A welding system for an automotive tube beam assembly

Abstract

This invention discloses a welding system for an automotive tubular beam assembly, belonging to the field of automotive laser welding technology. It includes a welding table for laser welding an outer tubular beam and an inner tubular beam. The welding table has an inner tubular beam support welding module, a welding working surface module, and a spin adjustment module arranged horizontally in sequence. A workstation scaffold is located on one side of the welding table, and a combined fusion welding module is connected to the workstation scaffold via a hydraulic device. The inner tubular beam support welding module includes a support base mounted on the welding table, with clamping openings on the support base. This invention achieves synchronous downward movement of the combined fusion welding module, which drives the inner expansion component and electromagnetic pressure plate to press down synchronously. Multiple synergistic effects between the inner and outer tubular beams, through the inner expansion component squeezing the inner tubular beam, ensure a tight fit between the inner and outer tubular beams. Combined with laser welding and fusion welding, this effectively eliminates defects such as incomplete welds and porosity, resulting in a uniform and strong weld formation and significantly improved welding strength.

Description

Technical Field

[0001] This invention relates to the field of automotive laser welding technology, and more particularly to a welding system for automotive tube beam assemblies. Background Technology

[0002] The automotive tubular beam assembly (especially the instrument panel crossbeam) is a key load-bearing component of the vehicle body, providing the mounting base for the instrument panel, airbags, etc., and participating in collision energy absorption. With the continuous development of new energy vehicles, the requirements for lightweight vehicle bodies are becoming increasingly stringent. The same tubular beam structure is becoming increasingly complex, and the material combinations (steel, aluminum, magnesium, etc.) are becoming increasingly diverse, which places higher demands on the quality of its welding connections.

[0003] The welding of tube beams in the existing technology has the following problems: traditional welding processes (resistance welding, laser welding, etc.) cannot ensure a tight fit between the inner and outer tube walls at the diameter change connection of rectangular tube beams, resulting in defects such as welding deformation and incomplete welding; dedicated production lines have poor flexibility and high changeover costs; and such problems also exist when sleeves are needed to improve strength during vehicle maintenance. Based on this, a welding system for automotive tube beam assemblies is proposed. Summary of the Invention

[0004] The purpose of this invention is to solve the problem that traditional welding processes (resistance welding, laser welding, etc.) in the prior art are difficult to ensure a tight fit between the inner and outer pipe walls at the diameter change connection of rectangular tube beams, resulting in welding deformation, incomplete welding and other defects. Therefore, a welding system for automotive tube beam assemblies is proposed.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A welding system for an automotive tube beam assembly includes a welding table for laser welding an outer tube beam and an inner tube beam. The welding table is horizontally arranged with an inner tube beam top support welding module, a welding working surface module, and a spin adjustment module. A work station rack is provided on one side of the welding table, and a combined fusion welding module is connected to the work station rack via a hydraulic device. The inner tube beam top support welding module includes a support base set on a welding workbench. The support base has a clamping port, and a synchronous pressure clamp is set in the clamping port to clamp the inner tube beam and achieve inner support. An adjustment frame is connected to the outside of the support base through a rotating ring. The adjustment frame is connected to a laser welding head through a laser welding adjustment component. The welding work surface module includes a positioning platform installed on the welding workbench, and the positioning platform is equipped with a heat dissipation and adsorption device. The spin adjustment module includes a follower stage mounted on the welding table via a follower seat, a work plate mounted on the follower stage, a positioning plate rotatably mounted on the inner wall of the work plate, an external holding port adapted to the outer tube beam on the positioning plate, and an electric drive assembly for controlling the rotation of the positioning plate on the work plate. The combined welding module includes a positioning plate connected to a hydraulic device. The positioning plate has a laser welding through-hole. A welding seat is provided on one side of the positioning plate. Multiple multi-point welding parts are provided at the bottom of the welding seat. An electromagnetic adsorption fastening part is provided on the welding seat.

