A method for cutting the lower cover plate of a railway freight car traction beam

Abstract

A method for cutting the lower cover plate of a railway freight car traction beam, belonging to the field of railway freight car component processing technology, includes three steps: pre-layout, optimized layout, and process verification. Pre-layout involves first arranging the lower cover plates of the traction beam, and then nesting the small parts required for railway freight car component processing within the remaining material of the lower cover plates. Optimized layout includes determining the position and size of the process tie rods based on the pre-layout, adjusting the position of the lower cover plates of the rear traction beam so that the front end of the rear lower cover plate is nested within the opening end of the previous lower cover plate, and determining the specifications of the raw materials based on the layout results. Process verification involves selecting a raw material according to the specifications of the raw materials in the layout diagram for a cutting production experiment, and tracking and verifying the cutting dimensions and welding quality of the lower cover plate of the traction beam. This invention can effectively reduce waste of remaining material, improve material utilization, and also reduce the time spent manually assembling process tie rods, improving production efficiency and ensuring part quality.

Description

Technical Field

[0001] This invention belongs to the field of railway freight car component processing technology, and relates to a method for producing lower cover plates, particularly a method for producing lower cover plates for railway freight car traction beams. Background Technology

[0002] The lower cover plate of the traction beam is generally an open structure, and the main components assembled in the open structure include the impact seat, coupler, channel steel support beam, and coupler tail frame support plate. The opening size and flatness of the lower cover plate of the traction beam affect the assembly quality of the coupler and the welding quality of the traction beam, thus affecting driving safety.

[0003] The lower cover plate of the traction beam has an open structure, which is prone to deformation under stress during CNC blanking, leveling, and welding, resulting in dimensional and flatness deviations. Currently, the solution to the dimensional deviation problem of the open structure of the lower cover plate is to add process tie rods to form a closed structure at the opening end, and then remove the tie rods after the lower cover plate is welded. While the closed structure formed by the process tie rods solves the dimensional and flatness deviation problem of the lower cover plate, it is limited by the size of the vehicle parts, resulting in insufficient utilization of the remaining material inside the open structure and material waste.

[0004] Therefore, in order to solve this problem, the present invention proposes a method for cutting the lower cover plate of the traction beam of a railway freight car. Summary of the Invention

[0005] In view of the shortcomings of the prior art described above, the purpose of this invention is to provide a method for cutting the lower cover plate of the traction beam of railway freight cars, which solves the technical problem that the residual material in the inner cavity of the opening structure of the lower cover plate of the traction beam cannot be fully utilized, resulting in material waste.

[0006] To achieve the above and other related objectives, the present invention provides a method for cutting the lower cover plate of a railway freight car traction beam, comprising the following steps:

[0007] Step 1. Pre-sorting

[0008] S1. Cover plates under at least two rows of longitudinally parallel traction beams;

[0009] S2. At least two rows of traction beam under-cover plates are arranged laterally. During the arrangement process, the front end of the rear traction beam under-cover plate and the end of the opening of the previous traction beam under-cover plate are on the same vertical line.

[0010] S3. Arrange the small parts required for the processing of railway freight car components in the remaining material of the lower cover plate of the traction beam;

[0011] Step 2. Optimize the layout

[0012] S1. Based on the pre-layout structure, determine the position and size of the process tie rod, and determine the specifications of the raw materials. The distance from the process tie rod to the end of the opening of the lower cover plate of the traction beam shall not exceed 150mm.

[0013] S2. After determining the position and size of the process tie rod, adjust the position of the lower cover plate of the rear traction beam so that the front end of the lower cover plate of the rear traction beam is nested inside the opening end of the lower cover plate of the previous traction beam.

[0014] Step 3. Process Validation

[0015] Based on the raw material specifications in the layout drawing, select raw materials for cutting tests, and verify the resulting traction beam underplate:

[0016] If the process validation fails, the sample layout is adjusted and the process validation is performed again until the process validation passes.

[0017] If the process verification is successful, the sample will be mass-produced.

[0018] In any of the above schemes, the preferred option is that, in step S4 of step one, during the small parts arrangement process, the ratio of the number of small parts to the number of traction beams is arranged according to the ratio required by the vehicle model drawings or the production plan quantity ratio.

[0019] In any of the above solutions, it is preferred that the width of the process strip in step S1 of step two is 30-50mm.

[0020] Preferably, in step three, the verification items for process verification are:

[0021] 1. After the lower cover plate of the traction beam is CNC cut, check whether the process tie rod is broken or deformed, and whether the dimensions of the parts meet the requirements of the drawings;

[0022] 2. After the lower cover plate of the traction beam is leveled, check whether the process tie rod is broken or deformed, and whether the dimensions of the parts meet the requirements of the drawings.

