JP2626471B2 - Manufacturing method of vehicle structure - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a fabrication how suitable car structure when combined <br/> the fabrication how the car structure relates, in particular panels by joining them by welding to fabricate car body structure those related <br/> to.

[0002]

2. Description of the Related Art In recent years, there has been an increasing demand for higher speed railway vehicles. However, increasing the speed of railway vehicles causes problems such as track destruction, increased noise during traveling, and increased power cost. In order to solve these problems, it is necessary to reduce the weight according to the running speed of the railway vehicle. Also, when a railway vehicle passes at high speed in a tunnel, a large pressure fluctuation occurs in a short time. Therefore, the structure of the vehicle, in addition to the load of passengers, various equipment and the weight of the structure,
The pressure due to the above-mentioned pressure fluctuation outside the vehicle repeatedly acts on the structure.

[0003] A conventional railcar structure is composed of a hexahedron consisting of a roof, a side, an underframe, and a wife, and is composed of a bone member as a strength member and an outer plate for separating the inside and outside of the vehicle. Examples of the material include a mild steel plate, a stainless steel plate, an aluminum alloy plate, and an aluminum alloy extruded material. In particular, as a light weight device, one using a light-alloy brazed honeycomb panel disclosed in Japanese Patent Application Laid-Open No. 3-90468 is known.

[0004]

When a block such as a roof block or a side block is manufactured by combining and welding the above-mentioned brazed aluminum honeycomb panels (hereinafter simply referred to as "honeycomb panels") of the prior art, the heat input by welding is required. The effect on the brazing part must be reduced. Further, each block made of the honeycomb panel is made thinner in order to reduce the weight. For this reason, in order to secure the strength, high-quality two-surface welding must be performed to transmit power to each face plate efficiently. When welding the front and back surfaces of a honeycomb panel, remove the panel from the assembly jig after welding the front side, and
It is expected that the work will be reversed with a tool or the like, then set on another jig and welded on the back surface, but during this time the combination accuracy may be reduced.

An object of the present invention is to prevent deformation.
Then, it is to provide a production how of the car body structure that can be fabricated with high quality of the vehicle structure.

A second object of the present invention is to provide a method for manufacturing a side block.

[0007]

The above object is achieved by a plurality of honeycombs.
The cam panel is aligned with the first reference plate along the longitudinal direction of the vehicle.
In addition, the second reference plate is not overlapped on the honeycomb panel.
Scissors, one of the first reference plate or the second reference plate
From the side of the reference plate along the line to be welded.
From the welding groove penetrating the reference plate, the honeycomb
The panels are welded together, then the first reference plate,
A plurality of honeycomb panels and the second reference plate;
Object to be welded, and then from the other reference plate side
A line is provided on the reference plate along the line, and the
The honeycomb panels can be welded to each other from the contact groove.
And can be achieved by

A second object is to extend the length of the vehicle along the longitudinal direction.
, The upper block constituting the upper part than the window, the vehicle
Long along the longitudinal direction of the
Attach the lower block and the blow panel to the side
On the first reference plate so as to compose the second reference
A plate is stacked on the honeycomb panel and sandwiched, and the first
Reference plate or one reference plate side of the second reference plate
The reference plate is provided on the reference plate along a line to be welded.
From the welding groove penetrating the plate, the upper block and the
Blow panel, the lower block and the blow panel
And the first reference plate,
The upper block, the blow panel, and the lower block
The object consisting of the lock and the second reference plate is inverted.
Then, from the other reference plate side, along the line to be welded,
From the welding groove provided in the reference plate and penetrating the reference plate,
The upper block and the blow panel, the lower
Weld the block and the blow panel
And can be achieved by

[0009]

According to the present invention, a honeycomb is sandwiched between two reference plates.
Inverts the muo-anel so that it does not deform
It is capable of producing a high quality vehicle structure.

[0010] According to the method of the second object, a high-quality side block is provided.
A lock can be made.

[0011]

[Example] When a railway car travels in a tunnel at high speed,
The pressure difference inside and outside the vehicle changes rapidly. Especially when vehicles pass each other in a tunnel, a large pressure fluctuation occurs in a short time. Therefore, the structure of the vehicle is exposed to the load due to the above-mentioned inside and outside pressure difference in addition to the loads and structures of the passengers and various devices. Therefore, it is necessary to improve the rigidity of the structure and the strength against the pressure load. The structure of the vehicle for suppressing the stress concentration due to such a load is reduced to an approximately cylindrical structure, and the honeycomb panel constituting the vehicle structure also has a quadratic curved shape having a curvature.