[0006] As a preferred embodiment, the synchronous pressure clamp includes a compression port at the bottom of the clamping opening, a U-shaped clamping seat is provided inside the compression port, and an inner expansion member is slidably connected to both sides of the U-shaped clamping seat through the side wall. An inclined pressure block is provided on the back of the inner expansion member. The inclined pressure block is connected to the side wall of the U-shaped clamping seat through a repulsive force spring. The inner wall of the compression port has an inclined opening that matches the inclined pressure block.

[0007] As a preferred embodiment, the outer wall of the support base is provided with an annular groove, and the rotating ring is rotatably disposed in the annular groove, with its outer wall fixedly connected to the adjustment frame.

[0008] As a preferred embodiment, the laser welding adjustment component includes an adjustment port on an adjustment frame, an adjustment push rod on the adjustment frame, an output end of the adjustment push rod extending into the adjustment port and fixedly connected to an adjustment seat, the adjustment seat and the adjustment port being connected by a sliding groove, and one end of the adjustment seat being connected to the laser welding head via a torsion shaft.

[0009] As a preferred embodiment, the heat dissipation adsorption device includes a filter chamber opened inside the positioning platform, adsorption fans are provided on both sides of the filter chamber, and a centralized adsorption hole is opened on the top of the filter chamber.

[0010] As a preferred embodiment, the follower seat is provided with axial limiting plates on both sides, and the follower stage is provided with axial limiting ports on both sides that are adapted to the axial limiting plates. The bottom of the follower stage is fixedly connected to the follower seat by a support spring.

[0011] As a preferred embodiment, the electric drive assembly includes a rotary motor mounted on a follower platform, with a rotating worm gear fixedly connected to the output end of the rotary motor, and a rotating worm wheel ring that meshes with the rotating worm gear fixedly connected to the side wall of the positioning plate.

[0012] As a preferred embodiment, the electromagnetic adsorption fastening component includes an electromagnetic pressure plate that is slidably disposed on the welding base. The electromagnetic pressure plate has an electromagnetic layer inside, which is used to achieve a tight fit between the outer tube beam and the inner tube beam. The top of the electromagnetic pressure plate is connected to the upper surface of the welding base through a reset spring plate.

[0013] As a preferred embodiment, one side of the welding base is provided with a transverse pressure ridge that applies pressure to the U-shaped clamping seat, which is used to simultaneously drive the U-shaped clamping seat to move downward when the welding base moves downward.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention achieves synchronous downward movement of the combined fusion welding module, thereby driving the inner expansion component and electromagnetic pressure plate to press down synchronously. Multiple synergistic effects are achieved between the inner and outer tube beams. The inner expansion component squeezes the inner tube beam, allowing the inner and outer tube beams to fit tightly together. Combined with laser welding and fusion welding, this effectively eliminates defects such as incomplete welds and porosity, resulting in a uniform and firm weld formation and significantly improving welding strength.

[0015] 2. In this invention, while the hydraulic device drives the combined welding module to descend, the horizontal pressure ridge triggers the inner support clamp, the electromagnetic pressure plate synchronously engages, and the multi-point welding parts are pre-fixed. Combined with the servo motor-driven spin adjustment module and the indexable laser welding head, the positioning, clamping, pre-welding, laser welding, and heat dissipation and smoke exhaust are automatically completed in one working cycle, which greatly shortens the auxiliary time. Attached Figure Description

