Method and equipment for levelling the wall panels of a rail vehicle body

Abstract

The present application relates to the technical field of vehicle body wall plate leveling, and particularly relates to a rail passenger car body wall plate leveling method and equipment, the leveling method being: a magnetic attraction piece is attracted to a vehicle body wall plate position to be leveled outside a vehicle, the magnetic attraction piece is internally provided with a heating piece and a cooling piece, the heating piece first heats the vehicle body wall plate position to be leveled, and the cooling piece cools the heated position, thereby completing leveling of the vehicle body wall plate position to be leveled. The leveling equipment comprises the magnetic attraction piece, which is used for being attracted to the vehicle body wall plate to be leveled and provides a force for forcibly flattening and tightening the vehicle body wall plate, and the magnetic attraction piece has a containing space; the heating piece and the cooling piece are both arranged in the containing space and are used for heating and cooling the vehicle body wall plate. The inductive heating tube and the cold water spraying piece are integrated in the magnetic attraction piece, water is sprayed to cool the wall plate outside the vehicle, the risk of rust caused by accumulated water to the vehicle body is avoided, the anticorrosion capability of the whole vehicle is improved, and the service life of the rail passenger car is prolonged.

Description

Technical Field

[0001] This invention relates to the field of vehicle body wall panel leveling technology, and more particularly to a method and equipment for leveling the vehicle body wall panels of rail passenger cars. Background Technology

[0002] With the rapid development of the rail passenger vehicle industry, the market's requirements for the appearance quality of rail passenger vehicle sidewalls are continuously increasing. The flatness of the sidewalls has become one of the core indicators for measuring the manufacturing precision and visual quality of the vehicle body. Currently, the main body of the sidewalls of rail passenger vehicles mostly adopts a plate-beam structure, which requires extensive use of welding processes during manufacturing. However, after the sidewall beams and columns are welded to the wall panels, they are prone to overall shrinkage and deformation due to thermal stress. In areas without beam and column support or with large beam-column spacing, the wall panels generally exhibit loosening, ultimately resulting in an uneven surface of the wall panels. This seriously affects the appearance quality of the vehicle body and restricts the upgrading of the manufacturing quality of rail passenger vehicles.

[0003] To address the issue of wall panel flatness, the rail passenger vehicle industry currently widely employs sheet metal adjustment techniques, with electromagnetic leveling solutions being the most prevalent. For example... Figure 1 As shown, the technical logic of this scheme is as follows: the wall panel 3 is fixed by electromagnet 1 in conjunction with electromagnetic leveling clamp 2, and then the wall panel is heated by oxyacetylene torch 4. After the wall panel temperature rises to 700℃, it is rapidly cooled by water spray gun 5. By taking advantage of the thermal expansion and contraction effect of heating and rapid cooling, the wall panel is locally contracted and tightened, thereby improving its flatness.

[0004] However, existing electromagnetic leveling technology has many drawbacks: First, temperature control is difficult. When manually operating an oxy-acetylene torch to heat the inner side of the wall panel, the temperature is difficult to control precisely. Overheating can easily cause sheet metal instability and aggravate wall panel deformation, while underheating will not achieve the leveling effect. Second, during electromagnetic leveling, the outside of the car is pressed down by electromagnets, which can pull the wall panel outward. There is no space outside the car to burn fire, so heating can only be done inside the car by spraying water for cooling. Spraying water for cooling inside the car will cause water to accumulate in the car body. It is difficult to completely remove the water later, which can easily cause the car body to rust and significantly reduce the corrosion resistance of the entire vehicle. Third, manual operation is risky and labor-intensive. The up and down adjustment of the electromagnetic leveling clamps depends entirely on manual labor, which not only requires a large number of personnel and is labor-intensive, but also easily causes personnel injuries. Fourth, the degree of automation is low. The entire process operation is complex. The manual operation mode leads to a large workload and difficulty in improving leveling efficiency, which cannot meet the needs of mass production and high efficiency of rail passenger cars.

[0005] The shortcomings of the existing technologies mentioned above not only limit the accuracy and efficiency of leveling the wall panels of rail passenger vehicles, but also increase the cost and quality risks in vehicle manufacturing. Therefore, developing a rail passenger vehicle wall panel leveling method and equipment that is accurate, safe to operate, highly automated, and does not cause water accumulation inside the vehicle is of great practical significance for improving the manufacturing quality of rail passenger vehicles, reducing production losses, and promoting the upgrading of industry processes. Summary of the Invention

[0006] To address the aforementioned technical problems, embodiments of the present invention provide a method and equipment for leveling the wall panels of a rail passenger vehicle, achieving safe operation, high degree of automation, and preventing water accumulation inside the vehicle.

