CN112045326A - Flexible production line and production process for underframe of railway wagon - Google Patents
Flexible production line and production process for underframe of railway wagon Download PDFInfo
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- CN112045326A CN112045326A CN202010773394.XA CN202010773394A CN112045326A CN 112045326 A CN112045326 A CN 112045326A CN 202010773394 A CN202010773394 A CN 202010773394A CN 112045326 A CN112045326 A CN 112045326A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61F—RAIL VEHICLE SUSPENSIONS, e.g. UNDERFRAMES, BOGIES OR ARRANGEMENTS OF WHEEL AXLES; RAIL VEHICLES FOR USE ON TRACKS OF DIFFERENT WIDTH; PREVENTING DERAILING OF RAIL VEHICLES; WHEEL GUARDS, OBSTRUCTION REMOVERS OR THE LIKE FOR RAIL VEHICLES
- B61F1/00—Underframes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61F—RAIL VEHICLE SUSPENSIONS, e.g. UNDERFRAMES, BOGIES OR ARRANGEMENTS OF WHEEL AXLES; RAIL VEHICLES FOR USE ON TRACKS OF DIFFERENT WIDTH; PREVENTING DERAILING OF RAIL VEHICLES; WHEEL GUARDS, OBSTRUCTION REMOVERS OR THE LIKE FOR RAIL VEHICLES
- B61F1/00—Underframes
- B61F1/08—Details
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- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Automatic Assembly (AREA)
Abstract
The invention discloses a flexible production line of a railway wagon chassis and a production process, wherein the flexible production line of the railway wagon chassis comprises more than 2 railway wagon chassis stations, the more than 2 railway wagon chassis stations are continuously and sequentially arranged along the production and transportation direction of the railway wagon chassis, and the central lines of the more than 2 railway wagon chassis stations are positioned on the same straight line; the automatic conveying vehicle is arranged in the station of the underframe of the railway wagon, and the underframe of the railway wagon shuttles among more than 2 stations of the underframe of the railway wagon through the automatic conveying vehicle so as to sequentially complete each process of the production of the underframe of the railway wagon. The invention adopts a standard station metronomic production concept, stations are conveyed by an automatic conveying vehicle, and the underframe steel structure can realize through type unimpeded operation conveying on each station, can simultaneously operate on a plurality of stations, and greatly improves the production efficiency.
Description
Technical Field
The application belongs to the technical field of wagon production, and particularly relates to a wagon chassis flexible production line and a production process.
Background
The railway freight car can be divided into open wagon, flat wagon, tank wagon, hopper wagon and other types according to different structures. For example: a C70EH universal open top, a C80B open top, a C80EH universal open top, an X70 flat top, an L70 grain hopper car, and the like.
Traditional rail wagon chassis production line must respectively on ten station then accomplish the equipment one by one, expend man-hour, and production efficiency is low, still has the potential safety hazard simultaneously. The tool of the chassis production line of the railway wagon is disassembled and transported to the stock from the process design, the installation of process equipment and the product model changing, so that a large amount of time is consumed, the material waste is caused after the long production period, and the manufacturing cost is increased.
Disclosure of Invention
In order to solve the technical problems, the invention provides a flexible production line of a railway wagon chassis and a production process thereof, which improve the production conversion efficiency of the railway wagon chassis production line, reduce the production conversion period of a tool and improve the product quality.
The technical scheme adopted for achieving the purpose of the invention is that the flexible production line of the underframe of the railway wagon comprises more than 2 stations of the underframe of the railway wagon, the more than 2 stations of the underframe of the railway wagon are continuously and sequentially arranged along the production and transportation direction of the underframe of the railway wagon, and the central lines of the more than 2 stations of the underframe of the railway wagon are positioned on the same straight line;
the flexible production line station of the railway wagon underframe further comprises an automatic transmission vehicle, and the railway wagon underframe shuttles among more than 2 railway wagon underframe stations through the automatic transmission vehicle so as to sequentially complete each process of the railway wagon underframe production.
Optionally, the number of the railway wagon underframe stations is 9, and the stations are respectively arranged in sequence:
the underframe assembling station is used for assembling each beam structure and accessories of the railway wagon underframe;
a base frame welding station for welding flat welding seams among beam structures of the base frame of the railway wagon;
the underframe welding station II is used for welding the welding seams at the connecting positions of the beam structures in a turnover manner;
the underframe welding three stations are used for assembling the upper cover plate of the sleeper beam and the upper cover plate of the cross beam and repairing welding blind areas of the previous working procedures;
the underframe assembling two stations are used for assembling the floor;
the underframe welding four stations are used for welding the floor and the connecting welding seams of the beam structures;
the five stations are used for welding the weld joint on the front side of the floor;
six stations for welding the underframe are used for assembling accessories and repairing welding blind areas of the previous working procedures;
and the underframe handing-over station is used for detecting the key size of the underframe of the railway wagon and adjusting the height difference of each beam structure.
Optionally, the number of the chassis welding stations of the rail wagon is 10, four standby chassis welding stations are arranged between the four chassis welding stations and the five chassis welding stations, and the four standby chassis welding stations are also used for welding the floor and the connecting weld of each beam structure.
