Bogie frame manufacturing method, bogie and rail vehicle

Abstract

This application provides a bogie frame manufacturing method, a bogie, and a rail vehicle. The manufacturing method includes: installing side beam webs on a frame base plate, the side beam webs extending longitudinally and perpendicular to the frame base plate; a predetermined distance is left between the side beam webs and the edge of the frame base plate; installing crossbeam webs on the frame base plate, the crossbeam webs extending laterally and perpendicular to the frame base plate; the two ends of the crossbeam webs are connected to the side beam webs; installing upper side beam plates to the top of the side beam webs; installing upper crossbeam plates to the top of the crossbeam webs, the upper crossbeam plates being located between the two upper side beam plates and connected to the inner edge of the upper side beam plates. This application provides a bogie frame manufacturing method, a bogie, and a rail vehicle that significantly reduces welding processes, thereby reducing welding-related problems. Furthermore, the frame manufacturing can be completed using a single assembly table, greatly improving assembly efficiency and reducing production costs.

Description

Technical Field

[0001] This application relates to rail vehicle manufacturing technology, and more particularly to a bogie frame manufacturing method, a bogie, and a rail vehicle. Background Technology

[0002] The bogie is a crucial component of rail vehicles, located at the bottom of the car to support its weight and enable running and steering functions. The bogie frame is the core component, bearing the load and providing mounting interfaces. Traditional frames consist of crossbeams and side beams, mostly box-shaped beams, welded separately from steel plates and then joined together in an "H" shape.

[0003] Traditional welding methods involve numerous steps, resulting in significant welding deformation and cumbersome subsequent correction processes, which greatly impacts the dimensional accuracy and production efficiency of the structure. Furthermore, the production process requires welding, straightening, and assembling each component in stages, leading to a complex production line layout, lengthy inter-process times, and a long production cycle with high costs. Moreover, the numerous weld joints in a modular structure create dense stress concentration points, making it susceptible to weld fatigue cracking under prolonged alternating loads, thus reducing the reliability of the structure.

[0004] Furthermore, the bogie is one of the most important components of a rail vehicle, accounting for 25%-40% of the total vehicle weight. Therefore, lightweight bogie design makes a significant contribution to rail vehicle development. Some manufacturers have implemented a series of improvements to lightweight bogies, with most focusing on frame materials (such as carbon fiber, titanium alloy, and magnesium alloy) and reducing the number of components. Some have also improved the frame structure, such as using bogies with built-in axle boxes. A few manufacturers have designed the bogie side beams as I-beams; however, through practical experience in the industry, technicians have found that because the side beams have at least three curved sections, the bending process for the I-beam shape is extremely difficult to achieve. This makes it hard to improve manufacturing efficiency and achieve a satisfactory yield, thus hindering production.

[0005] Furthermore, a swing arm positioning seat is provided at the bottom of the side beam for connecting the swing arm type axle box. For traditional box-type side beams, the two-piece structure of the swing arm positioning seat cannot be applied to I-shaped side beams, and the connection strength does not meet the design requirements. Summary of the Invention

[0006] To address one of the aforementioned technical deficiencies, this application provides a bogie frame manufacturing method, a bogie, and a rail vehicle.

[0007] According to a first aspect of the embodiments of this application, a method for manufacturing a steering frame is provided, comprising: Side beam webs are installed at both ends of the frame base plate in the transverse direction. The side beam webs extend longitudinally and are perpendicular to the frame base plate. A preset distance is left between the side beam webs and the edge of the frame base plate. A crossbeam web is installed at both ends of the longitudinal direction of the frame base plate. The crossbeam web extends laterally and is perpendicular to the frame base plate. The two ends of the crossbeam web are connected to the side beam webs. The middle part of the upper side beam plate is installed to the top of the side beam web plate; the upper side beam plate extends longitudinally and its end is bent upward. The upper crossbeam plate is installed at the top of the web of the crossbeam. The upper crossbeam plate is located between the two upper side beam plates and is connected to the inner edge of the upper side beam plates.

[0008] According to a second aspect of the embodiments of this application, a bogie is provided, which is manufactured using the above-described manufacturing method.

[0009] According to a third aspect of the embodiments of this application, a rail vehicle is provided, including: a bogie as described above.

[0010] The technical solution provided in this application embodiment involves installing side beam webs at both ends of the frame base plate in the transverse direction. The side beam webs extend longitudinally and are perpendicular to the frame base plate. A predetermined distance is maintained between the side beam webs and the edge of the frame base plate. Cross beam webs are installed at both ends of the frame base plate in the longitudinal direction. The cross beam webs extend transversely and are perpendicular to the frame base plate. The two ends of the cross beam webs are connected to the side beam webs. The middle part of the upper side beam plate is installed to the top of the side beam web. The upper side beam plate extends longitudinally, with its end bent upwards. The upper cross beam plate is installed to the top of the cross beam web. The upper cross beam plate is located between the two upper side beam plates and is connected to the inner edge of the upper side beam plate. This significantly reduces welding processes, thereby reducing problems caused by welding. Furthermore, the frame manufacturing can be completed using a single assembly table, reducing the number of assembly tools and the process of transferring between processes, greatly improving assembly efficiency and reducing production costs. Attached Figure Description

[0011] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a schematic diagram of the bogie structure provided in an embodiment of this application; Figure 2 This is a schematic diagram of the bogie frame provided in an embodiment of this application; Figure 3 This is another schematic diagram of the bogie frame provided in the embodiments of this application; Figure 4A schematic diagram of a bogie with a side beam web and a cross beam web provided on the bottom plate of the frame, as provided in an embodiment of this application; Figure 5 This is a schematic diagram of the structure of the bogie with stiffeners provided in the embodiments of this application; Figure 6 This is a schematic diagram of the structure of the bogie with an upper side beam plate provided in the embodiment of this application; Figure 7 This is a schematic diagram of the structure of a bogie with a side beam flange provided in an embodiment of this application; Figure 8 This is a schematic diagram of the structure of the bogie with an upper crossbeam plate provided in the embodiments of this application; Figure 9 This is a schematic diagram of the structure of a bogie with a stop provided in an embodiment of this application; Figure 10 This is a structural schematic diagram of the upper side beam plate and the side beam flange plate in the bogie provided in the embodiments of this application; Figure 11 A side view of the bogie frame provided in an embodiment of this application; Figure 12 A flowchart illustrating the method for manufacturing a steering frame according to an embodiment of this application; Figure 13 A top view of the bogie side beam provided in an embodiment of this application; Figure 14 This is a structural schematic diagram of the upper side beam plate in the side beam provided in an embodiment of this application; Figure 15 This is a schematic diagram of the connection between the upper side beam plate and the frame bottom plate in the side beam provided in an embodiment of this application; Figure 16 This is a schematic diagram of the connection between the upper side beam plate and the side beam flange plate in an embodiment of this application. Figure 17 This is a schematic diagram of the structure of the bogie side beam with the side beam web installed during the assembly process, provided in an embodiment of this application. Figure 18 This is a schematic diagram of the structure of the bogie side beam with the side beam stiffening plate installed during the assembly process, provided in an embodiment of this application. Figure 19 This is a schematic diagram of the structure of the bogie side beam with the upper side beam plate installed during the assembly process, provided in an embodiment of this application. Figure 20 This is a schematic diagram of the structure of the bogie side beam with side beam flange installed during the assembly process, provided in an embodiment of this application. Figure 21 An exploded view of the bogie side beam provided in an embodiment of this application; Figure 22 This is a schematic diagram of the structure of the rotating arm positioning seat provided in the embodiments of this application; Figure 23 This is a front view of the swing arm positioning seat provided in an embodiment of this application; Figure 24 A top view of the swing arm positioning seat provided in the embodiments of this application; Figure 25 This is a schematic diagram of the connection between the swing arm positioning seat and the side beam web provided in an embodiment of this application; Figure 26 This is a schematic diagram of the structure connecting the swing arm positioning seat and the axle box swing arm provided in the embodiments of this application; Figure 27 An exploded view showing the connection between the swing arm positioning seat and the axle box swing arm provided in an embodiment of this application; Figure 28 A partial view of the braking device installed on the bogie according to an embodiment of this application; Figure 29 Another partial view of the braking device provided in the embodiments of this application, mounted on the bogie; Figure 30 This is a schematic diagram of the brake hanger installed on the side beam according to an embodiment of this application; Figure 31 An exploded view of the brake hanger and side beam installation provided in an embodiment of this application; Figure 32 This is a schematic diagram of the structure of the brake hanger provided in the embodiments of this application; Figure 33 This is a schematic diagram of the frame welding system provided in the embodiments of this application; Figure 34 This is a schematic diagram of the structure provided in the embodiment of this application, showing the welding fixture rotated by 45° during frame welding; Figure 35 This is a schematic diagram of the structure of the frame welding system provided in the embodiments of this application, showing the welding fixture rotated by 90°. Figure 36 This is a structural schematic diagram of the welding fixture frame in the frame welding system provided in the embodiments of this application; Figure 37 This is a schematic diagram of the welding fixture in the frame welding system provided in the embodiments of this application; Figure 38 A schematic diagram illustrating the structure for fixing the base plate of the frame onto the welding fixture and completing the welding of some components; Figure 39 A schematic diagram of a collaborative robot set in the middle of a welding fixture, provided for an embodiment of this application; Figure 40 A schematic diagram illustrating the welding of the structure of this application using a traditional industrial welding robot; Figure 41A schematic diagram illustrating the welding of the middle section of a collaborative robot according to an embodiment of this application; Figure 42 for Figure 41 A partial view in the middle; Figure 43 This is a schematic diagram illustrating a collaborative robot performing welding in a confined space, as provided in an embodiment of this application. Figure 44 for Figure 43 A partial view in the middle; Figure 45 This is a schematic diagram of a collaborative robot welding in a confined space.