[0007] To achieve the above objectives, this invention provides a method for leveling the wall panel of a rail passenger vehicle. A magnetic suction device is attached to the position of the wall panel to be leveled outside the vehicle. The magnetic suction device has a built-in heating element and a cooling element. The heating element first heats the position of the wall panel to be leveled, and the cooling element cools the heated position, thereby completing the leveling of the position of the wall panel to be leveled.

[0008] For example, in at least one embodiment of the rail passenger vehicle body wall panel leveling method provided in this disclosure, the magnetic attractor is an electromagnet, the heating element is an inductive heating tube, and the heating element heats the position of the body wall panel to be leveled to a temperature of (650-700℃) ± 5℃.

[0009] For example, in at least one embodiment of the rail passenger car body wall panel leveling method provided in this disclosure, the cooling component is a cold water spray component, which sprays and cools the heated position.

[0010] For example, in at least one embodiment of the rail passenger vehicle body wall panel leveling method provided in this disclosure, after the leveling of the body wall panel at the position to be leveled is completed, the magnetic suction component is raised or lowered or moved horizontally to the next position for leveling, until the leveling of the entire body wall panel is completed.

[0011] This invention also provides a rail passenger car body wall panel leveling device, comprising: A magnetic suction device is used to attach to a vehicle body wall panel to be leveled and to provide a force for the vehicle body wall panel to be forcibly flattened and tightened. The magnetic suction device has a receiving space. A heating element and a cooling element are both disposed within the accommodating space for heating and cooling the vehicle body wall panel.

[0012] For example, in at least one embodiment of the rail passenger car body wall panel leveling equipment provided in this disclosure, the magnetic attractor is an electromagnet, the heating element is an inductive heating tube, the cooling element is a cold water spraying element, and the cooling element has a plurality of spray heads.

[0013] For example, at least one embodiment of the rail passenger car body wall panel leveling equipment provided in this disclosure has an opening on one side of the accommodating space and also includes an electromagnet cover panel, which is disposed at the opening.

[0014] For example, in at least one embodiment of the rail passenger car body wall panel leveling equipment provided in this disclosure, the electromagnet cover panel has a plurality of clearance openings, the clearance openings being correspondingly arranged with the spray head; the accommodating space has a plurality of partitions, the partitions dividing the accommodating space into a plurality of grooves, and the heating element and the cooling element being distributed in the grooves.

[0015] For example, the rail passenger car body wall panel leveling equipment provided in at least one embodiment of this disclosure further includes: An electromagnetic shielding base plate is disposed at the bottom of the trench; An electromagnet heat insulation bushing and an electromagnetic shielding bushing are arranged sequentially in the groove, and a heating element and a cooling element are arranged inside the electromagnetic shielding bushing.

[0016] For example, the rail passenger car body wall panel leveling equipment provided in at least one embodiment of this disclosure further includes: The lifting and traversing device includes a magnetic suction component mounted on it, which is driven by the device to perform both lifting and horizontal movement.

[0017] Compared with existing technologies, the railcar body wall panel leveling method and equipment provided in this invention have significant technical advantages: integrating the inductive heating tube and the cold water spray component inside the magnetic suction component enables water spray cooling of the wall panels from outside the vehicle. This design changes the situation of water accumulation caused by water spray cooling inside the vehicle in existing technologies, avoids the risk of rust caused by water accumulation, improves the corrosion resistance of the entire vehicle, and extends the service life of the railcar.

[0018] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments of this application will be briefly introduced below. Obviously, the drawings described below are merely some exemplary embodiments of this application. For those skilled in the art, other drawings can be obtained based on the content of the exemplary embodiments of this application and these drawings without any creative effort.

[0020] Figure 1 This is a schematic diagram of the electromagnetic leveling scheme in the prior art.

[0021] Figure 2 This is a schematic diagram of the leveling equipment in one embodiment of the present invention; Figure 3 for Figure 2 A schematic diagram of the exploded structure of the leveling equipment in the embodiment; Figure 4 for Figure 2 A cross-sectional view of the leveling equipment in the embodiment; Figure 5 for Figure 2 Another cross-sectional view of the leveling equipment in the embodiment; Figure 6 for Figure 2 A schematic diagram of the lifting and traversing device in the embodiment; In the diagram: 1. Electromagnet; 2. Electromagnetic leveling clamp; 3. Wall panel; 4. Oxyacetylene torch; 5. Water spray gun; 100. Magnetic suction component; 110. Accommodation space; 111. Opening; 120. Partition; 121. Groove; 200. Heating component; 300. Cooling component; 310. Spray head; 400. Electromagnet cover panel; 410. Leaving opening; 500. Electromagnetic shielding base plate; 600. Electromagnetic heat insulation bushing; 700. Electromagnetic shielding bushing; 800. Lifting and traversing device. Detailed Implementation

[0022] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0023] To keep the drawings concise, each figure only schematically shows the parts relevant to the invention, and they do not represent the actual structure of the product. Furthermore, for ease of understanding, in some figures, components with the same structure or function are shown only schematically, or only one is labeled. In this document, "one" not only means "only one," but can also mean "more than one."