[0016] Figure 1 This is a three-dimensional structural schematic diagram of a welding system for an automotive tube beam assembly proposed in this invention; Figure 2 This is a structural schematic diagram of the tube beam top support welding module, welding working surface module, and spin adjustment module in the welding system of an automotive tube beam assembly proposed in this invention. Figure 3 This is a schematic diagram of the combined state structure of the inner tube beam top support welding module in the welding system of an automotive tube beam assembly proposed in this invention. Figure 4 This is a schematic diagram of the structure of the inner tube beam top support welding module in the welding system of an automotive tube beam assembly proposed in this invention; Figure 5 This is a schematic diagram of the internal tube beam top support welding module in the welding state of a welding system for an automotive tube beam assembly proposed in this invention. Figure 6 This is a schematic diagram of the spin adjustment module in the welding system of an automotive tube beam assembly proposed in this invention. Figure 7 This is a schematic diagram showing the positional relationship between the spin adjustment module and the combined fusion welding module in the welding system of an automotive tube beam assembly proposed in this invention. Figure 8 This is a schematic diagram of the combined state structure of the synchronous pressure fixture in the welding system of an automotive tube beam assembly proposed in this invention; Figure 9 This is a schematic diagram of the combined state of the welding seat in the welding system of an automotive tube beam assembly proposed in this invention.

[0017] In the diagram: 1. Welding table; 2. Hydraulic device; 3. Support base; 4. Rotating ring; 5. Adjusting frame; 6. Laser welding head; 7. Positioning table; 8. Follower table; 9. Tool holder; 10. Positioning holder; 11. Outer holding port; 12. Positioning pressure plate; 13. Laser welding through port; 14. Fusion welding seat; 15. Extrusion port; 16. U-shaped clamping seat; 17. Inner expansion component; 18. Inclined follower block; 19. Adjusting push rod; 20. Adjusting seat; 21. Adsorption fan; 22. Axial limiting plate; 23. Rotary motor; 24. Rotating worm gear; 25. Electromagnetic pressure plate; 26. Return spring plate; 27. Horizontal pressure ridge; 28. Follower seat. Detailed Implementation

[0018] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0019] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0020] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0021] Example, refer to Figures 1 to 9A welding system for an automotive tube beam assembly includes a welding table 1 for laser welding an outer tube beam and an inner tube beam. The welding table 1 is horizontally arranged with an inner tube beam top support welding module, a welding working surface module, and a spin adjustment module. A work station scaffold is provided on one side of the welding table 1. A combined fusion welding module is connected to the work station scaffold via a hydraulic device 2. The hydraulic device 2 is equipped with a high-precision displacement sensor and a proportional valve, which can realize uniform lifting and pressure control of the combined fusion welding module. This is existing technology and will not be described in detail here. The inner tube beam top support welding module is used to squeeze the inner tube beam from both sides, so that the inner tube beam will generate outward expansion force on both its upper and lower surfaces under the squeezing force, improving the sealing effect between it and the outer tube beam and ensuring the subsequent fusion welding effect; the welding working surface module is used to position the welding point between the outer tube beam and the inner tube beam, and to effectively dissipate heat and absorb waste gas at the welding position; the spin adjustment module is used to rotate the inner tube beam to adjust the position of the laser welding surface.

[0022] The inner tube beam top support welding module includes a support base 3 set on the welding table 1. The support base 3 has a clamping port, and a synchronous pressure clamp is set in the clamping port to clamp the inner tube beam and achieve internal support. Further, the synchronous pressure clamp includes a compression port 15 set at the bottom of the clamping port. A U-shaped clamping seat 16 is set in the compression port 15. Both sides of the U-shaped clamping seat 16 are slidably connected to the side wall with an inner expansion member 17. The inner expansion member 17 is made of chromium zirconium copper alloy and has an arc-shaped contact surface at the front end, which matches the shape of the inner wall of the inner tube beam. The arc-shaped surface design of the inner expansion member 17 avoids local stress concentration and effectively prevents deformation of the inner tube beam. The inner expansion pressing component 17 has a sloping pressing block 18 on its back. The sloping pressing block 18 is connected to the side wall of the U-shaped clamping seat 16 through a repulsive force spring. The inner wall of the extrusion port 15 has a sloping opening that matches the sloping pressing block 18. The sloping angle of the sloping pressing block 18 is 30° to 45°.