FIG. 1 is an exploded perspective view showing an example of a honeycomb panel used for a vehicle structure according to the present invention, and FIG. 2 is a plan view thereof. The honeycomb panel 1 includes a honeycomb core 2 as a core material, an external connection member 3 as an end material, and a pair of face plates 4 and 5. All materials are light alloy materials. For example, the materials of the honeycomb core 2 and the face plates 4 and 5 are as follows.
It is JIS standard A6N01.

The honeycomb core 2 has a structure in which corrugated plates are overlapped so as to form hexagonal cells, and their gaps are joined with a brazing material. In the honeycomb panel 1, a strength member 6 made of a light alloy is incorporated in order to further secure necessary strength. As an example, FIG. 1
Oite, core 2 of the honeycomb panel 1 thickness 0.2mm, the
The height is 58 mm, the thickness of the face plates 4 and 5 is 1 mm, and the thickness of the external bonding material 3 is 2 mm. Further, the size of the panel alone is limited by the size of the furnace for brazing, and is, for example, about 4 m in length and about 1.2 m in width.

After preparing the components constituting the honeycomb panel 1 as described above, a brazing process is performed to integrate the components into one panel. This brazing,
A brazing material, for example, BA
4045 is clad, assembled as a panel in a jig, and heated.

The strength member 6 together with the outer connecting member 3 contributes to the improvement of out-of-plane bending rigidity. And the face plate 4 on the surface,
By arranging the honeycomb cores 2 between the holes 5, the distance in the thickness direction is sufficiently secured to increase the section modulus, and the rigidity of the honeycomb panel 1 is secured.

FIG. 3 is a view showing a procedure for manufacturing a side block of a vehicle structure from the honeycomb panel 1, the blow-by panel 1a, and the entrance panel 8. First, at least the next process welded portion of the manufactured honeycomb panel 1 is trimmed with high precision using a trimming machine as shown in FIG. 4 to form a weld groove. In FIG. 4, in a state where the honeycomb panel 1 to be processed is placed on the base 12 and restrained, a welding groove of the next process of the honeycomb panel 1 is processed by the processing head 10. These operations are automatically performed by a numerical control system incorporated in the control panel 11. The present trimming machine can also process the honeycomb panel 1 in the minimum unit and the long block.

A plurality of honeycomb panels 1 having a groove formed by the trimming machine are prepared, arranged in the plane direction on a jig, and the curved surfaces of the adjacent honeycomb panels 1 are positioned and restrained. Then, the curved surfaces of the adjacent honeycomb panels 1 are joined by welding to produce a long block 7. For such welding in the direction of the curved surface, it is preferable to use laser beam welding, which has a very small heat input and can suppress distortion deformation. The long block 7 and the blow panel 1 manufactured in this manner.
a, The entrance / exit panel 8 is positioned at a predetermined position and constrained, and joined by MIG or TIG welding to form the side block 9. The blow-in panel 1a and the entrance / exit panel 8 may be constituted by a honeycomb panel, and a portion where an excessively large load acts locally may be formed of a mold.

FIG. 5 shows an example of a laser beam welding apparatus, in which the groove of the honeycomb panel 1 constrained by a pair of upper and lower jigs 18 is passed through a welding groove 17 provided in the jigs 18. Join at 15. 13 is a laser oscillator, 14 is a control panel, and 16 is a processing table. Next, the whole is lifted and turned upside down while restraining the welded portion so as not to be deformed, lowered to the original position, and the back side is welded, and the production of the long block 7 is completed. High-speed MIG or TIG welding is used for welding in the longitudinal direction and the remaining curved surface direction. This is because even if the groove portion of the long block 7 made by laser beam welding is somewhat inaccurate due to distortion or the like, MIG or TIG welding has a wide margin, so that the groove portion is slightly irregular. Is acceptable. Further, by first welding the curved surface direction to produce the long block 7, the remaining longitudinal welding is a continuous linear welding, which has an advantage that automation is easy.

