Aluminum alloy air reservoir for truck

Abstract

The utility model belongs to truck spare parts technical field, concretely relates to a kind of aluminium alloy air cylinder for truck, including air cylinder and baffle, baffle includes welding ring, adapter ring and pressure shell that are connected in turn and smooth transition;Welding ring is the cylinder with both ends opening, outer diameter is consistent with the inner diameter of air cylinder, based on outer wall and the inner wall welding connection of air cylinder, pressure shell is cambered surface structure;Adapter ring realizes shape transition between welding ring and pressure shell.Due to the pressure resistance of cambered surface structure under the condition of unit thickness is highest, so the utility model can increase the pressure resistance of baffle without using increase baffle thickness and without setting reinforcing rib, ensure that baffle will not be caused by pressure difference change baffle deformation even failure, avoid the stress concentration caused by weld thickening and non-smooth structure simultaneously, completely eradicate the security risk of truck aluminium alloy air cylinder baffle failure.

Description

Technical Field

[0001] This utility model belongs to the technical field of truck parts and components, specifically relating to an aluminum alloy air tank for trucks. Background Technology

[0002] Aluminum alloy air tanks are pressurized gas storage devices in truck braking systems. They are used to store high-pressure air compressed by an air compressor (air pump) and are used in truck braking systems. They have functions such as energy storage, filtration, pressure stabilization, and cooling, and are key components to ensure safe driving of vehicles.

[0003] During road tests, it was found that the pressure difference between the different chambers of the existing three-chamber air tank changes with vehicle acceleration and braking. Due to insufficient rigidity of the baffles, the internal baffles will deform when the pressure difference is large. Over time, this will cause material fatigue failure, which in turn will lead to baffle failure, posing a safety hazard.

[0004] Since the air cylinder is made of aluminum alloy, existing technologies to solve this problem involve thickening the partition or adding reinforcing ribs to increase its strength. Thickening the partition increases the overall weight and widens the weld, leading to stress concentration. Reinforcing ribs requires additional stamping or welding, which also leads to stress concentration. Neither of these methods can eliminate the hidden dangers.

[0005] Truck air tanks are equipped with drain valves to drain water periodically, preventing moisture from freezing in cold external environments and the risk of ice crystals clogging brake lines during exhaust. For this reason, each chamber of a multi-chamber air tank needs to be equipped with a drain valve. However, due to the different filling and emptying points and filling pressures of each chamber, the drainage cycle is difficult to control. Utility Model Content

[0006] In view of this, the present invention provides an aluminum alloy air cylinder for trucks. The main body of the partition adopts an arc-shaped structure with one side protruding. Since the arc-shaped structure has the highest pressure resistance per unit thickness, the present invention can increase the pressure resistance of the partition without increasing the thickness of the partition or setting reinforcing ribs, ensuring that the partition will not deform or even fail due to pressure difference changes. At the same time, it avoids stress concentration caused by weld thickening and non-smooth structure, completely eliminating the safety hazard of partition failure of truck aluminum alloy air cylinders.

[0007] To achieve the above-mentioned technical objectives, the specific technical solution adopted by this utility model is as follows:

[0008] An aluminum alloy air reservoir for trucks, used for storing air in truck braking systems, the air reservoir comprising: An air pump is cylindrical in shape with end caps at both ends. The partition, in at least one set, has a pressure-bearing part that is an arc-shaped structure protruding to one side, fixed inside the air cylinder and coaxially arranged with the air cylinder, dividing the air cylinder into at least two air chambers; Wherein: the air cylinder is provided with at least two air nozzles; each air nozzle is connected to each of the air chambers; the partition includes a welding ring, a transition ring and a pressure-bearing shell connected in sequence; the welding ring is a cylindrical shape with open ends, the outer diameter is the same as the inner diameter of the air cylinder, and it is welded to the inner wall of the air cylinder based on the outer wall; the pressure-bearing shell is an arc-shaped structure; the transition ring realizes the shape transition between the welding ring and the pressure-bearing shell.

