High-reliability carbon fiber special-shaped suspension beam with inner and outer smooth surfaces and manufacturing method thereof

Abstract

The invention provides a high-reliability carbon fiber special-shaped suspension beam with inner and outer smooth surfaces and a manufacturing method thereof, and relates to the field of railway vehicles. The high-reliability inner and outer smooth surface carbon fiber special-shaped suspension beam comprises a suspension beam main body, the suspension beam main body is made of carbon fibers, the interior of the suspension beam main body is hollow, at least one side of the suspension beam main body is provided with a wing plate, the wing plate is provided with a first connecting hole, and the two ends of the suspension beam main body are provided with connecting end parts. And a second connecting hole is formed in the connecting end part. According to the high-reliability carbon fiber special-shaped suspension beam with the inner smooth surface and the outer smooth surface, due to the fact that the carbon fiber composite material is adopted, the suspension beam has the characteristics of being high in strength, high in modulus, free of plastic deformation, free of creep deformation, small in thermal expansion coefficient and the like, and the rigidity, the strength and the corrosion resistance of the special-shaped suspension beam are enhanced through the suspension beam made of the carbon fiber material; meanwhile, compared with an existing aluminum profile suspension beam, the weight is reduced by 50%, energy consumption during vehicle operation is reduced, and the service life of the suspension beam is prolonged.

Description

Technical Field

[0001] The present invention relates to the field of rail vehicles, and in particular to a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces and a manufacturing method thereof. Background Art

[0002] As the operating speed of rail vehicles continues to increase, the technical requirements for various components are also constantly increasing, among which improving component performance, reducing energy loss, and reducing manufacturing and operating costs are particularly prominent; currently, the suspension beam is made of extruded aluminum profiles. Although the weight of aluminum suspension beams is lighter than that of steel suspension beams, the material is soft and lacks rigidity. At the same time, the thermal expansion coefficient and creep are large. The vehicle is prone to vibration during high-speed driving and is easily corroded by the medium. At the same time, there are fractures and cracks at the connection position of the root of the wing panel. Under the existing conditions, the above defects are gradually magnified, which greatly limits the actual application of aluminum profile suspension beams. Summary of the invention

[0003] The invention provides a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces, which is used to solve the problems of poor chemical corrosion resistance, small thermal expansion coefficient and poor fatigue resistance of the existing suspension beams.

[0004] The present invention provides a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces, comprising: A suspension beam body, wherein the material of the suspension beam body is carbon fiber, the interior of the suspension beam body is hollow, a wing plate is provided on at least one side of the suspension beam body, the wing plate is provided with a first connecting hole, and connecting end portions are provided at both ends of the suspension beam body, and the connecting end portions are provided with a second connecting hole.

[0005] According to a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces provided by the present invention, the connection between the connecting end and the suspension beam body is set to a curved surface.

[0006] According to a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces provided by the present invention, the connecting end portion comprises: First top plate; A second top plate, wherein the first top plate and the second top plate are both connected to the suspension beam body, and the first top plate and the second top plate are arranged at intervals; Two side plates, the two side plates are spaced apart between the first top plate and the second top plate, and the two side plates are respectively connected to the first top plate, the second top plate and the suspension beam body.

[0007] According to a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces provided by the present invention, a plurality of the second connection holes are arranged at intervals on the second top plate, and the width of the second top plate is greater than the width of the suspension beam body.

[0008] According to a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces provided by the present invention, the connection between the side plate and the first top plate and the second top plate are all configured as rounded corners.

[0009] According to a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces provided by the present invention, the two side plates and the first top plate are both provided with inclined surfaces on a side away from the suspension beam body.

[0010] According to a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces provided by the present invention, the width of the wing plate gradually increases in a direction approaching the suspension beam body.

[0011] According to a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces provided by the present invention, the suspension beam body includes a first beam body and a second beam body, a folded edge is provided at the connection between the first beam body and the second beam body, and the first beam body is connected to the second beam body through the folded edge.

[0012] According to the high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces provided by the present invention, the side wall thickness of the suspension beam body is 6-8mm.

[0013] The present invention also provides a method for manufacturing a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces, the manufacturing method is used to manufacture any of the above-mentioned high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces, comprising: Winding carbon fiber prepreg on the surface of the memory mandrel; The carbon fiber prepreg of the same thickness is laid in the upper mold and the lower mold respectively; The memory core shaft is placed between the upper mold and the lower mold, and the suspension beam is obtained by an integrated molding process.

[0014] The high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces provided by the present invention adopts carbon fiber composite materials, so that the suspension beam has the characteristics of high strength, high modulus, no plastic deformation, no creep, small thermal expansion coefficient, etc. The suspension beam made of carbon fiber material enhances the rigidity and corrosion resistance of the special-shaped suspension beam, and at the same time reduces the weight by 50% compared with the existing aluminum profile suspension beam, reduces the energy consumption during vehicle operation, and increases the service life of the suspension beam. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0016] Figure 1 It is a schematic diagram of the three-dimensional structure of the high-reliability internal and external smooth carbon fiber special-shaped suspension beam provided by the present invention.

