Method of making light-weight chassis

FIELD: machine building.

SUBSTANCE: chassis is composed of 3D composite structure comprising bearing layers made up of thin-wall preforms to support reinforcing elements bound of binding compound. At least, one of said bearing layers is made bulky by forming stiffness ribs composed of bulged hemispheres regularly distributed over layer surface and connection two-layer stiffness ribs formed of preform sections not used in hemisphere formation. Remaining sections are used to make connection sites. Reinforcing elements represent twisted bundles of multi-fiber composite materials to be arranged between surfaces of stiffness elements. Rounded sections of bundles are located inside and around hemispheres to fill free space between stiffness elements with self-curing compound.

EFFECT: decreased weight and sizes, improved operating performances.

 

The invention relates to mechanical engineering and can be used in the design and manufacture of lightweight products, particularly those that include a large number of devices and links between them.

A known method of manufacturing a multilayer in which a pre-shirred filler inserted between sheet coverings and connect the casing with the filler by diffusion welding (see A.S. No. 177511149 A1, CL B23K 20/14).

Widespread technology of composite structures in which the materials for the reinforcement using glass, carbon, organic, boron, basalt fibers, and combinations thereof. Properties of composite products formed not only accessories, but also, to a large extent, its styling. Obtained and are finding increasingly widespread use of synthetic foam for different binders density 500-900 kg/m3and resistance RSG27-58 MPa, which are used where high specific stiffness and good adhesive properties (1).

As the prototype used a method of manufacturing composite articles in which the load-bearing layers are made of thin-walled workpieces are placed on them, reinforcing elements, and the free space between the bearing layers filled binder, obwolo ivyshim reinforcing elements, then binder utverjdayut, forming a mechanical connection between the carrier layers, and also between the supporting layer and the reinforcing elements (2).

The disadvantage of this method is that the thickness of the bearing layer of composite products is determined by their ability to provide technological rigidity of the layer, which become possible subsequent Assembly of the composite product. In this regard, the manufacture of panels of material with a thickness of several tenths of a millimeter problematic, and at the same time, the thickness of the workpiece determines the possibility of reducing the weight of composite structures.

For additional rigidity to the specified layers on them through the operation of punching perform the stiffeners, but the traditional stamping this leads to the extraction of the source material, the uneven thickness and excessive deformation to the formation of cracks.

Often the artboard carry the load attached elements of the electrical installation in the form of bundles, signaling devices, sensors, solar cells and other components of electrical systems. In the electrical design uses electrical panel attached to their harness Assembly, by means of which provide communication between the individual electric is practical components. The wiring, switch, electrical circuit, typically require protection from external influences, such as electromagnetic, radiation, and other, which degrades overall mass characteristics of the products.

The objective of the proposed technical solution is the improvement of the overall mass of the mounting panels, increasing reliability, and reducing the complexity, time and cost of their production by expanding the functionality of the items in the equipment mounting panel, as well as the use of more advanced technologies and materials.

It is known that the greatest rigidity and strength for a given thickness of material of the workpiece has a workpiece, which give a spherical shape. This fact is the basis for implementation of the above goals. These goals are achieved by the fact that in the known method of manufacturing a composite panel, the panel is carried out in a volume of the composite structure, comprising formed of thin-walled workpieces bearing layers, on which place the reinforcing elements and unite them through a linking compound, at least one of the supporting layers perform three-dimensional, by forming, without changing the thickness of the workpiece material, the stiffening elements, which form in the form of evenly raspredelennyh surface layer convex hemispheres and connecting two ribs, which is formed of the sections of the workpiece are not involved in the formation of the hemispheres; from other parts of the workpiece to form the connecting platform by which combine elements of rigidity, and the reinforcing elements are in the form of twisted bundles of stranded composite materials and is placed between the surfaces of stiffeners, with the rounded sections of bundles are placed in and around the hemispheres, then the free space between the surfaces of stiffeners and other layers fill in a self-curing pinakamaganda.

To optimize the production of voluminous layers perform electro-power impact of using the technology of magnetic-pulse processing.

To extend the functionality of composite artboard as reinforcing elements use the wiring from electrical wires to form electrical panel, which can perform the additional function of switching an electrical circuit. For shielding electrical circuits bearing layers panel made of a conductive material to form electrical panel with shielded wiring. To improve the shielding properties pane and reliable removal of static electricity from the surfaces of the panel and the supporting layers panel electrically connected at the connecting sites volumetric load-bearing layers and form the bulk of the shielding structure of equal potential. To reduce the contact resistance between the layers panel connecting them perform electro-welding. To provide mechanical and electrical connections between any points in the installation space, the light mounting panel perform the iterative, the links panel interconnected by a flexible reinforcing elements with the possibility of packaging the panels and form a transformed light mounting panel. Flexible reinforcing elements connecting links transforming the artboard, or part of them perform elastic, shape memory, and form a self-extracting light mounting panel.

