JPH0733016A - Manufacture of vehicle body structure and its device - Google Patents

Abstract

PURPOSE:To provide manufacture and device for attaining high quality, high precision and high efficiency in a vehicle body structure constituted by combination of panels. CONSTITUTION:Honeycomb panels 1 are welded by laser beam in curvature direction, so that a long-length panel is made. A plurality of long-length blocks 7 are arrayed. By welding them is longitudinal direction by MIG/TIG, a block is manufactured in high precision in suppressing the deformation. Honeycomb panels 1 are constrained in jig. Then, by welding the upper and the lower side without releasing the constraint due to jig welding grooves, decrease in precision is prevented and jig efficiency is obtained.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle structure manufacturing method and apparatus, and more particularly to a vehicle structure manufacturing method and apparatus suitable for manufacturing a vehicle structure by combining panels and joining them by welding. Is.

[0002]

2. Description of the Related Art In recent years, there has been an increasing demand for high speed railway vehicles. However, increasing the speed of railway vehicles causes problems such as track disruption, increased noise during running, and increased power costs. In order to solve these problems, it is necessary to reduce the weight according to the running speed of the railway vehicle. Also, when railway cars pass each other at high speed in a tunnel, large pressure fluctuations occur in a short time. Therefore, in addition to the passengers, the loads of various devices and the weight of the structure, the structure of the vehicle is
The above-mentioned pressure due to the pressure fluctuation outside the vehicle repeatedly acts on the structure.

A conventional railcar structure is composed of a hexahedron of a roof portion, a side portion, an underframe portion, and a gable portion, and is composed of a skeleton member as a strength member and an outer plate for partitioning the inside and outside of the vehicle. Examples of the material include mild steel plate, stainless steel plate, aluminum alloy plate, and aluminum alloy extruded material. In particular, a light alloy brazing honeycomb panel disclosed in Japanese Patent Application Laid-Open No. 3-90468 has been known as a light-weight brazing honeycomb panel.

[0004]

When a block such as a roof block or a side block is manufactured by combining and welding the above-mentioned conventional brazed aluminum honeycomb panels (hereinafter, simply referred to as a honeycomb panel), the heat input from the welding causes a problem. The effect on the brazing part must be reduced. In addition, each block made of the honeycomb panel is thinned in order to reduce the weight. Therefore, in order to secure the strength, it is necessary to perform high-quality two-face welding for efficiently transmitting the force to each face plate. When welding the front and back sides of a honeycomb panel, after welding the front side, remove the panel from the assembly jig
Although it is expected that the work will be reversed by welding, etc., and then set on another jig to weld the back side, there is a risk that the accuracy of the combination will decline during this time.

An object of the present invention is to provide a vehicle structure manufacturing method and apparatus capable of preventing deterioration and deformation of combination accuracy and manufacturing a high quality vehicle structure.

[0006]

[Means for Solving the Problems] The above object is to construct a long block by welding a plurality of honeycomb panels forming a quadratic curved surface by welding in a method for manufacturing a vehicle body structure including a honeycomb panel, This is achieved by arranging a plurality of the long blocks in the width direction thereof and joining them in the longitudinal direction by welding to form a structure block, and joining the plurality of structure blocks by welding.

[0007] Further, the above object is to hold a plurality of honeycomb panels in a positioned state and to hold them, and a jig in which bonding welding portions on both front and back surfaces of each honeycomb panel are opened, and the jigs. This is achieved by comprising a support means that is inverted while holding the panel.

[0008]

According to the present invention, since the curved surfaces of the adjacent honeycomb panels are first welded and joined together, complicated positioning of the curved surfaces can be performed in the minimum unit state of the honeycomb panel, so that the distortion is minimized. A high-precision long block can be obtained. By combining the long blocks or other panels or the like and welding in the longitudinal direction, continuous welding in the longitudinal direction becomes possible and the automation of welding becomes easy.

Further, according to the present invention, the joints of adjacent honeycomb panels and the like are opened and restrained so as not to interrupt the welding line during the combination welding, and once restrained, the restraint is not released. By using a manufacturing device that can weld both sides of
Each block can be manufactured efficiently.

[0010]

[Example] When a railway vehicle travels at high speed in a tunnel,
The pressure difference between the inside and outside of the vehicle changes rapidly. Especially when vehicles pass each other in a tunnel, large pressure fluctuations occur in a short time. Therefore, the structure of the vehicle is exposed to the load due to the pressure difference inside and outside the vehicle in addition to the loads of the passengers and various devices and the structure. Therefore, the rigidity of the structure and the strength against pressure load must be improved. The structure of the vehicle for suppressing the stress concentration due to such a load has an approximately cylindrical structure, and the honeycomb panel forming the vehicle structure also has a quadric surface shape with a curvature.

