城轨车辆一体式贯通道配套端墙结构设计及焊接工艺

Structural design and welding process of the end wall for one-piece gangway used on urban rail vehicle

阐述了一体式贯通道在城市轨道车辆中的应用及其机构组成、性能特点、安装方式和注意事项等方面的内容。针对一体式贯通道系统的安装要求,完成了车辆端墙结构的重新设计,并通过数值模拟的方法对电阻点焊接头剪切拉伸状态下焊点处应力分布进行分析,结合实际生产需要给出适合的焊接工艺以完成车体端墙结构的装配。结果表明,一体式贯通道优化了地铁车辆的美观度和实用性,数值模拟方法的应用能够有效评估点焊接头的承载能力,并可在实际生产中作为选择制定焊接工艺参数的有效依据,在积累城市轨道车辆设计经验的同时进一步提高了地铁车辆市场竞争力。

This paper illuminated the application on urban rail vehicles,constitution of the mechanism,performance characteristics,installation method and announcements of the one-piece gangway. The redesign of the end wall structure was completed in view of installation method of gangway. The stress distribution of resistance spot welding joint under shear tension condition was analyzed by the numerical simulation method. Combined with the actual production requirement,the suitable welding process was provided to complete the assembly of the end wall structure of urban rail vehicle. The results showed that the aesthetic extent and practicability of urban rail vehicles were optimized by adopting one-piece gangway. The bearing capacity of resistance spot welding joint could be effectively assessed by means of numerical simulation method,which provided effective basis for the selection of welding parameters. Thus,the design experience in the respect of urban rail vehicle can be accumulated and the market competitiveness is also further improved.