JP2001233203A - Method of manufacturing for structure and structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To accurately inexpensively manufacture a railway rolling stock car body and a structure having a curved surface part. SOLUTION: A face plate 51 has a curved surface, and the forefront part of a rolling stock is constituted by assembling blocks having a lattice-shaped rib 55 on an inside surface. A rib 56 is provided in an outer peripheral part of the inside surface of the blocks 50. The plural blocks 50 are placed on a stand. End surfaces of outer peripheral ribs 56 of the mutual adjacent blocks are brought into contact with each other. A bar-shaped metal fitting 60 is penetrated through respective holes of the outer peripheral ribs 56 to join the mutual blocks. Connecting parts of outside surfaces of the blocks are smoothed. Next, a sealant is put in a groove of the outside surface of a boundary of the connecting parts of the blocks, and painting is performed thereafter.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a relatively large structure by combining a plurality of curved plates. For example, it is suitable for manufacturing a leading part of a leading car of a railway vehicle.

[0002]

2. Description of the Related Art The leading portion of a leading vehicle of a railway vehicle has a three-dimensional curved surface from the viewpoint of air resistance and design. It also requires a fairly complicated surface.

As disclosed in Japanese Patent Application Laid-Open No. Sho 62-160954, the curved surface portion of the leading vehicle is composed of a skin plate, a vertical bone, and a horizontal bone. The vertical and horizontal bones have a curved surface along the curved surface of the outer skin, and are cut out from a plate. The vertical and horizontal bones are provided with cuts, one into the other. The outer skin is divided into small blocks and is curved by press molding.

First, a vertical bone and a horizontal bone are assembled on an underframe of a vehicle body to integrate the three members. Next, an outer skin is put on the frame composed of the vertical bone and the horizontal bone, and they are integrated by welding.

[0005] In addition, aeronautical technology No. 506 pages 32 to 36 show a method of manufacturing an aircraft fuselage. The inner surface of the outer plate is cut to a required thickness, and the plates are stacked to increase the thickness, and then molded by a press. Next, a plurality of curved plates are connected to produce an airframe.

[0006] Japanese Patent Application Laid-Open No. 9-309164 (EP 0
As in the case of 197943 A2), there is a friction stir welding method as a joining means.

[0007]

The above-mentioned Japanese Patent Application Laid-Open No. 62-16 / 1987.
In the manufacturing method disclosed in Japanese Patent Publication No. 095, the outer skin, the vertical bone, and the horizontal bone are separately formed to have curved surfaces, and are integrated by welding. Since the outer skin is manufactured by pressing, a uniform curved surface is often not obtained when a plurality of outer skins are joined. For this reason, after welding, the weld bead must be cut with a grinder, and further cutting near the joint of the outer skin is required, which is expensive.

The aeronautical technology No. The manufacturing method of 506 indicates that the inner surface of the outer plate is cut to change the plate thickness, and then pressed to form a curved surface. According to this, it is thought that it can be manufactured at low cost. However, after changing the thickness,
That is, when a plate provided with ribs is pressed to form a three-dimensional curved surface, the following problem is likely to occur. The plate portion between the ribs does not have a curved surface, but has a flat shape. Further, when pressed, the length of the side of the plate changes greatly. In particular, when the shape of the plate is trapezoidal when viewed from the surface side of the plate, these are remarkably exhibited.

An object of the present invention is to provide an inexpensive structure for a vehicle or the like.

[0010]

SUMMARY OF THE INVENTION It is an object of the present invention to make a plurality of blocks adjacent to each other, in which the outer peripheral ribs are brought into contact with each other, and the adjacent blocks are connected by a rod-shaped metal fitting passing through a hole provided in the rib. Then, the sealant is filled in the groove on the outer surface side of the block and between the adjacent blocks.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A case where the present invention is applied to a leading portion of a leading vehicle of a railway vehicle will be described below with reference to the drawings. In FIG. 2, a block 50 for the size of the vehicle is shown.
The size and the like are schematically shown.

[0012] As shown in FIG.
2, S3 has a three-dimensional curved surface curved along the longitudinal direction and the width direction of the vehicle body. In part S3 there is a window C in the driver's seat. The portion S3 often has a curved surface further projecting from the curved surface. Therefore, the portion S3 often has a complicated curved surface. The part S4 is the guest room part, and the entrance D1,
D2, there is a window W. Since the outer surface of this portion is linear along the longitudinal direction of the vehicle body, it has a conventional configuration. The leading vehicle includes a frame 100 constituting the floor, a curved portion S3 placed on the frame 100, a straight portion S4, and curved portions S2 and S3 installed at the tip of the curved portion S3.