[0017] Figure 2 The diagram is a top view of the structure of a carbon fiber special-shaped suspension beam with high reliability and smooth inner and outer surfaces provided by the present invention.

[0018] Figure 3 It is a side view structural schematic diagram of a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces provided by the present invention.

[0019] Figure 4 The present invention is a schematic diagram of the cross-sectional structure of a carbon fiber special-shaped suspension beam with high reliability and smooth inner and outer surfaces.

[0020] Reference numerals: 110, suspension beam body; 111, arc surface; 112, first beam body; 113, second beam body; 114, folded edge; 120, wing plate; 130, connecting end; 131, first top plate; 132, second top plate; 133, side plate; 134, inclined surface. DETAILED DESCRIPTION

[0021] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be clearly and completely described below in conjunction with the drawings of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0022] In the description of the embodiments of the present invention, it should be noted that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore cannot be understood as limitations on the embodiments of the present invention. In addition, the terms "first", "second", and "third" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0023] In the description of the embodiments of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "connected" and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the embodiments of the present invention can be understood according to specific circumstances.

[0024] In the embodiments of the present invention, unless otherwise clearly specified and limited, the first feature being "above" or "below" the second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, the first feature being "above", "above" and "above" the second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. The first feature being "below", "below" and "below" the second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0025] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the embodiment of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0026] Combine the following Figure 1-Figure 4 A schematic diagram of the specific structure of the high-reliability internal and external smooth carbon fiber special-shaped suspension beam of the present invention is described.

[0027] Figure 1 The three-dimensional structure schematic diagram of the high-reliability internal and external smooth carbon fiber special-shaped suspension beam provided by the present invention is illustrated. Figure 2 The schematic diagram of the top view of the structure of the high-reliability internal and external smooth carbon fiber special-shaped suspension beam provided by the present invention is illustrated. Figure 3 The schematic diagram of the side view structure of the high reliability internal and external smooth carbon fiber special-shaped suspension beam provided by the present invention is illustrated as follows: Figures 1 to 3As shown, the high-reliability inner and outer smooth carbon fiber special-shaped suspension beam includes a suspension beam body 110, the material of the suspension beam body 110 is carbon fiber, the interior of the suspension beam body 110 is hollow, at least one side of the suspension beam body 110 is provided with a wing plate 120, the wing plate 120 is provided with a first connecting hole, and both ends of the suspension beam body 110 are provided with connecting end portions 130, and the connecting end portions 130 are provided with a second connecting hole.

[0028] The high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces provided by the present invention adopts carbon fiber composite materials, so that the suspension beam has the characteristics of high strength, high modulus, no plastic deformation, no creep, small thermal expansion coefficient, etc. The suspension beam made of carbon fiber material enhances the rigidity and corrosion resistance of the special-shaped suspension beam, and at the same time reduces the weight by 50% compared with the existing aluminum profile suspension beam, reduces the energy consumption during vehicle operation, and increases the service life of the suspension beam.

[0029] In one embodiment of the present invention, Figure 3 As shown, the connection between the connection end 130 and the suspension beam body 110 is set as a curved surface 111. Specifically, there is a certain height difference between the connection end 130 and the suspension beam body 110. In order to achieve a smooth transition between the two, both sides of the connection between the connection end 130 and the suspension beam body 110 are set as curved surfaces 111, so that a smooth transition structure is formed between the connection end 130 and the suspension beam body 110. In traditional structural design, a right-angle transition is adopted between the connection end 130 and the suspension beam body 110, which is easy to cause stress concentration at the connection. Stress concentration will cause the material to bear excessive stress in a local area, thereby reducing the strength and reliability of the structure, and may even cause the generation and expansion of cracks; by setting the connection between the connection end 130 and the suspension beam body 110 as a curved surface 111, the stress can be effectively dispersed to avoid excessive concentration of stress in a local area. The curved surface transition allows the stress to be evenly distributed along the arc direction, thereby significantly reducing the stress peak at the connection. Since the transition of the arc surface 111 can effectively avoid stress concentration, the local stress impact and fatigue damage to the suspension beam body 110 during use will be greatly reduced, so that the overall structural strength and durability of the suspension beam are significantly improved, thereby extending the service life of the suspension beam.

[0030] In one embodiment of the present invention, the connecting end portion 130 includes a first top plate 131, a second top plate 132 and two side plates 133. The first top plate 131 and the second top plate 132 are both connected to the suspension beam body 110, and the first top plate 131 and the second top plate 132 are arranged at intervals. The two side plates 133 are arranged at intervals between the first top plate 131 and the second top plate 132, and the two side plates 133 are symmetrically arranged, and the two side plates 133 are respectively connected to the first top plate 131, the second top plate 132 and the suspension beam body 110.

