Processing device and method of lightweight high-strength high-speed rail sleeper framework

Abstract

The application discloses a kind of processing device of lightweight high-strength high-speed rail sleeping frame, including guide seat, first drive component, laying mechanical arm, mounting bracket, second drive component, adsorption component, laying roller and ultrasonic probe;The guide seat is used to support each component of the whole processing device and electrically connected with each component;The first drive component is arranged in the inside of guide seat;The laying mechanical arm is installed on guide seat, and the first drive component is connected with laying mechanical arm, for driving laying mechanical arm moves along guide seat;The mounting bracket is installed in the output end of laying mechanical arm;The second drive component is installed in the inside of mounting bracket;The adsorption component is installed at both ends of mounting bracket, for adsorbing carbon fiber prepreg;The laying roller is installed in the inside of mounting bracket, and the top of laying roller is connected with second drive component, and the second drive component is used to drive laying roller to move back and forth on mounting bracket.

Description

Technical Field

[0001] This invention relates to the field of high-speed rail supporting facility processing technology, specifically to a processing device and method for a lightweight, high-strength high-speed rail sleeper frame. Background Technology

[0002] With the rapid development of my country's high-speed rail industry, the operating speed of high-speed trains is also on the rise, placing more stringent requirements on the lightweight, high strength, and fatigue resistance of vehicle components. As the core load-bearing component of high-speed sleeper carriages, the sleeper frame not only needs to bear the weight of passengers and bedding but also needs to withstand complex loads such as vibration and impact during train operation. Its performance directly affects the safety, comfort, and energy consumption of the carriage.

[0003] Currently, most high-speed rail sleeper berth frames are made of steel or aluminum alloy. While steel frames offer high strength, their heavy weight significantly increases overall train energy consumption and they are prone to corrosion and high maintenance costs. Aluminum alloy frames, although achieving a certain degree of weight reduction, lack the strength and fatigue resistance required for the long-term operation of high-speed trains, and are prone to deformation and cracking under prolonged vibration loads, affecting their service life. To address these issues, carbon fiber composite materials, with their superior properties such as high specific strength, light weight, corrosion resistance, fatigue resistance, and low thermal conductivity, are gradually becoming the preferred material for lightweight upgrades of high-speed rail components. Their density is only about 1 / 4 that of steel, while their strength can reach 3-5 times that of steel. Applying carbon fiber to high-speed rail sleeper berth frames can significantly reduce frame weight and train energy consumption while significantly improving the frame's load-bearing capacity and service life.

[0004] However, the processing characteristics of carbon fiber differ significantly from those of traditional metals, and existing metal frame processing equipment and methods cannot be directly applied to the processing of carbon fiber high-speed rail sleeper frames. Currently, carbon fiber components are mostly processed using manual laying and molding methods, which suffer from low processing efficiency, poor molding accuracy, and inconsistent component quality. Furthermore, existing processing equipment lacks precise control over the laying accuracy, molding pressure, and curing temperature of the carbon fiber prepreg, easily leading to defects such as delamination, bubbles, and cracks in the molded sleeper frames, failing to meet the stringent quality standards of high-speed rail components.

[0005] Meanwhile, there is a lack of specialized processing equipment and systematic processing methods for carbon fiber high-speed rail sleeper frames in the existing technology, which restricts the large-scale application of carbon fiber materials in the field of high-speed rail sleeper frames and makes it difficult to meet the development needs of lightweight and high-strength high-speed rail carriages.

[0006] Therefore, developing a processing device and method that can achieve efficient and precise processing of carbon fiber high-speed rail sleeper frames has become a pressing technical challenge in this field. Summary of the Invention

[0007] The purpose of this invention is to provide a processing device and method for lightweight and high-strength high-speed rail sleeper frames, aiming to improve the problems of existing high-speed rail sleeper frames being heavy and lacking strength, as well as the low processing efficiency and high defect rate of carbon fiber sleeper frames.

[0008] This invention is implemented as follows: To achieve the above objectives, according to one aspect of the present invention, the present invention provides a processing apparatus for a lightweight, high-strength high-speed rail sleeper frame, comprising: The guide seat is used to support the various components of the entire processing device and to electrically connect with each component. A first drive assembly is disposed inside the guide seat; A tiling robotic arm is mounted on a guide seat, and the first drive assembly is connected to the tiling robotic arm to drive the tiling robotic arm to move along the guide seat; Mounting bracket, which is installed at the output end of the tiling robot arm; The second drive assembly is mounted inside the mounting bracket; An adsorption assembly is installed at both ends of the mounting frame and is used to adsorb carbon fiber prepreg. A laying roller is mounted inside the mounting frame, and the top end of the laying roller is connected to a second drive assembly, which is used to drive the laying roller to move back and forth on the mounting frame. An ultrasonic probe is installed at the rear end of the laying roller and is used to detect whether there are air bubbles and gaps in the laying of carbon fiber prepreg after the laying roller presses the carbon fiber prepreg.

[0009] Preferably, the guide seat has a control box on the front, a power connection slot and a communication slot on one side, a base plate on both sides of the bottom of the guide seat, and multiple bottom holes on the base plate; the upper surface of the guide seat has a first guide groove, and a first bearing is provided at both ends of the first guide groove; the upper surface of the guide seat has guide rods at both the front and rear ends, and the guide rods have ear plates at both ends that are connected to the guide seat.

[0010] Preferably, the control box integrates a control module, which is electrically connected to a path planning module, a pressure control module, an adsorption and bonding module, an ultrasonic detection module, a repair module, a wireless communication module, and a power supply module. The control module controls the operation of the entire processing device. The path planning module plans the path for the laying robotic arm to lay the carbon fiber prepreg. The pressure control module controls the pressure of the laying roller on the carbon fiber prepreg. The adsorption and bonding module controls the adsorption assembly to adsorb and lay the carbon fiber prepreg. The ultrasonic detection module detects the prepreg after rolling to determine if air bubbles or gaps exist. The repair module, upon determining the presence of air bubbles or gaps, controls the nearby adsorption module to lift the prepreg and then re-roll it to remove air bubbles. The wireless communication module wirelessly connects to the laying roller to receive data transmitted by the roller. The power supply module supplies power to the entire processing device.