This embodiment is a case where the present invention is applied to a relatively large curved surface portion (a portion where the height of the vehicle body is high) S3. Curved surface S
1, S2 can be manufactured in the same manner. The curved surface portion S3 is configured by connecting a plurality of blocks 50 in the longitudinal direction and the width direction of the vehicle.

In FIGS. 1 and 3 to 6, block 50
Consists of a face plate 51 forming the outer surface of the vehicle, and a plurality of ribs 55 protruding from the inner surface of the face plate 51. The rib 55 includes a plurality of vertical ribs along a vertical direction (vertical direction) and a plurality of horizontal bones along a horizontal direction (horizontal direction). The ribs 55 are connected to each other to form a lattice. The protrusion of the rib 55 is usually constant.

The rib 55 has ribs 56 located on the four sides of the outer periphery of the rectangular block 50. When the plurality of blocks 50 are arranged at predetermined positions, the outer peripheral ribs 56 come into contact with each other. The outer peripheral rib 56 has a plurality of holes h. The outer peripheral end surface e of the outer peripheral rib 56 is a flat surface.

[0016] The leading portion of the leading vehicle of the railcar has a smaller height and a smaller width toward the leading end. For this reason, as shown in FIG. 5, the planar shape of one block 50 is often not a square but a trapezoid.

FIG. 4 schematically shows a curved surface portion S3 composed of a plurality of blocks. Assuming the right half of S3, blocks 50A, 50B, 50C, 5
It is composed of six blocks consisting of 0D, 50E and 50F. The end face e1 is the right half of S3, and the end face e2 is the underframe 1.
Combined with 00.

The assembly of the blocks will be described with reference to FIG. First, a plurality of blocks 50 located at predetermined positions are placed on a gantry. The gantry conforms to the outer shape of the vehicle and is a welded structure obtained by simplifying conventional vertical and horizontal bones. A plurality of blocks 50 are mounted on this base,
5 and 56 are placed downward (step S1
00).

Next, two adjacent blocks 50, 50
Ribs 56, 56 are fastened with a rod-shaped fitting 60, for example, a bolt and nut. The rod-shaped fitting 60 passes through a hole h provided in the ribs 56, 56. Each pair of holes h of the outer peripheral rib 56
An outer peripheral rib 56 outer peripheral end face e at the end of the face plate 51 of one block 50 provided at the same distance from the outer surface of the face plate 51
Is the outer peripheral rib 5 at the end of the face plate 51 of the other block 50.
6 is in contact with the outer peripheral end face e.

In this manner, all blocks 50 are temporarily connected. Next, the positions of the individual blocks 50 are adjusted so that the outer surfaces of the connecting portions between the blocks become smooth. Since the contact surface e of the outer peripheral rib 56 is flat, the block can be moved in any direction in the plane.

For this reason, the block can be positioned within the range of the difference between the hole diameter and the rod diameter only by attaching the rod-shaped bracket 60. Even if the entire block has irregularities in the curved surface, the irregularities can be corrected by attaching the rod-shaped metal fittings. If the difference between the hole diameter and the rod diameter is 1 mm, for example,
The step on the outer surface can be limited to a maximum of 1 mm. By reducing the difference between the hole diameter and the rod diameter, or by tapering the tip of the rod-shaped fitting, the amount of step on the outer surface can be reduced (FIG. 1, step S110).

Next, there is a groove on the outer surface side of the boundary between adjacent blocks 50. This groove is filled with the sealant S from the outer surface side. The outer surface side of the sealant S is finished according to the outer surface of the face plate 51 (step S130).

Next, the tips of the outer peripheral ribs 56 are welded to each other. Since the tip of the rib 56 is welded, the influence of welding heat on the outer surface side is small, and distortion can be reduced. The welding is performed continuously or intermittently (step S150).

Next, this structure is placed on the underframe 100 of the vehicle and connected (step S170).

Next, after the assembly, the outer surface of the face plate 51 including the seal s is coated (step S19).
0).

In the above, depending on the accuracy of the block 50 and the like, the rod-shaped metal fitting 60 can be a knock pin. After the assembly, the weight can be reduced by removing the rod-shaped metal fitting 50 or omitting the welding of the tip of the rib 56.

Thus, a plurality of blocks can be assembled accurately and easily, and a structure having airtightness on the inner and outer surfaces can be obtained. Since the structure has high accuracy, the finish of the coating is good and a good-looking curved surface is obtained.

