Railway vehicle air duct repairing method

Abstract

The invention discloses a railway vehicle air duct repairing method, relates to the technical field of air duct repairing, and solves the problems that an existing traditional repairing technology mainly depends on a whole block replacement method, and although defects can be thoroughly eliminated, the cost is high, and the construction period is long due to the fact that the whole section of air duct is directly dismantled and replaced in a local damaged area. The method comprises the steps of integrally checking the railway vehicle air duct, and marking an air duct repairing point needing to be repaired; dividing the air duct repair points into non-through damage points, through damage points and deformation sunken points according to the conditions of the air duct repair points; according to the characteristics of the non-through damage points, the through damage points and the deformation sunken points, repairing and the like are conducted. The invention aims to quickly and efficiently carry out targeted repair on local damage and deformation of the air duct of the railway vehicle, greatly improve the repair efficiency and prolong the service life of the repaired air duct.

Description

Technical Field

[0001] The present invention belongs to the technical field of air duct repair, and particularly relates to a method for repairing an air duct of a rail vehicle. Background Art

[0002] As a core component of the air conditioning and ventilation system, the air duct of a rail vehicle undertakes functions such as air transportation, pressure balance, and temperature regulation. Its structural integrity directly affects passenger comfort and system energy efficiency. However, during long-term operation, the air duct is prone to damage such as unpenetrated cracks, penetrated breakages, and local deformation and depression due to mechanical vibration, air flow impact, temperature difference deformation, and external environmental erosion. Traditional repair techniques mainly rely on the method of replacing the whole piece. For local damaged areas, the entire section of the air duct is directly removed and replaced. Although this method can completely eliminate defects, it is costly. The cost of aluminum air duct materials and customized processing accounts for more than 70% of the total maintenance cost. Moreover, the construction period is long, and it is necessary to coordinate component disassembly, new part production, and installation and commissioning, resulting in an extended vehicle outage time. In addition, destructive operations are frequent, which easily damages surrounding connecting structures such as flanges and brackets, increasing the risk of secondary failures. Therefore, there is an urgent need to invent a repair method for rail vehicles that can quickly and efficiently target local damage and deformation of the air duct of rail vehicles, greatly improving the repair efficiency and the service life after repair. Summary of the Invention

[0003] To solve the above technical problems, the present invention provides a method for repairing an air duct of a rail vehicle. By designing a repair method for rail vehicles, it can quickly and efficiently target local damage and deformation of the air duct of rail vehicles, greatly improving the repair efficiency and the service life after repair.

[0004] The technical solution adopted by the present invention is as follows:

[0005] A method for repairing an air duct of a rail vehicle includes the following steps:

[0006] Step 1: Inspect the air duct of the rail vehicle as a whole and mark the air duct repair points that need to be repaired;

[0007] Step 2: Classify the air duct repair points into unpenetrated breakage points, penetrated breakage points, and deformation and depression points according to the conditions of the air duct repair points;

[0008] Step 3: Repair respectively according to the characteristics of the unpenetrated breakage points, penetrated breakage points, and deformation and depression points; the unpenetrated breakage points and penetrated breakage points adopt the in-situ repair method, and the deformation and depression points adopt the method of disassembling and repairing the air duct in sections.

[0009] Among them, the method for marking the points that need to be repaired is to visually inspect the breakage points and mark them with a red marker pen;

[0010] By adopting the above technical solution, the existing air duct in the subway rail vehicle is made of aluminum cladding, which is relatively light and easy to cut and process, so the aluminum cladding can be repaired in situ;

[0011] By classifying the air duct repair points that need to be repaired, clarifying the repair steps, reducing human judgment errors, and ensuring consistency in repair quality.

[0012] Preferably, the non-penetrating damaged points in step 2 are damaged points that are surface damaged but not penetrating.

[0013] Preferably, the judgment standard of the deformation depression point in step 2 is to touch the suspected damaged position lightly with a hand, apply light pressure inward to feel the amount of movement of the plate, and if the depression does not rebound, it is considered to be a through damage.

[0014] The above technical solution clarifies the definitions of various types of damage points, avoids confusion in repair types, and facilitates subsequent batch repairs by category.