[0009] To maximize the pressure resistance of the partition, the convex side of the partition faces the air chamber with the lower maximum inflation pressure.

[0010] To maximize the pressure-bearing capacity of the partition plate per unit thickness, the cross-sectional shape of the pressure-bearing shell is one of the following: circular arc, ellipse, or parabola.

[0011] To balance lightweight and pressure resistance, the pressure-bearing shell adopts the inflection point dimensions of minimum wall thickness and minimum axial length.

[0012] To facilitate processing and further avoid stress concentration, the thickness of the partition is uniform.

[0013] To improve the uniformity of force distribution, the axis of the welding ring coincides with the axis of the air cylinder.

[0014] To improve pressure resistance consistency, the partition is a one-piece molded structure.

[0015] To facilitate the installation of the pre-welding partition, a weld seam clearance groove is provided on the welding ring; the diameter of the weld seam clearance groove is 3-5mm, and the length is a semi-cylinder with the same width as the welding ring.

[0016] To meet the mainstream demand for aluminum alloy gas storage tanks, the cross-sectional shape of the pressure shell is arc-shaped, and the thickness of the partition is 2.5-3.5mm.

[0017] To achieve high-strength installation of the partition based on a narrow weld seam, the width of the weld ring is 8-12 mm.

[0018] To avoid stress interference between the air nozzle and the partition, the distance between each air nozzle and each partition is greater than 40mm.

[0019] To prevent residual water inside the air cylinder from freezing, the air cylinder also includes an anti-icing sleeve; the anti-icing sleeve is fitted around the outer periphery of the air cylinder and includes: An insulation layer is fitted around the outer periphery of the gas storage cylinder; A heat-conducting layer is disposed within the insulation layer and is attached to the outer wall of the gas storage cylinder; A heat buffer is disposed in the insulation layer and is thermally conductive with the heat-conducting layer. It absorbs heat when the gas storage cylinder is filled with gas and releases heat when the gas storage cylinder is discharged.

[0020] For ease of installation, the heat buffer is housed in a bag-shaped or box-shaped container; the bag-shaped or box-shaped container is fixed to the gas storage cylinder by being covered by the insulation layer.

[0021] By adopting the above technical solution, this utility model can also bring the following beneficial effects: This utility model divides the entire partition into a welding ring, a transition ring, and a pressure-bearing shell. The welding ring fits into the inner wall of the air cylinder to provide the overall welding foundation for the partition. The pressure-bearing shell is the main pressure-bearing structure of the partition. The transition ring is a smooth transition between the welding ring and the pressure-bearing shell based on a transition ring, which can avoid weak strength areas caused by too large transition angles, and can also support integrated stamping processing. Based on the characteristic that the spherical shell structure has a greater ability to resist internal pressure than external pressure, this utility model sets the protruding part of the pressure-bearing shell to face the air cavity with lower design pressure, which can further reduce the wall thickness of the partition. This invention provides a design inflection point that simultaneously balances lightweight and pressure resistance, and can provide a guiding basis for the overall design of the partition. This utility model proposes a variety of pressure-bearing shell structures with high pressure resistance per unit thickness, which are easy to adapt to different stamping processes; The partition of this utility model is a one-piece molded structure with high consistent strength; The clearance groove in this utility model facilitates the installation of the partition into the air cylinder; This utility model provides a partition shape and size suitable for classic scenarios, which is applicable to the existing mainstream aluminum alloy gas storage tank requirements; This invention provides an anti-icing sleeve for a multi-chamber gas storage cylinder. In low-temperature environments, the sleeve insulates the gas storage cylinder, extending the freezing time. Based on the first law of thermodynamics, when gas is filled into the cylinder, the compression of the gas in each chamber releases heat, while during exhaust, it absorbs heat, increasing the risk of freezing. This invention incorporates a heat-conducting layer and a heat buffer. The heat buffer absorbs heat during filling and releases heat during exhaust, further increasing the difficulty of freezing and reducing the risk of freezing within a certain range. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this disclosure, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the external structure of an aluminum alloy air tank for trucks according to a specific embodiment of this utility model. Figure 2 This is a perspective view of an aluminum alloy air tank for trucks according to a specific embodiment of the present utility model. Figure 3 This is a schematic diagram of the partition structure in a specific embodiment of the present invention; Figure 4 This is a schematic diagram of the structure when an anti-icing sleeve is added to the outer periphery of the gas storage cylinder in a specific embodiment of this utility model.