The proposed method allows to use the artboard instead of the existing cellular, manufacturing technology which considerably harder, and the technological cycle incomparably longer. This technical solution allows for a wide variety component materials, the thicknesses of the workpieces, the diameters of the spheres, a number of ribs, their thickness and height and other parameters stiffeners, as well as materials, size and number of reinforcing elements. Use as reinforcing elements twisted bundles of electrical wires significantly extends the functionality of the panels reduces the total weight of the products, as twisted harness is from wires, as elements of composite reinforcing structure, perform the second function is to perceive a significant part of the mechanical load, without requiring, in the case of the use of the carrier layers of electrically conductive materials, the use of shielding shells harnesses. The thickness of, for example, aluminum protection cable network at frequencies from 30 kHz to 30 GHz, which usually requires protection, should be from 0.5 mm to 0.05 mm load-Bearing panel with the specified thicknesses of the blanks for them, in good agreement with the capabilities of the proposed method. Increases the reliability of the switching circuits, as in the greater part of their length they are protected from external influences layers panel and pinakamaganda. Multilink installation and electrical panels allow for mechanical and electrical connections any point mounting space. In the transport position multilink panel occupy the minimum amount and can be used with success in transforming the structures of such products as solar panels, antennas, etc. that are increasingly used in aerospace and other industries.

The larger layers using electro-power impact on the blank, the duration of which is 10-50 microseconds, significantly (the number of times) to reduce the time of manufacture of the panels and their consumption, as well as to reduce the thickness of the blanks, as the stiffeners are in the process of a single technological cycle.

The essence of the method is illustrated in figure 1 to 31.

Figures 1 and 2 shown in the projection due two projections surround the base layer of the composite panel of rectangular shape.

Figure 3 on an enlarged scale showing a section a-a on the elements of the stiffness of the bearing volume of the layer panel.

Figs.4 and 5 show in projection due two projections surround the base layer of the composite panel round shape.

Figure 6 and 7 shows the projection in communication two projections surround the base layer panel of rectangular form with reinforcing elements disposed between the inner surfaces of the stiffeners.

On Fig on an enlarged scale shows a section b-B on the elements of the stiffness of the bearing volume of the layer panel with reinforcing elements.

In figures 9 and 10 show in projection due two projections surround the base layer panel round shape with reinforcing elements disposed between the inner surfaces of the stiffeners.

Figure 11 on an enlarged scale shows a cut-In on the hemispherical element stiffness carrying the bulk of the layer panel with reinforcing elements.

On Fig and 13 shown in projection due two projections surround the base layer panel direct the coal form with reinforcing elements, placed between the outer surfaces of the stiffening elements.

On Fig and 15 shown in projection due two projections surround the base layer panel round shape with reinforcing elements placed between the outer surfaces of the stiffening elements.

On Fig and 17 shown in projection due two projections surround the base layer panel of rectangular form with reinforcing elements disposed between the inner surfaces of the stiffeners and the flat bearing panel of rectangular shape.

On Fig and 19 shown in projection due two projections surround the base layer panel round shape with reinforcing elements disposed between the inner surfaces of the stiffeners and the flat carrier round shape.

On Fig and 21 shown in projection due two projections surround the base layer panel of rectangular form with reinforcing elements placed between the outer surfaces of the stiffening elements and the flat bearing panel of rectangular shape.

On Fig and 23 shown in projection due two projections surround the base layer panel round shape with reinforcing elements placed between the outer surfaces of the stiffening elements and the flat bearing layer round shape.

On Fig and 25 shown in projection due two projections surround nosego layer panel of rectangular form with reinforcing elements, placed between the inner and outer surfaces of the stiffening elements and the flat bearing layers of rectangular shape.

On Fig and 27 shown in the projection due two projections surround the base layer panel round shape with reinforcing elements disposed between the inner and outer surfaces of the stiffening elements and the flat bearing layers round shape.

On Fig shows a composite panel consisting of two facing each other volumetric load-bearing layers of reinforcing elements disposed between the inner and outer surfaces of stiffeners and two flat bearing layers located on the outer sides of the composite panel.

On Fig shown curved composite panel with curved volumetric bearing layer and the reinforcing elements placed between the inner and outer surfaces of its stiffeners and two curved bearing layers, spaced from the outer and inner sides of the curved composite panel.

On Fig shown curved composite panel consisting of two facing each other curvilinear volume bearing layer with reinforcing elements disposed between the inner and outer surfaces of their stiffeners and two curved bearing layers located is connected with the outer and inner sides of the curved composite panel.

On Fig shows the three-tier convertible lightweight panel, which at composite panels are positioned at different angles relative to the middle panel, which is manifested in two mutually perpendicular planes.