[0023] 3. After the lower cover plate of the traction beam is welded and assembled, check whether the dimensions of the parts meet the requirements of the drawings. If they do, cut off the process tie rods and grind them.

[0024] Preferably, in step three, the method for adjusting the sample layout when the process verification fails is as follows:

[0025] If the process tie rod deforms, increase the width of the process tie rod;

[0026] If the dimensions of the lower cover plate of the traction beam exceed the tolerance after leveling, then shorten the distance from the process tie rod to the opening end of the lower cover plate of the traction beam.

[0027] The preferred method among the above options is to increase the width of the process tie rod by increasing the width of the process tie rod by 10mm each time until the process tie rod shows no obvious deformation.

[0028] The preferred method among the above options is to shorten the distance between the process tie rod and the end of the opening of the lower cover plate of the traction beam by reducing the distance between the process tie rod and the end of the opening of the lower cover plate of the traction beam by 10mm each time, until the end dimension of the process tie rod is within ±1mm of the dimension required by the drawing.

[0029] As described above, the method for cutting the lower cover plate of the railway freight car traction beam according to the present invention has the following beneficial effects:

[0030] 1. In this invention, by optimizing and adjusting the positioning dimensions of the process tie rod at the open end of the traction beam, the lower cover plates of the traction beam can be nested together, and small parts can be produced in the remaining material position, reducing the waste of remaining material and thus improving the material utilization rate.

[0031] 2. In this invention, the process guide rod is retained during the CNC blanking process, which reduces the time spent manually assembling the process guide rod, improves production efficiency, and ensures the quality of the parts. Attached Figure Description

[0032] Figure 1 The diagram shown is a schematic diagram of the pre-sorting process of this invention.

[0033] Figure 2 The diagram shown illustrates the optimized layout process of this invention.

[0034] Component designation explanation

[0035] 1-Traction beam lower cover plate; 2-Process tie rod; 3-Extension plate; 4-Rear follower plate seat plate; 5-Stiffener plate. Detailed Implementation

[0036] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0037] Please see Figures 1 to 2It should be understood that the structures, proportions, sizes, etc., illustrated in the accompanying drawings are merely for illustrative purposes to aid those skilled in the art and to facilitate understanding and reading. They are not intended to limit the scope of the invention and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of the invention, should still fall within the scope of the technical content disclosed in this invention. Furthermore, the terms such as "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention's implementation.

[0038] Example 1

[0039] Please see Figure 1-2 This invention provides a method for cutting the lower cover plate of a railway freight car traction beam, comprising the following steps:

[0040] Step 1. Pre-sorting

[0041] S1. Two rows of traction beam lower cover plates 1 are arranged in parallel longitudinal direction; the two adjacent sides of the upper and lower rows of traction beam lower cover plates 1 are fitted together, so that the adjacent sides of the two traction beam lower cover plates 1 can be cut at one time during the material cutting process, reducing the number of cuttings and thus improving cutting efficiency. At the same time, it can also reduce material waste.

[0042] S2. Two rows of traction beam lower cover plates 1 are arranged laterally. During the arrangement process, the front end of the lower cover plate 1 of the rear traction beam and the end of the opening of the lower cover plate 1 of the previous traction beam are on the same vertical line.

[0043] S3. Arrange the small parts required for the processing of railway freight car components in the remaining material of the lower cover plate 1 of the traction beam.

[0044] The nesting method for smaller items is as follows:

[0045] According to such Figure 1 As shown, based on the external area of ​​the smaller parts, the arrangement order follows the principle of prioritizing larger areas. First, insert the extension plate 3, which can be inserted into the square notch and triangular area of ​​the lower cover plate 1 of the traction beam. Then, insert the rear support plate 4, which can be inserted into the square notch area of ​​the lower cover plate 1 of the traction beam. Finally, insert the reinforcing plate 5 in the remaining space.

[0046] During the nesting process, the number of parts is nested proportionally according to the demand. For example, for one vehicle, the ratio of 1: 3: 4: 4 is 2: 3: 4: 4. One sheet of sheet can produce two vehicles.

[0047] Step 2. Optimize the layout

[0048] S1. Based on the pre-layout structure, determine the position and size of the process tie rod 2, and determine the specifications of the raw materials;

[0049] The method for determining the position of the process pull bar 2 is as follows: after the small parts are arranged, the process pull bar 2 is located behind the opening end of the lower cover plate 1 of the traction beam and close to the end of the small parts. At the same time, the distance between the process pull bar 2 and the opening end of the lower cover plate 1 of the traction beam is not greater than 150mm.

[0050] The width of process strip 2 is 30mm, but not limited to 30mm. It can be adjusted according to the actual production situation, such as the width of process strip 2 being 30-50mm.