[0023] It should be noted that under the action of the transverse pressure rib 27, the U-shaped clamping seat 16 in contact with it will move downward. During the downward movement of the U-shaped clamping seat 16, the inclined surfaces on both sides will be squeezed by the inclined surfaces on both sides along with the pressure block 18, which will drive the inner expansion pressure member 17 to move towards the middle, thereby squeezing the inner tube beam in the U-shaped clamping seat 16. At the same time, the electromagnetic adsorption fastening member will attract the inner tube beam under the outer tube beam sleeve to be guided outward. Under the combined action of the squeezing force of the inner expansion pressure member 17 on both sides and the electromagnetic adsorption fastening member above, the inner tube beam will be squeezed outward, so that the two sides that need to be laser welded and fusion welded will be in close contact.

[0024] It should be noted that when the electromagnetic layer in the electromagnetic adsorption fastening component is energized, it generates a magnetic field of 0.3 to 0.5T, which attracts the ferromagnetic inner tube beam and guides the inner tube beam upward to fit against the upper wall of the outer tube beam. The horizontal extrusion force applied by the inner expansion components 17 on both sides can be adjusted by the pre-compression amount of the repulsion spring, which is usually 200 to 500N. The forces are applied in the vertical and lateral directions in coordination, so that a uniform contact pressure is formed between the inner tube beam and the outer tube beam, eliminating gaps.

[0025] The support base 3 is externally connected to an adjustment frame 5 via a rotating ring 4. The adjustment frame 5 is connected to a laser welding head 6 via a laser welding adjustment component. An annular groove is provided on the outer wall of the support base 3. The rotating ring 4 is rotatably set in the annular groove and is rotatably connected to the annular groove. Its outer wall is fixedly connected to the adjustment frame 5. In the unprocessed state, it can ensure that the support base 3 is always in an open state above.

[0026] Furthermore, the laser welding adjustment component includes an adjustment port on the adjustment frame 5. The adjustment frame 5 is provided with an adjustment push rod 19, which is an electric push rod and is existing technology, so it will not be described in detail here. The output end of the adjustment push rod 19 extends into the adjustment port and is fixedly connected to an adjustment seat 20. The adjustment seat 20 and the adjustment port are connected by a sliding groove to realize the limited sliding of the adjustment seat 20 in the adjustment port. One end of the adjustment seat 20 is connected to the laser welding head 6 through a torsion shaft.

[0027] The welding work surface module includes a positioning platform 7 installed on the welding workbench 1. The positioning platform 7 is equipped with a heat dissipation and adsorption device. The heat dissipation and adsorption device includes a filter chamber opened inside the positioning platform 7. Adsorption fans 21 are arranged on both sides of the filter chamber. A filter device is arranged inside the filter chamber. A concentrated adsorption hole is opened at the top of the filter chamber. The suction force generated by the adsorption fans 21 can be concentrated in the concentrated adsorption hole to achieve cooling of the welding part above and absorption of exhaust gas.

[0028] The spin adjustment module includes a follower stage 8 mounted on the welding table 1 via a follower seat 28. Further, axial limiting plates 22 are provided on both sides of the follower seat 28, and axial limiting ports adapted to the axial limiting plates 22 are opened on both sides of the follower stage 8. The bottom of the follower stage 8 is fixedly connected to the follower seat 28 via a support spring. The follower stage 8 can move up and down following the up and down movement of the welded pipe beam.

[0029] A work plate 9 is provided on the follower table 8. A positioning plate 10 is rotatably mounted on the inner wall of the work plate 9. The positioning plate 10 has an external holding port 11 that is adapted to the outer tube beam. An electric drive assembly for controlling the rotation of the positioning plate 10 is provided on the work plate 9. Further, the electric drive assembly includes a rotary motor 23 mounted on the follower table 8. A rotating worm gear 24 is fixedly connected to the output end of the rotary motor 23. A rotating worm wheel ring that meshes with the rotating worm gear 24 is fixedly connected to the side wall of the positioning plate 10. Under the action of the rotary motor 23, the rotating worm gear 24 will drive the positioning plate 10 connected to the rotating worm wheel ring to rotate.

