Auxiliary tooling and method for drilling and riveting chassis side beams and castings

Abstract

The auxiliary tooling and method for drilling and riveting the chassis side beams and castings described in the present invention propose a new type of drilling and riveting auxiliary tooling to solve the riveting processing problems of the aluminum alloy chassis side beams and castings in a targeted manner, in order to realize a drilling and riveting process with strong practicality, high drilling accuracy and high processing efficiency, effectively solve the problems of the existing chassis side beams being difficult to accurately drill and the unstable product quality after riveting, reduce the intensity of on-site processing work and improve production efficiency. The auxiliary tooling includes a support plate, an F-shaped clamping bar, a support frame, a positioning support block and a magnetic drill. The support plate has a flat plate structure, the cross-sectional shape of the support frame is L-shaped, and the positioning support block has at least two continuous T-shaped structures connected as one. The support frame is provided with a through groove with a rectangular cross-section between its two right-angled folded edges, and the outer edge of the side beam is pressed into the through groove.

Description

Technical Field

[0001] The invention relates to an auxiliary tooling suitable for drilling and riveting a chassis side beam and a casting of an aluminum alloy EMU and an improvement in the riveting process thereof, and belongs to the field of rail vehicle design. Background Art

[0002] With the rapid development of EMU technology and the increase in train running speed, the car body structure design and assembly processing technology have been continuously optimized and improved, and the car body structure design has become more mature.

[0003] As one of the important parts of the aluminum alloy car body, the chassis is directly connected to the bogie and plays a pivotal role in connection and load distribution. The precise positioning size of the anti-roll mounting seat, an important accessory on the side beam, will directly affect the quality and safety of the car body. Therefore, high requirements are put forward for the processing position and size, product quality and other performance of such anti-roll mounting seats.

[0004] The existing aluminum alloy body chassis side beam accessory - the anti-roll mount is an aluminum alloy structure directly welded to the side beam. It is difficult to adjust and repair due to welding deformation factors, and it is difficult to ensure the dimensional tolerance requirements. The newer and improved design is to change the anti-roll mount from an aluminum alloy structure to a casting structure, and fix the casting to the side beam through rivets by manual drilling on site. Therefore, the design structure of the side beam, the installation space position of the anti-roll mount, and manual drilling and other artificial uncertainties directly determine the difficulty of on-site drilling and the accuracy of the drilled holes.

[0005] For example, the applicant currently designs and uses a certain type of aluminum alloy urban rail train, the anti-roll mounting seat is a casting structure, and the spatial position of the side beam structure and the anti-roll mounting seat makes it difficult to clamp and fix the anti-roll mounting seat on site; at the same time, affected by the spatial installation position of the anti-roll mounting seat and manual operation and other human uncertainties, on the one hand, the size of the drilled holes in the aluminum alloy side beam profile is difficult to meet the tolerance size requirements required for riveting, that is, the drilling accuracy cannot be guaranteed; on the other hand, the manual on-site drilling work is labor-intensive and the production efficiency is low; in addition, unreasonable riveting process steps will increase the difficulty of riveting, easily causing the rivets to loosen or gaps to appear on the contact surface between the casting and the side beam, and the product quality cannot be guaranteed.

[0006] In view of this, this application is hereby filed. Summary of the invention

[0007] The auxiliary tooling and method for drilling and riveting chassis side beams and castings described in the present invention are designed to solve the problems existing in the above-mentioned prior art and to propose a new type of drilling and riveting auxiliary tooling to specifically solve the riveting processing problems of aluminum alloy chassis side beams and castings, in order to achieve a drilling and riveting process with strong practicality, high drilling accuracy and high processing efficiency, effectively solving the problems of difficulty in accurate drilling of existing chassis side beams and unstable product quality after riveting, reducing the intensity of on-site processing work and improving production efficiency.

[0008] In order to achieve the above design objectives, the present application proposes a new auxiliary tooling for drilling and riveting the chassis side beams and castings, which mainly includes a support plate, an F-type clamping rail, a support frame, a positioning support block and a magnetic drill.

[0009] Wherein, the support plate has a flat plate structure, the cross-sectional shape of the support frame is L-shaped, and the positioning support block has at least two continuous T-shaped structures connected as one.

[0010] Furthermore, an optimization and improvement solution that can be adopted is that a through groove with a rectangular cross-section is provided between two right-angled folded edges of the support frame, and the outer edge of the side beam is inserted into the through groove.