[0015] Preferably, the method for repairing the unpenetrated damaged points in step 3 comprises the following steps:

[0016] A1: Clean the damaged ends of the air duct;

[0017] A2: Apply elastic sealant on the fracture;

[0018] A3: Press the original profile at the damaged part back to its original position and keep it for a certain period of time, preferably 1 to 3 minutes at room temperature;

[0019] A4: Apply elastic sealant evenly along the gap to repair the air duct.

[0020] By adopting the above technical solution, the air tightness is restored by elastic sealant to avoid air leakage in the air duct.

[0021] Preferably, the method for repairing the through-damaged point in step 3 comprises the following steps:

[0022] B1: trim the damaged part through the damaged point;

[0023] B2: According to the size of the damaged part, cut the aluminum cladding plate of appropriate size to obtain the cut plate;

[0024] B3: Clean the fracture of the damaged part;

[0025] B4: Apply elastic sealant evenly on the fracture of the damaged part and the joint of the cut plate;

[0026] B5: Butt the cut plate to the fracture of the damaged part and keep it for 1 to 3 minutes;

[0027] B6: Apply elastic sealant evenly along the gap;

[0028] B7: Select an aluminum plate and bond it to the cut plate. The size of the aluminum plate is larger than that of the cut plate, and the allowance on each side is ≥ 2 cm;

[0029] B8: Apply sealant at the contact parts between the four sides of the aluminum plate and the air duct to obtain a repaired air duct.

[0030] Preferably, the method for repairing the through-breaking damage point in step 3 includes the following steps:

[0031] B9: Paste the heat-insulating and heat-preserving material on the aluminum plate. The size of the heat-insulating and heat-preserving material is larger than that of the aluminum plate.

[0032] Adopt the above technical solution. The heat-insulating material reduces heat transfer and meets the requirements of the air duct in a high-temperature environment.

[0033] Furthermore, the heat-insulating material is an aluminum foil tape.

[0034] Preferably, the method for repairing the deformed and sunken point in step 3 is as follows:

[0035] C1: Clean the outer surface and inner cavity of the air duct;

[0036] C2: Separate the aluminum-clad plate of the air duct from the air duct flange;

[0037] C3: Remove the edge-sealing material at the connection of the aluminum-clad plate of the air duct;

[0038] C4: Cut the part of the aluminum-clad plate that needs to be repaired to obtain the cut aluminum-clad plate;

[0039] C5: Measure the size of the aluminum-clad plate that needs to be repaired, and cut the aluminum-clad plate of the corresponding size to obtain the aluminum-clad plate patch;

[0040] C6: Apply elastic sealant to the cross-section of the cut aluminum-clad plate;

[0041] C7: Connect the aluminum-clad plate patch to the cut aluminum-clad plate to obtain a repaired air duct;

[0042] C8: Connect the repaired air duct to the air duct flange.

[0043] Preferably, the elastic sealant used for repairing the non-through-breaking damage point and the through-breaking damage point in step 3 is a silicone sealant.

[0044] Adopt the above technical solution. The silicone sealant maintains stable performance in the range of -60°C to 250°C, is not easy to harden or crack in a high-temperature environment, is suitable for the sealing requirements of the vehicle exterior or ventilation system, and can prevent the material at this place from forming through-breaking or non-through-breaking damage points again; the silicone sealant does not contain organic components, is not easy to breed mold, and is suitable for a humid and enclosed environment; and the curing time is short, and it can be cured within 30 minutes.

[0045] Preferably, the elastic sealant used to repair the deformed and sunken points is a silane sealant.

[0046] With the above technical solution, the silane sealant is sufficient for use in medium-low temperature and medium-low vibration environments, and on the basis of meeting the foregoing performance, it has better anti-fatigue performance and anti-creep performance, and stronger long-term deformation recovery ability. Therefore, it is applicable to pipeline parts prone to deformation and depression.

[0047] Preferably, the cut surfaces of the aluminum-clad plate and the aluminum-clad plate filler after cutting both form an angle between 30° and 60°, and the angles of the aluminum-clad plate and the aluminum-clad plate filler after cutting are the same.

[0048] Preferably, the cut surfaces of the aluminum-clad plate and the aluminum-clad plate filler after cutting both form an angle of 45°.