FIG. 1 is an exploded perspective view showing an example of a honeycomb panel used in the vehicle structure of 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 coupling 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
It is JIS standard A6N01.

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

After the respective members constituting the honeycomb panel 1 as described above are punched down, a brazing process is performed in order to integrate them into a single panel. This brazing is
A brazing material such as BA on the surface of each member that constitutes the panel in advance.
4045 is clad and assembled as a panel in a jig and heated.

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

FIG. 3 is a diagram showing a procedure for manufacturing a side block of a vehicle body structure from the honeycomb panel 1, the blow-in panel 1a, and the doorway panel 8. First, at least the next-step 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, with the honeycomb panel 1 to be processed placed on the base 12 and constrained, the welding head of the next step of the honeycomb panel 1 is processed by the processing head 10. These operations are automatically performed by the numerical control system incorporated in the control panel 11. The trimming machine can also process the minimum unit of the honeycomb panel 1 and the long block.

A plurality of honeycomb panels 1 each having a groove formed by the trimming machine are prepared, arranged in a plane direction on a jig, and the curved surfaces of adjacent honeycomb panels 1 are positioned and restrained. Then, the curved surfaces of the adjacent honeycomb panels 1 are joined by welding to manufacture the long block 7. For such welding in the curved surface direction, it is preferable to employ laser beam welding which has extremely small heat input and can suppress strain deformation. The long block 7 and the wind-up panel 1 thus manufactured
a) The entrance / exit panel 8 is positioned and restrained at a predetermined position 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 formed of honeycomb panels, and a mold material may be used in a portion where excessive weight is locally applied.

FIG. 5 shows an example of a laser beam welding apparatus. A welding apparatus is provided in which a groove portion 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 jig 18. Join at 15. 13 is a laser oscillator, 14 is a control panel, and 16 is a processing table. Next, the entire welded portion is lifted and inverted while being restrained so as not to be deformed, lowered to the original position and the back surface 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 slightly inaccurate due to distortion or the like, the MIG or TIG welding has a wide margin, so that the groove portion is slightly misaligned. Is acceptable. In addition, by welding the curved surface direction first to manufacture the long block 7, the remaining longitudinal welding has the advantage that it becomes continuous linear welding and is easy to automate.

FIG. 6 shows an example of the MIG or TIG welding apparatus, and the side blocks are manufactured by the same method as the laser beam welding apparatus of FIG. Reference numeral 19 is a jig for the side block 9 for positioning and constraining the long block 7, the entrance / exit panel, and the blowing panel. Reference numeral 20 denotes a reversing shaft which is provided at an end of the jig 19 in the longitudinal direction and serves as a central axis when reversing. The jig 19 is provided with welding grooves 17 that are opened corresponding to the joining positions of adjacent panels such as the long block 7, the entrance / exit panel, and the blow-in panel. The welding device 24 performs welding while sensing the welding position with the sensor 23 through the welding groove 17. When the welding of one surface of the side block 9 in the jig 19 is completed, the jig 19 as a whole is reversed by the supporting device without releasing the constraint, and the welding work of the opposite surface of the side block 9 is performed. In this welding as well, each panel is joined by the welding device 24 through the welding groove 17 as described above.

FIG. 7 is a diagram showing a procedure for manufacturing the roof block 21 from the plurality of honeycomb panels 1. In this case as well, the roof blocks 21 are manufactured by manufacturing the long blocks 7 similarly to the side blocks 9 and then welding the long blocks 7 in the longitudinal direction. The honeycomb panel 1 is assembled into a long block 7 by welding after first performing groove forming in the curved surface direction.
After that, after the groove of the plane direction of the long block 7, that is, the end face in the width direction, the long block 7 is welded to join the roof block 21.

FIG. 8 is a bird's eye 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 quadric surface that conforms to a predetermined shape, that is, the shape of the portion of the vehicle structure where the long block is installed. Each honeycomb panel 1 is accurately positioned by the positioning 20a pin having a fixed position adjusting function of the honeycomb panel 1. After that, another reference plate 20 is placed on the honeycomb panel 1 and is connected by the connecting pins 20b to securely restrain the honeycomb panel 1. Honeycomb panel 1
Is constrained 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.
Welding is performed via the welding groove 17. Welding groove 1
7 is formed so as not to interrupt the welding line at all.
When the front surface is welded, it is inverted and the back surface is welded. By configuring the reference plate 20 so as not to interrupt the welding line, it is possible to improve accuracy and work efficiency.