[0012] Figure label: 1-Side beam; 11-Upper side beam plate; 111-Middle plate section; 112-Extension section; 113-First bending section; 114-Second bending section; 13-Side beam web; 14-Side beam flange; 141-Width-changing section; 142-Equal width section; 1421-Transition section; 1422-Connecting section; 15-Side beam upright plate; 16-Side beam middle stiffener plate; 17-First-stage cap upright plate; 18-First-stage cover plate; 2-Crossbeam; 21-Frame base plate; 211-First center hole; 22-Upper crossbeam plate; 221-Second center hole; 23-Crossbeam web; 24-Crossbeam vertical plate; 25-Crossbeam stiffening plate; 26-Auxiliary connectors; 3-Rotating arm positioning seat; 31-Connecting arm; 311-Mounting platform; 312-Through hole; 313-Notch; 314-First connecting section; 315-Second connecting section; 32-Joint; 33-Supporting member; 331-Protrusion; 41-Brake hanger; 411-Side beam connecting seat; 412-Hanger body; 413-Lifting part; 42-External mounting seat; 43-Internal mounting seat; 431-Positioning groove; 44-Brake caliper; 45-Equipment installation part; 46-Tread cleaner; 5-Primary suspension device; 6-Secondary suspension system; 7-Traction device; 91-Axle box swing arm; 92-Swing arm node; 921-Axle end protrusion; 93-Wheel. Detailed Implementation

[0013] To make the technical solutions and advantages of the embodiments of this application clearer, the exemplary embodiments of this application will be described in further detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not an exhaustive list of all embodiments. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other.

[0014] This embodiment provides a method for manufacturing a bogie frame, which can be applied to rail vehicles, such as EMU trains, subway cars, light rail vehicles, or other vehicles that can run on tracks. The rail vehicle includes a car body and a bogie mounted beneath the car body. The bogie, as a crucial component of the rail vehicle, bears the load and facilitates the movement of the car body. The bogie frame is the core component of the bogie, bearing the load of the car body and providing connection interfaces for various components. The manufacturing method provided in this embodiment reduces welding processes, thereby improving production efficiency and yield.

[0015] In this embodiment, the direction of travel of the rail vehicle is referred to as longitudinal, the direction of track width is referred to as transverse, and the direction of car height is referred to as vertical.

[0016] like Figures 1 to 12 As shown, this embodiment first provides a brief description of the bogie structure. The bogie provided in this embodiment includes: a frame, wheelsets, a primary suspension system 5, a secondary suspension system 6, and a traction device 7. The wheelsets are located on both sides of the frame, and each wheelset includes an axle and wheels 93 symmetrically arranged on the axle, as well as axle boxes. A primary suspension system 5 is provided between the axle boxes and the frame to buffer the forces acting between the frame and the wheelsets.

[0017] The secondary suspension device 6 is located between the frame and the car body to buffer the forces acting between them. The traction device 7 is located between the frame and the car body to transmit longitudinal traction or braking force.

[0018] The frame includes: frame base plate 21, upper crossbeam plate 22, crossbeam web plate 23, upper side beam plate 11, and side beam web plate 13.

[0019] The frame base plate 21 is a plate-like structure, roughly rectangular, with its long side extending laterally and its short side extending longitudinally. Side beam installation areas are located at both ends of the frame base plate 21, and a crossbeam installation area is located in the middle.

[0020] The side beam web 13 extends longitudinally and is vertically connected to the side beam mounting area of ​​the frame base plate 21. A predetermined distance is maintained between the side beam web 13 and the short edge of the frame base plate 21. The upper side beam plate 11 is connected to the top of the corresponding side beam web 13, and predetermined distances are maintained between the side beam web 13 and the upper side beam plate 11 on both sides. The projection area of ​​the upper side beam plate 11 on the frame base plate 21, together with the side beam web 13 and the upper side beam plate 11, forms an "I"-shaped structure in cross-section.

[0021] The crossbeam web 23 extends laterally, connecting between the two side beam webs 13, and is perpendicularly connected to the frame bottom plate 21. A predetermined distance is also maintained between the crossbeam web 23 and the long edge of the frame bottom 21. There are two crossbeam webs 23, spaced apart. The upper crossbeam plate 22 connects the tops of the two crossbeam webs 23, and is connected to the upper side beam plate 11.

[0022] In the above structure, the frame base plate 21 serves as the bottom structure of the frame, and the upper side beam plate 11 and the upper cross beam plate 22 are connected to form the top structure of the frame. The side beam web plate 13 and the cross beam web plate 23 are correspondingly connected between the frame base plate 21 and the upper side beam plate 11 and the upper cross beam plate 22, serving as the vertical force bearing structure, and together with the top structure and the bottom structure, they form an internally hollow structure.

[0023] Compared to traditional box-type frames, the solution provided in this embodiment significantly reduces the number of uprights, thereby substantially reducing the bogie's weight and facilitating lightweight design. Furthermore, it reduces the number of welding processes, further minimizing problems caused by welding deformation.

[0024] During the production process, the frame base plate 21 is fixed on the assembly table, and then the following steps are performed.

[0025] Step 101: Install side beam webs at both ends of the frame base plate. The side beam webs extend longitudinally and are perpendicular to the frame base plate. A preset distance is left between the side beam webs and the edge of the frame base plate.

[0026] Step 102: Install crossbeam webs at both ends of the longitudinal direction of the frame base plate. The crossbeam webs extend laterally and are perpendicular to the frame base plate. The two ends of the crossbeam webs are connected to the side beam webs.

[0027] Step 103: Install the middle part of the upper side beam plate to the top of the side beam web plate; the upper side beam plate extends longitudinally and its end is bent upward.