[0011] The specific drilling and riveting positioning structure is that, at the lower surface of the side beam, the support plate and the casting are respectively located on the lower surface of the side beam, and the magnetic drill is located on the support plate; at least one F-shaped clamp is clamped and fixed on the upper surface of the support plate and the vertical ends of the lower surface of the side beam, and at least one F-shaped clamp is clamped and fixed on the vertical ends of the casting and the lower surface of the side beam;

[0012] At the inner inclined surface of the side beam, the positioning support block and the casting are respectively located on the inner inclined surface of the side beam, the magnetic drill is located on the positioning support block, and the support frame is located at the outer edge of the lower surface of the side beam; at least one F-shaped clamp is clamped and fixed between the upper surface of the positioning support block and the bottom surface of the support frame in the vertical direction, and at least one F-shaped clamp is clamped at both ends of the casting and the bottom surface of the support frame in the vertical direction.

[0013] The structural design and positioning connection method of the auxiliary tooling mentioned above are designed according to the structural characteristics of the side beams and castings. It can flexibly convert the magnetic drill positioning reference surface, use the inner bevel of the side beam and the lower surface of the side beam as the positioning reference surface, design a positioning support block parallel to the inner bevel of the side beam, and design a support plate parallel to the lower surface of the side beam, and clamp and position the casting in the lateral and vertical directions respectively, which provides the necessary prerequisite for the accuracy of mechanical drilling.

[0014] The structural design of the positioning support block is based on the structure of the side beam and the shape and size characteristics of the casting, avoiding interference with the casting and meeting the travel requirements of the magnetic drill mechanical drilling at the inner inclined surface of the side beam. It can ensure the requirements of positional dimensional tolerances such as flatness and verticality as a whole, and ensure the accuracy of the drilled holes.

[0015] Based on the auxiliary tooling used for drilling and riveting the chassis side beam and the casting, the present application also proposes an improved riveting process method, which includes the following implementation steps:

[0016] (1) Rivet pull riveting process test;

[0017] (2) Marking the side beams to locate the dimensions of the castings;

[0018] (3) Drill positioning holes and rivet positioning on the aluminum profile on the lower surface of the side beam to match the rivet holes of the casting;

[0019] (4) Match the rivet holes of the casting to the inner inclined aluminum profile of the side beam and drill positioning holes and pull rivets for positioning;

[0020] (5) Drill holes and rivet at other locations of the side beam aluminum profile to match the rivet holes in the casting.

[0021] Furthermore, before riveting the physical product, a riveting process test is carried out on the rivets to verify the equipment capability of the rivet gun and the quality of the rivets.

[0022] Furthermore, a magnetic drill is used to mechanically drill holes in the side beam profile matching the rivet holes of the casting.

[0023] Auxiliary tooling is used to perform the following drilling and riveting positioning respectively: at the lower surface of the side beam, the support plate and the casting are respectively located on the lower surface of the side beam, and the magnetic drill is located on the support plate; at least one F-shaped clamp is clamped and fixed on the upper surface of the support plate and the vertical ends of the lower surface of the side beam, and at least one F-shaped clamp is clamped and fixed on the vertical ends of the casting and the lower surface of the side beam;

[0024] At the inner inclined surface of the side beam, the positioning support block and the casting are respectively located on the inner inclined surface of the side beam, the magnetic drill is located on the positioning support block, and the support frame is located at the outer edge of the lower surface of the side beam; at least one F-shaped clamp is clamped and fixed between the upper surface of the positioning support block and the bottom surface of the support frame in the vertical direction, and at least one F-shaped clamp is clamped at both ends of the casting and the bottom surface of the support frame in the vertical direction.

[0025] In summary, the auxiliary tooling and method for drilling and riveting the chassis side beam and casting of the present application have the following advantages and beneficial effects:

[0026] 1. According to the structural characteristics of the side beams and castings of the existing aluminum alloy EMUs, the proposed drilling and riveting auxiliary tooling can flexibly convert the magnetic drill positioning reference surface, and use the inner inclined surface and the lower surface of the side beam as the positioning reference surface, respectively, which provides the necessary prerequisite for the accuracy of mechanical drilling. The auxiliary tooling is highly practical and flexible to operate.