The method is as follows. Of thin-walled workpiece is formed into bulk carrier layer 1, in which the stiffening elements in the form of evenly distributed over the surface layer of convex hemispheres 2 and connecting two ribs 3, which are formed from sections of thin-walled workpiece, not involved in the formation of the hemispheres. Of the remaining areas of the workpiece to form a connecting pad 4, by means of which combine elements of the stiffness. The thickness of the walls surround the base layer at all sites remains almost equal to the thickness of the workpiece. The reinforcing elements 5 are in the form of flexible twisted bundles of stranded composite materials and is placed between the surfaces of stiffeners, with the rounded sections of bundles are placed in and around the hemispheres 2, after which the free space between the surfaces of the stiffening elements surround the base layer panel and other layers fill in a self-curing pinakamaganda, which in the drawings conventionally not shown, so as not to obscure other ELEH the coefficients of the panel. In those cases, when the reinforcing materials are used bundles of wires, three-dimensional supporting layer made of conductive materials such as aluminum alloys. To increase rigidity of the composite panel to surround the supporting layer on one or two sides attach flat bearing layers 6, which in the case of manufacturing of electrical panels also are made of electrically conductive material, simultaneously performing a shielding function. The required strength and rigidity of the panel can be provided as the thickness of its bearing layers and their number. With increasing number of load-bearing layers can be increased and the number of reinforcing elements and their materials. Form panel also affects its mechanical properties. On Fig shows mounting of the composite panel curved shape made on the basis of the curved surround the base layer 7 and a curved layers 8 and 9 in the form of curved plates. On Fig shows mounting of the composite panel curved shape made on the basis of the curvilinear volume bearing layer 7 and 10 and curved layers 9 and 11 in the form of curved plates.

On Fig shows the three-tier composite panel, which at composite panels 12 and 13 are arranged at different angles relative to the middle panel 14, p is yavlayushiesya in two mutually perpendicular planes.

The proposed method of manufacture and Assembly of the panels does not limit them neither in the form nor the size. Therefore, they can be used as load-bearing structural elements, which can be placed elements of different systems, and the necessary connection, which reinforcing elements in the form of a flexible wiring harness can be output to the outside as on the edges of the panels, so their planes, as shown in Fig.

The most effective structural solutions can be achieved when using multilink convertible mounting and wiring of panels, which can provide mechanical and electrical connection between any two points in space. Such panels in the transport position are placed in the form of packets, which occupies a minimum volume, and spontaneously disclosed, providing all required forms and dimensions in working position.

The method was tested in the manufacture of experimental samples of electrical panels flat and curvilinear forms. The dimensions of the panels 200 200 mm Bearing layers were made of aluminum foil AD1 thickness of 0.15 mm Radius sphere stiffeners was 5 mm Gap between the layers of reinforcing ribs 1 mm Reinforcing elements were made of twisted wire harnesses, made on the basis of basalt fibers, and that the same wires brand MS-25-14. As a binder used procompany SC-74. Curing was carried out under normal weather conditions. Forming bulk load-bearing layers were produced with the use of magnetic-impulse installation energy intensity of 0.5 kJ. Physico-mechanical model tests for strength, rigidity and stability has shown positive results.

The application of the proposed technology can improve the overall dimensions and mass characteristics of the products. The execution of the bearing layer using electro-power impact on the blank, which lasts 10-50 microseconds, significantly (several times) to reduce the time of manufacture of the panels and their consumption, so as to reduce the thickness of the workpieces due to the introduction of stiffening elements, which are performed during a single technological cycle, leaving unchanged the thickness of the material. In addition, improved operational characteristics of the products, including, electrocimesanoat explosion protection, explosion and fire safety.

Sources of information

1. UDK(03 5)T. Ternopil. Spatially reinforced composite materials. The Handbook. Moscow. The engineering. 1987.

2. SU 706377A, 30.12.79.

3. EN 2096678 Cl, 20.11.1997.

4. EN 2314202 C1, 04.07.2007.

5. US 4278485 A, 14.07.1981.

6. EP 0312151 A1, 19.04.1981.

1. The way made the I light mounting panel when the panel is carried out in a volume of the composite structure, comprising formed of thin-walled workpieces bearing layers, on which place the reinforcing elements and unite them through a linking compound, wherein at least one of the bearing layer performs three-dimensional, by forming, without changing the thickness of the workpiece material, the stiffening elements in the form of evenly distributed over the surface layer of convex hemispheres and connecting two ribs, which are formed of the sections of the workpiece are not involved in the formation of the hemispheres, from other parts of the workpiece to form the connecting platform by which combine elements of the stiffness, and the reinforcing elements are in the form of twisted bundles of stranded composite materials and is placed between the surfaces of stiffeners, with the rounded sections of bundles are placed in and around the hemispheres, then the free space between the surfaces of stiffeners and other layers fill in a self-curing pinakamaganda.

2. The method according to claim 1, characterized in that the three-dimensional supporting layer perform electro-power impact.

3. The method according to claim 1, characterized in that the reinforcing elements use the wiring of the wiring etc is water and form electrical panel.

4. The method according to claim 3, characterized in that the load-bearing layers of the composite panel made of a conductive material, electrically connecting them together, forming the bulk of the shielding structure of equal potential, and receive electrical panel with shielded wiring.

5. The method according to claim 4, characterized in that the connection of the layers panel perform electro-welding.

6. The method according to claim 1 or 3, characterized in that the light mounting panel perform iterative, links panel, connect the 2 with each other via a flexible reinforcing elements, with the possibility of packaging the panels and form a transformed light mounting panel.

7. The method according to claim 6, characterized in that at least part of the flexible reinforcing elements between the panels perform elastic, shape memory, and form a self-extracting light mounting panel.



 

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