AEE intelligently manufactured rail transit car body friction stir welding equipment to help rail transit development

With the “eight verticals and eight horizontals” of the domestic high-speed rail network and the establishment of subways and intercity railways in major cities, the demand for rail transit car bodies such as subways, urban rails, high-speed rails, and high-speed rails has greatly increased. Friction stir welding is the key processing procedure of the main components of the rail car body-side walls and floor, which has a great impact on the production efficiency and quality of the car body.

AEE intelligent manufacturing, a new chapter in localization

In June 2019, Aerospace Engineering Equipment (Suzhou) Co., Ltd. successfully won the bid for the 16-meter side wall friction stir welding equipment of CRRC Zhuzhou Electric Co., Ltd. by virtue of its excellent technical strength and reasonable price. In September, AEE won the bid for the 60-meter ultra-long moving gantry friction stir welding equipment of CRRC again, and the large-scale high-end intelligent friction stir welding equipment in the rail transit field opened a new chapter in localization.

Previously, the relevant friction stir welding equipment used by major domestic OEMs was aging and inefficient, heavily dependent on imports, long maintenance periods, and difficult technical optimization. Mr. Yang Guoshun, general manager of AEE, said, “In the Pentium era, the older generations of Zhuzhou Machinery Plant used their youth to localize key rail transit technologies. In the 21st century, we will use our technology to localize the equipment that produces key rail transit components."

In August 2020, the large-span long-stroke moving gantry friction stir welding equipment developed by the equipment company for CRRC Zhuzhou Electric Locomotive Co., Ltd. was officially delivered for the welding production of rail transit car bodies.

Flexible and intelligent, feel comfortable welding

The production method and accuracy of the car body profile itself often result in unpredictable position changes of the weld of friction stir welding in the Y and Z directions. When the friction stir welding joint and the weld are offset, welding defects will occur . Traditional welding control requires the operator to follow the welding head and adjust the coordinate position of the welding head in the Y and Z directions in real time. With the upgrading of car body products, the length of car body parts continues to increase, and the difficulty and strength of manual adjustment are sharply increased. It is very easy to produce welding defects due to judgment or operation errors, and ultimately lead to a significant reduction in production efficiency.

In order to realize the intelligent automatic control of product welding, the long-span long-stroke moving gantry friction stir welding equipment adopts constant pressure control technology to automatically detect the welding depth and make adaptive adjustments to achieve automatic control of the welding depth in the Z direction; laser tracking and scanning technology Real-time detection of welding seam position, real-time automatic adjustment of welding Y-direction position; combined with CNC programming and one-key tool setting functions, complete one-key start welding, and realize automatic welding of rail train car body products. Highly flexible chemical equipment, the welding fixture can be adjusted through simple operation, and different products can be switched and clamped on the same tooling.

Aiming at the characteristics of intelligent and flexible friction stir welding of rail transit car bodies, the equipment has also developed a special friction stir welding operation interface. Users can implement equipment control, tooling switching, process changes, data traceability, etc. on this interface jobs. Using this intelligent interface, one-key start welding can be realized efficiently, bid farewell to the trouble of "adjust one equipment once for a product", and realize the real efficient and intelligent manufacturing of rail transit car body products.

Speed up and create efficiency, experience high-speed rail speed

It takes an average of 2 hours to weld a set of car bodies in the original car body production workshop, and one car body can be welded a day. With the rapid development of urban rail, the welding capacity of the car body workshop will quadruple on the original basis. The young designers of the equipment company took a multi-pronged approach to increase the equipment's rapid traverse speed from 3000mm/min to 30000mm/min, optimize the process parameters, and directly double the original welding speed of 1000mm/min to 2000mm/min. At the same time, change The manual clamping method in which the original product clamping time exceeds the welding time, and the automatic tooling dedicated for car body products, realizes one-key quick clamping of the product, so that the product is only 2-3 minutes of preparation time from positioning to starting welding. Far below the original 10-15 minutes.

The increase in welding speed and the automation of tooling, the increase in empty travel speed, the production efficiency of car body products has been shortened from the original 2 hours/piece to the fastest 0.8 hours/piece, and the welding production efficiency has soared.

We have many ways to speed up and create benefits!

Deformation control to produce high-end products

After the car body product is welded, the overall deformation can reach 10mm or more, which exceeds the maximum deformation allowed by the design. The workers are troubled by this. The traditional method is to increase the flame correction process to correct the product. The process is complicated, difficult, and low in efficiency, which seriously affects the production efficiency and quality of side wall panels and long floors. The large-span long-stroke moving gantry friction stir welding equipment utilizes the matching follow-up compression wheel, anti-deformation design of the tooling, welding pressure control and process parameter matching, and easily controls the post-welding deformation of the product within 3mm to meet the deformation requirements , Without orthopedics, product quality has been greatly improved.

Product quality control, we are professional!

The large-span and long-stroke moving gantry friction stir welding equipment developed by the equipment company has high-speed dynamic response, constant pressure control, automatic welding seam tracking, intelligent clamping system, welding parameter tracing system, and solves the problem of intelligent high-speed small deformation welding. The intelligent production of car body products has broken the situation that high-end intelligent equipment is imported and key technologies are stuck in the neck, and has successfully contributed to the rapid development of rail transit car body manufacturing.

At the awarding ceremony of the Space Information Industry Exhibition of the 22nd China International Industry Fair, the friction stir welding equipment for rail transit car bodies developed by Aerospace Engineering Equipment (Suzhou) Co., Ltd. won the Product Award of the 22nd China International Industry Fair Space Information Industry Exhibition .