[0028] Step 104: Install the upper crossbeam plate to the top of the crossbeam web. The upper crossbeam plate is located between the two upper side beam plates and is connected to the inner edge of the upper side beam plates.

[0029] Compared to the traditional method of welding crossbeams and side beams as independent components, this embodiment assembles the side beam web, crossbeam web, upper side beam plate, and upper crossbeam plate sequentially onto the frame base plate 21. The resulting frame has no independent side beams or crossbeams, significantly reducing the number of components. Furthermore, the frame can be manufactured using only one assembly table, reducing the number of assembly tools and the process of transferring components between different processes, greatly improving assembly efficiency and reducing production costs.

[0030] The technical solution provided in this embodiment involves installing side beam webs at both ends of the frame base plate in the transverse direction. The side beam webs extend longitudinally and are perpendicular to the frame base plate. A predetermined distance is maintained between the side beam webs and the edge of the frame base plate. Cross beam webs are installed at both ends of the frame base plate in the longitudinal direction. The cross beam webs extend transversely and are perpendicular to the frame base plate. The two ends of the cross beam webs are connected to the side beam webs. The middle part of the upper side beam plate is installed to the top of the side beam web. The upper side beam plate extends longitudinally, with its end bent upwards. The upper cross beam plate is installed to the top of the cross beam web. The upper cross beam plate is located between the two upper side beam plates and is connected to the inner edge of the upper side beam plates. This significantly reduces welding processes, thereby reducing problems caused by welding. Furthermore, the frame manufacturing can be completed using a single assembly table, reducing the number of assembly tools and the process of transferring between processes, greatly improving assembly efficiency and reducing production costs.

[0031] Based on the above technical solution, a horizontal beam upright plate 24 is also adopted, extending longitudinally. The horizontal beam upright plate 24 is located between the web plates 13 of the two side beams, with its bottom end connected to the frame bottom plate 21 and its two ends connected to the web plates 23 of the horizontal beams, respectively. The horizontal beam upright plate 24 is located in the middle region of the frame bottom plate 21, which can further enhance the load-bearing capacity and longitudinal force transmission in the middle region of the frame.

[0032] The traction device includes a traction pin, the top of which is connected to the vehicle body, and the bottom of which engages with the frame. Specifically, the frame base plate 21 has a first center hole 211 through which the center pin of the bogie passes, and the upper crossbeam plate 22 has a second center hole 221, the position of which corresponds to the first center hole 211. The traction pin passes through the second center hole 221 and the first center hole 211 sequentially from top to bottom. The side of the center pin has a longitudinal stop for transmitting longitudinal force between the frame base plate 21 and the upper crossbeam plate 22.

[0033] The number of the above-mentioned crossbeam uprights 24 is two, which are arranged on both sides of the first central hole 211, which can improve the reliability and stability of longitudinal force transmission.

[0034] Based on the above scheme, before installing the upper side beam plate in step 103, a crossbeam upright plate 24 is also installed in the middle of the frame base plate 21. The crossbeam upright plate 24 extends longitudinally and is perpendicular to the frame base plate 21, and the two ends of the crossbeam upright plate 24 are connected to the crossbeam web plate 23 respectively.

[0035] Furthermore, multiple weight-reduction holes are opened on the base plate 21 of the frame, and weight-reduction holes are also opened on the crossbeam upright plate 24. The purpose is to further reduce the weight of the frame while ensuring that the load-bearing and transmission of force meet the requirements.

[0036] Based on the above technical solution, the middle part of the upper beam plate 11 is flat, the end of the upper beam plate 11 is bent upward, the middle part of the upper beam plate 11 is connected to the frame bottom plate 21 through the side beam web plate 13, and a preset distance is left between the side beam web plate 13 and both sides of the upper beam plate 11.

[0037] Furthermore, a swing arm positioning seat 3 is connected to the lower end of the upper side beam plate 11. The swing arm positioning seat 3 is also connected to the end of the side beam web plate 13. The swing arm positioning seat 3 is used to connect with the axle box swing arm. Specifically, the swing arm positioning seat 3 can be connected to the end of the side beam web plate 13.

[0038] Before installing the side beam web 13, in step 103 above, the swing arm positioning seat 3 is first installed at both ends of the side beam web 13, and the bottom end of the swing arm positioning seat 3 is connected to the frame base plate 21. In the step of installing the upper side beam 11, the lower surface of the end of the upper side beam 11 is also connected to the swing arm positioning seat 3.

[0039] Based on the above technical solution, the frame also includes: side beam uprights 15 and side beam flanges 14. The side beam uprights 15 extend longitudinally and are vertically connected to the upper end surface of the upper side beam 11, with a predetermined distance maintained between the side beam uprights 15 and the two sides of the upper side beam 11. The side beam flanges 14 are connected to the top of the side beam uprights 15. One end of the side beam flanges 14 is connected to the end of the upper side beam 11, and the other end is connected to the middle upper surface of the upper side beam 11.

[0040] The side beam flange 14, the side beam upright 15, and the upper side beam plate 11 are connected to form an I-shaped structure.

[0041] Based on this, before installing the upper crossbeam plate in step 104, the method further includes: installing the side beam upright plate 15 onto the upper end surface of the upper side beam plate 11. The side beam upright plate 15 extends longitudinally and is perpendicular to the upper side beam plate 11, with a predetermined distance between the side beam upright plate 15 and the two side edges of the upper side beam plate 11. Then, the side beam wing plate 14 is installed onto the top of the side beam upright plate 15. The side beam wing plate 14 extends longitudinally, with one end connected to the end of the upper side beam plate 11 and the other end connected to the middle of the upper side beam plate 11.

[0042] In addition, after installing the side beam flange 14, the process also includes: installing the first-stage cap plate 17 to the end of the upper side beam plate 11, and then installing the first-stage cover plate 18 to the end of the side beam flange 14, with the first-stage cover plate 18 connected to the top of the first-stage cap plate 17.

[0043] Furthermore, the frame also includes: side beam stiffening plates 16 and crossbeam stiffening plates 25. The side beam stiffening plates 16 are vertically connected to both sides of the side beam web 13, with their top ends connected to the middle of the upper side beam plate 11 and their bottom ends connected to the frame base plate 21. The crossbeam stiffening plates 25 are vertically connected to the inner side of the crossbeam web 23, with their top ends connected to the upper crossbeam plate 22 and their bottom ends connected to the frame base plate 21.

[0044] The side beam stiffening plate 16 strengthens the side beam web 13, increasing its strength. The cross beam stiffening plate 25 strengthens the cross beam web 23, increasing its strength.

[0045] Before installing the upper side beam plate 11 in step 103 above, the method further includes: installing side beam central stiffening plates 16 on both sides of the side beam web plate 13, with the bottom end of the side beam central stiffening plates 16 connected to the frame base plate 21. Alternatively, crossbeam stiffening plates 25 can be installed on the inner side of the crossbeam web plate 23, with the bottom end of the crossbeam stiffening plates 25 connected to the frame base plate 21.

[0046] The formation process of the upper side beam plate 11 is as follows: the raw steel plate used to form the upper side beam plate 11 is placed in the mold, and pressure is applied to the mold by a bending machine until the mold is closed. The middle part of the resulting upper side beam plate 11 is flat, and the ends are bent upward. The internal structure of the mold is set accordingly according to the bending shape of the upper side beam plate 11.

[0047] After installing the upper crossbeam plate 22, at least one of the following is installed on the upper crossbeam plate 22: a transverse stop mounting seat, a longitudinal stop mounting seat, and a vibration damper mounting seat. The transverse stop mounting seat is used to install transverse stops to limit lateral displacement between the traction device and the frame. The longitudinal stop mounting seat is used to install longitudinal stops to limit the longitudinal position between the traction device and the frame and to transmit longitudinal forces. The vibration damper mounting seat is used to install transverse vibration dampers; one end of the transverse vibration damper is connected to the vibration damper mounting seat, and the other end is connected to the traction device, used to buffer lateral forces between the traction device and the frame.