[0051] S2. After determining the position of the process tie bar 2, adjust the position of the lower cover plate 1 of the rear traction beam so that the front end of the lower cover plate 1 of the rear traction beam is nested in the open end of the lower cover plate 1 of the previous traction beam, and the distance between the front end of the lower cover plate 1 of the rear traction beam and the process tie bar 2 is 2mm.

[0052] Of course, the distance between the front end of the lower cover plate 1 of the rear traction beam and the process tie bar 2 is not limited to 2mm. It can be adjusted according to the actual production situation. For example, the distance between the front end of the lower cover plate 1 of the rear traction beam and the process tie bar 2 is 1 to 3mm.

[0053] Step 3. Process Validation

[0054] According to the raw material specifications in the layout diagram, select a raw material that is larger than the layout specification for cutting and production, and verify the traction beam lower cover plate 1 obtained from the cutting and production.

[0055] If the process validation fails, the sample layout is adjusted and the process validation is performed again until the process validation passes.

[0056] If the process verification is successful, the sample will be mass-produced.

[0057] In this process, the layout specification is the smallest specification size. Since it is not possible to purchase a single sheet of the layout specification, a cutting test is usually conducted using a sheet larger than the layout specification. After verification, the sheet is purchased according to the process specifications for mass production.

[0058] As a further description of the above embodiments, in this invention, the layout can be performed at the control terminal of the CNC blanking machine before blanking production; alternatively, the layout can be performed on the programming software and then transmitted to the CNC system of the CNC blanking machine before blanking production.

[0059] As a further description of the above embodiments, in the pre-layout process of step one, the horizontal and vertical arrangements are not limited to two sets of traction beam lower cover plates 1, and can be increased or decreased according to the actual needs on site. For example, three rows of traction beam lower cover plates 1 can be arranged longitudinally and two rows can be arranged horizontally; or two rows can be arranged longitudinally and three rows can be arranged horizontally, etc.

[0060] As a further description of the above embodiment, in step S4 of step one, during the small parts arrangement process, the ratio of the number of small parts to the number of traction beams is arranged according to the ratio required by the vehicle model drawings or the production plan quantity ratio.

[0061] As a further description of the above embodiments, step three, the verification items for process verification are:

[0062] 1. After the lower cover plate 1 of the traction beam is CNC cut, check whether the process tie rod 2 is broken or deformed, and whether the dimensions of the parts meet the requirements of the drawings;

[0063] 2. After the lower cover plate 1 of the traction beam is leveled, check whether the process tie rod 2 is broken or deformed, and whether the dimensions of the parts meet the requirements of the drawings.

[0064] 3. After the lower cover plate of the traction beam is welded and assembled, check whether the dimensions of the parts meet the requirements of the drawings. If they do, cut off the process tie rod 2 and grind it.

[0065] In this process, the part size refers to the size of the lower cover plate 1 of the traction beam.

[0066] As a further description of the above embodiments, the method for adjusting the sampling when the process verification fails in step four is as follows:

[0067] If process tie rod 2 deforms, the width of process tie rod 2 shall be increased. The specific method is as follows:

[0068] The width of process tie rod 2 is increased by 10mm each time until there is no obvious deformation of process tie rod 2. The flatness of process tie rod 2 shall not exceed 5mm.

[0069] If the end dimension of the process tie rod at the bottom of the lower cover plate 1 of the traction beam exceeds the tolerance after leveling, then shorten the distance from the process tie rod 2 to the opening end of the lower cover plate 1 of the traction beam. The specific method is as follows:

[0070] Each time, reduce the distance from the process tie rod 2 to the opening end of the lower cover plate 1 of the traction beam by 10mm until the end dimension of the process tie rod 2 is within ±1mm of the dimension required by the drawing.

[0071] Of course, each increase in the width of the process tie rod 2 and decrease in the distance from the process tie rod 2 to the opening end of the lower cover plate 1 of the traction beam is not limited to 10mm, and can be adjusted accordingly based on the actual construction situation.

[0072] This method has been applied in batches in aluminum alloy funnel carts, saving 25.12 kg per sheet of sheet per cart. Each cart saves 12.56 kg of raw materials and 50 yuan per cart.

[0073] Example 2

[0074] Step 1. Pre-sorting

[0075] S1. Determine the number of traction beam under-cover plates 1 that can be arranged longitudinally and laterally according to the specifications of the raw materials on site;

[0076] S2. Arrange the corresponding number of traction beam under-cover plates 1 in the longitudinal and transverse directions according to the determined quantity;

[0077] During the arrangement process, the adjacent edges of the lower cover plates 1 of the two longitudinally adjacent traction beams are attached, and the front end of the lower cover plate 1 of the rear traction beam is on the same vertical line as the opening end of the lower cover plate 1 of the previous traction beam.

[0078] S3. Arrange the small parts required for the processing of railway freight car components in the remaining material of the lower cover plate 1 of the traction beam.