FIG. 6 shows an example of a MIG or TIG welding apparatus, and a side block is manufactured in the same manner as the laser beam welding apparatus shown in FIG. Reference numeral 19 denotes a jig for the side block 9 for positioning and restricting the long block 7, the entrance panel, the blow-by panel and the like. Reference numeral 20 denotes a reversing axis provided at a longitudinal end of the jig 19 and serving as a central axis when reversing. The jig 19 is formed with welding grooves 17 that are opened corresponding to the joining positions of adjacent panels such as the long block 7, the entrance panel, and the blow-by panel. The welding device 24 performs welding while sensing the welding position with the sensor 23 via the welding groove 17. When the welding of one side of the side block 9 in the jig 19 is completed, the entire jig 19 is turned over by the support device without releasing the restraint, and the opposite side of the side block 9 is welded. In this welding, each panel is joined by the welding device 24 via the welding groove 17 in the same manner as described above.

FIG. 7 is a diagram showing a procedure for manufacturing a roof block 21 from a plurality of honeycomb panels 1. Also in this case, the roof block 21 is manufactured by manufacturing the long blocks 7 in the same manner as the side blocks 9 and then welding the long blocks 7 in the longitudinal direction. First, the honeycomb panel 1 is assembled as a long block 7 by welding after first performing a groove process in a curved surface direction.
Then, after the edge processing of the long block 7 in the plane direction, that is, the end face in the width direction is performed, the roof block 21 is manufactured by joining the long block 7 by welding.

FIG. 8 shows a bird view of the long block combination device. Honeycomb panel 1 trimmed with high precision
Is placed on the reference plate 20. The reference plate 20 is accurately manufactured so as to have a quadratic curved surface that matches a predetermined shape, that is, a shape of a portion where the long block of the vehicle structure is installed. Each honeycomb panel 1 is accurately positioned by a positioning pin 20a having a function of adjusting the fixed position of the honeycomb panel 1. After that, another reference plate 20 is placed on the honeycomb panel 1 and connected by the connecting pins 20b to securely restrain the honeycomb panel 1. Honeycomb panel 1
Is restrained so as to be sandwiched between the two reference plates 20, so that the panel surface portion which is weak against local force can be protected.
The welding is performed via the welding groove 17. Welding groove 1
Reference numeral 7 is formed so as not to interrupt the welding line at all.
After the welding of the front surface is completed, the surface is inverted and the back surface is welded. By configuring the reference plate 20 so as not to block the welding line, it is possible to improve the accuracy and the work efficiency. The reference plates 20 and 20 are the jigs 19 and 1 shown in FIG.
9

FIG. 9 shows a method for welding both the front and back surfaces of the honeycomb panel 1. That is, first, the laser light is applied to the MIG or TIG provided on the upper face plate 4.
Laser beam welding is performed on the groove portion of the lower face plate 5 through the root gap for use. Then, the upper face plate 4 is
By performing G or TIG welding, welding from only one side can be performed, and the work of inverting when joining the honeycomb panels 1 can be eliminated, so that work efficiency and accuracy can be improved.

FIG. 10 shows a bird's-eye view of the side block combination device. This device also has the same function as the long block combination device in FIG. The welding groove 17 is formed corresponding to a groove portion adjacent to each other or adjacent to another panel so as not to hinder welding. Since all welding can be performed without removing the honeycomb panel 1 from the restraining jig, that is, the reference plate 20, a block with high accuracy and high quality can be manufactured. The configuration of the connecting pin 20b and the reference plate connecting hole 20c will be described with reference to FIG. The connection pins 20b and the reference plate connection holes 20c are accurately installed and formed on the respective reference plates 20 so that the positioning can be performed accurately. Connect the connecting pin 20b to the reference plate connecting hole 20c.
By fitting in, the pair of reference plates 20 is accurately positioned. Then, the nut 20e is pressed through the pressing portion 20d.
Thus, the plurality of honeycomb panels 1 are accurately and reliably restrained. By doing so, each block can be manufactured with high accuracy and high work efficiency.

When each structural block is completed, an outfitting mounting seat is attached to these blocks. The outfitting mounting seat may be of the rail type shown in FIG. That is, the outfitting mounting rail 32 that forms the outfitting mounting seat is disposed so as to extend in the longitudinal direction of the roof block 21, for example, and is mounted by a joining method such as rivet bonding. The fixing strength of the outfitting component mounting rail 32 can be improved by fixing the outfitting component mounting rail 32 to an external connection member or a strength member of each honeycomb panel. By the way, as the strength member installed in the honeycomb panel supporting the fitting fitting mounting rail 32, the mounting operation can be simplified by using a hollow extruded material having a rectangular cross-sectional shape, and the strength is sufficient. Can be something. The outfit fitting mounting rail 32 can be adjusted in the longitudinal direction when the outfitting equipment is mounted, and can absorb welding distortion and deformation in the entire vehicle body set.