[0049] With the above technical solution, by making the cut surfaces of the aluminum-clad plate and the aluminum-clad plate filler after cutting both form an angle between 30° and 60°, when the cutting angle is 30°, under the same thickness judgment standard, the contact area is about twice that of right-angle cutting. When the cutting angle is 60°, under the same thickness judgment standard, the contact area is about 1.15 times that of right-angle cutting; a larger contact surface allows the elastic sealant to evenly fill the gap, forming a continuous glue layer, reducing the risk of air leakage. The increased bonding area can disperse external forces such as vibration and wind pressure, reducing the probability of degumming or cracking at the joint; the sharp edges of right-angle cutting are prone to stress concentration, while bevel cutting disperses stress through a gentle transition. The 30°-60° bevel makes the external force transfer more evenly along the thickness direction of the glue layer and the aluminum-clad plate, reducing the risk of fatigue crack propagation caused by stress concentration.

[0050] The high anti-fatigue property of the silane sealant compensates for the small deformation of the bevel joint, forming a double protection of "elastic buffer + mechanical dispersion". Compared with the combination of right-angle cutting and ordinary sealant, the fatigue life of the repaired part of the method adopted in this application for parts prone to deformation and depression is increased by 50% - 70%; the silane sealant has a strong deformation recovery ability under long-term static load, but the creep inhibition effect depends on the bonding area. Therefore, the bevel cutting method increases the contact area, and cooperates with the silane sealant to produce a greater creep inhibition effect, reducing the creep stress per unit area; the temperature resistance of the silane glue adapts to the deformation compensation requirements of the bevel joint, avoiding high-temperature softening or low-temperature embrittlement of the glue layer.

[0051] Preferably, after repairing the deformed and sunken points in step 3, the reinforcement plates at other deformed cracks in the air duct are also repaired. The specific steps for repairing the reinforcement plates in the air duct are as follows:

[0052] Step D1: Oppositely attach the "I"-shaped aluminum reinforcement plate to the inner side between the deformed air duct outlets;

[0053] Step D2: Adjust the height of the reinforcement plate in the air duct;

[0054] Step D3: Rivet the connection between the "I"-shaped aluminum reinforcement plate and the air duct.

[0055] Preferably, when applying the elastic sealant with the nozzle of the glue gun to the cross-section of the cut aluminum cladding plate, the inclination angle is the same as that of the cross-section of the cut aluminum cladding plate; the width of the applied glue is controlled within 3-5 mm, and the thickness is controlled within 1-2 mm.

[0056] In summary, due to the adoption of the above technical solutions, the beneficial effects of the present invention are as follows:

[0057] 1. By designing a repair method for rail vehicles, it can quickly and efficiently repair the local damage and deformation of the air ducts of rail vehicles. While improving the repair efficiency, it greatly reduces the repair cost. And by classifying the repair points of the air ducts that need to be repaired, the repair steps are clarified, reducing human judgment errors and ensuring the consistency of repair quality;

[0058] 2. The silicone sealant maintains stable performance in the range of -60°C to 250°C, is not prone to hardening or cracking in high-temperature environments, is suitable for the sealing requirements of the vehicle exterior or ventilation systems, and avoids the re-formation of through or non-through breakage points at this location; the silicone glue does not contain organic components, is not prone to mildew growth, and is suitable for humid and enclosed environments; and the curing time is short, and it can be cured within 30 minutes;

[0059] 3. The silane sealant is sufficient for use in medium and low-temperature and medium and low-vibration environments, and on the basis of meeting the foregoing performance, it has better anti-fatigue performance and anti-creep performance, and stronger long-term deformation recovery ability. Therefore, it is suitable for pipeline parts that are prone to deformation depressions;

[0060] 4. The cut surfaces of the cut aluminum cladding plate and the aluminum cladding plate filler both form an angle between 30° and 60°. When the cutting angle is 30°, under the same thickness judgment standard, the contact area is about twice that of right-angle cutting. When the cutting angle is 60°, under the same thickness judgment standard, the contact area is about 1.15 times that of right-angle cutting; a larger contact surface allows the elastic sealant to evenly fill the gap, forming a continuous glue layer, reducing the risk of air leakage. The increased bonding area can disperse external forces such as vibration and air pressure, reducing the probability of degumming or cracking at the joint; the sharp edges of right-angle cutting are prone to stress concentration, while bevel cutting disperses stress through a gentle transition. The 30°-60° bevel makes the external force more evenly transmitted along the thickness direction of the glue layer and the aluminum cladding plate, reducing the risk of fatigue crack propagation caused by stress concentration;