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

[0025] It should be noted that when an element is referred to as being "set on" another element, it can be directly set on the other element or indirectly set on the other element. It should be understood that the terms "length," "width," "upper," "lower," "front," "rear," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention.

[0026] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a number" means two or more, unless otherwise explicitly specified.

[0027] Please see Figures 2-5 This illustration shows a railcar body wall panel leveling device according to an embodiment of the present invention, including a magnetic suction component 100, a heating component 200, and a cooling component 300. The magnetic suction component 100 is used to attract the body wall panel to be leveled and provides a force to forcibly flatten and tighten the body wall panel. The magnetic suction component 100 has a receiving space 110, and the heating component 200 and the cooling component 300 are both disposed in the receiving space 110 for heating and cooling the body wall panel. The magnetic suction component 100 can be an electromagnet, the heating component 200 can be an inductive heating tube, and the cooling component 300 can be a cold water spray component, which has several spray heads 310.

[0028] For example, the magnetic attractor 100 can be an electromagnet, with its shape and size customized according to the actual conditions of the railcar body wall panel. The electromagnet has a large adsorption surface to ensure full contact with the wall panel and provide sufficient adsorption force. The electromagnet's internal design includes a receiving space 110 for integrating the heating element 200 and the cooling element 300. The electromagnet's outer shell is made of high-strength, wear-resistant metal material, ensuring both the electromagnet's structural strength and preventing damage from collisions or friction during use.

[0029] The main function of the magnetic chuck 100 is to adhere to the vehicle body wall panel to be leveled, providing a force that forcibly flattens and tightens the panel. When the electromagnet is energized, it generates a strong magnetic field that tightly holds the wall panel in place, maintaining its stable position during leveling. This attraction not only overcomes the deformation forces caused by thermal stress and relaxation in the wall panel but also ensures smooth adjustment of the panel's flatness during heating and cooling. For example, when heating and cooling the wall panel, the magnetic chuck 100 prevents unnecessary displacement due to thermal expansion and contraction, ensuring the accuracy of the leveling effect.

[0030] The heating element 200 can be an inductive heating tube, specifically an electromagnetic induction heating coil integrated inside the magnetic element 100. The electromagnetic induction heating coil is made of a material that is resistant to high temperatures and has good electrical conductivity.

[0031] The function of heating element 200 is to rapidly heat the vehicle body wall panels. During the leveling process, the electromagnetic induction heating coil, under high power, can rapidly raise the temperature of the wall panels in a short time. The wall panels need to reach a temperature of 650-700℃ ± 5℃ within 18 seconds to meet the heating temperature control requirements. This rapid and precise heating method allows the wall panels to be heated evenly, providing a good foundation for subsequent cooling and contraction. For example, by controlling the heating temperature and time, problems such as sheet metal instability and aggravated wall panel deformation due to overheating, or failure to achieve the leveling effect due to insufficient heating, are avoided.

[0032] The cooling component 300 is a cold water spray component, also integrated inside the magnetic component 100. The cooling component 300 has several spray heads 310, which are arranged in a matrix on the cooling component 300. The spray heads 310 are manufactured using a high-precision process, enabling precise water spray control. The cooling component 300 has internal water flow channels connected to an external cold water supply system, ensuring sufficient cold water supply to each spray head 310.

[0033] The main function of the cooling component 300 is to rapidly cool the wall panel after it reaches the heating temperature. When the wall panel temperature reaches 650-700℃ ± 5℃, the cold water spray component is activated, and the spray heads 310 begin spraying water to rapidly cool the wall panel. Because the spray heads 310 are arranged in a matrix and can be controlled, and in conjunction with multiple temperature sensors, precise spraying in different areas can be achieved. This cooling method allows the surface of the wall panel to cool and contract rapidly first, while the interior cools and contracts slowly later, thus creating a large temperature gradient and internal stress within the wall panel, making the wall panel appear "taut" and achieving a smooth effect. For example, when leveling a large area of ​​wall panel, the spray intensity and duration of the spray heads 310 at different locations can be precisely controlled according to the temperature changes in different areas of the wall panel, ensuring a uniform improvement in the smoothness of the entire wall panel.

[0034] Current electromagnetic leveling technology uses electromagnets and electromagnetic leveling clamps to firmly fix the wall panels. Because the outside of the vehicle is pressed down by the electromagnets, there is no space to use an oxy-acetylene torch for heating, so heating can only be done inside the vehicle. After heating, rapid cooling is required, which necessitates spraying water inside the vehicle, leading to water accumulation. This accumulated water is difficult to completely remove, easily causing rust on the vehicle body and significantly reducing the vehicle's overall corrosion resistance.