[0030] The combined welding module includes a positioning plate 12 connected to the hydraulic device 2. The positioning plate 12 has a laser welding through-hole 13, which provides clearance for the operation of the laser welding head 6. A welding seat 14 is provided on one side of the positioning plate 12. Multiple multi-point welding components are provided at the bottom of the welding seat 14. The multi-point welding components are multiple welding electrodes arranged at intervals. An electromagnetic adsorption fastening component is provided on the welding seat 14.

[0031] Furthermore, the electromagnetic adsorption fastening component includes an electromagnetic pressure plate 25 that is slidably disposed on the welding seat 14. The electromagnetic pressure plate 25 has an electromagnetic layer inside, which is used to achieve a tight fit between the outer tube beam and the inner tube beam. The top of the electromagnetic pressure plate 25 is connected to the upper surface of the welding seat 14 through a reset spring plate 26. A transverse pressure rib 27 is provided on one side of the welding seat 14 to apply pressure to the U-shaped clamping seat 16, which is used to synchronously drive the U-shaped clamping seat 16 to move downward when the welding seat 14 moves downward. The multi-point welding components are evenly arranged along the length direction of the positioning pressure plate 12. The energizing time and current intensity of each welding component can be independently controlled to achieve pre-fusion fixation. The lower end face of the electromagnetic pressure plate 25 is provided with a high-temperature resistant insulating layer (such as mica sheet) to prevent welding spatter and adhesion.

[0032] When the system proposed in this invention is in operation, the inner tube beam is first placed inside the U-shaped clamping seat 16, and the outer tube beam is sleeved on the outside of the inner tube beam and positioned by the outer holding opening 11. The hydraulic device 2 drives the combined welding module to descend, and the horizontal pressure ridge 27 pushes the U-shaped clamping seat 16 to move downward. The inclined surface interacts with the pressure block 18 and the inclined surface opening, causing the inner expansion pressure member 17 to squeeze the inner tube beam inward. At the same time, the electromagnetic pressure plate 25 is energized to generate magnetic force, which attracts the inner tube beam upward. Under the action of lateral pressure and upward attraction, the inner tube beam fits tightly against the upper wall and side wall of the outer tube beam.

[0033] Subsequently, the multi-point welded parts are energized to achieve pre-welding and fixation at several points. Then, the laser welding head 6 is adjusted to a suitable angle and position via the adjustment frame 5, and the laser emits light. At the same time, the rotary motor 23 drives the positioning plate 10 to rotate, and the laser welding head 6 completes the circumferential or segmented weld. During the welding process, the adsorption fan 21 continuously exhausts smoke and dissipates heat. After welding is completed, the electromagnetic pressure plate 25 is de-energized and reset, the hydraulic device 2 is lifted, and the inner expansion component 17 retracts under the action of spring force, allowing the finished product to be removed.

[0034] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A welding system for an automotive tubular beam assembly, comprising a welding table (1) for laser welding an outer tubular beam and an inner tubular beam together, characterized in that, The welding workbench (1) is horizontally arranged with an inner tube beam top support welding module, a welding working surface module and a spin adjustment module. A work station frame is arranged on one side of the welding workbench (1). A combined fusion welding module is connected to the work station frame through a hydraulic device (2). The inner tube beam top support welding module includes a support base (3) set on a welding workbench (1). The support base (3) has a clamping port. The clamping port is provided with a synchronous pressure clamp for clamping the inner tube beam to achieve internal support. The support base (3) is connected to an adjustment frame (5) outside through a rotating ring (4). The adjustment frame (5) is connected to a laser welding head (6) through a laser welding adjustment component. The welding work surface module includes a positioning platform (7) installed on the welding workbench (1), and the positioning platform (7) is equipped with a heat dissipation adsorption device; The spin adjustment module includes a follower stage (8) set on the welding table (1) via a follower seat (28), a work plate (9) set on the follower stage (8), a positioning plate (10) rotatably set on the inner wall of the work plate (9), an outer holding port (11) adapted to the outer tube beam is opened on the positioning plate (10), and an electric drive assembly for controlling the rotation of the positioning plate (10) is set on the work plate (9). The combined welding module includes a positioning plate (12) connected to a hydraulic device (2). The positioning plate (12) has a laser welding through-hole (13). A welding seat (14) is provided on one side of the positioning plate (12). Multiple multi-point welding parts are provided at the bottom of the welding seat (14). An electromagnetic adsorption fastening part is provided on the welding seat (14).