Next, a method of manufacturing the block 50 will be described with reference to FIG. First, a plate is cut slightly larger than the size of the block 50 (step S200). The plate is made of an aluminum alloy and has a thickness of, for example, 40 mm.

Next, the plate is pressed with a mold and bent into a predetermined curved surface to form a curved plate, which is annealed (step S21).
0). The press is performed by heating the plate to about 300 ° C. Next, with the curved plate sandwiched between the molds at a predetermined pressure,
Anneal at about 350 ° C. for about 40 minutes.

Next, a reference surface is provided by cutting the outer surface side (outer surface side of the vehicle) of the curved plate using a 5-axis machining center or the like until the material surface is removed (step S230).

Next, the curved plate is inverted, and the inner surface side (the inner surface side of the vehicle) of the curved plate is cut to form ribs 55 and 56 (step S250). Further, the processing is advanced to complete the inner surface of the face plate 51. The dimensions of the ribs 55 and 56 are, for example, 30 mm in height, 6 mm in thickness, and 200 mm in pitch. The roundness of the base between the ribs 55 and 56 and the face plate 51 is, for example, 5 mm.

Next, the curved plate is turned over, and the outer surface of the face plate 51 is cut and finished (step S270). The thickness of the face plate is, for example, 2 mm. In addition, the thickness can be increased in a portion depending on required strength conditions.

Next, in the same state, the outer periphery of the block is trimmed to finish the end face c of the rib 56, and a hole h is opened (step S290). The diameter of the hole h is, for example, 13 mm.

Thus, the face plate 5 having an accurate curved surface
1 and a rib structure having high rigidity with accurate dimensional accuracy can be obtained. Further, since the trimming and the perforation are performed by the NC processing, a curved plate (block) 50 having an accurate outer shape and an assembly standard can be obtained.

The technical scope of the present invention is not limited to the language described in each claim of the claims or the language described in the section of the means for solving the problems, and is easily replaced by those skilled in the art. It extends to a range.

[0036]

According to the present invention, since a block having ribs of an accurate assembling reference is mounted on a gantry and assembled by attaching a bar-shaped bracket, a vehicle or a structure can be manufactured accurately and at low cost.

[Brief description of the drawings]

FIG. 1 is a sectional view of a main part of a leading portion of a vehicle according to an embodiment of the present invention, and is a sectional view taken along line 2-2 of FIG.

FIG. 2 is a perspective view of a leading portion of the vehicle configured in FIG. 1;

FIG. 3 is a perspective view of one block of FIG. 1;

FIG. 4 is a side view of a part of the vehicle body shown in FIG. 2;

FIG. 5 is a plan view of a block constituting the vehicle body shown in FIG. 2;

FIG. 6 is a side view of the vehicle body shown in FIG. 2;

FIG. 7 is a flowchart illustrating a method of manufacturing a vehicle body.

FIG. 8 is a flowchart illustrating a method of manufacturing a block.

[Explanation of symbols]

50, 50A, 50B, 50C, 50D, 50E, 50
F: Block, 51: Face plate, 55: Rib, 56: Outer peripheral rib, 60: Bar-shaped bracket, 100: Underframe.

Claims (9)

[Claims] 1. A plurality of blocks are made adjacent to each other. At this time, the ribs on the outer periphery are brought into contact with each other, and the adjacent blocks are joined by a rod-shaped metal fitting penetrating a hole provided in the rib. Filling a groove on the outer surface between the adjacent blocks with a sealant. 2. The method of manufacturing a structure according to claim 1, wherein the adjacent blocks are connected to each other with the rod-shaped metal fitting.
Welding the ribs to each other. 3. The method of manufacturing a structure according to claim 1, wherein an outer surface of said block including a portion of said sealant is painted next. 4. A plurality of blocks are integrated by contacting outer peripheral ribs with each other, and there is a rod-shaped metal fitting penetrating the contacted ribs. A groove between the filler and a sealant. 5. The structure according to claim 4, wherein an outer surface of said block including a portion of said sealant is painted. 6. The structure according to claim 4, wherein said rib is a flat surface. 7. A plurality of blocks are integrally formed by contacting outer peripheral ribs, there is a hole penetrating the contacted ribs, and the tips of the contacted ribs are welded to each other. A groove on an outer surface side, wherein a groove between the adjacent blocks is filled with a sealant. 8. The structure according to claim 7, wherein said rib is a flat surface. 9. A plurality of blocks are integrated by contacting outer peripheral ribs with each other, and there is a rod-shaped metal fitting penetrating the contacted ribs. A grooved space is filled with a sealant, and an outer surface of the block including the sealant is painted.