[0035] This solution integrates the heating element 200 and the cooling element 300 within the magnetic element 100. While the electromagnet attracts the wall panel outside the vehicle, it precisely coordinates the heating and cooling of the wall panel. External water cooling avoids water accumulation inside the vehicle, effectively improving the vehicle's corrosion resistance. Simultaneously, the relatively large external operating space facilitates equipment installation, debugging, and maintenance, enhancing the operability and stability of the entire leveling process.

[0036] During operation, firstly, place the magnetic chuck 100 of the railcar body wall panel leveling equipment at a suitable position on the outside of the wall panel to be leveled, ensuring full contact between the magnetic chuck 100 and the wall panel. Then, activate the magnetic chuck 100 through the external control system to generate a magnetic field, firmly adhering to the wall panel. Simultaneously, check whether the heating element 200, cooling element 300, and related temperature sensors and control systems are functioning properly, ensuring all components are in standby mode.

[0037] After confirming that the equipment is functioning normally, the heating element 200 is activated, meaning the electromagnetic induction heating coil begins operation. Under high power, the electromagnetic induction heating coil rapidly raises the wall panel temperature, reaching 650-700℃ ±5℃ within 18 seconds. During this process, a temperature sensor monitors the wall panel temperature in real time and feeds the temperature data back to the PLC system. The PLC system precisely controls the power of the electromagnetic induction heating coil according to the preset temperature standard, ensuring the accuracy of the heating temperature.

[0038] Once the wall panel temperature reaches the set standard, the PLC system immediately activates the cooling component 300, and the cold water spray component begins operation. The matrix-arranged spray heads 310 spray precisely in different areas of the wall panel based on temperature information from the temperature sensors. The cold water rapidly contacts the high-temperature wall panel, causing the surface to cool and shrink quickly. Meanwhile, the interior cools more slowly, creating a temperature gradient and internal stress, gradually smoothing the wall panel. During the cooling process, the temperature sensors continuously monitor temperature changes, and the PLC system adjusts the spray intensity and duration of the spray heads 310 based on the temperature feedback to ensure precise control of the cooling process.

[0039] After the heating and cooling process, the flatness of the wall panel is effectively improved under the effects of thermal expansion and contraction and internal stress. At this point, turn off the power to the magnetic suction device 100 to demagnetize it, and remove the leveling equipment from the wall panel to complete one wall panel leveling operation.

[0040] This leveling equipment uses an electromagnetic induction heating coil for heating, combined with a temperature sensor and PLC system, to precisely control the heating temperature and time of the wall panel. Compared to existing technologies where manual operation of an oxyacetylene torch makes precise temperature control difficult, this solution effectively avoids overheating or underheating, ensuring the stability and reliability of the leveling effect and completely solving the problem of uneven sheet metal caused by instability and overheating.

[0041] By integrating the inductive heating element and the cold water spray component inside the magnetic chuck 100, water spray cooling of the wall panels can be achieved from the outside of the vehicle. This design completely changes the situation of water accumulation caused by water spray cooling inside the vehicle in existing technologies, avoids the risk of rust caused by water accumulation, significantly improves the corrosion resistance of the entire vehicle, and extends the service life of the railcar.

[0042] The entire system is automated through a PLC system, reducing manual operation. Electromagnetic induction heating and cold water spray cooling are both performed automatically by the system, requiring minimal human intervention and reducing the risks and labor intensity associated with manual operation. Simultaneously, the automated operation mode improves leveling efficiency, better meeting the demands of mass production and high efficiency for rail passenger vehicles.

[0043] In some examples, the receiving space 110 has an opening 111 on one side and also includes an electromagnet cover panel 400 disposed at the opening 111. The electromagnet cover panel 400 has several clearance openings 410, which are correspondingly disposed with the spray head 310. The receiving space 110 has several partitions 120, which divide the receiving space 110 into several grooves 121, in which the heating element 200 and the cooling element 300 are distributed. It also includes an electromagnetic shielding base plate 500, an electromagnet heat insulation bushing 600, and an electromagnetic shielding bushing 700. The electromagnetic shielding base plate 500 is disposed at the bottom of the groove 121, the electromagnet heat insulation bushing 600 and the electromagnetic shielding bushing 700 are sequentially disposed in the groove 121, and the heating element 200 and the cooling element 300 are disposed within the electromagnetic shielding bushing 700.

[0044] For example, the opening 111 on one side of the accommodating space 110 provides a convenient passage for the installation, maintenance, and repair of internal components. The area of ​​the opening 111 covers most of the area on one side of the accommodating space 110, making it convenient for operators to operate the internal equipment. For example, when it is necessary to replace the heating element 200 or clean the cooling element 300, the operator can easily remove or insert the relevant components through the opening 111.