2. The welding system for an automotive tubular beam assembly according to claim 1, characterized in that, The synchronous pressure clamp includes a squeezing port (15) at the bottom of the clamping port. A U-shaped clamping seat (16) is provided inside the squeezing port (15). Both sides of the U-shaped clamping seat (16) are slidably connected to the side walls of the side walls. An inclined pressure block (18) is provided on the back of the inner pressure block (17). The inclined pressure block (18) is connected to the side wall of the U-shaped clamping seat (16) through a repulsive force spring. The inner wall of the squeezing port (15) is provided with an inclined opening that matches the inclined pressure block (18).

3. The welding system for an automotive tubular beam assembly according to claim 1, characterized in that, The outer wall of the support base (3) is provided with an annular groove, and the rotating ring (4) is rotatably set in the annular groove, and its outer wall is fixedly connected to the adjustment frame (5).

4. The welding system for an automotive tubular beam assembly according to claim 1, characterized in that, The laser welding adjustment component includes an adjustment port on the adjustment frame (5). An adjustment push rod (19) is provided on the adjustment frame (5). The output end of the adjustment push rod (19) passes through the adjustment port and is fixedly connected to an adjustment seat (20). The adjustment seat (20) and the adjustment port are connected by a sliding groove. One end of the adjustment seat (20) is connected to the laser welding head (6) through a torsion shaft.

5. The welding system for an automotive tubular beam assembly according to claim 1, characterized in that, The heat dissipation adsorption device includes a filter chamber opened inside the positioning platform (7), an adsorption fan (21) is provided on both sides of the filter chamber, and a concentrated adsorption hole is opened on the top of the filter chamber.

6. The welding system for an automotive tubular beam assembly according to claim 1, characterized in that, The follower seat (28) is provided with axial limiting plates (22) on both sides, and the follower stage (8) is provided with axial limiting ports on both sides that are adapted to the axial limiting plates (22). The bottom of the follower stage (8) is fixedly connected to the follower seat (28) by a support spring.

7. The welding system for an automotive tubular beam assembly according to claim 1, characterized in that, The electric drive assembly includes a rotary motor (23) mounted on the follower stage (8), with a rotating worm gear (24) fixedly connected to the output end of the rotary motor (23), and a rotating worm wheel ring that meshes with the rotating worm gear (24) fixedly connected to the side wall of the positioning plate (10).

8. The welding system for an automotive tubular beam assembly according to claim 1, characterized in that, The electromagnetic adsorption fastening component includes an electromagnetic pressure plate (25) that is slidably disposed on the welding seat (14). The electromagnetic pressure plate (25) has an electromagnetic layer inside, which is used to achieve a tight fit between the outer tube beam and the inner tube beam. The top of the electromagnetic pressure plate (25) is connected to the upper surface of the welding seat (14) through a reset spring plate (26).

9. The welding system for an automotive tubular beam assembly according to claim 2, characterized in that, The welding base (14) is provided with a transverse pressure rib (27) on one side to apply pressure to the U-shaped clamping base (16), which is used to drive the U-shaped clamping base (16) to move down simultaneously when the welding base (14) moves down.

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