Optionally, a hoisting system is arranged in a station for assembling the underframe and is used for loading each beam structure; the assembly jig of the first underframe assembly station is of a through structure, and the middle part of the first underframe assembly station is a transmission area for the automatic transmission vehicle to shuttle;
the top of a chassis equipment station is provided with and send a machine and linkage, send a machine to pass through linkage hangs the installation, send a machine to be used for sending and feeding the welding wire of tack welding when carrying out each roof beam structure equipment.
Optionally, be provided with welding robot in a chassis welding station, the welding track has been arranged to the both sides of a chassis welding station, welding robot install respectively in a chassis welding station both sides on the welding track.
Optionally, a workpiece positioner and a welding robot are arranged in the second underframe welding station, and the workpiece positioner is used for overturning a workpiece to be welded; welding tracks are arranged on two sides of the two stations for welding the bottom frame, and the welding robots are respectively installed on the welding tracks on two sides of the two stations for welding the bottom frame.
Optionally, a hoisting system is arranged in the three stations for welding the underframe and is used for feeding the upper cover plate of the sleeper beam and the upper cover plate of the cross beam.
Optionally, a hoisting system is arranged in the second station for assembling the underframe and is used for loading the floor.
Optionally, a workpiece positioner and a welding robot are arranged in the chassis welding quadruplex station, and the workpiece positioner is used for overturning a workpiece to be welded; welding tracks are arranged on two sides of the four stations for welding the bottom frame, and the welding robots are respectively installed on the welding tracks on two sides of the four stations for welding the bottom frame.
Optionally, the five welding stations of the underframe are provided with a workpiece positioner and a welding robot, the workpiece positioner is used for overturning the workpiece to be welded, and the welding robot is installed on the walking gantry.
Optionally, a workpiece positioner is arranged at the chassis welding six stations and used for overturning the workpiece to be welded.
Optionally, the flexible production line for the underframe of the railway wagon further comprises a data acquisition and processing system, wherein the data acquisition and processing system is used for acquiring data of the tools of the stations of the underframe of the railway wagon and analyzing the data;
the number of the automatic conveying vehicles is more than 2, the number of the automatic conveying vehicles is 2, each group of automatic conveying vehicles can shuttle between two adjacent underframe stations of the railway wagon, and the automatic conveying vehicles are arranged to cover each underframe station of the railway wagon;
the automatic transmission vehicle is provided with a wireless control module and a wired control module, and is in data communication with the data acquisition and processing system through the wireless control module;
the rail wagon chassis flexible production line is paved with rails in the whole line, and the automatic conveying vehicle runs on the rails.
Optionally, a base platform is laid on the ground of the whole line of the flexible production line of the underframe of the railway wagon, the base platform is flush with the ground, and all tools of all stations of the underframe of the railway wagon are connected with the base platform through threaded fasteners;
the base platform is provided with more than 1T-shaped groove, the section of the T-shaped groove is inverted T-shaped, and a bolt in the threaded fastener is inverted in the T-shaped groove.
Optionally, the flexible production line for the underframe of the railway wagon further comprises an operation worker operation area and a line side warehouse material storage area, wherein the operation worker operation area and the line side warehouse material storage area are located on two sides of the area where the station of the underframe of the railway wagon is located.
Based on the same invention concept, the invention also provides a wagon underframe production process based on the wagon underframe flexible production line, wherein each process of wagon underframe production is sequentially completed on more than 2 wagon underframe stations, and the wagon underframe is transmitted among the stations through the automatic transmission vehicle;
the method specifically comprises the following steps:
a step of underframe assembly, in which each beam structure of the underframe of the railway wagon and accessories thereof are assembled;
a chassis welding step, in which flat welds between beam structures of the chassis of the railway wagon are welded;
a second process of welding the underframe, namely welding the welding seams at the connecting positions of the beam structures in a turnover manner;
the underframe welding comprises three procedures, namely assembling an upper cover plate of the sleeper beam and an upper cover plate of the cross beam and repairing welding blind areas of the previous procedures;
a second step of assembling the underframe, wherein the floor is assembled;
welding the underframe, namely welding the floor and the connecting weld joints of the beam structures;
welding the bottom frame, namely welding the weld joint on the front side of the floor;
six processes of chassis welding, namely assembling accessories and repairing welding blind areas of the previous processes;
and in the underframe handing-over process, detecting the key size of the underframe of the railway wagon and adjusting the height difference of each beam structure.
According to the technical scheme, the flexible production line of the underframe of the railway wagon adopts a standard station metronomic production concept, the stations of the underframe of the railway wagon are integrated, a plurality of stations of the underframe of the railway wagon are continuously and sequentially arranged along the production and transportation direction of the underframe of the railway wagon, the central lines of the stations are positioned on the same straight line, workpieces are sequentially transmitted among the stations through the automatic transmission vehicle, and the steel structure of the underframe can realize through-type unimpeded operation on the stations, so that all processes of production of the underframe of the railway wagon are sequentially completed.