[0048] Based on the above technical solution, this embodiment provides a specific implementation method: Fix the frame base plate 21 to the workbench. Weld the side beam web 13, cross beam web 23, and cross beam vertical plate 24 to the frame base plate 21 accordingly. Figure 4 As shown, the side beam web 13 is pre-assembled with swing arm positioning seats 3 on both sides.

[0049] Then, side beam stiffening plates 16 are welded to both sides of the side beam web 13, and cross beam stiffening plates 25 are welded to the inside of the cross beam web 23, as follows. Figure 5 As shown. Then, the upper side beam plate 11 is welded to the side beam web plate 13 and the swing arm positioning seat 3, as follows. Figure 6 As shown.

[0050] Next, the side beam upright plate 15 is welded to the upper surface of the end of the upper side beam plate 11, and then the side beam flange 14 is welded to the top of the side beam upright plate 15, with one end of the side beam flange 14 connected to the end of the upper side beam plate 11 and the other end connected to the middle of the upper side beam plate 11, as shown. Figure 7 As shown. In this step, a tie cap plate 17 is welded to the end of the upper side beam plate 11, and a tie cover plate 18 is welded to the end of the side beam wing plate 14. The tie cover plate 18 is welded to the top of the tie cap plate 17.

[0051] The primary cover plate 18 can also be pre-welded to the side beam flange 14 and then welded as a whole to the top of the side beam upright plate 15 and the primary cap upright plate 17.

[0052] The primary cover plate 18 can also be integrated with the side beam flange 14 as a single steel plate, which can reduce welding processes, thereby reducing welding deformation, reducing subsequent adjustment steps, improving production efficiency, improving finished product quality, and reducing production costs.

[0053] Next, the upper crossbeam plate 22 is welded to the top of the crossbeam web plate 23, and the ends of the upper crossbeam plate 22 are welded to the upper side beam plates 11 on both sides, as follows. Figure 8 As shown. Then, weld the corresponding damper mounting seats, transverse stop seats, longitudinal stop seats, and other auxiliary connecting parts 26 onto the frame, such as... Figure 9 As shown.

[0054] Based on the above technical solutions, this embodiment provides a frame welding system that can weld the frame, which can significantly reduce production costs and reduce steps such as adjusting position and repositioning, thereby greatly improving production efficiency.

[0055] The frame welding system provided in this embodiment is as follows: Figures 33 to 45 As shown, the component numbers in the welding system are only applicable to... Figures 33 to 45 For other attached figures with repeated numbers, please refer to the corresponding embodiment section.

[0056] The frame welding system provided in this embodiment includes: a welding fixture 4, a collaborative robot 5, and a positioner 6. The welding fixture 4 is equipped with a fixing component for securing the frame, so that the frame is fixed to the welding fixture 4 and rotates together with it. A robot arm base 41 is provided on the side of the welding fixture 4, and the robot arm base 41 protrudes from the side of the welding fixture 4.

[0057] The collaborative robot 5 is mounted on the robotic arm base 41. The collaborative robot 5 can be a model already available in this field. It is small in size, and the robotic arm base 41 only needs to be about 20cm × 20cm in size to accommodate the installation of the collaborative robot 5. Moreover, the unit price of the collaborative robot 5 is low, around 200,000 yuan per unit, which is less than one-tenth of that of an industrial welding robot.

[0058] The positioner 6 is mounted on the ground. The rotation output end of the positioner 6 is connected to the welding fixture 4, which drives the welding fixture 4 and the collaborative robot 5 to rotate together. The rotation center line extends horizontally. The positioner 6 also adopts existing technologies in the field. The connection and driving method between the positioner 6 and the welding fixture 6 can be implemented based on existing technologies.

[0059] In traditional solutions, industrial welding robots are placed on the ground, and the welding fixture needs to be rotated up and down according to the welding requirements to keep the weld seam horizontal and ensure a uniform and reliable weld. Before the welding fixture is rotated, the industrial welding robot needs to retract its arm back to its initial position, and after rotation, it extends its arm to move to the target position for positioning and welding. This process takes a considerable amount of time.

[0060] The collaborative robot 5 provided in this embodiment is fixed on the welding fixture 4 and rotates synchronously with the welding fixture 4. Therefore, the arm of the collaborative robot 5 does not need to retract and can remain at the weld position. After the welding fixture 1 flips, it can directly perform the next welding operation at the weld position, saving the time of movement and positioning, greatly shortening the welding period and improving production efficiency. In addition, the unit price of the collaborative robot is low, which can significantly reduce production costs.

[0061] Two positioners 6 are provided, one on each side of the welding fixture 4 along its length; the center lines of the rotation output ends of the two positioners 6 are collinear. The two positioners 6 drive the welding fixture 4 to rotate up and down from both sides, which is more suitable for larger workpieces, especially for welding bogie frames.

[0062] Figure 33 A schematic diagram showing welding fixture 4 in a horizontal position is provided. Figure 34 The diagram shows the positioner 6 driving the welding fixture 4 and the collaborative robot 5 to rotate approximately 45°. Figure 35 A schematic diagram shows the positioner 6 driving the welding fixture 4 and the collaborative robot 5 to rotate approximately 90°.

[0063] Based on the above technical solution, the welding fixture 4 is a rectangular frame. Each long side of the welding fixture 4 is provided with two robot arm bases 41, which are spaced apart and have a preset distance from the short side of the welding fixture 4. For example, four robot arm bases 41 are provided on the welding fixture 4 to install four collaborative robots 5. The position of each collaborative robot 5 can be set according to the size of the frame, the position to be welded, and the working radius of the collaborative robot 5.

[0064] The collaborative robot 5 is smaller in size, and its robotic arm is much shorter than that of an industrial robot. Therefore, it can reach into narrow spaces to perform welding. There is no need to interrupt welding to adjust the frame position to adapt to the robot's working radius, which simplifies the welding process and enables uninterrupted continuous welding, thereby improving production efficiency.

[0065] Furthermore, such as Figures 36 to 39 As shown, the welding fixture 4 has a mounting slot 42 in the middle, and a mounting interface is provided in the mounting slot 42 for mounting the collaborative robot 5. The collaborative robot 5 is also positioned in the middle of the welding fixture 4, which expands the welding range and allows welding to be performed on the central area of ​​the structure.

[0066] The fasteners include a vertical clamping member 43 and a side clamping member 44. The vertical clamping member 43 is located at the edge of the welding fixture 1 and can apply a downward clamping force to the frame base plate from above.

[0067] The vertical clamping member 43 can be implemented in various ways, for example, by using a steel plate, one end of which is fixed to the frame of the welding fixture, and the other end which overlaps the upper surface of the frame base plate. The steel plate is provided with bolt holes, and the steel plate is pressed against the frame base plate by tightening the vertical bolts downwards.

[0068] Alternatively, hydraulic mechanisms, cylinders, or other components can be used to apply pressure to the base plate from above, fixing it to the frame of the welding fixture.

[0069] The side clamping member 44 is located on the edge of the welding fixture 4, specifically on the side of the frame base plate, and can apply a horizontal inward clamping force to the frame base plate.

[0070] The side clamping member 44 can also be implemented in various ways. For example, a slide rail can be provided on the frame surface of the welding fixture 4, and a clamping block can move along the slide rail in cooperation with it. The clamping block and the threaded rod are connected by threads. Rotating the threaded rod causes the clamping block to move along the slide rail, thereby applying clamping force to the frame base plate or loosening the frame base plate.