[0011] Preferably, the first drive assembly includes a first drive screw and a first servo motor. The first drive screw is installed inside the first guide, and both ends of the first drive screw are provided with first adapters, which are interference-fitted with a first bearing. The end of the first drive screw facing the first servo motor is provided with a drive slot. The end of the first servo motor that is in contact with the guide seat is provided with a plurality of first fixing feet, and the first fixing feet are provided with a plurality of first fixing holes. The first servo motor is fixed to the guide seat by bolts passing through the first fixing holes, and the output end of the first servo motor is inserted into the drive slot at the end of the first drive screw. Two connecting wires are provided on the side of the first servo motor, and the ends of the connecting wires are provided with connecting plugs. The connecting plugs are electrically connected to the connecting slots. The two connecting wires serve as the power supply line and signal transmission line of the first servo motor, respectively.

[0012] Preferably, the bottom end of the tiling robot arm is provided with a base, the bottom end of the base is provided with a connecting block, the middle of the connecting block is provided with a first threaded hole, the first threaded hole is threadedly connected to the first drive screw; the front and rear ends of the base are provided with sleeve joints, the middle of the sleeve joint is provided with a linear bearing; the output end of the tiling robot arm is provided with a rotary motor, the output end of the rotary motor is provided with a drive shaft, the bottom end of the drive shaft is provided with a connecting plate, and the edge of the connecting plate is provided with multiple connecting holes.

[0013] Preferably, the bottom surface of the mounting frame is provided with a second guide groove, the two ends of the second guide groove are provided with second bearings, the two ends of the mounting frame are provided with mounting plates, the middle of the mounting plate is provided with a through hole; the middle of the mounting frame is provided with a mounting column, the top of the mounting column is provided with a mounting plate, the edge of the mounting plate is provided with a mounting hole, and the mounting plate and the connecting plate are connected by bolts; The second drive assembly includes a second servo motor and a second drive screw. The second drive screw is installed inside a second guide groove. The second drive screw has second adapters at both ends, and the second adapters are interference-fitted with a second bearing. The second servo motor has multiple second fixing feet at one end of the mounting bracket, and multiple second fixing holes on the second fixing feet. The second servo motor is fixed to the mounting bracket by bolts passing through the second fixing holes. The output end of the second servo motor has a drive shaft, which is connected to the second drive screw.

[0014] Preferably, the adsorption assembly includes an electric suction cup and a drive cylinder. The drive cylinder has connecting plates on both sides of one end that is attached to the mounting plate. The connecting plates have multiple bolt holes, and the drive cylinder is fixed to the mounting plate by bolts passing through these bolt holes. The output end of the drive cylinder has a piston rod, and the bottom end of the piston rod has a second splicing plate. The top end of the electric suction cup has a connecting column, and the top end of the connecting column has a first splicing plate. The first splicing plate and the second splicing plate are connected by bolts. The electric suction cup is provided with a first wire, and the end of the first wire has a first connecting female connector, which is electrically connected to the tiling robot arm.

[0015] Preferably, the laying roller has a connecting frame at one end, a connecting rod at the top of the connecting frame, a support plate on the side of the connecting rod, a square hole on the support plate, and the support plate mates with the square hole for mounting an ultrasonic probe. A slider is located at the top of the connecting rod, and a second threaded hole is located in the middle of the slider. The slider is installed inside a second guide groove, and the second threaded hole is threadedly connected to a second drive screw. The laying roller integrates a microprocessor, which is electrically connected to a lithium battery, a pressure sensor, and a data transmission module. The lithium battery powers the entire laying roller, the pressure sensor measures the pressure exerted by the laying roller on the carbon fiber prepreg, and the data transmission module wirelessly transmits the data measured by the pressure sensor to the control box.

[0016] According to a second aspect of the present invention, the present invention provides a method for processing a lightweight, high-strength high-speed rail sleeper frame, the specific steps of which are as follows: S100: Epoxy flame retardant resin-based carbon fiber prepreg is selected. The prepreg is left to stand for 2-4 hours in an environment of 25±2℃ and 40%-60% humidity, and unqualified prepreg is removed. S200. Clean the upper and lower molds of the molding die, apply release agent evenly to the surface of the cavity, and let stand for 10-15 minutes until the release agent dries. S300: By setting the laying parameters through the control box on the guide seat, the laying robotic arm is started to drive the mounting frame, the second drive component, the laying roller, the ultrasonic probe, and the adsorption component to work. At the same time, the second drive component drives the laying robotic arm to move. The adsorption component adsorbs the cut carbon fiber prepreg and lays it layer by layer onto the surface of the lower mold cavity. The laying roller rolls and vents air simultaneously during the laying process. During the laying process, the ultrasonic probe detects in real time whether there are gaps and air bubbles in the laid area. The number of laying layers is 8-16 layers, and the laying directions of adjacent layers are staggered at 90°. S400. Check the paving quality. After checking the paving quality, start the pressure curing mechanism and drive the upper mold to descend and close the mold. S500: Set the curing parameters, start the temperature control mechanism and the pressure curing mechanism to achieve closed-loop control of temperature and pressure, and the curing time is 60-90 minutes; After S600 curing is completed, the cooling components are activated to cool the component to room temperature. Then the mold is opened and the carbon fiber reclining skeleton is removed. S700. Grind and repair the components, inspect their dimensions, strength and appearance, reject unqualified products, and number and package qualified products.