The invention provides a production process of a railway wagon underframe, which is implemented by depending on the flexible production line of the railway wagon underframe, and sequentially finishes various working procedures of the production of the railway wagon underframe on various stations which are continuously and sequentially arranged and the central lines of which are positioned on the same straight line, and the specific working procedures are as follows: the method comprises the following steps of firstly assembling the underframe (assembling each beam structure and accessories thereof) → firstly welding the underframe (welding each beam structure flat weld) → secondly welding the underframe (overturning and automatically welding weld seams between each beam) → thirdly welding the underframe (assembling the sleeper beam upper cover plate, repair welding blind areas) → thirdly welding the underframe twice (assembling the floor) → thirdly welding the underframe four steps (automatically welding the floor with each beam and accessories) → thirdly welding the underframe five steps (automatically welding the floor front weld seam) → thirdly welding six steps (assembling accessories, repair welding blind areas) → firstly handing over the underframe to check (type checking), and conveying the railway wagon underframe between the stations through an automatic conveying vehicle, so that the takt production is realized, the finished underframe is automatically offline after automatic detection, and the production mode of the wagon underframe steel structure is fundamentally simplified.
Compared with the prior art, the flexible production line and the production process for the underframe of the railway wagon adopt a standard station metronomic production concept, automatic conveying vehicles are used for conveying stations, the underframe steel structure can realize through type barrier-free operation conveying on each station, the operation can be simultaneously carried out on a plurality of stations, the production efficiency is greatly improved, the underframe 28 of the C70EH type open wagon can be produced daily, and the production tempo is 34 minutes per platform.
Drawings
Fig. 1 is a layout structure view of a flexible production line of a railway wagon chassis in embodiment 1 of the present invention;
FIG. 2 is a schematic view of a fishbone chassis;
FIG. 3 is a schematic structural view of a chassis assembling station of the flexible production line of the railway wagon chassis in FIG. 1;
FIG. 4 is a schematic structural diagram of a chassis welding station of the flexible production line of the railway wagon chassis in FIG. 1;
FIG. 5 is a schematic structural diagram of a chassis welding station of the flexible production line of the chassis of the railway wagon in FIG. 1;
FIG. 6 is a schematic structural diagram of a chassis welding three-station of the flexible production line of the railway wagon chassis in FIG. 1;
FIG. 7 is a schematic structural diagram of a second station for assembling the underframe of the flexible production line of the railway wagon underframe shown in FIG. 1;
FIG. 8 is a schematic structural diagram of four stations for welding the underframe of the flexible production line of the underframe of the railway wagon in FIG. 1;
FIG. 9 is a schematic structural diagram of five stations for chassis welding of the flexible production line of the railway wagon chassis in FIG. 1;
FIG. 10 is a schematic structural diagram of six stations for chassis welding of the flexible production line of the railway wagon chassis in FIG. 1;
FIG. 11 is a schematic structural view of a base platform of the flexible production line of the railway wagon chassis of FIG. 1;
fig. 12 is a process flow chart of the production process of the railway wagon underframe in embodiment 2 of the invention.
Description of reference numerals: 100-flexible production line of underframe of railway wagon; 10-assembling a station on the underframe; 20-welding a station on the underframe; 30-two stations for welding the underframe; 40-three stations for welding the underframe; 50-two stations for assembling the underframe; 60-four stations for welding the underframe; 70-five stations for welding the underframe; 80-six stations for welding the underframe; 90-underframe handing-over and checking; 110-track; 120-base platform, 121-T-shaped groove; 130-operating worker work area; 140-line side warehouse material storage area; 150-automatic transport vehicle; 160-a work station.
200-fishbone type underframe; 210-end beam assembly; 220-corbel composition; 230-small beam; 240-side beam assembly; 250-longitudinal beam composition; 260-beam assembly; 270-floor; 280-middle beam.
Detailed Description
In order to make the present application more clearly understood by those skilled in the art to which the present application pertains, the following detailed description of the present application is made with reference to the accompanying drawings by way of specific embodiments.
Example 1:
the embodiment of the invention provides a flexible production line 100 for underframe of railway wagon, which has a structure shown in figure 1 and comprises more than 2 stations of underframe of railway wagon, wherein the more than 2 stations of underframe of railway wagon are continuously and sequentially arranged along the production and transportation direction of underframe of railway wagon, and the central lines of the more than 2 stations of underframe of railway wagon are positioned on the same straight line; the automatic conveying vehicle is arranged in the station of the underframe of the railway wagon, and the underframe of the railway wagon shuttles among more than 2 stations of the underframe of the railway wagon through the automatic conveying vehicle so as to sequentially complete each process of the production of the underframe of the railway wagon.
In the flexible production line 100 for the underframe of the railway wagon, the number of stations and the structures of the stations are determined according to the underframe of the railway wagon to be produced, the flexible production line 100 for the underframe of the railway wagon does not need to change the process setting of the existing underframe of the railway wagon, but can realize the takt production of a production line, and the finished underframe is automatically off-line after being automatically detected, so that the production mode of a steel structure of the underframe of the wagon is fundamentally simplified.
The following describes the structure of the flexible production line 100 for the underframe of a railway wagon in detail, taking the production of a fishbone underframe as an example:
the fishbone underframe 200 is the most commonly used underframe structure in railway freight cars, and as shown in fig. 2, the fishbone underframe 200 mainly comprises beam structures (including a middle beam assembly 280, an end beam assembly 210, a sleeper beam assembly 220, a small cross beam 230, a side beam assembly, a longitudinal beam assembly 250 and a cross beam assembly 260) and a floor 270, and is named because the shape thereof is similar to a fishbone. The center sill assembly 280 is the main support beam of the fishbone chassis 200, serving as the "main spine of the fishbone"; the number of the small cross beams 230 and the longitudinal beam assemblies 250 is determined according to the specific size of the fishbone chassis 200; a floor overlies each beam structure.