[0061] 5. The high fatigue resistance of silane sealant compensates for the slight deformation of the bevel joint, forming a double protection of "elastic buffer + mechanical dispersion". Compared with the combination of right-angle cutting and ordinary sealant, the fatigue life of the repaired parts that are prone to deformation and depression is increased by 50% to 70% by the method adopted in this application; Silane sealant has strong deformation recovery ability under long-term static load, but the creep inhibition effect depends on the bonding area. Therefore, the bevel cutting method increases the contact area, cooperates with silane sealant to produce a greater creep inhibition effect, and reduces the creep stress per unit area; The temperature resistance of silane glue is adapted to the deformation compensation requirements of the bevel joint, avoiding high-temperature softening or low-temperature brittle cracking of the glue layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0062] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0063] Figure 1 It is a schematic diagram of the repair process of the rail vehicle air duct in the present invention;

[0064] Figure 2 It is a schematic diagram of the overall structure of the rail vehicle air duct;

[0065] Figure 3 It is a schematic diagram of the penetration part of the aluminum cladding plate;

[0066] Figure 4 This is a schematic diagram of the butt joint between the cut plate and the damaged part of the through-hole;

[0067] Figure 5 This is a schematic diagram after the thermal insulation material is pasted;

[0068] Figure 6 It is a schematic diagram of the depression of the air duct of a rail vehicle;

[0069] Figure 7 The picture before removing the old glue remaining at the air outlet of the air duct flange;

[0070] Figure 8 The picture shows the old glue left over from the air outlet of the air duct flange after it was removed;

[0071] Figure 9 A picture of aluminum cladding filler material is obtained for cutting aluminum cladding plates of corresponding size;

[0072] Figure 10 Pictures of reinforcement plates used to repair other deformation cracks in the air duct;

[0073] Figure 11 Photo of the updated aluminum cladding being aligned and fixed with paper tape at the replacement location of the air duct.

[0074] Reference numerals

[0075] 1-Aluminum cladding plate, 2-Duct flange. Detailed implementation manners

[0076] To make the objectives, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application. Apparently, the described embodiments are only a part rather than all of the embodiments of the present application. Components of the embodiments of the present application described and labeled in the accompanying drawings here can be arranged and designed in various different configurations. Therefore, the detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application claimed, but merely represents selected embodiments of the present application. All other embodiments obtained by those skilled in the art based on the embodiments of the present application without creative efforts fall within the scope of protection of the present application.

[0077] In the description of the embodiments of the present application, it should be noted that the orientation or positional relationship indicated by the terms "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship when the inventive product is normally placed, and is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present application. In addition, the terms "first", "second", "third", etc. are only used for descriptive distinction and cannot be construed as indicating or implying relative importance.

[0078] The present invention will be described in detail below with reference to the drawings.

[0079] Embodiment 1

[0080] A method for repairing the air duct of a rail vehicle, referring to the attached Figures 1 - 2 , includes the following steps:

[0081] Step 1: Inspect the air duct of the rail vehicle as a whole, and mark the air duct repair points that need to be repaired; the method for marking the points that need to be repaired is to visually inspect the damaged points and mark them with a red marker pen;

[0082] By classifying the air duct repair points that need to be repaired, the repair steps are clarified, the human judgment error is reduced, and the consistency of the repair quality is ensured.

[0083] Step 2: Classify the air duct repair points into unpenetrated damaged points, penetrated damaged points, and deformed and sunken points according to the conditions of the air duct repair points;

[0084] Step 3: Repair respectively according to the characteristics of the unpenetrated damaged points, penetrated damaged points, and deformed and sunken points; the in-situ repair method is adopted for the unpenetrated damaged points and penetrated damaged points, and the air duct segment disassembly and repair method is adopted for the deformed and sunken points.

[0085] In this embodiment, the unpenetrated break point in step 2 is a break point with surface damage but not penetrated.

[0086] In this embodiment, the judgment criterion for the deformed and sunken point in step 2 is to gently touch the suspected damaged position by hand, apply a slight inward pressure to feel the amount of movement of the plate material. If the depression does not rebound, it is considered a penetrated break. The definitions of various break points are clarified to avoid confusion in the repair types and facilitate subsequent batch repair by category.

