WO2016124022A1 - 一种轨道车辆电气线束的设计及制作方法 - Google Patents

一种轨道车辆电气线束的设计及制作方法 Download PDF

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Publication number
WO2016124022A1
WO2016124022A1 PCT/CN2015/094110 CN2015094110W WO2016124022A1 WO 2016124022 A1 WO2016124022 A1 WO 2016124022A1 CN 2015094110 W CN2015094110 W CN 2015094110W WO 2016124022 A1 WO2016124022 A1 WO 2016124022A1
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Prior art keywords
harness
manufacturing
module
wiring
vehicle
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PCT/CN2015/094110
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English (en)
French (fr)
Inventor
董力群
侯秀芳
高月欣
赵婷婷
张善霞
桑占良
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CRRC Qingdao Sifang Co Ltd
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CRRC Qingdao Sifang Co Ltd
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    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2113/00—Details relating to the application field
    • G06F2113/16—Cables, cable trees or wire harnesses

Definitions

  • the invention relates to a design and a manufacturing method of an electric wire harness, in particular to a design and a manufacturing method of an electric wire harness for a rail transit vehicle.
  • the existing rail transit vehicles mainly include different series of vehicles such as EMUs, urban rail vehicles, railway passenger cars and light rails.
  • the electrical systems and structures have certain differences. Even if it is a train group, the vehicles in the group are different due to different functions.
  • the structure-to-electrical system setting has certain commonalities, but there are also some differences. Take the 8-group high-speed rail or motor train that is commonly used now as an example. From the perspective of car interior grouping and structural arrangement: there are drivers at both ends.
  • the head car of the room, the middle car has the same function according to different functions: one-seat car, second-class car, dining car, car with pantograph, car with toilet, car with mechanic room, etc.;
  • the electrical design of each car is usually carried out separately for each type of car. Therefore, there are also big differences in the design and manufacture of electric harnesses.
  • There are electrical harness wiring designs and The construction standards are not uniform and the construction quality is unstable.
  • the electric wire harness design and the supporting production method are separately applied to the car body of different structures, it takes time and labor, affects the research and development and production progress, and cannot form an effective one. Research and development heritage.
  • the main purpose of the present invention is to solve the above problems and deficiencies, and to provide an electric railway vehicle with an effective specification and improvement of electric line construction standards and quality, and improvement of research and development and production efficiency.
  • the design and production method of the wire harness is to solve the above problems and deficiencies, and to provide an electric railway vehicle with an effective specification and improvement of electric line construction standards and quality, and improvement of research and development and production efficiency.
  • a method and a method for manufacturing an electric harness for a railway vehicle comprising the following steps:
  • Step 1 Collect the basic information of the rail vehicle, and organize the data of the common features and the main differences in the basic information according to the electrical information, structural layout of the vehicle and the structural information of each vehicle.
  • the vehicles and parts with similar layouts on the vehicle and the structure of the vehicle are modularized or merged, and the basic data is collected and sorted during the process design planning to understand the commonality and characteristics of the entire vehicle. Consolidate data with commonality for similar design planning and production, and provide witness information for R&D heritage.
  • Step 2 Based on the vehicle structure layout, combined with the product manufacturing process flow and construction sequence, the wiring harness of the whole vehicle is divided according to the data information of step 1 to distinguish different wire harness modules.
  • the module division of the whole vehicle harness is beneficial to the subsequent development and production advancement.
  • Step 3 Perform wire harness design according to the characteristics of the different wire harness modules.
  • the wiring harness of the whole vehicle is divided into modules, and the same harness design is performed for the common wiring harness in the vehicle body of different structures, and the harness design is not required for each vehicle body, which can shorten the development time. Cheng.
  • step 4 a method of making a selectable harness is determined.
  • Step 5 The designed harness is selected according to the characteristics of the harness.
  • the same manufacturing method is carried out, and it is not necessary to separately consider the design and manufacturing method of the wire harness when designing each car body, and can be simultaneously produced, which can minimize the content of the current car wiring work, reduce the construction time, Shorten the occupancy of the station and improve the construction quality.
  • the basic information includes:
  • Vehicle grouping information information on the division of the same series of vehicles, system information of the entire group layout, and structural information;
  • Electrical system information electrical schematic diagram of the entire vehicle, principle of each electrical subsystem and wiring diagram information.
  • harness module divided in step 2 includes:
  • the harness module When setting the harness module, it is divided into a comprehensive angle, and the common harnesses are arranged into one module, which is conducive to the subsequent design and construction. At the same time, the formation of relevant documents is conducive to the development of inheritance.