[0071] Furthermore, a cantilever clamping member 45 is included, disposed at the edge of the welding fixture 4. The height of the cantilever clamping member 45 is greater than that of the vertical clamping member 43, and it can apply a downward clamping force to the side beams assembled on the frame base plate. As the collaborative robot 5 gradually welds the various components onto the frame base plate, the overall height of the frame increases, especially the side beams, which are located at the highest point of the frame. The cantilever clamping member 45 is used to clamp the upper surface of the side beams to compress the frame.

[0072] The cantilever clamping member 45 can be installed at the top corner of the welding fixture 4, with the top of the cantilever extending out. The end of the cantilever is provided with a structure for extending downward and clamping the frame. It can also be achieved by means of hydraulic mechanism, cylinder mechanism or other means.

[0073] For structures with complex designs, some welds are difficult to perform using traditional industrial welding robots. For example, when two plates form an angle of less than 30°, traditional welding torches struggle to bring the welding wire close to the weld area, making welding impossible. Figure 40 As shown.

[0074] During the operation, the base plate of the frame is first fixed to the welding fixture, and then the collaborative robot performs each welding step. When it is necessary to switch welding positions, the welding fixture is rotated by a positioner at a preset angle, and the collaborative robot rotates synchronously with the welding fixture.

[0075] The bogie mentioned above features a unified base plate, with the crossbeams and side beams mounted separately on the base plate. This significantly reduces the number of parts, thereby lowering the bogie's weight. Furthermore, all components of the frame can be installed on a single workbench, reducing storage, transportation, and labor costs associated with parts storage and transfer, thus improving production efficiency and reducing costs.

[0076] This integrated frame structure reduces the number of workstations required for frame welding, adopts single-station integration to reduce workflow, and allows for easy adjustment and deformation adjustment as needed during the welding process.

[0077] The crossbeams and side beams share the same frame base plate, which significantly reduces the number of weld joints, minimizes welding deformation, eliminates numerous straightening processes, and improves the overall dimensional accuracy of the frame, thereby increasing production efficiency. This structure allows for modular prefabrication of components using a building-block assembly method. Modules can be produced in parallel, resulting in a simpler production line layout, more efficient process coordination, and significant cost reduction during large-scale production. Furthermore, modular component replacement facilitates easier maintenance. The building-block welding method reduces the requirements for on-site welding operations, allowing for adjustments based on welding conditions, facilitating overall structural planning, and making welding quality control easier.

[0078] Based on the above technical solution, the implementation method of the frame is described in detail: The frame includes: a frame base plate 21, an upper crossbeam plate 22, a crossbeam web plate 23, an upper side beam plate 11, and a side beam web plate 13. The frame base plate 21 is a plate-like structure, roughly rectangular, with its long side extending laterally and its short side extending longitudinally. Side beam mounting areas are located at both ends of the frame base plate 21, and the middle is the crossbeam mounting area.

[0079] The side beam web 13 extends longitudinally and is vertically connected to the side beam mounting area of ​​the frame base plate 21. A predetermined distance is maintained between the side beam web 13 and the short edge of the frame base plate 21. The upper side beam plate 11 is connected to the top of the corresponding side beam web 13, and predetermined distances are maintained between the side beam web 13 and the upper side beam plate 11 on both sides. The projection area of ​​the upper side beam plate 11 on the frame base plate 21, together with the side beam web 13 and the upper side beam plate 11, forms an "I"-shaped structure in cross-section.

[0080] The crossbeam web 23 extends laterally, connecting between the two side beam webs 13, and is perpendicularly connected to the frame bottom plate 21. A predetermined distance is also maintained between the crossbeam web 23 and the long edge of the frame bottom 21. There are two crossbeam webs 23, spaced apart. The upper crossbeam plate 22 connects the tops of the two crossbeam webs 23, and is connected to the upper side beam plate 11. The upper crossbeam plate 22, the crossbeam web 23, and the frame bottom plate 21 also form an I-shaped cross-section.

[0081] In the above structure, the frame base plate 21 serves as the bottom structure of the frame, and the upper side beam plate 11 and the upper cross beam plate 22 are connected to form the top structure of the frame. The side beam web plate 13 and the cross beam web plate 23 are correspondingly connected between the frame base plate 21 and the upper side beam plate 11 and the upper cross beam plate 22, serving as the vertical force bearing structure, and together with the top structure and the bottom structure, they form an internally hollow structure.

[0082] Compared to traditional box-type frames, the solution provided in this embodiment significantly reduces the number of uprights, thereby substantially reducing the bogie's weight and facilitating lightweight design. Furthermore, it reduces the number of welding processes, further minimizing problems caused by welding deformation.

[0083] During production, the frame base plate 21 is fixed to the assembly table, and the web plates, top plates, and other components are sequentially assembled onto the frame base plate 21. Compared with the crossbeams and side beams in the traditional solution, this embodiment does not have independent side beams or crossbeam structures. The frame can be manufactured using only one assembly table, which reduces the number of assembly tools and the process of transferring between different processes, greatly improving assembly efficiency and reducing production costs.

[0084] Based on the above technical solution, a horizontal beam upright plate 24 is also adopted, extending longitudinally. The horizontal beam upright plate 24 is located between the web plates 13 of the two side beams, with its bottom end connected to the frame bottom plate 21 and its two ends connected to the web plates 23 of the horizontal beams, respectively. The horizontal beam upright plate 24 is located in the middle region of the frame bottom plate 21, which can further enhance the load-bearing capacity and longitudinal force transmission in the middle region of the frame.

[0085] The traction device includes a traction pin, the top of which is connected to the vehicle body, and the bottom of which engages with the frame. Specifically, the frame base plate 21 has a first center hole 211 through which the center pin of the bogie passes, and the upper crossbeam plate 22 has a second center hole 221, the position of which corresponds to the first center hole 211. The traction pin passes through the second center hole 221 and the first center hole 211 sequentially from top to bottom. The side of the center pin has a longitudinal stop for transmitting longitudinal force between the frame base plate 21 and the upper crossbeam plate 22.

[0086] The number of the above-mentioned crossbeam uprights 24 is two, which are arranged on both sides of the first central hole 211, which can improve the reliability and stability of longitudinal force transmission.

[0087] Furthermore, multiple weight-reduction holes are opened on the base plate 21 of the frame, and weight-reduction holes are also opened on the crossbeam upright plate 24. The purpose is to further reduce the weight of the frame while ensuring that the load-bearing and transmission of force meet the requirements.

[0088] Based on the above technical solution, the middle part of the upper beam plate 11 is flat, the end of the upper beam plate 11 is bent upward, the middle part of the upper beam plate 11 is connected to the frame bottom plate 21 through the side beam web plate 13, and a preset distance is left between the side beam web plate 13 and both sides of the upper beam plate 11.

[0089] A swing arm positioning seat 3 is connected to the lower end of the upper side beam plate 11. The swing arm positioning seat 3 is also connected to the end of the side beam web plate 13. The swing arm positioning seat 3 is used to connect with the axle box swing arm. Specifically, the swing arm positioning seat 3 can be connected to the end of the side beam web plate 13.

[0090] Based on the above technical solution, the frame also includes: side beam uprights 15 and side beam flanges 14. The side beam uprights 15 extend longitudinally and are vertically connected to the upper end surface of the upper side beam 11, with a predetermined distance maintained between the side beam uprights 15 and the two sides of the upper side beam 11. The side beam flanges 14 are connected to the top of the side beam uprights 15. One end of the side beam flanges 14 is connected to the end of the upper side beam 11, and the other end is connected to the middle upper surface of the upper side beam 11.

[0091] The side beam flange 14, the side beam upright 15, and the upper side beam plate 11 are connected to form an I-shaped structure.

[0092] Furthermore, the frame also includes: side beam stiffening plates 16 and crossbeam stiffening plates 25. The side beam stiffening plates 16 are vertically connected to both sides of the side beam web 13, with their top ends connected to the middle of the upper side beam plate 11 and their bottom ends connected to the frame base plate 21. The crossbeam stiffening plates 25 are vertically connected to the inner side of the crossbeam web 23, with their top ends connected to the upper crossbeam plate 22 and their bottom ends connected to the frame base plate 21.

