Interlocked Box Weld Structure for Rail Vehicle Deformation Control
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Solution Overview
Problem
Traditional multi-layer and multi-pass MAG arc welding of rail vehicle components results in severe welding deformation, requiring extensive manual adjustment and correction, leading to strength loss and performance degradation, with high material and labor costs, and poor deformation suppression.
Innovation Solution
A weld structure and device utilizing high-strength weather-resistant steel, combined with a laser-arc hybrid welding mechanism, multi-point flexible support, and real-time deformation adjustment through magnetic units and sensor feedback, to form a stable enclosed box-shaped structure with improved rigidity and reduced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multi-layer and multi-pass MAG arc welding is used to ensure load-bearing capacity, then the strength of rail vehicle components is improved, but welding deformation becomes severe requiring extensive manual adjustment
Solution Approach 1:
The patent applies preliminary action by pre-positioning support devices at multiple points along the welding path before welding begins. These supports are strategically placed to counteract the expected deformation forces during multi-layer and multi-pass MAG arc welding, preventing deformation before it occurs rather than correcting it afterward.
Solution Approach 2:
The patent implements parameter changes by adjusting the magnitude and distribution of support forces at different welding stages. The support devices can apply varying forces corresponding to different welding parameters (heat input, layer thickness, pass sequence), dynamically adapting to maintain dimensional accuracy throughout the welding process.
2Manufacturing precision
If manual adjustment and correction is performed after welding to correct deformation, then the shape accuracy is improved, but strength loss and performance degradation occur
Solution Approach 1:
The patent applies preliminary anti-action by using support devices that exert counter-forces during welding to prevent deformation. This proactive approach eliminates the need for post-welding manual adjustment and correction, thereby preserving the structural strength and performance of the welded components while maintaining shape accuracy.
3Device complexity
If traditional welding support is used, then the device complexity is low, but the ability to accurately and dynamically adjust for deformation is insufficient
Solution Approach 1:
The patent applies segmentation by dividing the welding support system into multiple independent support devices distributed along the welding path. Each support device can independently adjust its position and applied force, enabling precise local control of deformation while maintaining overall system manageability and avoiding excessive complexity.
4Manufacturing precision
If extensive manual adjustment is required after welding, then the manufacturing precision can be improved, but productivity decreases due to repeated checks and corrections
Solution Approach 1:
The patent applies preliminary action by implementing real-time monitoring and dynamic adjustment during the welding process itself. This prevents deformation from occurring in the first place, eliminating the need for post-welding repeated checks and corrections, thereby maintaining high manufacturing precision while significantly improving productivity and production efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances manufacturing accuracy, reduces costs, and improves production efficiency by precisely controlling welding deformation, suppressing defects, and refining microstructure performance, with a 5% improvement in mechanical properties and fatigue strength.
Implementation Method 1
laser-arc hybrid welding mechanism
Implementation Method 2
laser-arc hybrid welding mechanism
Implementation Method 3
real-time deformation adjustment through magnetic units
Implementation Method 4
adjustment portion regulates a flatness of the weld structure by adjusting a magnitude of a force acting on the weld surface
Data Source
AI summary
A welding structure, comprising: a first cover plate (10), a second cover plate (20), web plates (30), and rib plates (40). The first cover plate (10) and the second cover plate (20) are arranged at an interval. Multiple web plates (30) are arranged at intervals in a first direction, and are insertingly fitted to the first cover plate (10) and the second cover plate (20), respectively. Multiple rib plates (40) are arranged at intervals in a second direction, and are insertingly fitted to the first cover plate (10) and the second cover plate (20), respectively. The first direction and the second direction are perpendicular to each other. The web plates (30) and the rib plates (40) are insertingly fitted to each other. According to the welding structure, upper and lower cover plates of a box-shaped structure are insertingly connected and interlocked to form a stable closed box-shaped structure, so that the rigidity of the structure is improved. Also provided are a welding device and a welding method.