  • the manufacturing method in the step 4 includes:
  • the wire harness has a long length, is laid in the wire trough, and the wire harness having a fixed branch line position and a wire diameter of less than 14 mm 2 is pre-prepared by a 1:1 wire harness plate.
  • Group operation method
  • the wire diameter is small, the wire harness is concentrated, and the outlet position is large.
  • the wire harness is used, and the wire harness platform pre-group mode operation method is adopted;
  • the wire diameter is large, the wire harness is concentrated, and is laid in the wire trough.
  • the middle part does not need to thread the wire harness for threading, and the large-line automatic material feeding, the line groove layering laying, and the centralized binding and fixing the wire trough pre-group mode operation method;
  • the wiring of the part wiring is concentrated, and the wiring harness in which the branch line is dispersed is in the current vehicle wiring mode operation method.
  • Wiring harnesses with different structural characteristics are suitable for different design and manufacturing methods to improve the quality of harness design and production.
  • the driver cab wiring is performed by using a loose line, and the small harness is pre-assembled by a pre-group mode operation method.
  • the wiring harness in the passenger room is fabricated by using a pre-group mode of the wire harness platform and a pre-grouping method of the 1:1 wire harness chart; the switchboard and the end wiring are based on The characteristics of the harness module are respectively fabricated by a partial harness platform pre-group mode operation method and/or a current vehicle wiring mode operation method.
  • the under-voltage low-voltage circuit wiring module adopts a 1:1 wire harness drawing pre-grouping method to fabricate the wire harness, and pre-groups each wire harness in advance in the line slot; the under-high voltage loop wiring module The single-line blanking operation is carried out, and the wire harness platform pre-group mode operation method is performed in advance to perform the process production.
  • the same wiring harness module with the same structural characteristics adopts the same design and manufacturing method.
  • the same wiring harness module can cooperate with various manufacturing methods due to different wire harnesses, which can effectively improve the construction quality and ensure the electrical safety of the entire vehicle.
  • the basic data is collected and sorted first, the commonality and characteristics of the whole group of vehicles are understood, and the common data is merged to perform similar design. Plan and adopt the same production method and provide witness information for R&D heritage.
  • the module division of the whole vehicle's wiring harness is beneficial to the subsequent development and production promotion.
  • the same wiring harness design is carried out for the common wiring harness in different structures of the vehicle body, and it is not necessary to target each vehicle.
  • the wire harness design of the body can shorten the development time.
  • the same type of wire harness module in different car bodies the same production method, no need to consider the wire harness manufacturing method when designing each car body, and can be produced at the same time, can minimize the current car wiring operation Content, reduce construction time, shorten the occupancy of the station, and improve construction quality.
  • the division is comprehensive and comprehensive, taking full account of the common data information in the basic information, and sorting the common wiring harness into one module, which is conducive to the subsequent design and construction.
  • the formation of relevant documents is conducive to the development of inheritance. Wiring harnesses with different structural characteristics are suitable for different design and manufacturing methods to improve the quality of harness design and production.
  • the same wiring harness module with the same structural characteristics adopts the same design and manufacturing method.
  • the same wiring harness module can cooperate with various manufacturing methods due to different wire harnesses, which can effectively improve the construction quality and ensure the electrical safety of the entire vehicle.
  • the invention determines the design and manufacturing method of the electric harness by analyzing the electrical system and structural characteristics of the rail vehicle. Form the system standard design and production methods to ensure the accuracy of the line and the construction standards, effectively standardize and improve the electrical line construction standards and quality, improve production efficiency, and at the same time form a research and development heritage, shorten the development time.
  • the main purpose of the present invention is to solve the problems and deficiencies in the design and manufacture process of the existing railway vehicle electrical harness, and to provide an electric harness for a rail transit vehicle which can effectively standardize and improve the construction standard and quality of the electric circuit and improve the research and development and production efficiency. Design and production methods.
  • the invention provides a method for designing and manufacturing an electric harness for a railway vehicle, comprising the following steps:
  • Step 1 Collect basic information of the rail vehicle, and organize data information of common characteristics and main differences in the basic information according to the electrical information of the vehicle, the structural layout, and the structural information of each vehicle;
  • the basic information that needs to be collected includes:
  • the rail transit vehicle is designed as an electric wiring process design, and the same series of vehicles are divided, such as motor car (M car), motor car (Mc) with driver's cab, trailer (T car), trailer with driver's cab (Tc) .
  • M car motor car
  • Mc motor car
  • T car trailer
  • Tc driver's cab
  • grouping diagram structure layout drawing, main equipment layout drawing under the car, etc.