[0045] The electromagnet cover panel 400 is installed at the opening 111, serving to protect the internal components and seal the receiving space 110, effectively preventing external objects from colliding with or damaging the internal heating element 200 and cooling element 300. At the same time, the electromagnet cover panel 400 also prevents dust, debris, and other contaminants from entering the receiving space 110 and affecting the normal operation of the equipment.

[0046] Several clearance openings 410 are provided on the electromagnet cover panel 400, corresponding to the sprinkler heads 310. The shape and size of the clearance openings 410 match the sprinkler heads 310, ensuring that the sprinkler heads 310 can evenly spray cold water onto the wall panel through the clearance openings 410. The edges of the clearance openings 410 are smoothed to avoid wear on the sprinkler heads 310 and affecting the water spraying effect. For example, the diameter of the clearance opening 410 is slightly larger than the outer diameter of the sprinkler heads 310, ensuring that the sprinkler heads 310 will not wobble after installation and can spray water smoothly.

[0047] The partitions 120 within the accommodating space 110 are divided into horizontal and vertical partitions, arranged perpendicularly to each other, dividing the accommodating space 110 into several grooves 121. These grooves 121 provide orderly installation space for the heating element 200 and the cooling element 300, allowing them to be rationally distributed within the accommodating space 110. The partitions 120 are made of high-temperature resistant and highly insulating materials, such as ceramic plates, which effectively isolate the heat generated by the heating element 200, preventing heat transfer to other components, and also ensure electrical insulation to avoid faults such as short circuits. The dimensions and shape of the grooves 121 are designed according to the outlines of the heating element 200 and the cooling element 300, ensuring that the components can be tightly embedded in the grooves 121, improving the compactness and stability of the equipment. For example, for an inductive heating tube, the width and depth of the groove 121 will be slightly larger than the diameter and height of the inductive heating tube, facilitating installation and fixation.

[0048] An electromagnetic shielding base plate 500 is located at the bottom of the groove 121, primarily serving an electromagnetic shielding function. When the heating element 200 operates, the electromagnetic induction heating coil generates a strong electromagnetic field. The electromagnetic shielding base plate 500 effectively blocks the propagation of this electromagnetic field to other parts of the vehicle body, preventing interference with internal electronic equipment. The electromagnetic shielding base plate 500 is made of a high-permeability material, such as permalloy, which efficiently absorbs and shields electromagnetic radiation. For example, in rail passenger cars, the interior contains many sophisticated electronic control systems; the electromagnetic shielding base plate 500 can prevent electromagnetic interference generated by leveling equipment from affecting the normal operation of these systems.

[0049] An electromagnet heat insulation bushing 600 and an electromagnetic shielding bushing 700 are sequentially arranged in the groove 121, with the heating element 200 and cooling element 300 housed within the electromagnetic shielding bushing 700. The electromagnet heat insulation bushing 600 primarily isolates the heat generated by the heating element 200, preventing heat transfer to other parts of the magnetic attractor 100 and avoiding overheating that could affect the magnetism of the magnetic attractor 100 and the performance of other components. The electromagnet heat insulation bushing 600 is made of a high-temperature resistant, heat-insulating material, such as ceramic fiber. The electromagnetic shielding bushing 700 further enhances the shielding effect on the electromagnetic field generated by the heating element 200, ensuring that the electromagnetic field does not adversely affect the surrounding environment. Simultaneously, it also protects the heating element 200 and cooling element 300 from external electromagnetic interference, ensuring stable operation of the equipment. For example, when working in a high-temperature environment, the electromagnet heat insulation bushing 600 can effectively prevent the high temperature of the heating element 200 from damaging the magnetic element 100, while the electromagnetic shielding bushing 700 can ensure that the equipment is not affected by external electromagnetic interference and can accurately heat and cool the wall panel.

[0050] The partition 120 divides the accommodating space 110 into grooves 121, allowing the heating element 200 and cooling element 300 to be distributed in an orderly manner. This layout improves the compactness and stability of the internal structure of the equipment. During equipment operation, the components will not shift due to vibration or collision, ensuring the normal operation of heating and cooling functions. For example, even if the car body vibrates during railcar operation, the heating element 200 and cooling element 300 can still remain in the correct position, stably heating and cooling the wall panel to ensure leveling effect.

[0051] The installation of components such as the electromagnet cover panel 400, the electromagnetic shielding base plate 500, the electromagnet heat insulation bushing 600, and the electromagnetic shielding bushing 700 provides comprehensive protection for the equipment. The electromagnet cover panel 400 protects internal components from external damage, the electromagnetic shielding base plate 500 and the electromagnetic shielding bushing 700 prevent electromagnetic interference, and the electromagnetic heat insulation bushing 600 isolates heat. These measures work together to enhance the reliability of the equipment, reduce the possibility of equipment failure caused by external factors, and extend the service life of the equipment.