[0087] Embodiment 2

[0088] In this embodiment, the method for repairing the unpenetrated break point in step 3 includes the following steps:

[0089] A1: Clean the broken port of the air duct with alcohol;

[0090] A2: Apply silicone sealant at the broken port;

[0091] A3: Press the original profile at the damaged part back to its original position and maintain for a certain time, 2 minutes at normal temperature;

[0092] A4: After the sealant is firmly bonded, evenly apply silicone sealant along the gap, smear evenly and smoothly to obtain a repaired air duct.

[0093] Restore the airtightness through silicone sealant to avoid air leakage of the air duct.

[0094] Embodiment 3

[0095] In this embodiment, referring to the appendix Figure 3 , the method for repairing the penetrated break point in step 3 includes the following steps:

[0096] B1: Trim the damaged part at the penetrated break point;

[0097] B2: Cut the aluminum-clad board 1 with appropriate size according to the size of the damaged part to obtain a cut board;

[0098] B3: Clean the broken port of the damaged part with alcohol;

[0099] B4: Evenly apply silicone sealant at the broken port of the damaged part and the butt joint part of the cut board;

[0100] B5: Referring to the appendix Figure 4 , butt the cut board to the broken port of the damaged part and maintain for 1 - 3 minutes;

[0101] B6: Evenly apply silicone sealant along the gap;

[0102] B7: Clean the outer side of the air duct with alcohol. Select an aluminum plate and bond it to the cut plate. The size of the aluminum plate is larger than that of the cut plate, with a margin of 3 cm on each side. Apply a high-performance structural adhesive TS828 evenly on the surface of the aluminum plate.

[0103] B8: After the aluminum plate is completely bonded to the aluminum-clad plate 1, apply sealant at the contact parts around the aluminum plate and the air duct to obtain a repaired air duct.

[0104] In this embodiment, the method for repairing the through-breaking damage point in step 3 includes the following steps:

[0105] B9: Refer to the appendix Figure 5 , paste the heat-insulating and heat-preserving material on the aluminum plate. The size of the heat-insulating and heat-preserving material is larger than that of the aluminum plate.

[0106] Reduce heat transfer through the heat-insulating material to meet the air duct requirements in high-temperature environments.

[0107] In this embodiment, the heat-insulating material is an aluminum foil tape. After being firmly pasted, silicone sealant is also applied on the inner and outer sides of the aluminum foil tape. The application is uniform and smooth to ensure good sealing.

[0108] The silicone sealant maintains stable performance in the range of -60°C to 250°C, is not prone to hardening or cracking in high-temperature environments, is suitable for the sealing requirements of the vehicle exterior or ventilation systems, and avoids the re-formation of through-breaking or non-through-breaking damage points at this location; the silicone sealant does not contain organic components, is not prone to mildew growth, and is suitable for humid and enclosed environments; and it has a short curing time and can be cured within 30 minutes.

[0109] Example 4

[0110] In this embodiment, refer to the appendix Figure 6 , the method for repairing the deformed and sunken point in step 3 is as follows:

[0111] C1: Clean the outer surface and inner cavity of the air duct;

[0112] C2: Separate the aluminum-clad plate 1 of the air duct from the air duct flange 2;

[0113] C3: Refer to the appendix Figure 7 ~appendix Figure 8 , remove the old glue at the connection between the air duct flange 2 and the aluminum-clad plate 1, separate the aluminum-clad plate 1 from the air duct flange 2, remove the old glue at the residual outlet, and remove the edge-sealing material at the connection of the aluminum-clad plate 1 of the air duct;

[0114] C4: Cut the part of the aluminum-clad plate 1 that needs to be repaired to obtain the cut aluminum-clad plate 1;

[0115] C5: Refer to the appendix Figure 9 , measure the size of the aluminum-clad plate 1 that needs to be repaired, and cut the aluminum-clad plate 1 of the corresponding size to obtain the aluminum-clad plate patch;

[0116] C6: Apply silane sealant to the cross-section of the aluminum-clad panel 1 after cutting.

[0117] C7: Connect the aluminum-clad panel filler to the aluminum-clad panel 1 after cutting to obtain a repaired air duct.