According to such a configuration, since high-precision joining is possible, it is possible to greatly reduce the reworking work as before. Prior honeycomb panel 1
By performing low heat input and low strain welding such as laser beam welding, and then performing MIG or TIG welding with a large root gap allowance in the longitudinal direction.
Workability can be improved and man-hours can be reduced. The lower face plate is laser beam welded, and then the upper face plate is MIG or T
A block with high precision, high quality, and high rigidity can be manufactured by a manufacturing method that eliminates the reversal work of performing IG welding. Moreover, since the joining can be performed with high precision, the reworking work as before can be greatly reduced. In addition, by using a combination device that firmly restrains the panel and does not interrupt the welding line, it is possible to realize block production with high quality, high accuracy, and high work efficiency.

[0026]

According to the present invention as described above, according to the present invention, strange
Shape can be prevented, and a high-quality vehicle structure can be manufactured.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a honeycomb panel constituting a vehicle structure manufactured by a manufacturing method according to the present invention.

FIG. 2 shows a plan view of the honeycomb panel of FIG.

FIG. 3 is a diagram showing a procedure for fabricating a side block by combining and welding the honeycomb panels in one embodiment of the fabrication method of the present invention.

FIG. 4 is a perspective view showing a trimming machine for trimming a honeycomb panel and a long block shown in FIG. 2;

FIG. 5 is a perspective view showing a laser beam welding apparatus for manufacturing the long block of FIG. 3;

FIG. 6 is a perspective view showing a welding device in a state where a side block is being manufactured.

FIG. 7 is a diagram showing a procedure for fabricating a roof block by combining and welding honeycomb panels in one embodiment of the fabrication method of the present invention.

FIG. 8 is a perspective view showing a jig for manufacturing the long block of FIG. 3;

FIG. 9 is a sectional view of a welded portion for explaining one welding method for joining the honeycomb panels of FIG. 8;

FIG. 10 is a perspective view showing a jig for manufacturing a side block.

FIG. 11 is a cross-sectional view showing a structure of a reference plate connecting portion installed on the jig of FIGS.

FIG. 12 is a perspective view showing a roof block provided with outfitting mounting rails.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Honeycomb panel, 7 ... Long block, 9 ... Side block, 15 ... Welding device, 17 ... Welding groove, 18 ... Jig.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Ryoichi Takayama 794, Higashitoyoi, Kazamatsu-shi, Yamaguchi Prefecture Inside the Kasado Plant, Hitachi, Ltd. (56) References JP-A-5-139296 (JP, A) Hei 4-22744 (JP, B2)

Claims (2)

(57) [Claims] 1. A plurality of honeycomb panels are arranged on a first reference plate along the longitudinal direction of a vehicle, and a second reference plate is overlapped on the honeycomb panel and sandwiched, and the first reference plate or the first 2 is provided on the reference plate from one reference plate side of the reference plate along a line to be welded;
The honeycomb panels are welded to each other from a welding groove penetrating the reference plate. Next, the first reference plate, the plurality of honeycomb panels,
And inverting the object comprising the second reference plate, and then, from the other reference plate side, provided on the reference plate along a line to be welded, from the welding groove passing through the reference plate, Welding the honeycomb panels to each other, a method for manufacturing a vehicle structure. 2. An upper block that is longer in the longitudinal direction of the vehicle and forms an upper part than the window, a lower block that is longer in the longitudinal direction of the vehicle and forms a lower part of the window, and a blow panel Is mounted on a first reference plate so as to form a side block of a vehicle, and a second reference plate is overlapped on the honeycomb panel and sandwiched, and one of the first reference plate or the second reference plate is sandwiched. From the reference plate side, provided on the reference plate along the line to be welded,
The upper block and the blow panel, the lower block and the blow panel are respectively welded from the welding groove penetrating the reference plate, and then the first reference plate, the upper block, An object consisting of the blow-by panel, the lower block, and the second reference plate is inverted, and then provided on the reference plate along a line to be welded from another reference plate side, and the reference plate is The upper block and the blow panel and the lower block and the blow panel are welded from the penetrated welding groove, respectively.