[0052] The electromagnet heat insulation bushing 600 effectively isolates the heat generated by the heating element 200, allowing the heat to be applied more concentratedly to the wall panel and improving heating efficiency. Simultaneously, the electromagnetic shielding bushing 700 ensures that the electromagnetic field generated by the heating element 200 does not interfere with the cooling element 300, guaranteeing the stability and accuracy of the cooling process. For example, during heating, more heat can be transferred to the wall panel, allowing it to reach the set temperature in a shorter time. During cooling, the spray head 310 is unaffected by electromagnetic interference and can precisely spray cooling water onto the wall panel, thereby improving the overall leveling effect.

[0053] The partition 120 and various bushings protect the heating element 200 and cooling element 300, ensuring their performance is unaffected by external factors. Operating in a stable environment, the heating element 200 and cooling element 300 maintain consistently good performance, providing stable parameters for heating and cooling the wall panel, further enhancing the consistency and reliability of the leveling effect. For example, the heating element 200 will not reduce its heating power due to overheating, and the cooling element 300 will not experience uneven water spraying due to electromagnetic interference, ensuring that each leveling operation achieves the expected results.

[0054] The design of the opening 111 and the electromagnet cover panel 400 makes equipment maintenance and repair more convenient. When internal components need maintenance or replacement, simply remove the electromagnet cover panel 400 to easily access internal components such as the heating element 200 and cooling element 300 through the opening 111. This design reduces maintenance time and difficulty, and improves the maintainability of the equipment. For example, during routine maintenance, operators can quickly open the electromagnet cover panel 400 to check whether the spray head 310 is blocked or whether the inductive heating element is working properly, and address any problems promptly.

[0055] In some examples, such as Figure 6 As shown, it also includes a lifting and traversing device 800, and a magnetic suction component 100 is mounted on the lifting and traversing device 800 and driven by the lifting and traversing device 800, enabling it to move vertically and horizontally.

[0056] For example, the lifting and traversing device 800 is customized according to the size of the rail passenger car body wall panel and the space requirements for leveling operation. It usually has a sturdy base and a vertical column with lifting rails on the column for the vertical lifting of the magnetic component 100.

[0057] The lifting and traversing device 800 can be implemented in various ways, commonly including electric screw lifting mechanisms or hydraulic lifting mechanisms. Taking the electric screw lifting mechanism as an example, the motor drives the screw to rotate through the transmission device. The nut on the screw is connected to the mounting base of the magnetic component 100. As the screw rotates, the nut moves up and down along the screw, thereby realizing the lifting and lowering of the magnetic component 100.

[0058] The lateral movement mechanism enables the magnetic chuck 100 to move horizontally. This is typically achieved by mounting a linear guide rail and a drive unit on the base. The drive unit can be a motor coupled with a rack and pinion, or a linear motor. The motor drives the gears to roll on the rack, causing the magnetic chuck 100, mounted on the slider, to move horizontally along the linear guide rail. This design allows the magnetic chuck 100 to move laterally across the wall panel surface, leveling different areas of the wall panel and improving the coverage and uniformity of the leveling.

[0059] The magnetic suction component 100 is installed on the lifting and traversing device 800, and the entire leveling process is automated through program control. Operators only need to input relevant parameters of the wall panel into the control system, such as the wall panel thickness and leveling area. The lifting and traversing device 800 can then automatically adjust the position of the magnetic suction component 100 according to a preset program. For example, when leveling a large wall panel, the lifting and traversing device 800 can first move the magnetic suction component 100 to the starting position of the wall panel, and then sequentially perform adsorption, heating, and cooling operations on different areas of the wall panel according to a set path and speed. This eliminates the need for frequent manual adjustments to the position of the magnetic suction component 100, reducing manual intervention and lowering the operator's workload.

[0060] The automated operation of the lifting and traversing device 800 significantly improves labor efficiency and production productivity. In traditional leveling operations, manually adjusting the position of the magnetic chuck 100 is not only time-consuming and labor-intensive but also prone to errors. The lifting and traversing device 800 can quickly and accurately move the magnetic chuck 100 to the designated position, shortening the time required to level a single wall panel. For example, in the mass production of rail passenger vehicles, the leveling time for each wall panel can be significantly reduced, thereby improving overall production efficiency and meeting the needs of mass production of rail passenger vehicles.

[0061] The lifting and traversing device 800 can precisely control the position of the magnetic component 100, achieving high positioning accuracy in both vertical lifting and horizontal traversal. This allows the magnetic component 100 to accurately adhere to the position on the wall panel requiring leveling, and the heating and cooling components 200 can correspondingly and precisely heat and cool specific areas. Compared to manual operation, this precise positioning avoids uneven leveling caused by positional deviations, improving leveling accuracy. For example, when leveling slightly deformed areas on the wall panel, the lifting and traversing device 800 can precisely move the magnetic component 100 to that area, ensuring that the heating and cooling process effectively improves the flatness of that area.