For the fishbone underframe 200, the flexible production line 100 of the underframe of the railway wagon of the present embodiment is provided with 9 underframe stations, as shown in fig. 1, which are sequentially: the device comprises a first chassis assembling station 10, a first chassis welding station 20, a second chassis welding station 30, a third chassis welding station 40, a second chassis assembling station 50, a fourth chassis welding station 60, a fifth chassis welding station 70, a sixth chassis welding station 80 and a chassis inspection station 90. The 9 stations are continuously and sequentially arranged along the production and transportation direction of the underframe of the railway wagon, the central line of each station is on the same straight line, the base surface of the production line along the trend is provided with a track 110, the track 110 is provided with an automatic conveying vehicle 150 which comes and goes between the stations, and the steel structure of the underframe can realize through type unimpeded operation on each station.
The automatic conveying vehicle is provided with more than 2, and the specific quantity is decided according to the number of the stations. In this embodiment, 2 automatic conveying cars are in one group, and each group of automatic conveying cars can shuttle between two adjacent wagon chassis stations, that is to say, the specific number and distribution of the automatic conveying cars should satisfy and completely cover each wagon chassis station.
Preferably, the automatic transmission vehicle adopts an automatic RGV transmission trolley (a rail guided vehicle), adopts a slide wire power taking or super capacitor power supply mode, and adopts a 1435mm standard rail as the rail 110. Two automatic transmission vehicles are adopted for transmission of each underframe, the two transmission trolleys respectively have the functions of single action and linkage, and are linked when the underframe is transported, and the two transmission trolleys synchronously move the transport underframe; the two transmission trolleys move backwards and leave the lower part of the underframe. A walking driving device and a lifting jacking device are arranged on a body of the automatic conveying vehicle, and the jacking position of the lifting jacking device is the side bearing position of the steel structure of the underframe.
Referring to fig. 1, the entire flexible production line 100 for the underframe of the railway wagon is arranged in a production workshop, and an operator working area 130 is arranged on the inner side of the production line close to a wall, so that operators can walk and operate conveniently. The middle is a tooling equipment installation area, and the tooling of all stations is installed on the area. The outside is line limit storehouse material storage area 140 for corresponding depositing of station workbin, work or material rest. And a 3000mm material conveying line is arranged outside the line side warehouse, and the material transport vehicle runs on a 1435mm standard track. The material transport vehicle adopts an automatic loading and unloading mode, and the RGV automatic loading and unloading material vehicle can automatically stop at the line side storeroom of each station according to the instruction requirement of the command center. The material transport vehicle is provided with a cantilever loading and unloading system, and a material box and a material rack can be automatically placed in a customized area of the online side warehouse by adopting the cantilever loading and unloading system.
Specifically, the first chassis assembling station 10, the third chassis welding station 40, and the second chassis assembling station 50 all relate to the assembly of parts, and therefore the corresponding material storage areas 140 are disposed beside the first chassis assembling station 10, the third chassis welding station 40, and the second chassis assembling station 50. The main assembly work of the underframe is completed at the underframe assembly station 10, so that a plurality of parts are arranged and the sizes of the parts are large, material storage areas are arranged beside and in front of the underframe assembly station 10, and the material storage area in front is mainly used for storing the middle beam assembly 280.
The following describes the process and tooling configuration of each station in detail:
the underframe assembly station 10 is mainly used for assembling and tack welding various beam structures and accessories of the underframe of the railway wagon. The middle beam assembly 280, the end beam assembly 210, the sleeper beam assembly 220, the small cross beam 230, the side beam assembly, the longitudinal beam assembly 250 and the cross beam assembly 260 are assembled and spot-welded in an underframe assembling station 10.
Referring to fig. 3, a lifting system 11 is disposed in the underframe assembling station 10, the lifting system 11 is used for loading each beam structure, in order to facilitate loading, the lifting system 11 should be disposed to cross the underframe assembling station 10 and the side storage material storage area 140 for storing each beam structure, the lifting system 11 is preferably a KBK flexible lifting system, and a conventional overhead crane is not used for hoisting. The KBK flexible hoisting system is of an open top structure, and the passing of a crown block for welding is not influenced. The assembly jig 12 of the first chassis assembly station 10 is of a through type structure, the rail 110 longitudinally penetrates through the first chassis assembly station 10, and the middle of the first chassis assembly station 10 is a transfer area for the automatic transfer vehicle 150 to shuttle. The top of a station 10 for assembling the underframe is provided with a wire feeder and a suspension device, the wire feeder is mounted in a suspension way through the suspension device, and the wire feeder is used for feeding welding wires which are tack-welded when the beam structures are assembled.
The underframe welding station 20 is mainly used for welding flat weld joints among beam structures of the underframe of the railway wagon.