[0024] The components include: 1. Air cylinder; 11. Air nozzle; 2. Partition plate; 21. Welding ring; 22. Adapter ring; 23. Pressure shell; 24. Weld seam clearance groove; 3. End cap; 4. Insulation layer; 5. Heat-conducting layer; 6. Thermal buffer. Detailed Implementation

[0025] The embodiments of this disclosure will now be described in detail with reference to the accompanying drawings.

[0026] The following specific examples illustrate the implementation of this disclosure. Those skilled in the art can easily understand other advantages and effects of this disclosure from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of this disclosure, and not all of them. This disclosure can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this disclosure. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this disclosure.

[0027] It should be noted that various aspects of embodiments within the scope of the appended claims are described below. It will be apparent that the aspects described herein can be embodied in a wide variety of forms, and any particular structure and / or function described herein is merely illustrative. Based on this disclosure, those skilled in the art will understand that one aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number of aspects set forth herein can be used to implement the device and / or practice the method. Additionally, this device and / or method can be implemented using other structures and / or functionalities besides one or more of the aspects set forth herein.

[0028] It should also be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this disclosure. The illustrations only show the components related to this disclosure and are not drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0029] Furthermore, specific details are provided in the following description to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that the described aspects can be practiced without these specific details.

[0030] In one embodiment of this utility model, an aluminum alloy air tank for trucks is provided for storing air sources in truck braking systems, such as... Figure 1 , 2 As shown, the gas storage tank includes: Air pump 1 is cylindrical with end caps 3 installed at both ends; The partition 2, in at least one set, has a pressure-bearing part that is an arc-shaped structure protruding to one side, fixed inside the air cylinder 1, and coaxially arranged with the air cylinder 1, dividing the air cylinder 1 into at least two air chambers; Wherein: the air cylinder 1 is provided with at least two air nozzles 11; each air nozzle 11 is connected to each air chamber; the partition 2 includes a welded ring 21, a transition ring 22 and a pressure-bearing shell 23 connected in sequence; the welded ring 21 is a cylindrical shape with open ends, and its outer diameter is the same as the inner diameter of the air cylinder 1. It is welded to the inner wall of the air cylinder 1 based on the outer wall; the pressure-bearing shell 23 is an arc-shaped structure; the transition ring 22 realizes the shape transition between the welded ring 21 and the pressure-bearing shell 23.

[0031] In this embodiment, the main body of the partition 2 adopts an arc-shaped structure with one side protruding, which is consistent with the aluminum alloy material used in the air cylinder 1. Since the arc-shaped structure has the highest pressure resistance per unit thickness, this embodiment can increase the pressure resistance of the partition 2 without increasing the thickness of the partition 2 or setting reinforcing ribs, avoiding stress concentration caused by weld thickening and non-smooth structure, and completely eliminating the safety hazard of partition 2 failure in the truck aluminum alloy air cylinder 1.

[0032] like Figure 3 As shown, in this embodiment, the entire partition 2 is designed separately as a welding ring 21, a transition ring 22, and a pressure-bearing shell 23. The welding ring 21 is attached to the inner wall of the air cylinder 1 to provide the overall welding foundation for the partition 2. The pressure-bearing shell 23 is the main pressure-bearing structure of the partition 2. The transition ring 22 is a smooth transition between the welding ring 21 and the pressure-bearing shell 23 based on a transition ring, which can avoid the appearance of weak strength areas due to a large transition angle, and can also support integral stamping processing.

