RU2797221C1 - Method for assembling car bodies with frames of low rigidity - Google Patents

Abstract

FIELD: car building.

SUBSTANCE: invention is related to a method for assembling car bodies with frames of low rigidity. The jacks are placed in the initial position relative to the rail track with the carriages lowered down. The car frame is moved to the assembly position along the rails on bogies and it is installed in such a way that the ends of the frame are equidistant relative to the jacks. The grips are fixed with clamps on certain sections of the car frame, the frames are tightly pulled to the bogies by means of lanyards. The correction beam is rolled under the car frame in such a way that the jack bogies, when lifting, are in reliable contact with the lower supporting surfaces of the correction beam, and the support is located under the longitudinal beams of the car frame. Using the control panel, the jack bogies are raised until they touch the lower supporting surfaces of the corrective beam. Then the corrective beam on the jack bogies is raised until it touches the longitudinal beams of the frame with its support. The car frame is given the required buckling by further raising the corrective beam with jack bogies. After that, a technologically determined number of mobile screw jacks is installed under the side rail, pushing them between the floor and the lower surface of the side rail to obtain the required profile of the longitudinal bend of the car frame. By holding the frame elements in predetermined positions with grips and screw jacks, the required buckling profile of the car frame is maintained, including when rearranging the jacks and the corrective beam. Then, the side and end walls of the car body are sequentially installed and fixed, imparting rigidity to the frame and the entire structure of the car body as a whole as the side and end walls of the car body are welded to the frame. The mobile screw jacks and grips are dismantled, the jack carriages together with the corrective beam are lowered to the floor level, the corrective beam is removed from under the car, the grips are removed.

EFFECT: providing the possibility of imparting straightness or a given deflection to frames of cars and keeping them in the required state for carrying out the necessary assembly operations.

5 cl, 7 dwg

Description

The claimed invention relates to the field of car building and concerns a method for assembling car bodies with frames of low rigidity.

The technical problem lies in the fact that the currently manufactured frames of some cars, in particular refrigerated cars, have a relatively long length (about 20 meters), while the main load-bearing elements in their design are two longitudinally located (I-beams) beams. Because of this, the frames of such cars have relatively low rigidity in the longitudinal direction and sag significantly under the action of their own weight. The rigidity of the body of such a car is provided by connecting the side and end walls with the frame.

Based on the foregoing, it became necessary to create a method for assembling car bodies with frames of low rigidity, as well as to make the frames of such cars straight or given deflection required for assembling the car body.

The technical result, to which the claimed invention is directed, is to provide the possibility of imparting straightness or a given deflection to the frames of the cars and keeping them in the required state for the necessary assembly operations.

From the prior art (author's certificate for invention No. 846208, application No. 2849115, dated 08.31.1979, published on 07.15.1981, bull. No. 26), a method for assembling the car body is known, carried out as follows: the working bodies of the stand are in their original position, with at the same time, all clamps are retracted, the upper base stops are raised to a vertical position, the mobile platforms are in the extreme divorced position; the frame of the body is installed on the frame and pressed with clamps, the hinged stops are rotated and laid on the surface of the body frame; the side wall of the body is started from the side of the fixed racks, installed on the frame, touching the lower trim with additional base stops and the end of the trim in the folding stop; the working bodies of the stand return to their original position, the assembled body is removed from the stand.

Also from the prior art (author's certificate for invention No. 1757835, application No. 4910964 dated 12/17/1990, published: 08/30/1992. bull. No. 32) there is a method of assembly for welding cars, carried out as follows: the platforms are in the upper position, the body the car mounted on bogies is fed along the railway track to the stand for assembly and welding and fixed with a stop mechanism, air is supplied to the hydraulic cylinders and the platforms are lowered to the lower position, the roof of the car is fed into the body by an overhead crane and installed on the body, to align the wall of the body and fit for welding with a roof on the platforms, supports with swinging grips are installed on the platforms; after the roof is welded to the car body, the screw clamps are released and folded back, the screw jacks are released, the platforms are raised to the highest position and fixed, the car lock is removed and the car rolls out of the stand.