[0093] The side beam stiffening plate 16 strengthens the side beam web 13, increasing its strength. The cross beam stiffening plate 25 strengthens the cross beam web 23, increasing its strength.

[0094] Based on the above technical solution, this embodiment also provides a detailed description of the structure of the side beam: as follows Figure 10 , Figure 11 , Figures 13 to 21 As shown, the side beam includes: upper side beam plate 11, lower side beam plate, side beam web plate 13, side beam flange plate 14, and side beam upright plate 15, all of which are welded together.

[0095] The upper side beam 11 has a flat plate in the middle, with its ends bent upwards. The upper side beam 11 has an axisymmetric structure, with the axis of symmetry located in the middle of the aforementioned side beam 11 and parallel to the width direction of the upper side beam 11. The upper side beam 11 extends longitudinally, and its width direction is transverse.

[0096] The lower beam plate is the aforementioned frame base plate 21. The frame base plate 21 is located below the middle of the upper beam plate 11, parallel to the middle of the upper beam plate 11 and spaced apart from it. The side beam web plate 13 is vertically connected between the middle of the upper beam plate 11 and the frame base plate 21. The side beam web plate 13 and the two sides of the upper beam plate 11 are left with a predetermined distance, which means that the cross-section of the upper beam plate 11, the frame base plate 21, and the side beam web plate 13 is "I" shaped. The side beam web plate 13 is the main component that bears the vertical force.

[0097] The side beam flange 14 is located above the end of the upper side beam plate 11, and the side beam flange 14 and the upper side beam plate 11 are also arranged opposite each other with a certain distance between them. One end of the side beam flange 14 is connected to the end of the upper side beam plate 11, and the other end extends and connects to the middle of the upper side beam plate 11. Taking the upper surface of the middle part of the upper side beam plate 11 as the reference plane, the distance between the side beam flange 14 and the reference plane gradually increases along the direction from the middle of the upper side beam plate 11 to the end, which is equivalent to the side beam flange 14 being inclined, with its outer end being higher.

[0098] The side beam upright plate 15 is vertically connected between the end of the upper side beam plate 11 and the side beam flange 14, with a predetermined distance between the two sides of the side beam upright plate 15 and the side beam flange 14. This means that the cross-section of the side beam flange 14, the upper side beam plate 11, and the side beam upright plate 15 is "I" shaped, and the side beam upright plate 15 is the main component that bears the vertical force.

[0099] Regarding the aforementioned side beam structure, the middle section of the side beam connects to the crossbeam of the bogie, forming the bogie frame. Additionally, both ends of the upper side beam 11 are connected to the primary suspension system, and the bottom end of the primary suspension system is connected to the axle box. The middle section of the upper side beam is connected to the secondary suspension system, and the top of the secondary suspension system is connected to the bottom of the car body. The vertical force transmission path of the vehicle is: car body, secondary suspension system, side beam, primary suspension system, wheelset.

[0100] The aforementioned side beam with an "I"-shaped cross-section, while meeting vertical load-bearing capacity requirements, reduces the number of structural components, thereby lowering the weight of the side beam and achieving lightweight design. Furthermore, the side beam provided in this embodiment consists of two "I"-shaped structures, significantly reducing manufacturing difficulty, facilitating industrialization, improving production efficiency, and increasing yield. Moreover, the "I"-shaped cross-section of the side beam reduces the torsional stiffness of the bogie, thereby improving the bogie's track adaptability and enhancing comfort.

[0101] Furthermore, the upper beam plate 11 is divided into a middle plate segment 111 and extension segments 112, a first bending segment 113, and a second bending segment 114 sequentially disposed at both ends of the middle plate segment 111. The upper beam plate 11 has an axisymmetric structure, and the structures at both ends are identical.

[0102] The middle plate segment 111 is a horizontal plate. The length of the middle plate segment 111 matches that of the frame base plate 21, and the frame base plate 21 and the middle plate segment 111 are aligned vertically. The extension segment 112 is at the same height as the middle plate segment 111, which means that the extension segment 112 continues to extend horizontally outward from the outer end of the middle plate segment 111.

[0103] Using the upper surface of the middle section of the upper side beam plate 11 as the reference plane, the distance between the first bending segment 113 and the reference plane gradually increases along the direction from the middle to the end of the upper side beam plate 11, which is equivalent to the first bending segment 113 tilting upward. The first bending segment 113 and the extension segment 112 are smoothly transitioned by a curve. The angle between the first bending segment 113 and the reference plane is 135°-165°.

[0104] The second bending segment 114 bends upward at a larger angle, with its angle to the vertical less than 5°, approximating the vertical. The second bending segment 114 and the first bending segment 113 transition smoothly through a curve.

[0105] The inner end of the side beam flange 14 extends to connect with the middle plate section 111 of the upper side beam plate 11, and its outer end connects to the second bent section 114. The side beam flange 14 includes a widening section 141 and a constant-width section 142, the width of which remains constant. The width of the widening section 141 varies, specifically decreasing from the middle of the side beam towards the end. The widest end of the widening section 141 connects to the middle plate section 111.

[0106] The constant-width section 142 includes a transition section 1421 and a connecting section 1422. The transition section 1421 is located between the variable-width section 141 and the connecting section 1422. The transition section 1421 and the variable-width section 141 are coplanar, and their inclination patterns are consistent. The connecting section 1422 extends approximately horizontally, and the connecting section 1422 and the transition section 1421 are smoothly transitioned by a curve, with an obtuse angle between them, for example, 120°-170°.

[0107] Based on the above technical solution, a side beam stiffening plate 16 is also adopted, which is vertically connected to both sides of the side beam web 13. The top of the side beam stiffening plate 16 is connected to the middle of the upper side beam plate 11, and the bottom of the side beam stiffening plate 16 is connected to the frame base plate 21. There are multiple side beam stiffening plates 16, which are spaced apart along the longitudinal direction. The height dimension of the side beam stiffening plate 16 is the same as that of the side beam web 13, and the width dimension can be set according to the shape of the upper side beam plate 11 and the frame base plate 21. For example, a wider side beam stiffening plate 16 can be set at a wider position of the upper side beam plate 11 to improve the supporting capacity of the upper side beam plate 11, improve the connection strength and the reliability of vertical force bearing.

[0108] Based on the above technical solution, a first-stage cap tube upright plate 17 is provided at the end of the upper beam plate 11. One end of the first-stage cap tube upright plate 17 is connected to the outer surface of the end of the upper beam plate 11, and the other end branches into two cylindrical upright plates. The two cylindrical upright plates form a cylindrical shape, and the interior is used to accommodate the first-stage suspension device.

[0109] Correspondingly, the end of the side beam flange 14 is also provided with a primary suspension cover 18. The shape of the primary suspension cover 18 matches the shape of the primary suspension cap plate 17 and is connected to the top of the primary suspension cap plate 17. The top of the primary suspension device is mounted on the primary suspension cover 18. The primary suspension cover 18 is also provided with positioning holes for positioning the primary suspension device. The side beam flange 14 and the primary suspension cover 18 can be an integral structure, formed from a single steel plate, thereby reducing welding steps, reducing welding deformation, improving finished product quality, and reducing production costs.

[0110] Furthermore, a swing arm positioning seat 3 is provided at the end of the side beam web 13. The top of the swing arm positioning seat 3 is connected to the end of the upper side beam 11, specifically to the extension section 112 and the first bent section 113. The swing arm positioning seat 3 is used to connect the node end of the axle box. The other end of the axle box is connected to the bearing in the wheelset assembly. The swing arm type axle box can limit the lateral relative movement between the frame and the wheelset, avoiding large lateral relative displacement between the two.