[0033] In this embodiment, the air cylinder 1 adopts a traditional cylindrical structure, and its diameter and length are determined according to actual needs; this embodiment does not limit these dimensions. The number of partitions 2 in this embodiment is at least one set, dividing the air storage space inside the air cylinder 1 into at least two air chambers. Thus, one aluminum alloy air cylinder can achieve the functions of at least two traditional air cylinders. Different air chambers are used to supply different air needs, such as two separate chambers supplying air for the front and rear brakes respectively. If the number of partitions 2 is greater than one, the number of air chambers is three or more, and each air chamber can independently supply air for air-operated devices such as air suspension, clutch booster, differential lock, and air horn. Each air chamber is equipped with an air nozzle 11 to enable inflation, use, and deflation functions.

[0034] In this embodiment, in order to maximize the compressive strength of the partition 2, the protruding side of the partition 2 faces the air chamber with the lower maximum inflation pressure.

[0035] To maximize the pressure-bearing capacity of the partition 2 per unit thickness, the cross-sectional shape of the pressure-bearing shell 23 is one of a circular arc, an ellipse, or a parabola. In this embodiment, a pure circular arc structure is preferred. The pure circular arc structure can maximize the pressure resistance of the pressure-bearing shell 23 per unit thickness, while ensuring the overall strength of the partition 2 is improved, and at the same time reducing the thickness of the partition 2, thus achieving cost reduction and efficiency improvement.

[0036] In this embodiment, under the specific requirements of 1.2 MPa for the ultimate pressure difference between adjacent air chambers (air chambers on the concave side of partition 2 are emptied and those on the convex side are fully loaded) and 0.5 times safety margin, guiding key control data that take into account both lightweight and pressure resistance are designed: the pressure shell 23 adopts the inflection point dimensions of minimum wall thickness and minimum axial length.

[0037] To facilitate stamping and further avoid stress concentration, the thickness of the partition 2 in this embodiment is uniform.

[0038] The partition 2 prepared by the stamping process in this embodiment has the following advantages. Risk of fatigue failure without weld seams: Traditional stiffened partition plates 2 require welding multiple stiffeners to the plate. These weld seams, especially at the ends of the stiffeners, are areas of high stress concentration. Under long-term alternating gas pressure loads, they are highly susceptible to fatigue cracks, ultimately leading to the failure of partition plate 2. One-piece stamping completely eliminates these internal weld seams, fundamentally preventing this type of failure mode.

[0039] Streamlined structure with uniform stress distribution: The stamped arc-shaped pressure-bearing shell 23 is itself an excellent pressure-bearing structure. It can evenly transfer pressure along the curved surface to the surrounding welded ring 21, avoiding bending stress on the flat plate and stress concentration at the connection between the flat plate and the stiffener, resulting in higher pressure-bearing efficiency and longer pressure fatigue life.

[0040] Thinner material for equal strength: Due to the inherent high rigidity and strength of the curved bearing shell 23, the body thickness of the partition 2 can be thinner to achieve the same pressure resistance and rigidity as the traditional "flat plate + reinforcing rib". This means that while meeting the same performance requirements, the amount of material used can be reduced, achieving a lightweight design, which is crucial for reducing the weight of commercial vehicles and improving carrying efficiency.

[0041] Reduced processes and increased efficiency: Traditional processes require multiple steps, including material preparation (flat plate and multiple stiffeners), positioning of multiple stiffeners, multiple welding operations, and post-weld correction. Integrated stamping typically involves stamping in one go on a single press, significantly improving production efficiency.

[0042] Extremely high quality consistency: The stamping die ensures that every produced partition 2 is highly consistent in size, shape, and performance, with almost no individual differences. In contrast, the welding process heavily relies on the welder's skill level and is prone to defects such as porosity, slag inclusions, and incomplete penetration, resulting in greater quality fluctuations; this embodiment is more suitable for mass production.

[0043] In this embodiment, in order to ensure uniform force distribution, the axis of the welding ring 21 coincides with the axis of the air cylinder 1.