  • roof interior, under the car
  • vehicle end structure layout, equipment layout, electrical circuit layout, etc.
  • the EMUs are listed as the design of the electric wiring process, and the same series of vehicles are divided, such as the motor car (M car), the motor car (Mc) with the driver's cab, the trailer (T car), and the trailer with the driver's cab (Tc).
  • M car motor car
  • Mc motor car
  • T car trailer
  • Tc trailer with the driver's cab
  • the EMU includes four motor trains (M cars), two trailers (T cars), and one trailer at each end of the trailer (Tc) with a driver's cab.
  • M cars motor trains
  • T cars trailers
  • Tc trailer at each end of the trailer
  • Tc1/Tc2 cab layout, system structure, electrical system and wiring arrangement are 180° symmetrically similar;
  • M1-M2-T4-M3-M4 interior layout structure and electrical system and line layout are similar;
  • M1 and M3, M2 and M4, T3 and T4 are similarly arranged under the car;
  • the vehicles and parts with similar layouts on the vehicle and the structure of the vehicle are modularized or merged, and the basic data is collected and sorted during the process design planning to understand the commonality and characteristics of the entire vehicle. Consolidate data with commonality for similar design planning and production, and provide witness information for R&D heritage.
  • Step 2 Based on the vehicle structure layout, combined with the product manufacturing process flow and the construction sequence, the wiring harness of the whole vehicle is module-divided according to the data information described in step 1, and different harness modules are distinguished.
  • Pre-grouping module for the wiring harness of the passenger compartment of the vehicle b. Pre-grouping module for the wiring harness of the passenger compartment of the vehicle;
  • the module of the whole vehicle is divided into modules, which provides the basis for the subsequent development and production promotion.
  • Step 3 Integrate the characteristics of each harness module to perform harness design separately.
  • the wiring harness of the whole vehicle is divided into modules according to step 2, and the same harness design is performed for the common wiring harness in the vehicle body of different structures, and no separate harness design is required for each vehicle body. Can shorten the development schedule.
  • step 4 a method of making a selectable harness is determined.
  • the selectable manufacturing methods include: 1: 1 harness panel pre-grouping method, harness platform pre-group mode operation method, trunking pre-group mode operation method, and current vehicle wiring mode operation method. among them:
  • the wire harness that is laid in the wire trough and the middle part does not need to be threaded through the pipe, and adopts the wire line pre-group mode in which the large line is automatically cut, the line groove is layered, and the line is fixed and fixed.
  • the position where the branch line is dispersed is taken in the mode in which the vehicle is laid.
  • Wiring harnesses with different structural characteristics are suitable for different design and manufacturing methods to improve the quality of harness design and production.
  • Step 5 The designed harness is selected according to the characteristics of the harness.
  • each wire harness selects a suitable manufacturing method and a construction operation mode according to the wire harness characteristics in the manufacturing method in the step 4:
  • the wire harness module and the wire harness of each part in the module can be fabricated and constructed. for:
  • the cab space is small, the equipment is densely arranged, the line type is various, the wiring harness is widely distributed, and the equipment interface is many.
  • the cab wiring harness of the cab is continuously collected into a large harness by the small harness, so it is necessary to carry out the loose wire feeding and the small wire harness under the vehicle. Pre-wire bundle pre-group.
  • the wiring harness in the passenger interior includes the pre-installation module of the toilet and the wiring harness between the boxes, the pre-assembly module of the wiring compartment of the passenger compartment, the wiring module in the floor, the pipeline module on the vehicle, the module of the passenger compartment, and other functional area modules.
  • the line tube mode, the number of wire diameters, the ends of the wire harness, and the branch points are relatively small. Therefore, the wire harness pre-group and the 1:1 wire harness pattern are used.
  • the switchboard and end wiring include the wiring harness module between the switchboard and the end wiring harness module. Because the switchboard is the functional area for the convergence and distribution of the electrical system lines, multiple wirings under the vehicle, passenger compartment, and end are concentrated on the distribution panel. And the end area, so the area is complicated, the harness is concentrated, but the line is divided.
  • the wiring harness fixing method adopts the method of fixing the wire frame of the vehicle body. Therefore, the wiring of this area is mostly adopted by the partial wiring pre-group and part of the existing vehicle wiring. .
  • the low-voltage circuit under the vehicle is mostly the wiring route for the centralized control of the electric control system of the whole train.
  • the cable bundle is dense, the wire diameter is small, the through-line is many, the wire harness distribution is clear and accurate, the equipment position is fixed, and the accuracy is high. It is suitable for centralized planning and design of the wire harness, and adopts the 1:1 wire harness pattern and advances the wires in advance. Pre-set in the tank.