[0031] In one embodiment of the present invention, a plurality of second connection holes are arranged at intervals on the second top plate 132. Specifically, the second connection holes are waist-shaped holes, and three second connection holes are provided. The three second connection holes are arranged at intervals along the width direction of the second top plate 132. The width of the second top plate 132 is greater than the width of the suspension beam body 110, so as to increase the hole spacing between two adjacent second connection holes and the distance between the second connection holes located at the edge and the side plate 133. In order to prevent the hole edge from being squeezed and damaged due to bolt connection and vehicle running vibration during the installation and commissioning of the suspension beam, the hole spacing between two adjacent second connection holes is increased to increase the interlayer shear force of the hole edge, thereby preventing the squeeze damage caused by the concentrated force of the screw connection and the running vibration. By increasing the distance between the second connection holes located at the edge and the side plate 133, the interference of the side plate 133 with the installation of the bolts can be avoided.

[0032] In one embodiment of the present invention, the side plate 133 is perpendicular to the first top plate 131 and the second top plate 132. The side plate 133 is vertically connected to the first top plate 131 and the second top plate 132. This vertical connection structure enables the side plate 133 to effectively support the top plate and form a stable frame structure with the suspension beam body 110, and also makes the structure of the entire connection end 130 more compact and stable. The connection between the side plate 133 and the first top plate 131 and the second top plate 132 is set as a fillet, and the stress can be evenly distributed along the curve of the fillet, thereby significantly reducing the local stress peak to avoid stress concentration at the connection between the side plate 133 and the first top plate 131 and the second top plate 132. During the use of the suspension beam, the connection end 130 will bear loads from different directions, especially lateral loads. By adopting the fillet transition, the connection between the side plate 133 and the first top plate 131 and the second top plate 132 is more secure and can better withstand lateral forces, thereby improving the lateral restraint capacity of the entire suspension beam.

[0033] In one embodiment of the present invention, a slope 134 is provided on the side of the two side panels 133 and the first top panel 131 away from the suspension beam body 110, that is, the side of the two side panels 133 and the first top panel 131 away from the suspension beam body 110 is chamfered. This can leave space for the installation interface, avoid installation interference problems caused by excessively protruding structural edges, ensure that the suspension beam can be installed in place smoothly, and reduce the risk of damage caused by external forces such as collision and extrusion during construction or installation.

[0034] In one embodiment of the present invention, the width of the wing plate 120 gradually increases in a direction close to the suspension beam body 110. Specifically, Figure 2As shown, taking the wing plate 120 on the upper side of the suspension beam body 110 as an example, the width of the upper side of the wing plate 120 is smaller, and the width of the lower side of the wing plate 120 is larger. The connection strength between the wing plate 120 and the suspension beam body 110 is closely related to the contact area between them. By increasing the width of the lower side of the wing plate 120, the contact area between the wing plate 120 and the suspension beam body 110 is increased, which can significantly improve the connection strength between the wing plate 120 and the suspension beam body 110, thereby enhancing the overall structural stability of the suspension beam. A larger contact area means that stress can be distributed over a wider area, reducing the risk of local stress concentration.

[0035] In one embodiment of the present invention, the suspension beam body 110 includes a first beam body 112 and a second beam body 113, and a folding edge 114 is provided at the connection between the first beam body 112 and the second beam body 113, and the first beam body 112 is connected to the second beam body 113 through the folding edge 114. If the contact area between the first beam body 112 and the second beam body 113 is small, there is a risk of fatigue delamination after long-term fatigue and vibration. By providing a folding edge 114 at the connection between the first beam body 112 and the second beam body 113, the first beam body 112 is connected to the second beam body 113 through the folding edge 114, and the contact area with the second beam body 113 can be increased. This method not only improves the connection strength, but also effectively reduces the interlayer stress concentration, and reduces the formation and expansion risk of fatigue cracks. Preferably, the width of the folding edge 114 is 10 mm. Of course, the width of the folding edge 114 is not limited to this, and can also be 11 mm, 12 mm or larger.

[0036] In one embodiment of the present invention, the side wall thickness of the suspension beam body 110 is 6-8 mm, and the thickness of the wing plate 120 is 6-9 mm. Preferably, the side wall thickness of the suspension beam body 110 is 6.7 mm, and the thickness of the wing plate 120 is 8 mm.

[0037] In one embodiment of the present invention, Figure 4 The cross-sectional structure diagram of the high-reliability internal and external smooth carbon fiber special-shaped suspension beam provided by the present invention is illustrated as follows: Figure 4 As shown, the suspension beam adopts three laying forms to optimize the ply thickness and ply angle. Figure 4 Three different paving methods are used in Area A, Area B and Area C respectively. The specific paving methods are detailed in Table 1 below.