As a method of welding both the front and back surfaces of the honeycomb panel 1, there is a method shown in FIG. That is, first, laser light is emitted from the MIG or TIG provided on the upper face plate 4.
The groove portion of the lower face plate 5 is laser-beam welded through the root gap for use. Then, MI the upper face plate 4
G or TIG welding enables welding from only one side, and the work of reversing when joining the honeycomb panels 1 to each other can be eliminated, and 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 of FIG. The welding groove 17 is formed so as not to interfere with the welding so as to correspond to the adjacent groove portions between the honeycomb panels or other panels. Since all the welding can be performed without removing the honeycomb panel 1 from the restraint jig, that is, the reference plate 20, it is possible to manufacture a block with high accuracy and high quality. The structure of the connecting pin 20b and the reference plate connecting hole 20c will be described with reference to FIG. The connecting pin 20b and the reference plate connecting hole 20c are accurately installed and formed in each reference plate 20 so that they can be accurately positioned. Connect the connecting pin 20b to the reference plate connecting hole 20c.
By fitting in, the pair of reference plates 20 are accurately positioned. Then, the nut 20e is inserted through the pressing portion 20d.
The plurality of honeycomb panels 1 are accurately and surely restrained by tightening with. By doing so, each block can be manufactured with high precision and work efficiency.

After each structure block is completed, next, an outfitting mounting seat is attached to them. The equipment mounting seat may be of the rail type shown in FIG. That is, the outfitting equipment mounting rail 32 forming the outfitting seat is arranged, for example, so as to extend in the longitudinal direction of the roof block 21, and is mounted by a joining method such as rivet bonding. If the outfitting equipment mounting rail 32 is fixed to the external coupling member or the strength member of each honeycomb panel, the supporting strength of the outfitting equipment mounting rail 32 can be improved. By the way, as the strength member installed in the honeycomb panel that supports the outfitting equipment mounting rail 32, if the extruded mold member having a rectangular cross section is used, the mounting work can be simplified and the strength is sufficient. It can be anything. The outfitting component mounting rail 32 can be adjusted in the longitudinal direction when mounting the outfitting component, and can absorb welding distortion and deformation in the entire assembly of the vehicle body.

According to this structure, since highly accurate joining is possible, it is possible to greatly reduce the rework work that has been done up to now. Honeycomb panel 1 to be performed in advance
The joining in the curved surface direction is performed by low heat input, low distortion welding such as laser beam welding, and then MIG or TIG welding having a wide margin of root gap is performed in the longitudinal direction.
Workability can be improved and man-hours can be reduced. Also, the lower face plate is laser beam welded, and then the upper face plate is MIG or T.
By a manufacturing method that omits the inversion work of IG welding, it is possible to manufacture a block with high accuracy, high quality, and high rigidity. Moreover, since the welding can be performed with high precision, the rework work that has been done up to now 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.

[0025]

As described above, according to the present invention, it is possible to prevent deterioration of combination accuracy and manufacture a high-quality vehicle structure.

[Brief description of drawings]

1 is a perspective view showing a honeycomb panel forming 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] Fig. 3 is a diagram showing a procedure of manufacturing a side block by combining and welding honeycomb panels in one embodiment of a manufacturing method of the present invention.

FIG. 4 is a perspective view showing a trimming machine for trimming the honeycomb panel and the long block of FIG.

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

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

[Fig. 7] Fig. 7 is a diagram showing a procedure for manufacturing a roof block by combining and welding honeycomb panels in one embodiment of the manufacturing method of the present invention.

FIG. 8 is a perspective view showing a jig for producing the long block of FIG.

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

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

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

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

[Explanation of symbols]

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

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Ryoichi Takayama 794 Azuma Higashitoyo, Kudamatsu City, Yamaguchi Prefecture Hitachi Ltd. Kasado Plant

Claims (3)

[Claims] 1. A method for manufacturing a vehicle body structure comprising honeycomb panels, wherein a plurality of honeycomb panels forming a quadric surface are joined by welding in a curved direction to form a long block, and a plurality of the long blocks are formed to have a width. A method of manufacturing a vehicle body structure, comprising arranging in a direction and joining the longitudinal direction by welding to form a body structure block, and joining a plurality of the body structure blocks by welding. 2. The method of manufacturing a vehicle body structure according to claim 1, wherein when the long blocks are formed, the honeycomb panels are joined in a curved surface direction by laser beam welding. Method. 3. A jig in which a plurality of honeycomb panels are constrained and held in a positioned state, and each of the front and back surfaces of each honeycomb panel has an opening for each bonding weld, and the jig holds the plurality of honeycomb panels. An apparatus for manufacturing a vehicle structure, comprising: a supporting means that reverses in a state.