[0111] The assembly process of the aforementioned side beams is as follows: First step, as... Figure 16 As shown, the swing arm positioning seat 3 is welded to both ends of the side beam web 13, and then the side beam web 13 is welded to the upper surface of the frame base plate 21. The second step is as follows... Figure 17 As shown, side beam stiffening plates 16 are welded to both sides of the side beam web 13, and the bottom end of the side beam stiffening plates 16 is also welded to the frame base plate 21. The third step, as... Figure 18 As shown, the upper side beam plate 11 is welded to the top of the side beam web plate 13. Fourth step, as... Figure 19 As shown, the two side beam uprights 15 are welded to the corresponding positions of the upper side beam plate 11, and then the two side beam flanges 14 are welded to the top of the side beam uprights 15 and correspondingly welded to the upper side beam plate 11. In addition, the primary cap plate 1 and the primary cover plate 18 are also welded to them.

[0112] Based on the above technical solutions, this embodiment also provides an example of the implementation method of the rotating arm positioning seat 3, such as... Figures 22 to 27 As shown, the boom positioning seat 3 includes two connecting arms 31. The two connecting arms 31 are arranged opposite each other, with space between them to accommodate the bogie axle box boom 91. The ends of the two connecting arms 31 on the same side are connected together to form a joint 32. The side of the joint 32 protrudes in the direction away from the connecting arms 31 to form a connecting rib, which is connected to the end of the side beam web 13.

[0113] The top end of the connecting arm 31 and the top end of the joint 32 are connected to the upper beam plate 11, the bottom end of the joint 32 is connected to the frame base plate 21, and the bottom end of the connecting arm 31 is connected to the frame base plate 21.

[0114] Based on the aforementioned "I"-shaped side beam, the joint 32 in the swing arm positioning seat 3 is connected to the side beam web 13, and the axle box swing arm 91 is inserted between the two connecting arms 31 and connected to the connecting arms 31, thus realizing the connection between the swing arm axle box and the side beam.

[0115] Because the side beam has an "I"-shaped cross-section, while meeting the vertical load-bearing capacity requirements, the number of components in the side beam can be reduced, thereby lowering its weight and achieving lightweight design. It also reduces weld length and welding frequency, thus improving production efficiency. Furthermore, the swing arm positioning seat with this structure can be directly welded to the side beam web, eliminating the need for press-fitting. This process is simple and quick, and causes minimal damage to the side beam. It also eliminates the need for additional press-fitting fixtures, reducing production costs.

[0116] Furthermore, the included angle between the two connecting arms 31 is 0°-30°, which enables the force between the frame and the wheelset to be transmitted evenly, and can improve the strength of the side beam and the overall frame, ensuring the support strength.

[0117] The outer side of the connecting arm 31 is provided with a mounting platform 311, the surface of which is flat. At least two through holes 312 penetrating the thickness of the connecting arm are formed on the mounting platform 311. The through holes 312 on the two connecting arms 31 are symmetrically arranged. The axle box rotating arm is inserted between the two connecting arms 31, and a connecting pin is used to sequentially pass through the through hole 312 on the left side of the connecting arm 31, the rotating arm node, and the through hole 312 on the left side of the other connecting arm 31. Another connecting pin is used to sequentially pass through the through hole 312 on the right side of the connecting arm 31, the rotating arm node, and the through hole 312 on the right side of the other connecting arm 31, thus completing the connection between the axle box rotating arm and the rotating arm positioning seat.

[0118] Furthermore, the bottom of the mounting platform 311 may have an upwardly recessed notch 313 for accommodating the elastic node of the axle box swing arm, the notch 313 being located between two through holes 312. The notches 313 on the two connecting arms 31 are symmetrically arranged.

[0119] The axle box swing arm 91 has mounting holes, and the swing arm node 92 is disposed within these mounting holes with an interference fit. The swing arm node 92 is made by vulcanizing metal and rubber. Both axial ends of the swing arm node 92 have shaft end protrusions 921, which are embedded in notches 313 to achieve longitudinal and vertical limiting of the swing arm node 92. The connecting arm 31 itself can provide lateral limiting for the swing arm node 92.

[0120] The cross-section of the aforementioned shaft end protrusion 921 includes an arc and a line segment connecting the two ends of the arc. Correspondingly, the notch 313 is an arc-shaped notch that matches the shape of the shaft end protrusion 921, so that the swing arm node 92 fits against the swing arm positioning seat through the arc surface, ensuring connection accuracy and facilitating force transmission.

[0121] Furthermore, to enhance the vertical limiting and support of the swing arm node 92, a support member 33 is employed. The support member 33 has a protrusion 331 in its center that can be inserted into a notch 313, and connecting holes at both ends. The protrusion 331 of the support member 33 is inserted into the notch 313, and fasteners pass through the connecting holes to connect to the bottom end of the mounting platform 311. Fixing the support member 33 to the bottom end of the mounting platform 311 provides support and limiting for the swing arm node 92 from the bottom, further improving the reliability of the swing arm node 92 connection.

[0122] Based on the above scheme, protrusion 331 is a rectangular protrusion, with the same line segment length as the shaft end of the swing arm node 92. The lateral dimension of protrusion 331 matches the length of the shaft end of the swing arm node 92.

[0123] Based on the above scheme, the top of the connecting arm 31 includes a first connecting section 314 and a second connecting section 315, with an obtuse angle between them. The first connecting section 314 is connected to the extension section 112 of the upper beam plate 11, and the second connecting section 315 is connected to the first bent section 113 of the upper beam plate 11. This scheme allows the force to be uniformly transmitted upward and downward along the two connecting arm branches of the swing arm positioning seat to the axle box swing arm.

[0124] The above scheme connects the axle box and the side beam in the wheelset, so that the load between the wheelset and the frame can be transmitted evenly and smoothly, and the Y-shaped swing arm positioning seat 3 has sufficient rigidity to withstand bending stress and shear stress.

[0125] The swing arm positioning seat 3 can be formed by forging. The way the swing arm positioning seat 3 is connected to the end of the side beam web 13 can improve welding accuracy, reduce welding deformation, realize the integrated process of integral forging and welding, and reduce the weld length. Simulation analysis shows that the above-mentioned swing arm positioning seat can improve the strength and rigidity of the frame and achieve a lightweight effect.

[0126] The above solution is compatible with existing axle boxes with swing arms and can be directly applied to existing products. It can improve the standardization and modularity of bogies, reduce production costs, and facilitate assembly and maintenance.

[0127] Traditional frames are typically box-beam structures, with the brake hanger welded to the inner uprights of the frame, which occupies a large amount of space and cannot be adjusted after welding and fixing.

[0128] On the other hand, the brake hanger is welded to the surface of the inner vertical plate, resulting in significant welding stress and deformation. This affects the installation accuracy of the brake hanger and makes it prone to fatigue cracks after long-term operation, thus reducing the reliability of the bogie. Furthermore, to compensate for the impact of welding stress on structural strength, the plate thickness at the junction of the hanger and the frame needs to be appropriately increased, adding extra weight to the bogie and hindering lightweight design.

[0129] To address the aforementioned shortcomings of traditional solutions, this embodiment also provides an example of a brake hanger, such as... Figures 28 to 32 As shown, the braking device includes: a brake hanger 41, an outer mounting base 42, an inner mounting base 43, and a brake caliper. The outer mounting base 42 is located on the outer side of the side beam upright plate 15. Since the side beam upright plate 15, the side beam flange 14, and the upper side beam plate 11 form a recessed structure, the outer mounting base 42 is essentially embedded into the recessed structure on the outer side of the side beam. The outer mounting base 42 can be a plate-like structure with connecting holes.

[0130] The inner mounting base 43 is located on the inner side of the side beam upright plate 15, which is equivalent to being embedded in the recessed structure inside the side beam. The inner mounting base 43 can also be a plate-shaped structure with connecting holes.