Referring to fig. 4, a welding robot 21 is disposed in the chassis welding one-station 20, welding rails 22 are disposed on both sides of the chassis welding one-station 20, and the welding robot 21 is respectively mounted on the welding rails 22 on both sides of the chassis welding one-station. Adopt the flat welding position welding seam after the robot welding chassis equipment, welding robot 21 can adopt current welding robot, and concrete structure here is no longer repeated.
The second underframe welding station 30 is mainly used for performing turnover welding on welding seams at the connecting positions of the beam structures, namely, the welding seams at the relevant welding positions, such as the connection of the beams after the turnover welding underframe is assembled, are mainly completed.
Referring to fig. 5, a workpiece positioner 33 and a welding robot 31 are arranged in the second chassis welding station 30, and the workpiece positioner 33 is used for overturning a workpiece to be welded; welding rails 32 are arranged on two sides of the second chassis welding station 30, and the welding robots 31 are respectively installed on the welding rails 32 on two sides of the second chassis welding station 30. Adopt other hookup location welding seams after the robot welding chassis equipment, welding robot 31 can adopt current welding robot, and concrete structure here is no longer repeated.
And the underframe welding three stations 40 are mainly used for assembling the upper cover plate of the sleeper beam and the upper cover plate of the cross beam and welding blind areas of a process (underframe welding process) before repair welding.
Referring to fig. 6, a hoisting system 41 is disposed in the three underframe welding stations 40 for loading the upper cover plate of the sleeper beam and the upper cover plate of the cross beam, and for facilitating the loading, the hoisting system 41 should be disposed to cross the three underframe welding stations 40 and the material storage area 140 of the linear side warehouse for storing the workpieces such as the upper cover plate of the sleeper beam and the upper cover plate of the cross beam, and the hoisting system 41 is preferably a KBK flexible hoisting system. Welding blind areas, and assembled welding seams of the upper cover plate of the sleeper beam and the upper cover plate of the cross beam are manually welded. In order to facilitate welding, a workpiece positioner 42 is further arranged in the three underframe welding stations 40, and the workpiece positioner 42 is used for overturning the workpieces to be welded.
The second underframe assembly station 50 is mainly used for assembling the floor and related accessories. When the flexible production line 100 for the underframe of the railway wagon is used for producing the underframe of a flat wagon, the underframe assembling two station 50 can also complete the flat wagon crossrail assembling.
Referring to fig. 7, a lifting system 51 is disposed in the second underframe assembling station 50 for loading the floor, and for facilitating the loading, the lifting system 51 should be disposed across the second underframe assembling station 50 and the line side warehouse material storage area 140 for storing the floor, and the lifting system 51 is preferably a KBK flexible lifting system. In view of the fact that the production line can also be used for producing flatcar underframes, an assembly jig is also provided in the undercarriage assembly secondary station 50.
The underframe welding four-station 60 is mainly used for welding the floor and the connecting welding seams of the beam structures. When the flexible production line 100 for the underframe of the railway wagon is used for producing the underframe of the flat wagon, the underframe welding four stations 60 can also complete the turnover welding of the welding seam of the flat wagon along the beam.
Referring to fig. 8, a workpiece positioner 63 and a welding robot 61 are arranged in the chassis welding quadruplex station 60, and the workpiece positioner 63 is used for overturning a workpiece to be welded; welding rails 62 are arranged on two sides of the chassis welding quadruplex 60, and the welding robots 61 are respectively installed on the welding rails 62 on two sides of the chassis welding quadruplex 60. Adopt robot welding floor and each beam structure connecting weld, welding robot 61 can adopt current welding robot, and concrete structure is no longer repeated here.
Because the number of the connecting welding lines of the floor and each beam structure is large, the welding workload is large, and in order to shorten the production takt, preferably, four standby stations for chassis welding are arranged between the four stations 60 for chassis welding and the five stations 70 for chassis welding, namely 10 stations for the chassis of the railway wagon are arranged in the embodiment.
The four standby stations for welding the underframe are also used for welding the floor and the connecting weld joints of the beam structures, the structural arrangement of the four standby stations is completely the same as that of the four stations 60 for welding the underframe, and the specific tool configuration is not repeated here.
And the five stations 70 for welding the underframe are mainly used for welding the weld joint on the front side of the floor. Referring to fig. 9, the five-station chassis welding 70 is provided with a workpiece positioner 71 and a welding robot 72, the workpiece positioner 71 is used for turning over a workpiece to be welded, and the welding robot 72 is mounted on a traveling gantry 73.
The chassis welding six-station 80 is mainly used for assembling accessories and repairing a welding blind area of a previous process (a floor welding process). Referring to fig. 10, the chassis welding six-station 80 is provided with a workpiece positioner 81, and the workpiece positioner 81 is used for turning over a workpiece to be welded. Welding blind areas and welding seams after accessories are assembled are manually welded.
The underframe handing-over station 90 is mainly used for detecting the key size of the underframe of the railway wagon and adjusting the height difference of each beam structure. An online detection system is installed in the chassis inspection station 90, so that the key size of the chassis can be automatically detected, and detection data can be automatically uploaded. The underframe handing-over station 90 can adopt a car underframe three-dimensional detection system in the invention application with application number CN201911097539.2, on-line adjustment and correction system and method, and the detailed structure thereof is not described herein.