  • the high-voltage circuit under the vehicle is mostly the wiring route laid by the electric train system of the whole train. Compared with the characteristics of the low-voltage circuit harness, it has the large diameter of the wire, which is suitable for single-line blanking operation and pre-grouping of the wire bundle in advance.
  • the similar structure and connection mode are combined to reduce unnecessary duplication.
  • the same wiring harness module with the same structural characteristics adopts the same design and manufacturing method.
  • the same wiring harness module can cooperate with various manufacturing methods due to different wire harnesses, which can effectively improve the construction quality and ensure the electrical safety of the entire vehicle.
  • the same manufacturing method is carried out, and it is not necessary to separately consider the manufacturing method of the wire harness when designing each car body, and it can be produced at the same time, which can minimize the content of the current car wiring work, reduce the construction time, and shorten the station. Position occupancy, improve construction quality.
  • the basic data is collected and sorted first, the commonality and characteristics of the whole group of vehicles are understood, and the common data is merged to perform similar design. Plan and adopt the same production method and provide witness information for R&D heritage.
  • the module division of the whole vehicle's wiring harness is beneficial to the subsequent development and production promotion.
  • the same wiring harness design is carried out for the common wiring harness in different structures of the vehicle body, and it is not necessary to target each vehicle.
  • the wire harness design of the body can shorten the development time.
  • the same type of harness module in different body bodies performs the same
  • the production method does not need to consider the manufacturing method of the wire harness separately when designing each car body, and can be simultaneously produced, which can minimize the content of the current car wiring operation, reduce the construction time, shorten the occupancy of the table, and improve the construction quality.