[0038] Table 1 Considering the strength of the suspension beam laminate structure, some general empirical design criteria are adopted. When designing a balanced symmetrical laminate, the commonly used ply angles of 0°, +45°, -45°, and 90° have a ply ratio of no less than 10%. The present invention adopts ply angles of 0°, ±45°, and 90°, and the ply ratios are 58%, 26%, and 16%, respectively.

[0039] The present invention also provides a method for manufacturing a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces, the manufacturing method is used to manufacture the high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces described in any of the above embodiments, comprising: Winding carbon fiber prepreg on the surface of the memory mandrel; The carbon fiber prepreg of the same thickness is laid in the upper mold and the lower mold respectively; The memory core shaft is placed between the upper mold and the lower mold, and the suspension beam is obtained by an integrated molding process.

[0040] It should be noted here that the memory mandrel is a solidified polymer memory material, which is used to build a paving benchmark for the integrated molding of composite products with special hollow structures. It is rigid at room temperature and has a high hardness, which ensures the accuracy of the paving of the prepreg and reduces or avoids the displacement difference of the paving. It softens at high temperature and injects air pressure through the air inlet. At this time, the memory mandrel has the characteristics of an airbag to evenly apply expansion pressure to the inner wall of the special-shaped suspension beam, meeting the requirements of the bag pressing molding process, while ensuring the smoothness and dimensional accuracy of the inner wall of the special-shaped suspension beam. The memory mandrel is made of a mold to meet the normal temperature paving process, ensure the accuracy of paving, achieve a smooth inner wall of the product, and can be reused. The memory mandrel is formed in one piece through a bag pressing mold to ensure the dimensional accuracy of the shape. Its shape is 1mm smaller than the inner cavity of the special-shaped suspension beam as a whole, and the interior is a hollow tubular structure. After the molding and curing is completed, the outer surface is wrapped with 4mm carbon fiber prepreg and the two end molding nozzles are integrated into the special-shaped suspension beam mold, which greatly meets the process continuity and ensures the molding accuracy.

[0041] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces, characterized in that: include: A suspension beam body (110), wherein the material of the suspension beam body (110) is carbon fiber, the interior of the suspension beam body (110) is hollow, a wing plate (120) is provided on at least one side of the suspension beam body (110), the wing plate (120) is provided with a first connection hole, and connection end portions (130) are provided at both ends of the suspension beam body (110), and the connection end portions (130) are provided with a second connection hole.

2. The high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces according to claim 1, characterized in that: The connection point between the connection end portion (130) and the suspension beam body (110) is arranged as a curved surface (111).

3. The high-reliability internal and external smooth carbon fiber special-shaped suspension beam according to claim 1, characterized in that: The connecting end (130) comprises: A first top plate (131); a second top plate (132), wherein the first top plate (131) and the second top plate (132) are both connected to the suspension beam body (110), and the first top plate (131) and the second top plate (132) are arranged at an interval; Two side plates (133), the two side plates (133) are arranged between the first top plate (131) and the second top plate (132) at intervals, and the two side plates (133) are respectively connected to the first top plate (131), the second top plate (132) and the suspension beam body (110).

4. The high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces according to claim 3, characterized in that: A plurality of the second connection holes are arranged at intervals on the second top plate (132), and the width of the second top plate (132) is greater than the width of the suspension beam body (110).

5. The high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces according to claim 3, characterized in that: The connection points between the side plate (133) and the first top plate (131) and the second top plate (132) are all configured as rounded corners.

6. The high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces according to claim 3, characterized in that: The side of the side plate (133) and the first top plate (131) away from the suspension beam body (110) are both provided with an inclined surface (134).

7. The high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces according to any one of claims 1 to 6, characterized in that: The width of the wing plate (120) gradually increases in a direction approaching the suspension beam body (110).

8. The high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces according to any one of claims 1 to 6, characterized in that: The suspension beam body (110) comprises a first beam body (112) and a second beam body (113); a folded edge (114) is provided at the connection between the first beam body (112) and the second beam body (113); and the first beam body (112) is connected to the second beam body (113) via the folded edge (114).

9. The high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces according to any one of claims 1 to 6, characterized in that: The side wall thickness of the suspension beam body (110) is 6-8 mm.

10. A method for manufacturing a high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces, the method being used to manufacture the high-reliability carbon fiber special-shaped suspension beam with smooth inner and outer surfaces as claimed in any one of claims 1 to 9, characterized in that: include: Winding carbon fiber prepreg on the surface of the memory mandrel; The carbon fiber prepreg of the same thickness is laid in the upper mold and the lower mold respectively; The memory core shaft is placed between the upper mold and the lower mold, and the suspension beam is obtained by an integrated molding process.

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