[0118] C8: Apply sealant inside the air duct flange 2 to connect the air duct body to the flange. The parallelism of the two ends of the flange is less than 1 mm / m, perpendicular to the air duct main body. Use the same height of Armaflex to re-fill and make the connected air duct body and air duct flange 2 straight, beautiful, and closely fitted without gaps and Armaflex damage.

[0119] Silane sealant is sufficient for use in medium-low temperature and medium-low vibration environments. On the basis of meeting the aforementioned performance, it has better anti-fatigue performance and anti-creep performance, and stronger long-term deformation recovery ability. Therefore, it is suitable for pipeline parts prone to deformation and depression.

[0120] The preparation method of the cleaning solution in step C1 is to add 9 / 10 volume of clean water (45L) into a special bucket (50L), and then add 1 / 10 volume of the cleaning solution (5L), stir evenly for later use.

[0121] The method for cleaning the outer surface of the air duct in step C1 is as follows:

[0122] Dip an industrial cotton cloth into the prepared cleaning solution (keep it wrung out without dripping water) and wipe the floating dust and dirt on the outer wall of the air duct and the flange surface, wipe 2 - 3 times. Dip an industrial cotton cloth into clean water (keep it wrung out without dripping water) and scrub the residual cleaning agent, wipe 2 - 3 times. During the cleaning process, it is strictly prohibited for the cleaning solution and water to flow into the inner cavity of the air duct. The cleaning standard for the outer surface of the air duct is that there is no obvious floating dust when touched by hand, and the air duct, flange have no dirt, no floating dust, no moisture, showing the metal color, the anti-loosening mark is removed cleanly, and the residual cracked original glue at the air duct return air opening is removed cleanly and filled with glue.

[0123] The method for cleaning the inner cavity of the air duct in step C1 is as follows:

[0124] The dirt and floating dust in the inner cavity of the air duct are blown out of the inner cavity from the two ports of the air duct with a high-pressure air gun. It is prohibited to wash the inner cavity of the air duct with water to avoid causing the aluminum-clad panel 1 to get damp or damaged. After the floating dust in the inner cavity of the air duct is blown out, use a special tooling in cooperation with an industrial cotton cloth dipped in the prepared cleaning solution (keep it wrung out without dripping water) to clean the inner cavity, clean 5 - 7 times until the inner cavity of the air duct is clean, without dirt, without floating dust, showing the original color of the aluminum foil. Use a special tooling in cooperation with an industrial cotton cloth dipped in clean water (keep it wrung out without dripping water) to clean the inner cavity, clean 5 - 7 times. The cleaning standard for the inner surface of the air duct: there is no obvious floating dust when touched by hand. The inner wall of the air duct has no dirt, no floating dust, no moisture, showing the metal color.

[0125] The method for connecting the aluminum cladding patch to the cut aluminum cladding 1 in step C7 to obtain a repaired air duct is as follows:

[0126] Cover the updated aluminum cladding 1 on the air duct replacement position for alignment, and connect it with the aluminum cladding 1 using stainless steel reinforcement (apply silicone sealant on the contact surface between the reinforcement connecting plate and the aluminum cladding 1), refer to the appendix Figure 11 , and fix it with paper tape; the dimensional deviation after alignment is less than 2 mm; use aluminum foil paper with a width of 60 mm to paste the joints of the aluminum cladding 1, and the surface is required to be smooth and without wrinkles after pasting.

[0127] Example 5

[0128] In this embodiment, different from Example 4, the cut surfaces of the cut aluminum cladding 1 and the aluminum cladding patch both form an angle of 45°.

[0129] Adopting the above technical solution, when the cut surfaces of the cut aluminum cladding 1 and the aluminum cladding patch both form an angle between 30° and 60°, when the cutting angle is 30°, under the same thickness judgment standard, the contact area is about twice that of right-angle cutting; when the cutting angle is 60°, under the same thickness judgment standard, the contact area is about 1.15 times that of right-angle cutting; a larger contact surface allows the elastic sealant to evenly fill the gap, forming a continuous glue layer, reducing the risk of air leakage. The increased bonding area can disperse external forces such as vibration and wind pressure, reducing the probability of degumming or cracking at the joint; the sharp edge of right-angle cutting is prone to stress concentration, while bevel cutting disperses stress through a gentle transition. The 30° - 60° bevel makes the external force transfer more evenly along the thickness direction of the glue layer and the aluminum cladding 1, reducing the risk of fatigue crack propagation caused by stress concentration.