[0017] Preferably, the specific steps for laying the carbon fiber prepreg in step S300 are as follows: S310. Select the corresponding high-speed rail sleeper frame model through the control box of the guide seat. The path planning module inside the control box will plan the laying path according to the model of the high-speed rail sleeper frame. S320, the second drive component drives the laying robot arm to move to the starting position of laying; S330: The laying robot arm moves the adsorption component above the cut carbon fiber prepreg. The drive cylinder of the adsorption component drives the electric adsorption to adhere to the carbon fiber prepreg. Then the drive cylinder moves the carbon fiber prepreg upward so that the laying roller presses against the prepreg. During the adsorption process, the adsorption component is used selectively according to the size of the carbon fiber prepreg. S340: The robotic arm applies carbon fiber prepreg to the cavity of the lower mold according to the planned laying path. At the same time, the laying roller begins to roll and degas the carbon fiber prepreg. When the laying roller rolls near the adsorption component, the adsorption component is released. During the rolling process, the ultrasonic probe detects the rolled carbon fiber prepreg to ensure that the rolled carbon fiber prepreg does not have air bubbles or gaps. S350 When the ultrasonic probe detects air bubbles or gaps, it sends a signal to the control box. The control box then controls the adsorption component to pull apart the carbon fiber prepreg with air bubbles or gaps. Then the laying roller re-lays and presses the material until there are no more air bubbles or gaps. S360. Repeat steps S330-S350 to perform multi-layer bonding of the carbon fiber prepreg, and when bonding adjacent layers, the rotary motor at the output end of the laying robot arm should drive the carbon fiber prepreg to rotate 90°.

[0018] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention uses carbon fiber as the raw material for the high-speed rail sleeper frame. Compared with traditional steel and aluminum alloy materials, carbon fiber has a much lower density than steel and a higher strength, achieving a lightweight upgrade of the sleeper frame. This can significantly reduce the overall weight of the high-speed rail carriage and reduce the energy consumption of train operation. At the same time, carbon fiber has excellent corrosion resistance and fatigue resistance, which can significantly improve the service life of the sleeper frame and reduce maintenance costs, solving the technical pain points of existing sleeper frames such as large weight, insufficient strength, and easy corrosion.

[0019] 2. The laying robot arm of the present invention is equipped with an ultrasonic probe, which can monitor the carbon fiber impregnated material during the roller pressing and bonding process. If defects such as air bubbles and gaps occur during the roller pressing and bonding process, the ultrasonic probe will promptly feed the data back to the control box. The control box controls the electric suction cup to lift the carbon fiber impregnated material and then re-roll it to ensure that no defects such as air bubbles and gaps occur in the carbon fiber impregnated material during the roller pressing process, thus ensuring the quality of the sleeper frame processing.

[0020] 3. The processing method of the present invention has a clear process flow and is easy to operate. It can achieve standardized processing and has high processing efficiency. Compared with the traditional manual processing method, the processing efficiency is greatly improved, and the product consistency is good and the dimensional accuracy is high. It can meet the stringent quality standards of high-speed rail components and realize the large-scale production of carbon fiber high-speed rail sleeper frames, promoting the widespread application of carbon fiber materials in the field of high-speed rail components.

[0021] 4. The processing device and method of the present invention are highly versatile. They can adjust the mold cavity structure and processing parameters according to the requirements of different models and sizes of high-speed rail sleeper frames, adapt to the processing of various specifications of carbon fiber sleeper frames, have a wide range of applications, and have strong practicality and promotional value. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the invention from a top-down, front-end perspective; Figure 2 This is a schematic diagram of the overall structure of the invention from a front-end oblique tilting angle; Figure 3 This is a schematic diagram of the structure of the guide base of the present invention; Figure 4 This is a structural block diagram of the internal structure of the control box of the present invention; Figure 5 This is a schematic diagram of the structure of the first driving component of the present invention; Figure 6 This is a schematic diagram of the structure of the robotic arm for paving according to the present invention; Figure 7 This is a schematic diagram of the mounting bracket of the present invention; Figure 8 This is a schematic diagram of the structure of the second driving component of the present invention; Figure 9 This is a schematic diagram of the adsorption component of the present invention; Figure 10 This is a schematic diagram of the structure of the laying roller of the present invention; Figure 11 This is a structural block diagram of the internal structure of the laying roller of the present invention; Figure 12 This is a schematic diagram of the structure of the ultrasonic probe of the present invention; Figure 13 This is a flowchart of the processing method of the present invention.

[0023] In the diagram: 1. Guide seat; 11. Control box; 12. Power connection slot; 13. Connection slot; 14. Base plate; 15. Bottom hole; 16. First bearing; 17. First guide groove; 18. Ear plate; 19. Guide rod; 2. First drive assembly; 21. First drive screw; 211. First adapter; 212. Drive slot; 22. First servo motor; 221. First fixing foot; 222. First fixing hole; 223. Connection cable; 224. Connection plug; 3. Laying robot arm; 31. Base; 32. Connecting block; 33. First threaded hole; 34. Socket; 35. Linear bearing; 36. Rotary motor; 37. Drive shaft; 38. Connecting plate; 39. Connecting hole; 4. Mounting bracket; 41. Second guide groove; 42. Second bearing; 43. Mounting plate; 44. Through hole; 45. Mounting post; 46. 1. Mounting plate; 47. Mounting hole; 5. Second drive assembly; 51. Second drive screw; 511. Second adapter; 52. Second servo motor; 521. Drive shaft; 522. Second fixing foot; 523. Second fixing hole; 6. Adsorption assembly; 61. Electric suction cup; 611. Connecting post; 612. First splicing plate; 613. First wire; 614. First connecting female head; 62. Drive cylinder; 621. Piston rod; 622. Second splicing plate; 623. Connecting plate; 624. Bolt hole; 7. Laying roller; 71. Connecting frame; 72. Connecting rod; 73. Support plate; 74. Square hole; 75. Slider; 76. Second threaded hole; 8. Ultrasonic probe; 81. Spring; 82. Telescopic guide rod; 83. Block; 84. Pressure cap; 85. Stud; 86. Second wire; 87. Second connecting female head. Detailed Implementation