  • the division is comprehensive and comprehensive, taking full account of the common data information in the basic information, and sorting the common wiring harness into one module, which is conducive to the subsequent design and construction. .
  • the formation of relevant documents is conducive to the development of inheritance.
  • Wiring harnesses with different structural characteristics are suitable for different design and manufacturing methods to improve the quality of harness design and production.
  • the same wiring harness module with the same structural characteristics adopts the same design and manufacturing method.
  • the same wiring harness module is matched by different harnesses. A variety of production methods can effectively improve the construction quality and ensure the electrical safety of the entire group of vehicles.
  • the invention determines the design and manufacturing method of the electric harness by analyzing the electrical system and structural characteristics of the rail vehicle, forms a system standard design and manufacturing method, ensures the accuracy of the line and the consistency of the construction standard, effectively standardizes and improves the electric line construction standard and Quality, improve production efficiency, and at the same time form a research and development heritage, shortening the development time.

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Abstract

一种轨道车辆电气线束的设计及制作方法，主要目的在于解决现有轨道车辆电气线束在设计及制作过程中的问题和不足，提供一种根据轨道车辆的基础信息，对车辆的电气线束进行模块化分，对不同的线束模块分别进行设计及制作，可以有效规范和提升电气线路施工标准和质量，提高研发和生产效率的适合轨道交通车辆电气线束的设计及制作方法。

Description

一种轨道车辆电气线束的设计及制作方法
本申请要求于2015年02月04日提交中国专利局、申请号为201510059008.X、发明名称为“一种轨道车辆电气线束的设计及制作方法”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本发明涉及一种电气线束的设计及制造方法，尤其是一种轨道交通车辆电气线束的设计及制作方法。
背景技术
现有轨道交通车辆主要包括动车组、城轨车辆、铁路客车和轻轨等不同系列车辆，电气系统及结构存在一定的差异性，即使是一列车组，由于功用不同，其编组内的各车从结构到电气系统的设置在具有一定共性的同时也存在有一定差异，以现在普遍的使用的8编组高铁或动车为例，从车内编组及结构布置角度来说：有两端均设置带司机室的头车，中间车根据功能不同有一等座车、二等座车、餐车、带受电弓的车、带卫生间的车、带机械师室的车等等形式；从车下设备布置角度来说，动车和拖车的车下设备布置存在共性和差异。因此每节车厢在电气设置也会有所不同，对于各种车型的电气设计，通常是针对每一种车型分别进行，因此对于电气线束设计及制作也存在较大差异，存在电气线束布线设计及施工标准不统一、施工质量不稳定的问题，而且，如果针对不同结构的车体，分别进行电气线束的设计及配套的制作方法，耗时耗力，影响研发和生产进度，也不能形成有效的研发传承。
由于存在上述缺点，这种轨道交通车辆的电气线束设计及制作方法亟需改进。
发明内容
本发明主要目的在于解决上述问题和不足，提供一种可以有效规范和提升电气线路施工标准和质量、提高研发和生产效率的轨道交通车辆电气 线束的设计及制作方法。
为实现上述目的，本发明的技术方案是：
一种轨道车辆电气线束的设计及制作方法，包括如下步骤：
步骤1，收集轨道车辆的基础信息，根据车辆的电气信息、结构布局及各车辆的结构信息，整理基础信息中共性特点和主要差异的数据信息。
