnetic rings are used at the cable wall connection positions, so that it has good shielding properties. When the frequency is 950Hz, the shielding effectiveness can reach 100dB.

[0057] 3. Strong impact resistance: The interior of the welded aluminum honeycomb panel is a designable regular hexagonal column, and it is a sub-vacuum state structure, which has the ability to disperse impact loads and compress and absorb energy. According to test tests, a 25mm thick aluminum honeycomb panel sample can withstand a 1Kg aluminum bullet, which is vertically impacted at a speed of 340Km / h, and the aluminum bullet cannot penetrate the test sample.

[0058] 4. Good stability and not easy to age: The polyurethane foam of traditional large-plate shelters inevitably has the problem of polymer material aging, which causes the mechanical properties to decline after aging. This application is made of welded aluminum alloy and has no aging and degradation problems.

[0059] 5. Good thermal insulation: Traditional large-plate square cabins rely on large polyurethane panels as thermal insulation materials, and internal embedded skeletons or iron blocks as load-bearing structures. The design must consider both load-bearing and thermal insulation, which brings great difficulty and uncontrollability to the design and construction work. Once the design is changed, the subsequent workload is very large. This application uses welded aluminum honeycomb panels as the main material, and uses full welding to connect to ensure the overall sealing of the cabin. At the same time, the thermal conductivity of the welded aluminum honeycomb panels is 0.68W / mK. The cabin insulation and cabin insulation are designed and constructed separately, which can better ensure the thermal insulation effect of the cabin. The construction process is more controllable, the insulation material selection is more extensive, the degree of modularization is higher, the maintainability and security are stronger, and the rework workload can be reduced when the design is changed.

[0060] 6. Environmentally friendly and recyclable: Traditional large-plate shelters use a lot of non-metallic materials, which will cause environmental problems from manufacturing to disposal. This application is made of aluminum alloy, which is easy to recycle and reuse.

[0061] The present invention has been described in detail above. The above description is only a preferred embodiment of the present invention and should not limit the scope of implementation of the present invention. That is, all equivalent changes and modifications made within the scope of this application should still fall within the scope of the present invention.

Claims

1. A method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter, characterized in that: The following steps are involved: S100, cabin body assembly welding: the six cabin panels of the cabin body are respectively assembled and welded. After the assembly welding is completed, the six cabin panels are first spot welded and fixed and then integrally welded to form the cabin body. The cabin panels are aluminum honeycomb panels. S200, hatch door assembly welding: weld the door panels and door columns to form the hatch, and assemble the hatch and the cabin; S300, welding accessories inside the cabin; S400, laying insulation layer and interior panels inside the cabin; S500, apply topcoat, acceptance, delivery.

2. The method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter according to claim 1, characterized in that: The cabin plate is welded into a flat plate structure using aluminum honeycomb panels, side beam profiles are welded around the flat plate structure, and corner pieces are welded at the corners of the flat plate structure.

3. The method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter according to claim 2, characterized in that: In step S100, the cabin plate includes a cabin bottom plate, a cabin side plate and a cabin top plate, and the cabin assembly welding includes the following steps: S101, welding the cabin bottom plate; S102, welding the cabin side panels, and after welding, spot welding the cabin side panels and the cabin bottom panel; S103, welding the cabin top plate, and after welding, fix the cabin top plate and cabin side plates by spot welding; S104, integrally welding the cabin bottom plate, cabin side plate and cabin top plate.

4. The method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter according to claim 3, characterized in that: The cabin bottom plate and the cabin side plate are respectively welded to the right-angle side beam profile, and a first connecting edge and a second connecting edge extend from the right-angle side beam profile, forming a right angle between the first connecting edge and the second connecting edge, and a first bevel is opened on the right-angle side beam profile, and the inner wall and outer wall of the cabin side plate are respectively welded to the first connecting edge and the first bevel, and the outer wall of the cabin bottom plate is welded to the second connecting edge.

5. The method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter according to claim 3, characterized in that: The cabin top plate and the cabin side plate are respectively welded to the rounded edge beam profile, a third connecting edge and a fourth connecting edge are extended from the rounded edge beam profile, a rounded corner is formed between the third connecting edge and the fourth connecting edge, and a third groove and a fourth groove are opened on the rounded edge beam profile, the inner wall and the outer wall of the cabin top plate are respectively welded to the third connecting edge and the third groove, and the inner wall and the outer wall of the cabin side plate are respectively welded to the fourth connecting edge and the fourth groove.

6. The method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter according to claim 3, characterized in that: Adjacent aluminum honeycomb panels are respectively welded to the flat-angle side beam profiles, a fifth connecting edge is extended from the flat-angle side beam profile, a fifth groove is opened on the flat-angle side beam profile, the fifth connecting edge and the fifth groove are symmetrically arranged around the flat-angle side beam profile, and the inner wall and outer wall of the aluminum honeycomb panel are respectively welded to the fifth connecting edge and the fifth groove.

7. The method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter according to any one of claims 3 to 6, characterized in that: Before step S102, it also includes cabin partition wall assembly welding, and the cabin partition wall assembly welding and cabin bottom plate assembly welding are carried out simultaneously. After the assembly welding is completed, the cabin partition wall and the cabin bottom plate are spot welded.

8. The method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter according to claim 1, characterized in that: In step S300, the accessories include slide connectors, aluminum-clad iron composite components and / or buried iron components.

9. The method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter according to claim 3, characterized in that: In step 400, a PET insulation layer is first laid on the cabin bottom plate and then the floor is laid, a glass wool insulation layer is first laid on the cabin side plate and then the interior trim panel is laid, and a glass wool insulation layer is first laid on the cabin top plate and then the aluminum foil is laid.

10. The method for preparing a high-performance electromagnetic shielding aluminum honeycomb shelter according to claim 1, characterized in that: In step S500, a fluorocarbon topcoat is applied on the outer surface of the cabin, and an acrylic polyurethane topcoat is applied on the inner surface of the cabin.

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