In order to meet the production requirements of the underframe of the railway wagon with different sizes, in the embodiment, the station tools of the flexible production line 100 for the underframe of the railway wagon adopt a modularized concept, as shown in fig. 1, a base platform 120 is laid on the ground of the whole production line, the base platform 120 is flush with the ground, and all the tools of the stations of the underframe of the railway wagon are connected through the base platform 120 with threaded fasteners. Under the condition that the overall structural form of each process tool is basically consistent, the universal module unit can be quickly and conveniently installed.
Referring to fig. 11, more than 1T-shaped groove 121 is formed in the base platform 120, the cross section of the T-shaped groove 121 is in an inverted T shape, and all the full-line tools are connected with the base platform 120 by using standard bolts. A bolt in the threaded fastener is inverted in the T-shaped groove, the head of the bolt is positioned in the transverse section of the T-shaped groove, the screw rod extends out of the vertical section of the T-shaped groove, and then the T-shaped groove is locked through the nut.
In order to realize automatic production and detection, the flexible production line 100 for the underframe of the railway wagon further comprises a data acquisition and processing system, and the data acquisition and processing system is used for acquiring data of the tools of each station and analyzing the data.
Specifically, referring to fig. 3 to 10, in this embodiment, the data acquisition processing system includes a main control console and a plurality of workstation 160, the main control console may adopt any existing control device, such as a PC, a PLC, an FPGA, and the like, and the number of the workstation 160 should match the number of the workstations, that is, each workstation is configured with one workstation. MES systems are all configured in total console and station machine 160, the MES system through unified configuration of total console collects the data that each station machine 160 gathered and the data that the online detection system of station 90 was handed over to the chassis detects to carry out analysis processes to data, accomplish automated inspection, it can store, print and statistical analysis to detect data, can control the online production situation of chassis in real time, make things convenient for the enterprise to improve production management and quality control level.
In this embodiment, the automatic transfer cart 150 is provided with a wireless control module (for example, a bluetooth module, a WIFI module, a ZIGBEE module, etc.) and a wired control module (control handle), and the automatic transfer cart performs data communication with the data acquisition and processing system through the wireless control module, and wirelessly controls the operation of the automatic transfer cart 150. When the wireless control module breaks down, the wireless control module can be operated by field operators through the wired control module.
Example 2:
based on the same inventive concept, the present embodiment provides a wagon undercarriage production process, which is implemented based on the wagon undercarriage flexible production line 100 of embodiment 1, that is, each process of wagon undercarriage production is sequentially completed on each of the above wagon undercarriage stations, and the wagon undercarriages are transferred between the stations by an automatic transfer cart.
Referring to fig. 12, the process for producing the underframe of the railway wagon specifically comprises the following steps:
the underframe assembling process is implemented on an underframe assembling station 10, and mainly comprises the steps of assembling and tack-welding various beam structures (a middle beam assembly 280, an end beam assembly 210, a sleeper beam assembly 220, a small cross beam 230, a side beam assembly, a longitudinal beam assembly 250 and a cross beam assembly 260) and accessories of the underframe of the railway wagon. Tack welding is adopted for positioning welding, welding wires are automatically fed by a wire feeder, and a welding robot automatically performs welding.
And a chassis welding process, which is implemented on a chassis welding station 20 and mainly used for welding flat welds among beam structures of the chassis of the railway wagon, wherein a welding robot automatically performs welding.
And a second underframe welding process, which is implemented on the second underframe welding station 30 and mainly performs turnover welding on welding seams at the connecting positions of the beam structures, namely mainly completes welding seams at the relevant welding positions of the connection of the beams after the assembly of the turnover welding underframe, and automatically welds the welding seams at other connecting positions after the assembly of the underframe by adopting a robot.
And an underframe welding three working procedure which is implemented on an underframe welding three-station 40 and mainly comprises the steps of assembling the sleeper beam upper cover plate and the crossbeam upper cover plate and welding blind areas of the working procedure (underframe welding working procedure) before repair welding, wherein welding seams of the welding blind areas and the assembled welding seams of the sleeper beam upper cover plate and the crossbeam upper cover plate are manually welded.
And a second underframe assembling step, which is carried out at the second underframe assembling station 50 and mainly carries out the assembling of the floor and related accessories. When the chassis of the flat car is produced, the process carries out the assembly of the flat car crossmember.
And the four processes of chassis welding are implemented on the four chassis welding stations 60 and the four standby chassis welding stations, the welding of the connecting welding seams of the floor and each beam structure is mainly carried out, and the connecting welding seams of the floor and each beam structure are welded by adopting a robot. When the flatcar chassis is produced, the process carries out the turnover welding of the flatcar crossbeam welding seam.
And a fifth process of chassis welding, which is implemented on a fifth station 70 of chassis welding and mainly used for welding the weld joint on the front side of the floor. And welding the weld joint on the front surface of the floor by using a welding robot.
Six processes of chassis welding are carried out on six stations 80 of chassis welding, and mainly carry out the assembly of accessories and the welding blind area of the process (floor welding process) before repair welding, and the welding seam of the welding blind area and the welding seam after the assembly of the accessories are manually welded.
And the underframe handing-over process and the underframe handing-over station 90 mainly detect the key size of the underframe of the railway wagon and adjust the height difference of each beam structure. And the key size of the chassis is automatically detected through an online detection system, and detection data are automatically uploaded.