[0024] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0025] The following description, in conjunction with the accompanying drawings and specific embodiments, provides further details:

[0026] Example 1 like Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, this embodiment provides a processing device for a lightweight, high-strength high-speed rail sleeper frame. The device mainly consists of a guide seat 1, a first drive assembly 2, a laying robotic arm 3, a mounting frame 4, a second drive assembly 5, an adsorption assembly 6, a laying roller 7, and an ultrasonic probe 8. The guide seat 1 supports all components of the processing device and provides electrical connection to each component, ensuring stable operation. The guide seat 1 has a control box 11 on its front, an electrical connection slot 12 and a connection slot 13 on its side, and a base plate 14 fixed to the bottom of both sides. The base plate 14 has multiple bottom holes 15 for fixed installation. A first guide groove 17 is formed on the upper surface of the guide seat 1, with a first bearing 16 installed at both ends of the first guide groove 17. Guide rods 19 are also provided at the front and rear ends of the upper surface, and the two ends of the guide rods 19 are securely connected to the guide seat 1 via ear plates 18. The control box 11 integrates a control module, which is electrically connected to the path planning module, pressure control module, adsorption and bonding module, ultrasonic detection module, repair module, wireless communication module, and power supply module. The control module, as the core unit, coordinates the operation of the entire processing device. The path planning module is used to plan the movement path of the laying robot arm 3 to lay the carbon fiber prepreg. The pressure control module is used to precisely control the rolling pressure applied to the carbon fiber prepreg by the laying roller 7. The adsorption and bonding module is used to control the adsorption component 6 to complete the adsorption and laying action of the carbon fiber prepreg. The ultrasonic detection module is used to detect the carbon fiber prepreg after rolling to determine whether there are air bubbles or gap defects in the laid material. When the repair module detects air bubbles or gap defects, it controls the adsorption component 6 at the corresponding position to pull up the defective carbon fiber prepreg, and then the laying roller 7 is used to re-lay and roll it to achieve the effect of full air removal. The wireless communication module is used to establish a wireless connection with the laying roller 7 and receive the real-time operation data transmitted by the laying roller 7. The power supply module provides a stable power supply to all electrical components of the entire processing device.

[0027] like Figure 5 As shown, the first drive assembly 2 is installed inside the guide seat 1 and mainly consists of a first drive screw 21 and a first servo motor 22. The first drive screw 21 is assembled inside the first guide groove 17, and both ends of it are provided with first adapter parts 211. The first adapter parts 211 are connected to the first bearing 16 by an interference fit. The end of the first drive screw 21 facing the first servo motor 22 is machined with a drive slot 212. The end of the first servo motor 22 that is in contact with the guide seat 1 is provided with a plurality of first fixing feet 221, and a plurality of first fixing holes 22 are opened on the first fixing feet 221. 2. The first servo motor 22 is fixedly installed at the end of the guide seat 1 by bolts passing through the first fixing hole 222. The output end of the first servo motor 22 is inserted into the drive slot 212 at the end of the first drive screw 21 to realize power transmission. Two connecting lines 223 are led out from the side of the first servo motor 22. The end of the connecting line 223 is provided with a connecting plug 224. The connecting plug 224 is electrically connected to the connecting slot 13 on the guide seat 1. The two connecting lines 223 serve as the power supply line and signal transmission line of the first servo motor 22, respectively, to ensure power supply and signal interaction.

[0028] like Figure 6 and Figure 7 As shown, the tiling robot arm 3 is mounted on the guide seat 1 and connected to the first drive assembly 2. It is driven by the first drive assembly 2 to move linearly along the guide seat 1. The bottom end of the tiling robot arm 3 is provided with a base 31. A connecting block 32 is fixed at the bottom of the base 31. A first threaded hole 33 is machined in the middle of the connecting block 32. The first threaded hole 33 and the first drive screw 21 form a threaded transmission engagement. The front and rear ends of the base 31 are symmetrically provided with socket joints 34. A linear bearing 35 is installed in the middle of the socket joint 34. The linear bearing 35 slides with the guide rod 19 to improve the stability of the movement of the tiling robot arm 3. A rotary motor 36 is installed at the output end of the tiling robot arm 3. The output end of the rotary motor 36 is connected to the drive shaft 37. A connecting plate 38 is fixed at the bottom end of the drive shaft 37. Multiple connecting holes 39 for connection are opened on the edge of the connecting plate 38. Mounting bracket 4 is fixedly installed at the output end of paving robot arm 3. A second guide groove 41 is opened on its bottom surface. Second bearings 42 are installed at both ends of the second guide groove 41. Mounting plates 43 are provided at both ends of mounting bracket 4. A through hole 44 is machined in the middle of mounting plate 43. Mounting column 45 is provided in the middle of mounting bracket 4. Mounting plate 46 is fixed at the top of mounting column 45. Mounting hole 47 is opened on the edge of mounting plate 46. Mounting plate 46 and connecting plate 38 at the output end of paving robot arm 3 are fastened together by bolts to achieve stable assembly of mounting bracket 4 and paving robot arm 3.