因此针对整列车或一个编组单元，对于车上、车下结构布局类似的车型及部位进行模块化划分或合并，在工艺设计规划时进行基础数据的收集与整理，了解整组车辆的共性和特性，对有共性的数据进行合并整理，以进行类似的设计规划及制作，同时为研发传承提供见证资料。
步骤2，以车辆结构布局为基础，结合产品制造工艺流程和施工顺序，根据步骤1的数据信息对整车的线束进行模块划分，区别出不同的线束模块。
根据步骤1中的共性和特性数据信息，对整车的线束进行模块划分，有利于后续的研发和生产的推进。
步骤3，根据所述不同线束模块的特点分别进行线束设计。
根据步骤1中的共性和特点数据信息，对整车的线束进行模块划分，对于不同结构的车体中的共性线束进行相同的线束设计，无需针对各车体分别进行线束设计，可以缩短研发时程。
步骤4，确定可选择的线束制作方法。
步骤5，设计好的线束根据线束特点选择适用的制作方法。
对于相同类型的线束模块，进行相同的制作方法，无需在设计每个车体时分别考虑线束的设计及制作方法，并且可以同时生产，可以最大程度减少现车配线作业内容，降低施工时间、缩短台位占用，提高施工质量。
进一步的，所述基础信息包括：
车辆编组信息：同系列车型划分信息、整列编组布局系统信息、结构信息；
电气系统信息：整列车辆的电气原理图、各电气子系统原理及布线图信息。
进一步的，步骤2中划分的线束模块包括：
1)司机室模块
2)车上模块
3)车下模块
4)车端模块
不同车型，存在一定差异，在设定线束模块时，以综合全面的角度进行划分，将有共性的线束整理成一个模块，有利于后续的设计及制作施工。同时形成相关文件，有利于研发传承。
进一步的，所述步骤4中的制作方法包括：
1：1线束图板预组作业法
线束平台预组模式作业法
线槽预组模式作业法
现车布线模式作业法
进一步的，根据已设计好的各线束的特点，选用适合的制作方法：线束长度长，敷设于线槽，分支线出线位置固定、线径小于14mm2以下的线束采用1：1线束图板预组作业法；
线径小，线束部位集中，出线位置多，采用细化线束，线束平台预组模式作业法；
线径大，线束集中，敷设于线槽，中间部位不需要穿线穿管的线束，采用大线自动下料，线槽分层敷设、集中绑扎固定的线槽预组模式作业法；
部位布线量集中，分支线出现位置分散的线束采用现车布线模式作业法。
结构特点各不相同的线束，适用不同的设计及制作方法，以提高线束设计及制作的质量。
进一步的，所述司机室模块中，司机室配线采用散线下料，小线束车下提前线束平台预组模式作业法进行工艺制作。
进一步的，所述车上模块中，客室内线束采用线束平台预组模式作业法线路合1：1线束图板预组作业法进行工艺制作；配电盘及端部配线根据 线束模块特点分别采用部分线束平台预组模式作业法和/或现车布线模式作业法进行工艺制作。
进一步的，所述车下模块中，车下低压回路布线模块采用1：1线束图板预组作业法进行线束的工艺制作，并对各线束提前在线槽内预组；车下高压回路布线模块进行单线下料作业，提前进行线束平台预组模式作业法进行工艺制作。
进一步的，所述车端模块中，在设计过程中，根据端部的结构特点合并类似结构及连接方式。
结构特点相同的线束模块，采用相同的设计及制作方法，同一线束模块由于各线束的不同，配合多种制作方法，可以有效的提高施工质量，确保整组车辆的电气安全。
综上所述，在对轨道车辆线束进行设计及制作的过程中，首先进行基础数据的收集与整理，了解整组车辆的共性和特性，对有共性的数据进行合并整理，以进行类似的设计规划并采用相同的制作方法，同时为研发传承提供见证资料。根据步骤1中的共性和特性数据信息，对整车的线束进行模块划分，有利于后续的研发和生产的推进，对于不同结构的车体中的共性线束进行相同的线束设计，无需针对各车体分别进行线束设计，可以缩短研发时程。在研发时，不同车体中的相同类型的线束模块，进行相同的制作方法，无需在设计每个车体时分别考虑线束的制作方法，并且可以同时生产，可以最大程度减少现车配线作业内容，降低施工时间、缩短台位占用，提高施工质量。不同车型存在一定差异，因此在设定线束模块时，以综合全面的角度进行划分，充分考虑基础信息中的共性数据信息，将有共性的线束整理成一个模块，有利于后续的设计及制作施工。同时形成相关文件，有利于研发传承。结构特点各不相同的线束，适用不同的设计及制作方法，以提高线束设计及制作的质量。结构特点相同的线束模块，采用相同的设计及制作方法，同一线束模块由于各线束的不同，配合多种制作方法，可以有效的提高施工质量，确保整组车辆的电气安全。本发明通过对轨道车辆电气系统及结构特点分析，确定电气线束设计及制作方法， 形成系统标准的设计及制作方法，保证线路的准确性和施工标准的一致，有效规范和提升电气线路施工标准和质量，提高生产效率，同时形成研发传承，缩短研发时程。
具体实施方式
本发明主要目的在于解决现有轨道车辆电气线束在设计及制作过程中的问题和不足，提供一种可以有效规范和提升电气线路施工标准和质量，提高研发和生产效率的适合轨道交通车辆电气线束设计及制作方法。
本发明提供的一种轨道车辆电气线束的设计及制作方法，包括以下步骤：
步骤1，收集轨道车辆的基础信息，根据车辆的电气信息、结构布局及各车辆的结构信息，整理基础信息中共性特点和主要差异的数据信息；
需要收集的基础信息包括：
1、轨道车辆编组信息：
以轨道交通车辆整列为电气配线工艺设计对象，将同系列车型进行划分，如动车(M车)、带司机室的动车(Mc)、拖车(T车)、带司机室的拖车(Tc)。
根据整列编组系统信息(编组图、结构布局图、车下主要设备布置图等)，以及每个车型车顶、车内、车下、车端结构、布局、设备布置、电气线路布置等情况，将线路和结构相近的车型部位，进行划分，结构类似的情况进行合并。