[0130] The high anti-fatigue property of the silane sealant compensates for the small deformation of the bevel joint, forming a double protection of "elastic buffer + mechanical dispersion". Compared with the combination of right-angle cutting and ordinary sealant, the fatigue life of the repaired part of the method adopted in this application is increased by 50% - 70% for parts that are prone to deformation and depression; the silane sealant has a strong deformation recovery ability under long-term static load, but the creep inhibition effect depends on the bonding area. Therefore, the bevel cutting method increases the contact area, synergistically with the silane sealant to produce a greater creep inhibition effect, reducing the creep stress per unit area; the temperature resistance of the silane glue adapts to the deformation compensation requirements of the bevel joint, avoiding softening of the glue layer at high temperature or embrittlement at low temperature.

[0131] Example 6

[0132] In this embodiment, different from Example 4, the cut surfaces of the cut aluminum cladding 1 and the aluminum cladding patch both form an angle of 30°.

[0133] Example 7

[0134] In this embodiment, different from Embodiment 4, the cut surfaces of the aluminum clad plate 1 and the aluminum clad plate filler after cutting both form an angle of 60°.

[0135] Embodiment 8

[0136] In this embodiment, referring to the appendix Figure 10 , after repairing the deformed and sunken points in Step 3, the reinforcing plates at other deformed cracks in the air duct are also repaired. The specific steps for repairing the reinforcing plates inside the air duct are as follows:

[0137] Step D1: Stick the "I"-shaped aluminum reinforcing plate with a thickness of 1.5 mm and a material of T5052 on the inner side between the deformed air duct outlets. Apply silicone sealant at the joint between the aluminum reinforcing plate and the reinforcing plate inside the air duct.

[0138] Step D2: Adjust the height of the reinforcing plate inside the air duct.

[0139] Step D3: Rivet the connection between the "I"-shaped aluminum reinforcing plate and the air duct.

[0140] In this embodiment, when applying the glue with the glue gun nozzle for applying the elastic sealant to the cross-section of the cut aluminum clad plate 1, the inclination angle is the same as that of the cross-section of the cut aluminum clad plate 1; the width of the glue application is controlled within 3 - 5 mm, and the thickness is controlled within 1 - 2 mm.

[0141] Compared with the traditional method of replacing the whole piece, the air duct repair method of the present invention for rail vehicles significantly shortens the construction period through classification repair and in-situ treatment technology. For the traditional method, since it is necessary to coordinate disassembly, new part production (about 5 - 7 days) and installation and commissioning (about 2 - 3 days), the total outage time is usually 7 - 10 days; while the present invention compresses the repair time to 8 - 24 hours through local repair and segmented disassembly, specifically depending on the type and quantity of damage.

[0142] During the loss repair process of the third phase of Chengdu Metro Line 1 this time, the specific repair time is calculated as follows;

[0143] (1) Repair of non-penetrating damaged points: Cleaning, gluing, and curing only take 1 - 2 hours;

[0144] (2) Repair of penetrating damaged points: Cutting the aluminum plate, bonding, and sealing take 3 - 4 hours;

[0145] (3) Repair of deformed and sunken points (including segmented disassembly): Cleaning, cutting, replacement, and reinforcement take 6 - 8 hours;

[0146] Based on comprehensive calculations, the repair efficiency is increased by approximately 80% - 90%, the vehicle outage time is reduced by more than 85%, significantly reducing the losses caused by operation interruptions. In addition, the material cost is saved by 70% - 80% (no need to replace the entire aluminum air duct), and the labor cost is reduced by 60% - 70%. Taking a single repair as an example, the cost of the traditional solution including components and labor is about RMB 15,000, while the cost of the present invention is only RMB 3,000 - 4,000, and the comprehensive savings rate reaches more than 75%.

[0147] It should be noted that:

[0148] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present invention. Various modifications to these embodiments will be obvious to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but will be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for repairing the air duct of a rail vehicle, characterized in that, It includes the following steps: Step 1: Overall inspection of the air duct of the rail vehicle, and marking the repair points of the air duct that need to be repaired; Step 2: Classify the repair points of the air duct into unpenetrated damaged points, penetrated damaged points, and deformed and sunken points according to the conditions of the repair points of the air duct; Step 3: Repair respectively according to the characteristics of unpenetrated damaged points, penetrated damaged points, and deformed and sunken points; for unpenetrated damaged points and penetrated damaged points, the in-situ repair method is adopted, and for deformed and sunken points, the method of disassembling and repairing the air duct in sections is adopted.