[0079] Step 2. Optimize the layout

[0080] S1. Based on the pre-layout structure, determine the position and size of the process tie rod 2, wherein the distance from the process tie rod 2 to the end of the opening of the lower cover plate 1 of the traction beam is not greater than 150mm;

[0081] S2. After determining the position of the process tie rod 2, adjust the position of the lower cover plate 1 of the rear traction beam so that the front end of the lower cover plate 1 of the rear traction beam is nested inside the opening end of the lower cover plate 1 of the previous traction beam.

[0082] Step 3. Process Validation

[0083] The raw materials were cut into pieces for production, and the resulting lower cover plate 1 of the traction beam was verified.

[0084] If the process validation fails, the sample layout is adjusted and the process validation is performed again until the process validation passes.

[0085] If the process verification is successful, the sample will be mass-produced.

[0086] In summary, this invention effectively reduces waste of surplus materials, improves material utilization, and also reduces the time spent on manual assembly of the drawing process, thereby increasing production efficiency and ensuring part quality. Therefore, this invention effectively overcomes the various shortcomings of existing technologies and has high industrial application value.

[0087] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A method for cutting the lower cover plate of a railway freight car traction beam, characterized in that, Includes the following steps: Step 1. Pre-sorting S1. A cover plate (1) is placed under at least two rows of traction beams arranged in parallel longitudinal direction. S2. At least two rows of traction beam under-cover plates (1) are arranged laterally. During the arrangement process, the front end of the rear traction beam under-cover plate (1) and the end of the opening of the previous traction beam under-cover plate (1) are on the same vertical line. S3. Arrange the small parts required for the processing of railway freight car components in the remaining material of the lower cover plate (1) of the traction beam; Step 2. Optimize the layout S1. Based on the pre-layout structure, determine the position and size of the process pull bar (2) and the specifications of the raw materials. The distance from the process pull bar (2) to the opening end of the lower cover plate (1) of the traction beam shall not be greater than 150mm. S2. After determining the position and size of the process pull bar (2), adjust the position of the lower cover plate (1) of the rear traction beam so that the front end of the lower cover plate (1) of the rear traction beam is nested in the opening end of the lower cover plate (1) of the previous traction beam. Step 3. Process Validation According to the raw material specifications in the layout diagram, select raw materials for cutting tests, and verify the traction beam lower cover plate (1) obtained from the cutting production: If the process validation fails, the sample layout is adjusted and the process validation is performed again until the process validation passes. If the process verification is successful, the sample will be mass-produced.

2. The method for cutting the lower cover plate of the railway freight car traction beam according to claim 1, characterized in that: In step S4 of step one, during the small parts arrangement process, the ratio of the number of small parts to the number of traction beams is arranged according to the ratio required by the vehicle model drawings or the production plan quantity ratio.

3. The method for cutting the lower cover plate of the railway freight car traction beam according to claim 1, characterized in that: In step S1 of the second step, the width of the process strip (2) is 30-50 mm.

4. The method for cutting the lower cover plate of the railway freight car traction beam according to claim 1, characterized in that, In step three, the verification items for process validation are as follows:

1. After the lower cover plate of the traction beam (1) is cut by CNC, is the process tie rod (2) broken or deformed, and does the size of the part meet the requirements of the drawing? 2. After the lower cover plate of the traction beam (1) is leveled, check whether the process tie rod (2) is broken or deformed, and whether the dimensions of the parts meet the requirements of the drawings; 3. After the lower cover plate of the traction beam (1) is assembled by welding, check whether the size of the parts meets the requirements of the drawing. If it does, cut off the process tie rod (2) and grind it.

5. The method for cutting the lower cover plate of the railway freight car traction beam according to claim 1, characterized in that, In step three, the method for adjusting the sample layout when the process verification fails is as follows: If the process tie rod (2) deforms, then increase the width of the process tie rod (2); If the end dimension of the process tie rod is out of tolerance after the traction beam lower cover plate (1) is leveled, then shorten the distance from the process tie rod (2) to the end of the opening of the traction beam lower cover plate (1).

6. The method for cutting the lower cover plate of the railway freight car traction beam according to claim 5, characterized in that, The method to increase the width of the process tie rod (2) is as follows: increase the width of the process tie rod (2) by 10mm each time until the process tie rod (2) has no obvious deformation.

7. The method for cutting the lower cover plate of the railway freight car traction beam according to claim 5, characterized in that, The method to shorten the distance between the process tie rod (2) and the opening end of the lower cover plate (1) of the traction beam is as follows: reduce the distance between the process tie rod (2) and the opening end of the lower cover plate (1) of the traction beam by 10mm each time until the end dimension of the process tie rod (2) is within ±1mm of the dimension required by the drawing.

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