Application example:
an enterprise adopts the flexible production line 100 of the wagon underframe of the embodiment 1 and the production process of the wagon underframe of the embodiment 2 to produce the fishbone underframe. The operation is carried out on a plurality of stations simultaneously, the stations are conveyed by an RGV automatic conveying device, and the two-shift production is realized.
For a flexible production line 100 of the underframe of the railway wagon with 10 standard stations (four spare stations for welding the underframe), the production rhythm is 34 minutes per underframe of a daily model C70EH open wagon 28.
For a flexible production line 100 of rail wagon underframe with 9 standard stations, 16 underframe of a Nissan C70EH type open wagon has the production cycle time of 60 minutes per underframe.
Through the embodiment, the invention has the following beneficial effects or advantages:
1) the flexible production line for the underframe of the railway wagon adopts a standard station metronomic production concept, integrates the stations of the underframe of the railway wagon, continuously and sequentially arranges a plurality of stations of the underframe of the railway wagon along the production and transportation direction of the underframe of the railway wagon, the central lines of the stations are positioned on the same straight line, workpieces are sequentially transmitted among the stations through an automatic transmission vehicle, and the steel structure of the underframe can realize through type unimpeded operation on the stations, so that each process of producing the underframe of the railway wagon is sequentially completed.
2) The flexible production line for the underframe of the railway wagon adopts a modularized, generalized and extensible flexible design concept, and uses the T-shaped groove base platform to modularize the tool under the condition that the overall structural form of the tool in each process is basically consistent, so that the module unit can be installed quickly and conveniently.
3) According to the flexible production line of the underframe of the railway wagon, the whole line tooling is arranged on the T-shaped groove base platform, the modules are arranged by adopting the bolts, can be randomly disassembled, and can be quickly adjusted in position according to the change of products, and the width and the height directions are adjusted in place, so that the flexible production line is suitable for the manufacturing requirements of the fishbone underframe with different lengths, widths, structural forms and different process numbers, and the production change time is greatly shortened.
4) The flexible production line of the underframe of the railway wagon integrally adopts the control command center to control the operating system of each station and process the data acquired by the sensors of each station, so that automatic detection is completed, the detected data can be stored, printed and statistically analyzed, the online production condition of the underframe can be mastered in real time, and enterprises can conveniently improve the production management and quality control level.
5) The production process of the underframe of the railway wagon is implemented by depending on the flexible production line of the underframe of the railway wagon, and each process of producing the underframe of the railway wagon is sequentially completed on each station which is continuously and sequentially arranged and the central line of which is positioned on the same straight line, so that the production line takt is realized, the finished underframe is automatically off-line after being automatically detected, and the production mode of a steel structure of the underframe of the wagon is fundamentally simplified.
While the preferred embodiments of the present application have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all alterations and modifications as fall within the scope of the application.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present application without departing from the spirit and scope of the application. Thus, if such modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is intended to include such modifications and variations as well.
Claims (15)
1. The utility model provides a flexible production line of railway freight car chassis which characterized in that: the railway wagon chassis station system comprises more than 2 railway wagon chassis stations, wherein the more than 2 railway wagon chassis stations are continuously and sequentially arranged along the production and transportation direction of a railway wagon chassis, and the central lines of the more than 2 railway wagon chassis stations are positioned on the same straight line;
the flexible production line station of the railway wagon underframe further comprises an automatic transmission vehicle, and the railway wagon underframe shuttles among more than 2 railway wagon underframe stations through the automatic transmission vehicle so as to sequentially complete each process of the railway wagon underframe production.
2. A flexible production line for underframe of railway wagon as claimed in claim 1, wherein: the railway wagon chassis stations are 9 and are arranged in sequence:
the underframe assembling station is used for assembling each beam structure and accessories of the railway wagon underframe;
a base frame welding station for welding flat welding seams among beam structures of the base frame of the railway wagon;
the underframe welding station II is used for welding the welding seams at the connecting positions of the beam structures in a turnover manner;
the underframe welding three stations are used for assembling the upper cover plate of the sleeper beam and the upper cover plate of the cross beam and repairing welding blind areas of the previous working procedures;
the underframe assembling two stations are used for assembling the floor;
the underframe welding four stations are used for welding the floor and the connecting welding seams of the beam structures;
the five stations are used for welding the weld joint on the front side of the floor;
six stations for welding the underframe are used for assembling accessories and repairing welding blind areas of the previous working procedures;
and the underframe handing-over station is used for detecting the key size of the underframe of the railway wagon and adjusting the height difference of each beam structure.
3. A flexible production line for underframe of railway wagon as claimed in claim 2, wherein: the number of the chassis welding stations of the railway wagon is 10, four standby chassis welding stations are arranged between the four chassis welding stations and the five chassis welding stations, and the four standby chassis welding stations are also used for welding connecting welding seams between the floor and each beam structure.
4. A flexible production line for underframe of railway wagon as claimed in claim 2, wherein: a hoisting system is arranged in the underframe assembly station and used for loading each beam structure; the assembly jig of the first underframe assembly station is of a through structure, and the middle part of the first underframe assembly station is a transmission area for the automatic transmission vehicle to shuttle;
the top of a chassis equipment station is provided with and send a machine and linkage, send a machine to pass through linkage hangs the installation, send a machine to be used for sending and feeding the welding wire of tack welding when carrying out each roof beam structure equipment.