[0029] like Figure 8 and Figure 9As shown, the second drive assembly 5 is installed inside the mounting bracket 4 and consists of a second servo motor 52 and a second drive screw 51. The second drive screw 51 is assembled inside the second guide groove 41, and its two ends are provided with second adapter parts 511. The second adapter parts 511 are connected to the second bearing 42 by an interference fit. The end of the second servo motor 52 that is in contact with the mounting bracket 4 is provided with multiple second fixing feet 522. Multiple second fixing holes 523 are opened on the second fixing feet 522. The second servo motor 52 is fixed to the mounting bracket 4 by bolts passing through the second fixing holes 523. The output end of the second servo motor 52 is provided with a drive shaft 521, which is connected to the second drive screw 51 to transmit power to the second drive screw 51. Two sets of adsorption components 6 are installed at both ends of the mounting frame 4 to perform the adsorption operation of carbon fiber prepreg. The adsorption component 6 consists of an electric suction cup 61 and a drive cylinder 62. The drive cylinder 62 has connecting plates 623 on both sides of the end that is in contact with the mounting plate 43. Multiple bolt holes 624 are machined on the connecting plates 623. The drive cylinder 62 is fixed to the mounting plate 43 by bolts passing through the bolt holes 624. The output end of the drive cylinder 62 is provided with a piston rod 621. The bottom end of the piston rod 621 is fixed with a second splicing plate 622. The top end of the electric suction cup 61 is provided with a connecting post 611. The top end of the connecting post 611 is fixed with a first splicing plate 612. The first splicing plate 612 and the second splicing plate 622 are fastened together by bolts. A first wire 613 is led out from the electric suction cup 61. The end of the first wire 613 is provided with a first connecting female head 614. The first connecting female head 614 is electrically connected to the laying robot arm 3 to obtain power and control signals.

[0030] like Figure 10 , Figure 11 and Figure 13As shown, the laying roller 7 is installed inside the mounting frame 4, and its top end is connected to the second drive assembly 5. It is driven by the second drive assembly 5 to reciprocate along the mounting frame 4. One end of the laying roller 7 is provided with a connecting frame 71. The top of the connecting frame 71 is fixed with a connecting rod 72. The side of the connecting rod 72 is provided with a support plate 73. The support plate 73 is machined with a square hole 74 for mounting an ultrasonic probe 8. The top of the connecting rod 72 is fixed with a slider 75. The middle of the slider 75 is machined with a second threaded hole 76. The slider 75 is assembled inside the second guide groove 41, and the second threaded hole 76 forms a threaded transmission engagement with the second drive screw 51. The laying roller 7 integrates a microprocessor. The microprocessor is electrically connected to a lithium battery, a pressure sensor, and a data transmission module. The lithium battery powers the electrical components of the laying roller 7 itself. The pressure sensor detects the pressure value of the laying roller 7 when it rolls the carbon fiber prepreg. The data transmission module transmits the pressure data collected by the pressure sensor to the control box 11 wirelessly to realize real-time feedback of the pressure data. An ultrasonic probe 8 is installed at the rear end of the laying roller 7. It is used to detect whether there are air bubbles and gap defects in the laid carbon fiber prepreg after the laying roller 7 has finished rolling the carbon fiber prepreg. A spring 81 is provided at the middle of the top of the ultrasonic probe 8. A telescopic guide rod 82 is provided inside the spring 81 to ensure that the ultrasonic probe 8 can move up and down stably. The bottom of the ultrasonic probe 8 is lower than the bottom of the laying roller 7. A block 83 is provided on the end plate at the top of the spring 81. The block 83 is inserted into the square hole 74 of the support plate 73. A stud 85 is provided in the middle of the block 83. A pressure cap 84 is installed at the end of the stud 85 that passes through the square hole 74. The pressure cap 84 is pressed tightly on the upper surface of the support plate 73 to achieve a stable installation of the ultrasonic probe 8. A second wire 86 is led out from the ultrasonic probe 8. A second connecting female 87 is provided at the end of the second wire 86. The second connecting female 87 is used for electrical connection with the laying robot arm 3. The bottom of the ultrasonic probe 8 is wrapped with a flexible silicone coupling layer to avoid material damage caused by friction between the probe and the carbon fiber prepreg.

[0031] Working principle: This processing device uses the guide seat 1 as a support base. The control module in the control box 11 coordinates functions such as path planning, pressure regulation, adsorption bonding, ultrasonic detection, and defect repair. During operation, the first drive component 2 drives the laying robot arm 3 to move linearly along the guide seat 1. The path planning module plans the laying trajectory of the carbon fiber prepreg. Under control, the adsorption component 6 completes the adsorption and laying of the carbon fiber prepreg. The second drive component 5 drives the laying roller 7 to move back and forth along the mounting frame 4. The pressure control module precisely regulates the rolling pressure of the laying roller 7. The laying roller 7 rolls the carbon fiber prepreg, and its integrated pressure sensor provides real-time feedback of pressure data. The ultrasonic probe 8 at the rear synchronously detects whether there are air bubbles and gap defects in the material after laying. When a defect is detected, the repair module controls the adsorption component 6 at the corresponding position to pull up the prepreg in the defective area, and then the laying roller 7 re-presses to fully expel the air, ensuring that the carbon fiber prepreg is tightly bonded without defects, thus completing the automated laying processing of the high-speed rail sleeper frame.

[0032] Example 2 like Figure 13 As shown in the figure, this embodiment provides a method for processing a lightweight, high-strength high-speed rail sleeper frame. The specific steps of this processing method are as follows: S100 uses epoxy flame-retardant resin-based carbon fiber prepreg as the processing raw material. The carbon fiber precursor content of the prepreg is selected at 150-200 g / m² according to the wall thickness requirements of the sleeper frame, and the epoxy flame-retardant resin content is 37%-40%, ensuring the lightweight and high-strength performance of the raw material, while also possessing good flame retardancy, meeting the safety standards for high-speed rail components. The carbon fiber prepreg undergoes pretreatment by placing it in an environment with a temperature of 25±2℃ and a humidity of 40%-60% for 2-4 hours to eliminate internal stress and prevent wrinkles and cracks during installation. Simultaneously, the surface quality of the prepreg is inspected, and prepreg with damage, bubbles, or impurities is discarded to ensure raw material quality.

[0033] S200. Clean the upper and lower molds of the molding die, removing dust, impurities, and residual mold release agent from the surface of the mold cavity to ensure that the cavity surface is clean and smooth. Then, evenly coat the cavity surface with a layer of mold release agent. The mold release agent should be a high-temperature resistant, easy-to-peel silicone-based mold release agent. The coating thickness should be controlled at 0.05-0.1mm. After coating, place the mold in a room temperature environment and let it stand for 10-15 minutes until the mold release agent is completely dry to avoid affecting the molding quality and demolding effect of the component.