[0131] The brake hanger 41 is located on the inner side of the side beam, and the brake hanger 41 also has connecting holes. By passing fasteners through the connecting holes of each component, the brake hanger 41, the inner mounting base 43, the side beam upright plate 15, and the outer mounting base 42 are connected in sequence to realize the installation of the brake hanger 41 and the side beam.

[0132] The brake caliper is installed on the brake hanger 41. The brake caliper can be a structure corresponding to tread brakes or a structure corresponding to disc brakes.

[0133] The aforementioned brake hanger is installed on the side beam using fasteners instead of welding, thus eliminating the problems of welding deformation and fatigue cracks caused by welding, thereby improving the reliability of the bogie.

[0134] In addition, the aforementioned brake hanger can utilize the recessed space inside the side beam to reduce the distance between the brake hanger and the side beam, thereby reducing the space occupied by the braking device, making the structure more compact and reducing the difficulty of the position layout of each component.

[0135] The inner mounting base 43 has an inwardly recessed surface facing away from the side beam upright plate 15, forming a positioning groove 431. Correspondingly, a positioning protrusion is provided on the surface of the brake hanger 41 facing the inner mounting base 43. The positioning protrusion is embedded in the positioning groove 431 and can move within the positioning groove. During the installation of the brake hanger 41, the position of the brake caliper can be adjusted by moving the positioning protrusion within the positioning groove 431, moving the brake caliper to the target position. Especially for tread brakes, after a period of operation, the brake shoes wear and become thinner. The brake caliper can be moved closer to the wheel tread by moving the brake hanger 41 to meet braking requirements.

[0136] Alternatively, the position of the brake hanger 41 can be adjusted by moving the positioning protrusion within the positioning groove 431, thereby eliminating dimensional errors of various components, improving the fault tolerance rate, and ensuring production cycle time.

[0137] One embodiment is as follows: the positioning groove 431 extends in a direction parallel to the side beam flange 14, and both ends of the positioning groove 431 penetrate through both sides of the inner mounting base 43. The positioning groove 431 moves and adjusts its position along the extending direction of the side beam flange 14.

[0138] There is one inner mounting base 43, with four connecting holes. The position and size of the connecting holes correspond to the connecting holes on the side beam upright plate 15. Alternatively, there are two inner mounting bases 43, spaced apart along the extension direction of the side beam flange 14. Each inner mounting base 43 has two connecting holes, and the position and size of the connecting holes on the two inner mounting bases 43 correspond to the connecting holes on the side beam upright plate 15.

[0139] The advantage of having two inner mounting seats 43 is that the component size is smaller, making it easier to assemble in confined spaces. Furthermore, the distance between the two inner mounting seats 43 is adjustable, which can be adjusted according to the connection hole position of the side beam upright plate 15, thus solving the problem of component opening size errors and improving the tolerance for errors.

[0140] The inner mounting base 43 can be pre-welded to the side beam upright plate 15. For example, the back of the inner mounting base 43 is welded to the side beam upright plate 15, the top is welded to the side beam wing plate 14, and the bottom is welded to the upper side beam plate 11 for fixation.

[0141] Alternatively, the inner mounting base 43 may be fixed to the side beam upright plate 15 by fasteners during the installation of the brake hanger 41.

[0142] One embodiment is as follows: the inner mounting plate 43 has two connecting holes distributed on both sides of the positioning groove 431. The outer mounting plate 42 has corresponding connecting holes to be connected to the inner mounting plate 43 by fasteners.

[0143] The brake hanger 41 includes a side beam connecting seat 411, a hanger body 412, and a lifting part 413. One surface of the side beam connecting seat 411 is used to fit against and connect to the surface of the inner mounting seat 43. The hanger body 412 is disposed on the other surface of the side beam connecting seat 411 and extends in a direction perpendicular to the side beam upright plate 15. Two lifting parts 413 are spaced apart from the hanger body 412 and are used to connect brake calipers 44.

[0144] The lifting section 413 extends toward the wheel, and the brake caliper 44 is bolted to the bottom of the lifting section 413.

[0145] Furthermore, the braking device also includes an equipment connection part 45, which is located in the middle of the main body part 412 of the hanger. The equipment connection part 45 is a plate-shaped structure with connection holes for mounting the tread cleaner 46.

[0146] This embodiment also provides a bogie manufactured using any of the manufacturing methods described above. This embodiment also provides a rail vehicle, including the bogie provided above. The bogie and rail vehicle have the same technical effects as the manufacturing methods described above.

Claims

1. A method for manufacturing a bogie frame, characterized in that, include: Side beam webs are installed at both ends of the frame base plate in the transverse direction. The side beam webs extend longitudinally and are perpendicular to the frame base plate. A predetermined distance is left between the edge of the side beam web and the bottom plate of the frame; A crossbeam web is installed at both ends of the longitudinal direction of the frame base plate. The crossbeam web extends laterally and is perpendicular to the frame base plate. The two ends of the crossbeam web are connected to the side beam webs. The middle part of the upper side beam plate is installed to the top of the side beam web plate; the upper side beam plate extends longitudinally and its end is bent upward. The upper crossbeam plate is installed at the top of the web of the crossbeam. The upper crossbeam plate is located between the two upper side beam plates and is connected to the inner edge of the upper side beam plates.

2. The manufacturing method according to claim 1, characterized in that, Also includes: The side beam upright is installed on the upper end surface of the upper side beam plate. The side beam upright extends longitudinally and is perpendicular to the upper side beam plate. A preset distance is left between the side beam upright and the two side edges of the upper side beam plate. Install the side beam flange to the top of the side beam upright; the side beam flange extends longitudinally, with one end connected to the end of the upper side beam and the other end connected to the middle of the upper side beam.

3. The manufacturing method according to claim 1, characterized in that, Before installing the upper side beam, the following is also included: A horizontal beam upright plate is installed in the middle of the frame base plate; the horizontal beam upright plate extends longitudinally and is perpendicular to the frame base plate; the two ends of the horizontal beam upright plate are connected to the web of the horizontal beam.

4. The manufacturing method according to claim 1, characterized in that, Before installing the upper side beam, the following is also included: Side beam stiffener plates are installed on both sides of the side beam web, and the bottom end of the side beam stiffener plates is connected to the frame bottom plate. A crossbeam stiffener is installed on the inner side of the crossbeam web, and the bottom end of the crossbeam stiffener is connected to the frame base plate.

5. The manufacturing method according to claim 1, characterized in that, Before installing the side beam web, the process also includes: installing the swing arm positioning seat to both ends of the side beam web, with the bottom end of the swing arm positioning seat connected to the frame base plate. During the installation of the upper side beam plate, the lower surface of the end of the upper side beam plate is also connected to the swing arm positioning seat.

6. The manufacturing method according to claim 2, characterized in that, After installing the side beam flanges, the following is also included: Install the first-stage cap stand plate to the end of the upper side beam plate; The primary cover plate is installed to the end of the side beam flange, and the primary cover plate is connected to the top of the primary cap plate.

7. The manufacturing method according to claim 1, characterized in that, Before installing the upper side beam, the following is also included: The raw steel plate used to form the upper side beam is placed in the mold, and pressure is applied to the mold by a bending machine until the mold is closed. The middle part of the resulting upper side beam is flat, and the ends are bent upward.

8. The manufacturing method according to claim 1, characterized in that, After installing the crossbeam plate, the following is also included: Install at least one of the following on the upper crossbeam plate: a transverse stop mounting seat, a longitudinal stop mounting seat, and a vibration damper mounting seat.

9. A bogie, characterized in that, It is manufactured using the manufacturing method described in any one of claims 1-8.

10. A rail vehicle, characterized in that, include: The bogie as described in claim 9.

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