[0044] In this embodiment, in order to facilitate the installation of the pre-welding partition 2, a weld seam clearance groove 24 is provided on the welding ring 21; the weld seam clearance groove 24 has a diameter of 3-5mm and is a semi-cylinder with a length consistent with the width of the welding ring 21.

[0045] In this embodiment, in order to meet the mainstream demand for aluminum alloy gas storage tanks, the cross-sectional shape of the pressure shell 23 is arc-shaped, and the thickness of the partition 2 is 2.5-3.5mm.

[0046] In this embodiment, in order to achieve high-strength installation of the partition 2 based on a narrow weld, the width of the welding ring 21 is 8-12mm.

[0047] In this embodiment, in order to avoid stress interference between the air nozzle 11 and the partition 2, the distance between each air nozzle 11 and each partition 2 is greater than 40mm.

[0048] The following explanation uses a partition 2 designed to withstand an external pressure of 1.8 MPa as an example. In this specific embodiment, considering that the pressure in the convex side air chamber of the partition 2 is the maximum design pressure of 1.2 MPa, the air chamber on the concave side is emptied, and the pressure difference between the two sides is 1.2 MPa, the specific dimensional characteristics of the partition 2 are as follows: The overall diameter (outer diameter of welding ring 21) is 274mm, which is compatible with the inner radial direction of the gas cylinder 1; the axial length is 65mm; and the thickness is 3mm. The width of welding ring 21 is 10mm; the diameter of weld seam clearance groove 24 on welding ring 21 is 10mm, the width of the transition area on both sides is 1mm, and the length extends to the transition ring; the pressure shell 23 is an arc with an radius of 250mm; the large diameter part of the transition ring is consistent with welding ring 21, and an arc ring with a radius of 25mm is used for transition, and after transitioning to the small diameter, it connects to the circular end face of pressure shell 23. In this embodiment, the partition 2 is made of 5-series aluminum alloy sheet by stamping. The thickness of the partition material is reduced through structural optimization, and it does not deform when subjected to an external pressure of 2Mpa. While improving the strength of the partition, the weight is reduced by 11% compared with the previous gas cylinder partition.

[0049] In some embodiments, to prevent the undrained air from freezing inside the air cylinder 1, such as Figure 4 As shown, the gas cylinder 1 also includes an anti-icing sleeve; the anti-icing sleeve is fitted around the outer periphery of the gas cylinder 1 and includes: Insulation layer 4 is fitted around the outer periphery of air storage cylinder 1; The heat-conducting layer 5 is disposed inside the insulation layer 4 and is attached to the outer wall of the gas storage cylinder 1; The heat buffer 6 is set in the insulation layer 4 and is connected to the heat conduction layer 5 for heat conduction. It absorbs heat when the air storage cylinder 1 is filled with air and releases heat when the air storage cylinder 1 is discharged.

[0050] For ease of installation, the heat buffer 6 in this embodiment is housed in a bag-shaped container or a box-shaped container; the bag-shaped container or box-shaped container is covered and fixed on the gas storage cylinder 1 by the insulation layer 4.

[0051] In this embodiment, the anti-icing sleeve can be made of materials such as heat insulation cotton or heat insulation foam, and is wrapped around the outside of the air cylinder 1. It has clearance holes to facilitate the passage of each air nozzle 11, so as to prolong the temperature drop time of the air cylinder 1 in cold environments, thereby prolonging the icing cycle.

[0052] In this embodiment, the heat buffer 6 uses amorphous solids such as paraffin wax or ethylene glycol solution that can produce a certain phase change, or antifreeze with a freezing point lower than water, in bagged or boxed form. When the air tank 1 is filled with air, it absorbs the heat dissipated by the air compression. When the air tank 1 is discharged and absorbs heat, it transfers the absorbed heat to the air tank 1. During the use of the air tank 1, it reduces the temperature difference range of the air tank 1 and further increases the difficulty of freezing of residual water in each air chamber of the air tank 1 during truck operation.

[0053] In order to improve the heat absorption and heat dissipation efficiency of the heat buffer 6, a heat-conducting layer 5 is provided outside the air cylinder 1 in this embodiment. The heat-conducting layer 5 can be a structure with high thermal conductivity, such as copper sheet.