[0062] Through program control, the lifting and traversing device 800 can move the magnetic suction component 100 according to a preset path and method to perform comprehensive and uniform leveling of the wall panel. It can rationally plan the movement trajectory of the magnetic suction component 100 according to the shape and size of the wall panel, ensuring that all parts of the wall panel receive appropriate heating and cooling treatment, thereby making the flatness of the entire wall panel more uniform. For example, for large flat wall panels, the lifting and traversing device 800 can move the magnetic suction component 100 according to a grid-like path, ensuring that every area of ​​the wall panel surface is uniformly leveled, avoiding excessive local differences in flatness.

[0063] The lifting and traversing device 800 provides a relatively stable working platform for the magnetic suction component 100. During the leveling process, supported by the lifting and traversing device 800, the magnetic suction component 100 will not shift due to slight external vibrations or collisions, ensuring the smooth progress of the heating and cooling processes. For example, in a rail passenger vehicle production workshop, the surrounding environment may have certain vibrations. The lifting and traversing device 800 can effectively isolate these vibrations, keeping the magnetic suction component 100 stable during the leveling process, thereby improving the stability of the leveling effect.

[0064] Combined with program control, the lifting and traversing device 800 can achieve diverse leveling strategies. Based on the deformation of the wall panel and the leveling requirements, operators can select different leveling modes in the control system, such as row-by-row leveling, zone leveling, and focused area reinforcement leveling. The lifting and traversing device 800 will automatically adjust the movement and dwell time of the magnetic suction component 100 according to the selected mode to achieve the best leveling effect. This diverse leveling strategy enables the leveling equipment to better handle various complex wall panel deformations, further improving production flexibility and leveling effectiveness.

[0065] One embodiment of the present invention also proposes a method for leveling the sidewall panels of a rail passenger vehicle. At the start of leveling, the magnetic chuck is energized. Since the magnetic chuck is an electromagnet, the strong attraction generated by the electromagnet attracts it to the leveling position on the outer skin of the sidewall, ensuring a firm attachment. This step provides a stable foundation for subsequent heating and cooling operations. For example, in actual operation, the strength of the attraction force can be controlled by adjusting the current of the electromagnet to adapt to sidewall panels of different materials and surface conditions, ensuring that the magnetic chuck will not detach during the entire leveling process.

[0066] In existing electromagnetic leveling technology, the exterior of the vehicle is held down by electromagnets, leaving no space for heating operations. Heating and cooling can only be performed inside the vehicle, leading to problems such as water accumulation. This solution integrates the heating and cooling components within the magnetic attraction element, allowing heating and cooling to be completed simultaneously with the external wall panel. External operation not only avoids the problems of water accumulation inside the vehicle causing rust and reducing the vehicle's corrosion resistance, but also provides a more spacious operating area, facilitating equipment installation, debugging, and maintenance, while minimizing impact on other equipment and interior decorations.

[0067] The heating element uses an integrated inductive heating tube, or electromagnetic induction heating coil, within the magnetic chuck. Powering the inductive heating tube activates the wall panel heating. The heating time of the electromagnetic induction heating coil is controlled by a PLC. When the adsorbed sheet metal is heated to 650-700℃ ± 5℃, the inductive coil is energized, ending the heating process. This precise temperature control is achieved through a pre-programmed PLC system. It can accurately adjust the heating power and time based on parameters such as the wall panel's material and thickness, ensuring a stable and accurate temperature is achieved with each heating cycle. For example, for wall panels of different thicknesses, the PLC system can automatically adjust the heating time, ensuring that even thicker wall panels are heated evenly to the target temperature.

[0068] Compared to existing technologies where manual operation of an oxyacetylene torch makes precise temperature control difficult, this solution effectively avoids problems such as sheet metal instability and increased wall panel deformation due to overheating, or failure to achieve leveling due to insufficient heating, by precisely controlling the heating temperature and time. Stable and precise heating allows the wall panel to be heated evenly, providing a good foundation for subsequent cooling and shrinkage, thereby significantly improving the leveling effect and ensuring the stability of product quality.

[0069] The cooling component is a cold water spray system integrated within the magnetic suction unit. Once the wall panel is heated to the set temperature, the cold water spray system is activated via PLC control, achieving precise spraying of water onto the heated area. The spray nozzles on the cold water spray system evenly spray cold water onto the heated wall panel, causing it to cool and shrink rapidly. During the cooling process, because the surface of the wall panel cools and shrinks faster initially than the interior, a significant temperature gradient and internal stress are created, acting as if the panel is being "stretched," thus making the steel plate smoother. After spraying, the flatness of the wall panel is effectively improved.