Also, from the prior art (RF patent for utility model No. 89440 application 2009125168/22, dated 06/30/2009, application publication date: 12/10/2009 Bull. No. 34), a method for assembling and welding car frames is known, carried out as follows: all basing and the clamping devices are in the initial (retracted) position, the conductors are set by means of clamps on the base fixing boxes at distances corresponding to the distances between the axes of the transverse beams of the frame of the universal platform and are fixed on the rails with bolted connections; on the supporting elements of the conductors, the locating and clamping devices are mounted in the initial positions corresponding to the frame of the universal platform during its assembly and welding in an inverted position, with the help of hoisting and transport vehicles, the center beam is laid on the conductors; coaxial position of the center beam relative to the longitudinal axis of the stand is provided by centralizers mounted on the conductors of the frontal beams; on the control panel by pressing the button "Spinal beam clamp" include pneumatic cylinders, the spinal beam is fixed on all the mentioned conductors; then, step by step, the assembly of the main beam with transverse beams and side rails of the frame is performed, jack beams are laid on the plates of the conductors of the intermediate beams and the jack beams are fixed in vertical and horizontal positions by pneumatic cylinders of clamps; side straps are laid on the plates and plates of the corresponding conductors; clamps fix the position of the side straps on the stops on the corresponding conductors. The lower sheets of the frontal beams are laid on the conductors and the frontal beams are fixed with clamps in a vertical position. Further, saturation elements (sheets, scarves, linings, struts, etc.) are installed on the frame beams and the frame is welded in conductors. The assembly of the platform frames for the transportation of cars or a gondola car is carried out at the stand after the appropriate rearrangement of the conductors on the basis of the readjustment of the basing and clamping devices on them. On the control panels, the "Open All" button is pressed and the pneumatic actuators return to their original position all the working bodies of the locating and clamping devices.

In addition, from the prior art (author's certificate for invention No. 1276473 application 3524135, dated 12/20/1982, publication date of the application: 12/15/1986 bul. No. 46), a method for assembling and welding gondola cars is known, carried out as follows: front racks mounted on the base they are arranged symmetrically to the longitudinal axis, supports are placed between the posts, the frame of the gondola car is mounted on bogies and fed along the guides into the device, the mechanisms for installing and fixing the frame rigidly fix it. The side wall is installed in such a way that the lower trim rests on the frame beam and the soles of its uprights approximately coincide with the platforms of the corresponding beams, and the upper trim rests on the upright bodies, while ensuring the "collapse" of the wall with a vertical inclination angle of 3-5 degrees. The end walls are sequentially fed and installed above the lower trims on the front beams of the frame.

After the installation of the end walls, the mechanisms for capturing the side wall by the upper trim select the "collapse" of the walls. In this case, the frame and wall elements are fixed between the base elements. After welding is completed, all elements are turned off and the finished gondola car rolls out of the device.

The described method, according to the Applicant, is the closest analogue (prototype) of the claimed method of assembling car bodies with frames of low rigidity.

The disadvantage of the above well-known methods is the inability to impart straightness to the frame of the car or the required buckling profile when assembling the body.

The essence of the claimed invention is illustrated by graphic materials in figures 1÷7:

Figure 1 - Complex for implementing the method of assembling car bodies with frames of low rigidity (general view with a frame on bogies);

Figure 2 - Complex for implementing the method of assembling car bodies with frames of low rigidity (general view with a frame without bogies);

Fig.3 - Capture;

Fig.4 - Correction beam;

Fig.5 - Jack;

Fig.6 - Mobile screw jack;

Fig.7 - Possible options for the longitudinal bending of the car frame.

The complex for implementing the method of assembling car bodies with frames of low rigidity (figure 1, figure 2) consists of: grips 1, corrective beam 2, two jacks 3, mobile screw jacks 4.

Clamps 1 are designed to hold at predetermined points and limit the movement of the car frame upwards. Their device is shown in Fig.3. Capture 1 consists of the following main elements: rail 5 fixed on the foundation, paws 6 fixed on the transverse beam of the car frame and turnbuckle 7 connecting paws 6 with rail 5 and designed to select gaps and create a preload during fixation. The number of grips used is at least four and is determined by the buckling profile of the car frame.

Correction beam 2 is a prefabricated welded structure. Its device is shown in Fig.4. The correcting beam 2 consists of a stop 8 mounted on a frame 9, to which four wheels 10 are also fixed. Two handles 11 are provided for the convenience of moving the beam.

The design of the jack is shown in Fig.5. Jack 3 consists of base 12, carriage 13, guides 14, drive 15, end position sensors 16 and 17, contact sensor 18 with corrective beam 2, lugs 19, screw 20, frame 21. The jack operates on the principle of screw transmission, namely: the carriage 13 contains inside a hinged nut (not shown), which, when the screw 20 is rotated, moves up or down the screw together with the carriage 13.

The mobile screw jack 4 is made in the form of a prefabricated welded structure. Its device is shown in Fig.6. The screw jack consists of a body 22 with wheel supports 23 fixed on it. A screw 24 is screwed into the threaded hole of the body. The number of screw jacks is used at least four and is determined by the buckling profile of the car frame.

Possible variants of the buckling of the car frame (figure 7) are provided by holding the frame elements in the given positions with the grips 1 and screw jacks 4, including when rearranging the jacks 3 and the corrective beam 2.

The method is carried out as follows.