2、电气系统信息：
根据项目整列电车辆的气原理图，确认各电气子系统原理及布线图。
以动车组整列为电气配线工艺设计对象，将同系列车型进行划分，如动车(M车)、带司机室的动车(Mc)、拖车(T车)、带司机室的拖车(Tc)。以200公里8编组动车组为例进行说明，此8编组动车组由以下车体组成：
Tc1--M1-M2-T3-T4-M3-M4-Tc2
动车组中包括动车(M车)4个、拖车(T车)2个、带司机室的拖车(Tc)两端各一个。其中，Tc1/Tc2车上、车下布局、系统结构、电气系统及线路布置具有相近；
Tc1/Tc2司机室布局、系统结构、电气系统及线路布置180°对称相似；
M1-M2-T4-M3-M4车内布局结构及电气系统及线路布置相近；
M1和M3、M2和M4、T3和T4车下布置相近；
收集整理并记录以上基础信息后，确认同一系统的共性特点和主要差异，并根据以上特点，以列为单元，统一进行最基础的框架模式构建系统的线束模块，便于后续工程化设计。
因此针对整列车或一个编组单元，对于车上、车下结构布局类似的车型及部位进行模块化划分或合并，在工艺设计规划时进行基础数据的收集与整理，了解整组车辆的共性和特性，对有共性的数据进行合并整理，以进行类似的设计规划及制作，同时为研发传承提供见证资料。
步骤2，以车辆结构布局为基础，结合产品制造工艺流程和施工顺序，根据步骤1所述的数据信息对整车的线束进行模块划分，区别出不同的线束模块。
因为不同车型，在结构和电气系统方面存在一定差异，因引在此以综合全面的角度将各线束划分成以下四大模块，每个大模块中根据线束位置或功用又可细分不同的小模块：
1)司机室模块
a、司机室线束模块；
2)车上模块
a、厕所及盒子间线束预组模块；
b、车上客室线槽线束预组模块；
c、地板中布线模块；
d、配电盘间线束模块；
e、车上管路模块；
f、客室包间模块；
g、其他功能间模块；
h、车内端部线束模块；
3)车下模块
a、车下低压回路线槽线束模块；
b、车下高压回路线槽线束模块；
c、车下管路模块；
d、车下空腔模块；
4)车端模块
a、端部LJB箱与车钩预组模块；
b、车外端部过桥线模块；
根据步骤1中的共性和特性数据信息，对整车的线束进行模块划分，为后续的研发和生产的推进提供基础。
步骤3，综合各线束模块的特点分别进行线束设计。
根据步骤1中的共性和特点数据信息，对整车的线束进行如步骤2中的模块划分，对于不同结构的车体中的共性线束进行相同的线束设计，无需针对各车体分别进行线束设计，可以缩短研发时程。
步骤4，确定可选择的线束制作方法。
现有制作方法有多种，不同的制作方法，适用于不同的线束，在本实施例中，根据已确认好的线束模块及各模块中的线束特点，确定可选择的制作方法包括：1：1线束图板预组作业法、线束平台预组模式作业法、线槽预组模式作业法、现车布线模式作业法。其中：
1)1:1线束图板预组作业法
对于线束长度长、敷设于线槽、分支线出线位置固定、线径小于14mm2以下的线束进行统一1:1线束图板工艺设计及作业模式。
2)线束平台预组模式作业法
对于线径小、线束部位集中，出线位置多，采用细化线束，人工平台预组的模式。
3)线槽预组模式作业法
对于线径大、线束集中，敷设于线槽、中间部位不需要穿线穿管的线束，采取大线自动下料、线槽分层敷设、集中绑扎固定的线槽预组模式。
4)现车布线模式作业法
对于部位布线量集中，分支线出现位置分散等位置采取现车敷设的模式。
结构特点各不相同的线束，适用不同的设计及制作方法，以提高线束设计及制作的质量。
由于这四种线束制作方法均为现有的常规技术手段，具体制作工艺和方法步骤在此不再赘述。
步骤5，设计好的线束根据线束特点选择适用的制作方法。
针对不同部位及线束模块及线束的特点，本发明实施例中各线束根据线束特点在步骤4中的制作方法中选择适用的制作方法及施工作业模式：
结合步骤2中已划分好的线束模块及各模块中各线束的特点及步骤4中制作及施工方法，在本实施例中，各线束模块及模块中各部位线束可采用的制作及施工方法可为：
1)司机室模块
司机室空间狭小、设备布置密集，线型种类繁多、线束分布广泛、设备接口多等特点，司机室配线线束由小线束不断汇集为大线束，因此需进行散线下料、小线束车下提前线束预组。
2)车上模块
a、客室内线束
客室内线束包括厕所及盒子间线束预装模块、车上客室线槽线束预组模块、地板中布线模块、车上管路模块、客室包间模块、其他功能区域模块，这些线束模块多采用线槽、线管模式，线径种类多、线束贯通两端、分支点相对较少，因此采用线束预组和1:1线束图板作业模式。
b、配电盘及端部配线
配电盘及端部配线包括配电盘间线束模块及车内端部线束模块，因配电盘为电气系统线路汇聚和分配的功能区，车下、客室、端部等多处配线集中汇聚于配线盘和端部区域，因此此区域线路复杂、线束集中但线路分路多，线束固定方式多采用车体固定线架的方式，因此此区域的布线多采用部分线束预组、部分现车布线的方式。
3)车下模块
a、车下低压回路布线
车下低压回路多为整列车电气控制系统线路集中敷设的布线路径，具 有线束密集、线径小、贯通线多，线束分布清晰准确，设备位置固定，准确率高等特点，适合进行线束的集中规划设计，同时采用1:1线束图板模式，并对各线束提前在线槽内预组。
b、车下高压回路布线
车下高压回路多为整列车电气动力系统线路集中敷设的布线路径，与低压回路线束特点比较，具有线径的大的特点，适合进行单线下料作业，提前进行线束预组作业。
4)车端模块
根据端部结构特点，合并类似的结构及连接方式，减少不必要的重复。