[0070] Existing technology using water spray for cooling inside the vehicle leads to water accumulation inside the carriage, which is difficult to completely drain and can easily cause problems such as rust. This solution, however, uses external spray cooling, completely avoiding the problem of water accumulation inside the carriage, effectively improving the overall corrosion resistance of the vehicle and extending the service life of the railcar. Furthermore, precise spray control can adjust the spray intensity and duration according to temperature changes at different locations on the wall panels, further improving the uniformity of the cooling effect and the accuracy of leveling.

[0071] After leveling a specific position of the vehicle body wall panel, the magnetic suction device, driven by a lifting and traversing mechanism, moves up and down or horizontally to the next position to be leveled. This process of adsorption, heating, and cooling is repeated until the entire vehicle body wall panel is leveled. This automated positioning method, achieved through program-controlled lifting and traversing, allows for quick and accurate movement of the magnetic suction device to the designated position, reducing the time required to level a single wall panel. For example, when leveling large wall panels, the lifting and traversing device can level different areas of the panel sequentially according to a preset path and speed, eliminating the need for frequent manual adjustments to the magnetic suction device's position.

[0072] The entire process, coordinated with automated lifting and lateral movement equipment, achieves unmanned operation, significantly improving production efficiency. Compared to traditional manual operation, it not only reduces the time and effort required to manually adjust the position of the magnetic components but also lowers the risks and labor intensity of manual operation. Operators only need to input the relevant parameters of the wall panel into the control system, and the equipment can automatically complete the leveling work. The on-site operating environment is also significantly improved, transforming tedious and high-risk manual operation into an automated and intelligent operating mode, which better meets the needs of modern industrial production.

[0073] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the invention applied herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary technical means not disclosed herein. The specification and embodiments are to be considered exemplary only, and the true scope and spirit of this application are indicated by the following claims.

[0074] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, but various modifications can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A method for leveling the wall panels of a rail passenger car, characterized in that, The magnetic attachment is attached to the vehicle body panel outside the vehicle at the position to be leveled. The magnetic attachment has built-in heating and cooling components. The heating component first heats the position of the vehicle body panel to be leveled, and the cooling component cools the heated position, thereby completing the leveling of the position of the vehicle body panel to be leveled.

2. The method for leveling the wall panels of a rail passenger car body according to claim 1, characterized in that, The magnetic attraction element is an electromagnet, and the heating element is an inductive heating tube. The heating element heats the position of the vehicle body wall panel to be leveled to a temperature of (650-700℃) ± 5℃.

3. The method for leveling the wall panels of a rail passenger car according to claim 1, characterized in that, The cooling component is a cold water spray component, which sprays cold water to cool the heated area.

4. The method for leveling the wall panels of a rail passenger car body according to claim 1, characterized in that, After leveling the vehicle body wall panel at the desired leveling position, the magnetic attachment is raised or lowered or moved horizontally to level the next position until the entire vehicle body wall panel is leveled.

5. A rail passenger car body wall panel leveling device, characterized in that, include: A magnetic clasp (100) is used to attach to the vehicle body wall panel to be leveled and to provide a force for the vehicle body wall panel to be forcibly flattened and tightened. The magnetic clasp (100) has a receiving space (110). A heating element (200) and a cooling element (300) are provided in the receiving space (110) for heating and cooling the vehicle body wall panel.

6. The rail passenger car body wall panel leveling equipment according to claim 5, characterized in that, The magnetic attractor (100) is an electromagnet, the heating element (200) is an inductive heating tube, the cooling element (300) is a cold water spray element, and the cooling element (300) has a plurality of spray heads (310).

7. The rail passenger car body wall panel leveling equipment according to claim 6, characterized in that, The accommodating space (110) has an opening (111) on one side and also includes an electromagnet cover panel (400) disposed at the opening (111).

8. The rail passenger car body wall panel leveling equipment according to claim 7, characterized in that, The electromagnet cover panel (400) has a plurality of clearance openings (410), which are correspondingly arranged with the spray head (310); the accommodating space (110) has a plurality of partitions (120), which divide the accommodating space (110) into a plurality of grooves (121), and the heating element (200) and the cooling element (300) are distributed in the grooves (121).

9. The rail passenger car body wall panel leveling equipment according to claim 8, characterized in that, Also includes: An electromagnetic shielding base plate (500) is disposed at the bottom of the trench (121); An electromagnet heat insulation bushing (600) and an electromagnetic shielding bushing (700) are arranged sequentially in the groove (121), and a heating element (200) and a cooling element (300) are arranged inside the electromagnetic shielding bushing (700).

10. The rail passenger car body wall panel leveling equipment according to claim 7, characterized in that, Also includes: The lifting and traversing device (800) has a magnetic suction component (100) mounted on it and driven by it, enabling it to move up and down and traverse horizontally.

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