[0034] S300. Fix the guide seat 1 near the molding die to ensure that the entire processing device can lay carbon fiber prepreg on the molding die. Set the laying parameters through the control box 11 on the guide seat 1, and start the laying robot arm 3 to drive the mounting frame 4, the second drive component 5, the laying roller 7, the ultrasonic probe 8, and the adsorption component 6. At the same time, the second drive component 5 drives the laying robot arm 3 to move. The adsorption component 6 adsorbs the cut carbon fiber prepreg and lays it layer by layer onto the surface of the lower mold cavity. The laying roller 7 simultaneously rolls and vents air during the laying process, and the laying speed is controlled at 50-100 mm / s. During the laying process, the ultrasonic probe 8 detects in real time whether there are gaps and air bubbles in the laid area. The number of laying layers is 8-16, and the laying directions of adjacent layers are staggered at 90°. The specific steps for laying carbon fiber prepreg are as follows: S310. Select the corresponding high-speed rail sleeper frame model through the control box 11 of the guide seat 1. The path planning module inside the control box 11 will plan the laying path according to the model of the high-speed rail sleeper frame; or the path planning module has the laying path of each high-speed rail sleeper frame pre-stored. After the model of the high-speed rail sleeper frame is determined, the laying path of the corresponding model can be directly called.

[0035] S320, the second drive component 5 drives the laying robot arm 3 to the starting position of the laying; and during the laying process, the second drive component 5 will drive the laying robot arm 3 to move according to the laying path to ensure that the laying robot arm 3 can lay the entire lower model cavity.

[0036] S330, the laying robotic arm 3 moves the adsorption assembly 6 above the cut carbon fiber prepreg. The drive cylinder 62 of the adsorption assembly 6 drives the electric suction cup 61 to adhere to the carbon fiber prepreg. Then, the drive cylinder 62 moves the carbon fiber prepreg upward, so that the laying roller 7 presses against the prepreg. During the adsorption process, the adsorption assembly 6 is used selectively according to the size of the carbon fiber prepreg. When the carbon fiber prepreg is small, one adsorption assembly 6 is used. If the carbon fiber prepreg is too large, two adsorption assemblies 6 can be used. The adsorption assembly 6 can also be selected with multiple mounting mechanisms according to the usage requirements. S340: The robotic arm applies the carbon fiber prepreg to the cavity of the lower mold according to the planned application path. Simultaneously, the application roller 7 begins to roll and degas the carbon fiber prepreg. When the application roller 7 reaches the vicinity of the adsorption component 6, the adsorption component 6 is released. During the rolling process, the ultrasonic probe 8 detects the rolled carbon fiber prepreg to ensure it is free of air bubbles and gaps. After the adsorption component 6 releases the carbon fiber prepreg, the drive cylinder 62 lifts the electric suction cup 61 to prevent it from interfering with the operation of the application roller 7 and the ultrasonic probe 8. With the electric suction cup 61 lifted, the application roller 7 can then perform a wide-range back-and-forth rolling motion on the carbon fiber prepreg. S350, when the ultrasonic probe 8 detects air bubbles or gaps, it will send a signal to the control box 11. The control box 11 will control the adsorption component 6 to pull apart the carbon fiber prepreg with air bubbles or gaps, and then the laying roller 7 will press it again until there are no air bubbles or gaps. S360, repeat steps S330-S350 to perform multi-layer bonding of carbon fiber prepreg, and when bonding adjacent layers, the rotary motor 36 at the output end of the laying robot arm 3 should drive the carbon fiber prepreg to rotate 90°.

[0037] After the S400 carbon fiber prepreg is laid, check the laying quality to ensure there are no wrinkles, gaps, or displacement. Then, start the pressure curing mechanism through the control box 11. The hydraulic drive component moves the upper mold downward until the upper mold and lower mold are in contact, completing the mold closing action. During the mold closing process, control the descent speed of the upper mold to be 10-20 mm / s to avoid damage or displacement of the prepreg due to excessive speed.

[0038] After S500 and mold closing, the curing parameters are set via the control box 11: curing temperature 120-150℃, curing pressure 0.5-0.8MPa, and curing time 60-90 minutes. The temperature control mechanism is activated, and the heating element uniformly heats the mold cavity. A temperature sensor monitors the cavity temperature in real time, and the control box 11 adjusts the heating power based on the temperature feedback data to ensure the cavity temperature remains stable within the preset range. Simultaneously, the pressure curing mechanism maintains the preset pressure, and a pressure sensor monitors the pressure in real time, achieving closed-loop pressure control. During curing, vents in the inner wall of the mold cavity release gases generated during the prepreg curing process, preventing defects such as bubbles and delamination in the component.

[0039] After curing (S600), turn off the heating element and start the cooling assembly. The mold and component are rapidly cooled to room temperature (25±2℃) via cooling water pipes and a cooling fan. The cooling time is controlled at 30-45 minutes to prevent stress cracking due to excessive cooling. After cooling, start the pressure curing mechanism. The hydraulic drive assembly moves the upper mold upwards, separating it from the lower mold. Then, using a special demolding tool, gently remove the formed carbon fiber reclining skeleton from the lower mold cavity. The demolding process should be gentle to avoid damaging the surface and edges of the component.

[0040] S700. After demolding, the carbon fiber sleeper frame undergoes post-processing to remove residual release agent and burrs from the component surface. The edges and mounting holes 47 are polished and trimmed to ensure the component dimensions meet design requirements and the surface is smooth and free of defects. After post-processing, the components undergo comprehensive inspection, including dimensional, strength, and appearance checks. Dimensional checks are performed using high-precision calipers and a 3D scanner to measure the length, width, thickness, and position of the mounting holes 47, with dimensional errors controlled within ±0.3mm. Strength checks are conducted using a universal testing machine to measure the compressive strength, bending strength, and shear strength of the components, ensuring they meet the strength requirements of high-speed rail sleeper frames. Appearance checks are performed using a combination of visual inspection and magnification to check for defects such as cracks, bubbles, delamination, and damage on the component surface, rejecting unqualified products. Qualified products are numbered and packaged for assembly into high-speed rail sleeper carriages.