结构特点相同的线束模块，采用相同的设计及制作方法，同一线束模块由于各线束的不同，配合多种制作方法，可以有效的提高施工质量，确保整组车辆的电气安全。
对于相同类型的线束模块，进行相同的制作方法，无需在设计每个车体时分别考虑线束的制作方法，并且可以同时生产，可以最大程度减少现车配线作业内容，降低施工时间、缩短台位占用，提高施工质量。
在施工过程中，针对不同线束模块的设计及制作方法，要有不同的针对性措施，如：
1)明确预组模块与车辆线束的安装和电气接口关系，预留电缆长度，便于安装后的接线作业；
2)明确因施工顺序而必须提前装车的线束模块及范围，将线束提前组束；
3)其他根据具体的结构和施工特点确定灵活的便于施工的作业模式。
综上所述，在对轨道车辆线束进行设计及制作的过程中，首先进行基础数据的收集与整理，了解整组车辆的共性和特性，对有共性的数据进行合并整理，以进行类似的设计规划并采用相同的制作方法，同时为研发传承提供见证资料。根据步骤1中的共性和特性数据信息，对整车的线束进行模块划分，有利于后续的研发和生产的推进，对于不同结构的车体中的共性线束进行相同的线束设计，无需针对各车体分别进行线束设计，可以缩短研发时程。在研发时，不同车体中的相同类型的线束模块，进行相同 的制作方法，无需在设计每个车体时分别考虑线束的制作方法，并且可以同时生产，可以最大程度减少现车配线作业内容，降低施工时间、缩短台位占用，提高施工质量。不同车型存在一定差异，因此在设定线束模块时，以综合全面的角度进行划分，充分考虑基础信息中的共性数据信息，将有共性的线束整理成一个模块，有利于后续的设计及制作施工。同时形成相关文件，有利于研发传承。结构特点各不相同的线束，适用不同的设计及制作方法，以提高线束设计及制作的质量，结构特点相同的线束模块，采用相同的设计及制作方法，同一线束模块由于各线束的不同，配合多种制作方法，可以有效的提高施工质量，确保整组车辆的电气安全。
本发明通过对轨道车辆电气系统及结构特点分析，确定电气线束设计及制作方法，形成系统标准的设计及制作方法，保证线路的准确性和施工标准的一致，有效规范和提升电气线路施工标准和质量，提高生产效率，同时形成研发传承，缩短研发时程。
如上所述，结合所给出的方案内容，可以衍生出类似的技术方案。但凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (9)

  1. 一种轨道车辆电气线束的设计及制作方法，包括如下步骤：
    步骤1，收集轨道车辆的基础信息，根据车辆的电气信息、结构布局及各车辆的结构信息，整理基础信息中共性特点和主要差异的数据信息；
    步骤2，以车辆结构布局为基础，结合产品制造工艺流程和施工顺序，根据步骤1的数据信息对整车的线束进行模块划分，区别出不同的线束模块；
    步骤3，综合各线束模块的特点分别进行线束设计；
    步骤4，确定可选择的线束制作方法；
    步骤5，设计好的线束根据线束特点选择适用的制作方法。
  2. 如权利要求1所述的一种轨道车辆电气线束的设计及制作方法，其特征在于：所述基础信息包括：
    车辆编组信息：同系列车型划分信息、整列编组布局系统信息、结构信息；
    电气系统信息：整列车辆的电气原理图、各电气子系统原理及布线图信息。
  3. 如权利要求1所述的一种轨道车辆电气线束的设计及制作方法，其特征在于：步骤2中划分的线束模块包括：
    1)司机室模块
    2)车上模块
    3)车下模块
    4)车端模块。
  4. 如权利要求3所述的一种轨道车辆电气线束的设计及制作方法，其特征在于：所述步骤4中的制作方法包括：
    1：1线束图板预组作业法
    线束平台预组模式作业法
    线槽预组模式作业法
    现车布线模式作业法。
  5. 如权利要求4所述的一种轨道车辆电气线束的设计及制作方法，其特征在于：根据已设计好的各线束的特点，选用适合的制作方法：
    线束长度长，敷设于线槽，分支线出线位置固定、线径小于14mm2以下的线束采用1：1线束图板预组作业法；
    线径小，线束部位集中，出线位置多，采用细化线束，线束平台预组模式作业法；
    线径大，线束集中，敷设于线槽，中间部位不需要穿线穿管的线束，采用大线自动下料，线槽分层敷设、集中绑扎固定的线槽预组模式作业法；
    部位布线量集中，分支线出现位置分散的线束采用现车布线模式作业法。
  6. 如权利要求4所述的一种轨道车辆电气线束的设计及制作方法，其特征在于：所述司机室模块中，司机室配线采用散线下料，小线束车下提前线束平台预组模式作业法进行工艺制作。
  7. 如权利要求4所述的一种轨道车辆电气线束的设计及制作方法，其特征在于：所述车上模块中，客室内线束采用线束平台预组模式作业法线路合1：1线束图板预组作业法进行工艺制作；配电盘及端部配线根据线束模块特点分别采用部分线束平台预组模式作业法和/或现车布线模式作业法进行工艺制作。
  8. 如权利要求4所述的一种轨道车辆电气线束的设计及制作方法，其特征在于：所述车下模块中，车下低压回路布线模块采用1：1线束图板预组作业法进行线束的工艺制作，并对各线束提前在线槽内预组；车下高压回路布线模块进行单线下料作业，提前进行线束平台预组模式作业法进行工艺制作。
  9. 如权利要求4所述的一种轨道车辆电气线束的设计及制作方法，其特征在于：所述车端模块中，在设计过程中，根据端部的结构特点合并类似结构及连接方式。
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