5. A flexible production line for underframe of railway wagon as claimed in claim 2, wherein: be provided with welding robot in a chassis welding station, the welding track has been arranged to the both sides of a chassis welding station, welding robot install respectively in a chassis welding station both sides on the welding track.
6. A flexible production line for underframe of railway wagon as claimed in claim 2, wherein: a workpiece positioner and a welding robot are arranged in the second underframe welding station, and the workpiece positioner is used for overturning a workpiece to be welded; welding tracks are arranged on two sides of the two stations for welding the bottom frame, and the welding robots are respectively installed on the welding tracks on two sides of the two stations for welding the bottom frame.
7. A flexible production line for underframe of railway wagon as claimed in claim 2, wherein: and a hoisting system is arranged in the three stations for welding the underframe and is used for feeding the upper cover plate of the sleeper beam and the upper cover plate of the cross beam.
8. A flexible production line for underframe of railway wagon as claimed in claim 2, wherein: and a hoisting system is arranged in the second station for assembling the underframe and is used for loading the floor.
9. A flexible production line for underframe of railway wagon as claimed in claim 2, wherein: the four stations for welding the underframe are provided with a workpiece positioner and a welding robot, and the workpiece positioner is used for overturning a workpiece to be welded; welding tracks are arranged on two sides of the four stations for welding the bottom frame, and the welding robots are respectively installed on the welding tracks on two sides of the four stations for welding the bottom frame.
10. A flexible production line for underframe of railway wagon as claimed in claim 2, wherein: the five stations for welding the underframe are provided with a workpiece positioner and a welding robot, the workpiece positioner is used for overturning a workpiece to be welded, and the welding robot is arranged on the walking gantry.
11. A flexible production line for underframe of railway wagon as claimed in claim 2, wherein: and the six stations for welding the underframe are provided with workpiece position changing machines which are used for overturning the workpieces to be welded.
12. A railway wagon undercarriage flexible production line as defined in any one of claims 1-11, wherein: the flexible production line of the underframe of the railway wagon further comprises a data acquisition and processing system, wherein the data acquisition and processing system is used for acquiring data of the tools of all stations of the underframe of the railway wagon and analyzing the data;
the number of the automatic conveying vehicles is more than 2, the number of the automatic conveying vehicles is 2, each group of automatic conveying vehicles can shuttle between two adjacent underframe stations of the railway wagon, and the automatic conveying vehicles are arranged to cover each underframe station of the railway wagon;
the automatic transmission vehicle is provided with a wireless control module and a wired control module, and is in data communication with the data acquisition and processing system through the wireless control module;
the rail wagon chassis flexible production line is paved with rails in the whole line, and the automatic conveying vehicle runs on the rails.
13. A railway wagon undercarriage flexible production line as defined in any one of claims 1-11, wherein: a base platform is laid on the ground of the whole line of the flexible production line of the underframe of the railway wagon, the base platform is flush with the ground, and all tools of all stations of the underframe of the railway wagon are connected with the base platform through threaded fasteners;
the base platform is provided with more than 1T-shaped groove, the section of the T-shaped groove is inverted T-shaped, and a bolt in the threaded fastener is inverted in the T-shaped groove.
14. A railway wagon undercarriage flexible production line as defined in any one of claims 1-11, wherein: the flexible production line of the railway wagon underframe further comprises an operation worker operation area and a line side warehouse material storage area, wherein the operation worker operation area and the line side warehouse material storage area are located on two sides of the area where the railway wagon underframe stations are located.
15. A process for producing a railway wagon undercarriage based on the railway wagon undercarriage flexible production line as defined in any one of claims 1 to 14, wherein: sequentially finishing each process of the production of the underframe of the railway wagon on more than 2 stations of the underframe of the railway wagon, and transmitting the underframe of the railway wagon among the stations through the automatic transmission vehicle;
the method specifically comprises the following steps:
a step of underframe assembly, in which each beam structure of the underframe of the railway wagon and accessories thereof are assembled;
a chassis welding step, in which flat welds between beam structures of the chassis of the railway wagon are welded;
a second process of welding the underframe, namely welding the welding seams at the connecting positions of the beam structures in a turnover manner;
the underframe welding comprises three procedures, namely assembling an upper cover plate of the sleeper beam and an upper cover plate of the cross beam and repairing welding blind areas of the previous procedures;
a second step of assembling the underframe, wherein the floor is assembled;
welding the underframe, namely welding the floor and the connecting weld joints of the beam structures;
welding the bottom frame, namely welding the weld joint on the front side of the floor;
six processes of chassis welding, namely assembling accessories and repairing welding blind areas of the previous processes;
and in the underframe handing-over process, detecting the key size of the underframe of the railway wagon and adjusting the height difference of each beam structure.
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| CN202010773394.XA CN112045326A (en) | 2020-08-04 | 2020-08-04 | Flexible production line and production process for underframe of railway wagon |
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| CN202010773394.XA CN112045326A (en) | 2020-08-04 | 2020-08-04 | Flexible production line and production process for underframe of railway wagon |
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