[0041] In summary, compared with existing technologies, this application uses carbon fiber as the processing material for the high-speed rail sleeper frame. Compared with traditional steel and aluminum alloy materials, carbon fiber has a much lower density and greater strength than steel, achieving a lightweight upgrade of the sleeper frame. This significantly reduces the overall weight of the high-speed rail carriage and reduces train operation energy consumption. Simultaneously, carbon fiber has excellent corrosion resistance and fatigue resistance, which can significantly extend the service life of the sleeper frame and reduce maintenance costs, solving the technical pain points of existing sleeper frames such as large weight, insufficient strength, and susceptibility to corrosion. The laying robotic arm 3 is equipped with an ultrasonic probe 8, which can monitor the rolling and bonding of the carbon fiber impregnated material. If defects such as air bubbles and gaps occur during the rolling and bonding process, the ultrasonic probe 8 will promptly feed the data back to the control box 11. The control box 11 then controls the electric suction cup 61 to lift the carbon fiber impregnated material and re-roll it, ensuring that defects such as air bubbles and gaps do not occur during the rolling process, thus guaranteeing the quality of the sleeper frame processing. The processing method described in this application has a clear flow and is easy to operate. It enables standardized processing with high efficiency, significantly improving efficiency compared to traditional manual processing methods. Furthermore, it produces products with good consistency and high dimensional accuracy, meeting the stringent quality standards for high-speed rail components. This method allows for the large-scale production of carbon fiber high-speed rail sleeper frames, promoting the widespread application of carbon fiber materials in high-speed rail components. Moreover, the processing device and method are highly versatile. The mold cavity structure and processing parameters can be adjusted according to the requirements of different models and sizes of high-speed rail sleeper frames, adapting to the processing of various specifications of carbon fiber sleeper frames. It has a wide range of applications and strong practicality and promotional value.

[0042] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A processing device for a lightweight, high-strength high-speed train sleeper frame, characterized in that, include: The guide seat is used to support the various components of the entire processing device and to electrically connect with each component; A first drive assembly is disposed inside the guide seat; A tiling robotic arm is mounted on a guide seat, and the first drive assembly is connected to the tiling robotic arm to drive the tiling robotic arm to move along the guide seat; Mounting bracket, which is installed at the output end of the tiling robot arm; The second drive assembly is mounted inside the mounting bracket; An adsorption assembly is installed at both ends of the mounting frame and is used to adsorb carbon fiber prepreg. A laying roller is mounted inside the mounting frame, and the top end of the laying roller is connected to a second drive assembly, which is used to drive the laying roller to move back and forth on the mounting frame. An ultrasonic probe is installed at the rear end of the laying roller and is used to detect whether there are air bubbles and gaps in the laying of carbon fiber prepreg after the laying roller presses the carbon fiber prepreg.

2. The processing device for a lightweight, high-strength high-speed train sleeper frame according to claim 1, characterized in that, The guide seat has a control box on its front side, a power connection slot and a communication slot on one side, and a base plate on both sides of the bottom of the guide seat with multiple bottom holes. The upper surface of the guide seat has a first guide groove, and a first bearing is provided at both ends of the first guide groove. The upper surface of the guide seat has guide rods at both ends, and ear plates are provided at both ends of the guide rods to connect with the guide seat.

3. The processing device for a lightweight, high-strength high-speed train sleeper frame according to claim 2, characterized in that, The control box integrates a control module, which is electrically connected to a path planning module, a pressure control module, an adsorption and bonding module, an ultrasonic detection module, a repair module, a wireless communication module, and a power supply module. The control module controls the operation of the entire processing device. The path planning module plans the path for the laying robotic arm to lay the carbon fiber prepreg. The pressure control module controls the pressure of the laying roller on the carbon fiber prepreg. The adsorption and bonding module controls the adsorption components to adsorb and lay the carbon fiber prepreg. The ultrasonic detection module detects air bubbles and gaps in the rolled carbon fiber prepreg. The repair module, upon detecting air bubbles and gaps, controls the nearby adsorption module to lift the carbon fiber prepreg and then re-roll it to remove air bubbles. The wireless communication module wirelessly connects to the laying roller to receive data transmitted by the roller. The power supply module supplies power to the entire processing device.

4. The processing device for a lightweight, high-strength high-speed rail sleeper frame according to claim 3, characterized in that, The first drive assembly includes a first drive screw and a first servo motor. The first drive screw is installed inside a first guide groove, and both ends of the first drive screw are provided with first adapters, which are interference-fitted with a first bearing. The end of the first drive screw facing the first servo motor is provided with a drive slot. The end of the first servo motor that is in contact with the guide seat is provided with multiple first fixing feet, and the first fixing feet are provided with multiple first fixing holes. The first servo motor is fixed to the guide seat by bolts passing through the first fixing holes, and the output end of the first servo motor is inserted into the drive slot at the end of the first drive screw. Two connecting wires are provided on the side of the first servo motor, and the ends of the connecting wires are provided with connecting plugs. The connecting plugs are electrically connected to the connecting slots. The two connecting wires serve as the power supply line and signal transmission line of the first servo motor, respectively.

5. The processing device for a lightweight, high-strength high-speed train sleeper frame according to claim 4, characterized in that, The paving robot arm has a base at its bottom end, and a connecting block at the bottom end of the base. The connecting block has a first threaded hole in the middle, which is threadedly connected to a first drive screw. The base has symmetrical sleeve joints at its front and rear ends, and a linear bearing in the middle of the sleeve joint. The paving robot arm has a rotary motor at its output end, and a drive shaft at its output end. The drive shaft has a connecting plate at its bottom end, and the edge of the connecting plate has multiple connecting holes.