2. The method for repairing the air duct of a rail vehicle according to claim 1, characterized in that, The unpenetrated damaged points in Step 2 are damaged points with surface damage but not penetrated.

3. A method for repairing the air duct of a rail vehicle according to claim 1, characterized in that, The method for repairing unpenetrated damaged points in Step 3 includes the following steps: A1: Clean the broken end of the air duct; A2: Apply elastic sealant at the broken end; A3: Press the original profile at the damaged part back to its original position and keep it for a certain time of 1 - 3 minutes; A4: Apply elastic sealant evenly along the gap to obtain the repaired air duct.

4. A method for repairing an air duct of a rail vehicle according to claim 1, characterized in that, The method for repairing penetrated damaged points in Step 3 includes the following steps: B1: Trim the damaged part at the penetrated damaged point; B2: Cut the aluminum cladding plate (1) with appropriate size according to the size of the damaged part to obtain the cut plate; B3: Clean the broken end of the damaged part; B4: Apply high-performance structural sealant evenly at the broken end of the damaged part and the butt joint part of the cut plate; B5: Connect the cut plate to the broken end of the damaged part and keep it for 1 - 3 minutes; B6: Apply elastic sealant evenly along the gap; B7: Select an aluminum plate and bond it to the cut plate. The size of the aluminum plate is larger than that of the cut plate, and the margin on each side is ≥ 2 cm; B8: Apply sealant at the contact part between the four sides of the aluminum plate and the air duct to obtain the repaired air duct.

5. A method for repairing the air duct of a rail vehicle according to claim 4, characterized in that, The method for repairing penetrated damaged points in Step 3 includes the following steps: B9: Paste the heat-insulating and heat-preserving material on the aluminum plate. The size of the heat-insulating and heat-preserving material is larger than that of the aluminum plate.

6. A method for repairing an air duct of a rail vehicle according to claim 1, characterized in that, The method for repairing deformed and sunken points in Step 3 is: C1: Clean the outer surface and inner cavity of the air duct; C2: Separate the aluminum cladding plate (1) of the air duct from the air duct flange (2); C3: Remove the edge-sealing material at the connection of the aluminum cladding plate (1) of the air duct; C4: Cut the part of the aluminum cladding plate (1) that needs to be repaired to obtain the cut aluminum cladding plate (1); C5: Measure the size of the aluminum cladding plate (1) that needs to be repaired, and cut the aluminum cladding plate (1) with the corresponding size to obtain the aluminum cladding plate patch; C6: Apply elastic sealant to the section of the cut aluminum cladding plate (1); C7: Connect the aluminum cladding plate patch to the cut aluminum cladding plate (1) to obtain the repaired air duct; C8: Connect the repaired air duct to the air duct flange (2).

7. A method for repairing an air duct of a rail vehicle according to claim 6, characterized in that The cut surfaces of the cut aluminum cladding plate (1) and the aluminum cladding plate patch both form an angle between 30° and 60°, and the angles of the cut aluminum cladding plate (1) and the aluminum cladding plate patch are the same.

8. A method for repairing the air duct of a rail vehicle according to claim 6, characterized in that, After repairing the deformed and sunken points in Step 3, the reinforcing plate at other deformed cracks of the air duct is also repaired. The specific steps for repairing the reinforcing plate inside the air duct are: Step D1: Oppositely paste the "I”-shaped aluminum reinforcing plate inside between the air outlets of the deformed air duct; Step D2: Adjust the height of the reinforcing plate inside the air duct; Step D3: Rivet the connection between the "I”-shaped aluminum reinforcing plate and the air duct.

9. A method for repairing an air duct of a rail vehicle according to claim 6, characterized in that, When applying elastic sealant to the cross-section of the cut aluminum-clad panel (1) with the glue gun nozzle, the inclination angle is the same as that of the cross-section of the cut aluminum-clad panel (1); the width of the glue application is controlled within 3 - 5 mm, and the thickness is controlled within 1 - 2 mm.

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