Two jacks 3 are placed in their original position relative to the track with the carriages 13 lowered down. The car frame is moved to the assembly position along the rails on bogies (in the private version on technological bogies) and stopped in such a way that its ends are equidistant relative to the jacks 3. The grippers are fixed 1 with the help of paws 6 on certain sections of the car frame (in a particular embodiment, the number of grippers is used at least four and this number is determined by the profile of the buckling of the car frame). Using turnbuckles 7, the frame is tightly pulled to the carts (in the private version, to pre-installed screw jacks 4). If necessary, in a particular embodiment of the method, at least four mobile screw jacks 4 are preliminarily installed. Then the corrective beam 2 is rolled under the car frame so that the carriages 13 of the jacks 3 during lifting are in reliable contact with the lower supporting surfaces of the corrective beam 2, and stop 8 was under the longitudinal beams of the car frame. Using the control panel (not shown), the carriages 13 of the jacks 3 are raised until they touch the lower supporting surfaces of the corrective beam 2, and then the corrective beam 2 itself on the jack carriages is raised until it touches with its stop 8 longitudinal beams of the frame. Next, the frame of the car is given the required longitudinal bending by further lifting the corrective beam 2 by carriages 13 of jacks 3 (in a particular embodiment of the method, the frame of the car is given a longitudinal bend by further lifting of the corrective beam 2 by carriages 13 of jacks 3). After that, a technologically determined number of mobile screw jacks 4 is installed under the side trim of the car frame (in a particular embodiment of the method, under the transverse beams of the car frame), bursting them between the floor and the lower surface of the side trim to obtain the desired profile of the longitudinal bend of the car frame. In a particular embodiment of the method, if necessary, to achieve the desired profile of the buckling of the car frame, the carriages 13 of the jacks 3, together with the corrective beam 2, are lowered to the floor level, the corrective beam 2 is removed from under the car and, together with the jacks 3, is moved along the frame to another the place where the re-ascension takes place. Preservation of the required profile of the longitudinal bending of the car frame, including when rearranging the jacks 3 and the corrective beam 2, is ensured by holding the frame elements in the specified positions with the grippers 1 and screw jacks 4. Then, the side and end walls of the car body are sequentially installed and fixed, giving the frame and the whole structure of the car body as a whole rigidity. As the side and end walls of the car body are welded to the frame, the mobile screw jacks 4 and grips 1 are dismantled, the carriages 13 of the jacks 3 together with the corrective beam 2 are lowered to the floor level, the corrective beam is removed from under the car, the grips 1 are removed, the car is moved to next position.

The claimed invention is used in the workshops of the car assembly production of the JSC "Scientific and Production Corporation "Uralvagonzavod" and has confirmed its technical and economic efficiency.

Claims (5)

1. A method for assembling car bodies with frames of low rigidity, including the location of two jacks in the initial position relative to the track with the carriages lowered down, moving the car frame to the assembly position along the rails on bogies and installing it in such a way that the ends of the frame are equidistant relative to the jacks, fixing the grippers with paws on certain sections of the car frame, tightly pulling the frame to the bogies by means of lanyards, then rolling the corrective beam under the car frame so that the jack carriages when lifting are in reliable contact with the lower supporting surfaces of the corrective beam, and the stop is under the longitudinal car frame beams, after which, using the control panel, the jack carriages are raised until they touch the lower supporting surfaces of the corrective beam, then the corrective beam on the jack carriages is raised until it touches the longitudinal beams of the frame with its emphasis, the car frame is given the required longitudinal bending by further lifting the correcting beam with jack carriages, after that, a technologically determined number of mobile screw jacks is installed under the side rail, bursting them between the floor and the lower surface of the side rail to obtain the required longitudinal bending profile of the car frame, holding the frame elements in predetermined positions with grips and screw jacks ensure the preservation of the required profile of the buckling of the car frame, including when rearranging the jacks and the corrective beam, then sequentially install and fix the side and end walls of the car body, giving the frame and the entire structure of the car body as a whole rigidity as the side and end walls of the car body are welded to the frame, the mobile screw jacks and grips are dismantled, the jack carriages together with the corrective beam are lowered to the floor level, the corrective beam is removed from under the car, the grips are removed. 2. The assembly method according to claim 1, characterized in that at least four mobile screw jacks are pre-installed. 3. Assembly method according to claim 1, characterized in that at least four grips are used. 4. The assembly method according to claim 1, characterized in that a technologically determined number of mobile screw jacks is installed under the transverse beam, bursting them between the floor and the lower surface of the transverse beams. 5. The assembly method according to claim 1, characterized in that in order to achieve the required profile of the longitudinal bending of the car frame, the jack carriages together with the corrective beam are lowered to the floor level, the corrective beam is removed from under the car and, together with the jacks, are rearranged along the frame to another place, where the resurfacing takes place.

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