6. The processing device for a lightweight, high-strength high-speed rail sleeper frame according to claim 5, characterized in that, The mounting frame has a second guide groove on its bottom surface, and a second bearing is provided at both ends of the second guide groove. The mounting frame has mounting plates at both ends, and a through hole is provided in the middle of the mounting plate. The mounting frame has a mounting column in the middle, and a mounting plate is provided at the top of the mounting column. The mounting plate has mounting holes on its edge, and the mounting plate and the connecting plate are connected by bolts. The second drive assembly includes a second servo motor and a second drive screw. The second drive screw is installed inside a second guide groove. The second drive screw has second adapters at both ends, and the second adapters are interference-fitted with a second bearing. The second servo motor has multiple second fixing feet at one end of the mounting bracket, and multiple second fixing holes on the second fixing feet. The second servo motor is fixed to the mounting bracket by bolts passing through the second fixing holes. The output end of the second servo motor has a drive shaft, which is connected to the second drive screw.

7. The processing device for a lightweight, high-strength high-speed train sleeper frame according to claim 6, characterized in that, The adsorption assembly includes an electric suction cup and a drive cylinder. The drive cylinder has connecting plates on both sides of one end that is attached to the mounting plate. The connecting plates have multiple bolt holes, and the drive cylinder is fixed to the mounting plate by bolts passing through these bolt holes. The output end of the drive cylinder has a piston rod, and the bottom end of the piston rod has a second splicing plate. The top of the electric suction cup has a connecting column, and the top of the connecting column has a first splicing plate. The first and second splicing plates are connected by bolts. The electric suction cup is equipped with a first wire, and the end of the first wire has a first connecting female connector, which is electrically connected to the tiling robot arm.

8. The processing device for a lightweight, high-strength high-speed train sleeper frame according to claim 7, characterized in that, The laying roller has a connecting frame at one end, a connecting rod at the top of the connecting frame, a support plate on the side of the connecting rod, and a square hole on the support plate for mounting an ultrasonic probe. A slider is located at the top of the connecting rod, and a second threaded hole is located in the middle of the slider. The slider is installed inside a second guide groove, and the second threaded hole is threadedly connected to a second drive screw. The laying roller integrates a microprocessor, which is electrically connected to a lithium battery, a pressure sensor, and a data transmission module. The lithium battery powers the entire laying roller, the pressure sensor measures the pressure exerted by the laying roller on the carbon fiber prepreg, and the data transmission module wirelessly transmits the data measured by the pressure sensor to the control box.

9. A method for processing a lightweight, high-strength high-speed rail sleeper frame, using the processing apparatus for a lightweight, high-strength high-speed rail sleeper frame as described in claim 8, characterized in that... The specific steps of this processing method are as follows: S100: Epoxy flame retardant resin-based carbon fiber prepreg is selected. The prepreg is left to stand for 2-4 hours in an environment of 25±2℃ and 40%-60% humidity, and unqualified prepreg is removed. S200. Clean the upper and lower molds of the molding die, apply release agent evenly to the surface of the cavity, and let stand for 10-15 minutes until the release agent dries. S300: By setting the laying parameters through the control box on the guide seat, the laying robotic arm is started to drive the mounting frame, the second drive component, the laying roller, the ultrasonic probe, and the adsorption component to work. At the same time, the second drive component drives the laying robotic arm to move. The adsorption component adsorbs the cut carbon fiber prepreg and lays it layer by layer onto the surface of the lower mold cavity. The laying roller rolls and vents air simultaneously during the laying process. During the laying process, the ultrasonic probe detects in real time whether there are gaps and air bubbles in the laid area. The number of laying layers is 8-16 layers, and the laying directions of adjacent layers are staggered at 90°. S400. Check the paving quality. After checking the paving quality, start the pressure curing mechanism and drive the upper mold to descend and close the mold. S500: Set the curing parameters, start the temperature control mechanism and the pressure curing mechanism to achieve closed-loop control of temperature and pressure, and the curing time is 60-90 minutes; After S600 curing is completed, the cooling components are activated to cool the component to room temperature. Then the mold is opened and the carbon fiber reclining skeleton is removed. S700. Grind and repair the components, inspect their dimensions, strength and appearance, reject unqualified products, and number and package qualified products.

10. A method for processing a lightweight, high-strength high-speed train sleeper frame according to claim 9, characterized in that, The specific steps for laying the carbon fiber prepreg in step S300 are as follows: S310. Select the corresponding high-speed rail sleeper frame model through the control box of the guide seat. The path planning module inside the control box will plan the laying path according to the model of the high-speed rail sleeper frame. S320, the second drive component drives the tiling robotic arm to move to the starting position of tiling; S330: The laying robotic arm moves the adsorption component above the cut carbon fiber prepreg. The drive cylinder of the adsorption component drives the electric suction cup to adhere to the carbon fiber prepreg. Then, the drive cylinder moves the carbon fiber prepreg upward so that the laying roller presses against the prepreg. During the adsorption process, the adsorption component is used selectively according to the size of the carbon fiber prepreg. S340: The robotic arm applies carbon fiber prepreg to the cavity of the lower mold according to the planned laying path. At the same time, the laying roller begins to roll and degas the carbon fiber prepreg. When the laying roller rolls near the adsorption component, the adsorption component is released. During the rolling process, the ultrasonic probe detects the rolled carbon fiber prepreg to ensure that the rolled carbon fiber prepreg does not have air bubbles or gaps. S350 When the ultrasonic probe detects air bubbles or gaps, it sends a signal to the control box. The control box then controls the adsorption component to pull apart the carbon fiber prepreg with air bubbles or gaps. Then the laying roller re-lays and presses the material until there are no more air bubbles or gaps. S360. Repeat steps S330-S350 to perform multi-layer bonding of the carbon fiber prepreg, and when bonding adjacent layers, the rotary motor at the output end of the laying robot arm should drive the carbon fiber prepreg to rotate 90°.

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