[0054] During truck operation, the air reservoir 1 is constantly in a high-frequency inflation-deflation state. The anti-icing sleeve in this embodiment ensures that residual water does not solidify and freeze during truck operation. When the truck is parked, the insulation effect of the anti-icing sleeve and the heating effect of the heat buffer 6 significantly extend the freezing period. (If the truck is parked for an extended period in cold conditions, the air reservoir 1 is usually drained.) Overall, this embodiment extends the drainage period of the multi-chamber air reservoir 1 and significantly reduces the risk of residual water freezing.

[0055] The above description is merely a specific embodiment of this disclosure, but the scope of protection of this disclosure is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this disclosure should be included within the scope of protection of this disclosure. Therefore, the scope of protection of this disclosure should be determined by the scope of the claims.

Claims

1. An aluminum alloy air tank for trucks, used for storing air sources in truck braking systems, characterized in that, The gas storage tank includes: An air pump is cylindrical in shape with end caps at both ends. The partition, in at least one set, has a pressure-bearing part that is an arc-shaped structure protruding to one side, fixed inside the air cylinder and coaxially arranged with the air cylinder, dividing the air cylinder into at least two air chambers; Wherein: the air cylinder is provided with at least two air nozzles; each air nozzle is connected to each of the air chambers; the partition includes a welded ring, a transition ring and a pressure-bearing shell that are connected in sequence and smoothly transitioned; the welded ring is a cylindrical shape with open ends, the outer diameter of which is the same as the inner diameter of the air cylinder, and is welded to the inner wall of the air cylinder based on the outer wall; the pressure-bearing shell is an arc-shaped structure; the transition ring realizes the shape transition between the welded ring and the pressure-bearing shell.

2. The aluminum alloy air tank for trucks according to claim 1, characterized in that, The protruding side of the partition faces the air chamber where the maximum inflation pressure is lower.

3. The aluminum alloy air tank for trucks according to claim 1, characterized in that, The cross-sectional shape of the pressure shell is one of the following: circular arc, ellipse, or parabola.

4. The aluminum alloy air tank for trucks according to claim 3, characterized in that, The pressure-bearing shell adopts the inflection point dimensions of minimum wall thickness and minimum axial length.

5. The aluminum alloy air tank for trucks according to claim 4, characterized in that, The welding ring is provided with a weld seam clearance groove; the diameter of the weld seam clearance groove is 3-5mm, and the length is a semi-cylinder with the same width as the welding ring.

6. The aluminum alloy air tank for trucks according to claim 5, characterized in that, The pressure-bearing shell has an arc-shaped cross-section; the partition plate has a thickness of 2.5-3.5 mm; the welding ring has a width of 8-12 mm; and the distance between the air nozzle and the partition plate is greater than 40 mm.

7. The aluminum alloy air tank for trucks according to claim 1, characterized in that, The gas storage cylinder also includes an anti-icing sleeve; the anti-icing sleeve is fitted around the outer periphery of the gas storage cylinder and includes: An insulation layer is fitted around the outer periphery of the gas storage cylinder; A heat-conducting layer is disposed within the insulation layer and is attached to the outer wall of the gas storage cylinder; A heat buffer is disposed in the insulation layer and is thermally conductive with the heat-conducting layer. It absorbs heat when the gas storage cylinder is filled with gas and releases heat when the gas storage cylinder is discharged.

8. The aluminum alloy air tank for trucks according to claim 7, characterized in that, The heat buffer is contained in a bag-shaped or box-shaped container; the bag-shaped or box-shaped container is fixed to the gas storage cylinder by being covered by the insulation layer.

9. The aluminum alloy air tank for trucks according to claim 3, characterized in that, The partition has a uniform thickness and is a one-piece molded structure.

10. The aluminum alloy air tank for trucks according to claim 1, characterized in that, The axis of the welding ring coincides with the axis of the air cylinder.

Images