[0027] 2. Use a magnetic drill to match the rivet holes in the castings to mechanically drill the side beam profiles. Compared with the previous manual drilling, it avoids the influence of external uncertain interference factors, ensures the accuracy of drilling, reduces work intensity, significantly improves production efficiency, and ensures product quality.

[0028] 3. The improved drilling and riveting process of the side beams and castings clarifies the drilling and riveting operation steps, which greatly guarantees the product quality and avoids the rework of the physical product after riveting. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic diagram of the position and structure of the assembly processing of the chassis side beam and casting;

[0030] Figure 2 It is a process flow chart for drilling and riveting the side beam and casting;

[0031] Figure 3 It is a schematic diagram of the rivet process test;

[0032] Figure 4 It is a schematic diagram of the drilling and riveting of the lower surface of the chassis side beam with the casting;

[0033] Figure 5 yes Figure 4 AA section diagram of ;

[0034] Figure 6 It is a schematic diagram of the inner inclined surface of the chassis side beam and the drilling and riveting of the casting;

[0035] Figure 7 yes Figure 6 BB section schematic diagram;

[0036] Figure 8 It is a schematic diagram of the structural comparison of the support frame and the positioning support block; DETAILED DESCRIPTION

[0037] The present invention is further described in detail below in conjunction with the accompanying drawings.

[0038] Example 1 takes the drilling and riveting processing of the aluminum alloy underframe side beam and the anti-roll mounting seat casting of the intercity rail vehicle as an example.

[0039] like Figure 1 As shown, near the end of the single-side side beam 10 of the chassis (the figure shows a pillow beam 60 constituting the chassis, and a floor 70 installed on the chassis), the anti-roll mounting seat 20 is respectively installed and fixed to the lower surface 40 of the side beam and the inner inclined surface 50 of the side beam by rivets 30.

[0040] The structure of the side beam 10 is nearly cylindrical and irregular in shape, and the anti-roll mounting seat 20 is integrally machined to ensure that the machined rivet holes on the casting, the flatness of the casting, the angle and other position dimensions and tolerances meet the standard requirements.

[0041] The number of rivet holes located on the lower surface 40 of the side beam is 8, and the number of rivet holes located on the inner inclined surface 50 of the side beam is 6.

[0042] In order to achieve the processing accuracy requirements for drilling and riveting the above-mentioned chassis side beams and anti-roll mounting seats, the auxiliary tooling described in this application mainly includes a support plate 3, an F-shaped clamping rail 4, a support frame 6, a positioning support block 7 and a magnetic drill 8.

[0043] Wherein, the support plate 3 has a flat plate structure;

[0044] like Figure 8 As shown, the cross-sectional shape of the support frame 6 is L-shaped, and a cross-sectional shape of 4 mm is provided between the two right-angled edges. 2 A rectangular through groove 61, when the support frame 6 is padded on the outer side of the side beam 10, the outer edge of the side beam 10 is pressed into the through groove 61;

[0045] The positioning support block 7 preferably has at least two continuous T-shaped structures connected as one.

[0046] like Figure 4 and Figure 5 As shown, the above-mentioned auxiliary tooling is applied at the lower surface 40 of the side beam, the support plate 3 and the anti-roll mounting seat 20 are respectively located on the lower surface 40 of the side beam, and the magnetic drill 8 is located on the support plate 3; two F-shaped clamps 4 are clamped and fixed at the vertical ends of the upper surface of the support plate 3 and the lower surface 40 of the side beam, and the other two F-shaped clamps 4 are clamped at the vertical ends of the anti-roll mounting seat 20 and the lower surface 40 of the side beam.

[0047] like Figure 6 and Figure 7 As shown, the above-mentioned auxiliary tooling is applied to the inner inclined surface 50 of the side beam, the positioning support block 7 and the anti-roll mounting seat 20 are respectively located on the inner inclined surface 50 of the side beam, the magnetic drill 8 is located on the positioning support block 7, and the support frame 6 is located at the outer edge of the lower surface of the side beam 10; two F-shaped clamps 4 are clamped and fixed between the upper surface of the positioning support block 7 and the bottom surface of the support frame 6 in the vertical direction, and another F-shaped clamp 4 is clamped at both ends of the anti-roll mounting seat 20 and the bottom surface of the support frame 6 in the vertical direction.

[0048] like Figure 2 As shown, the casting riveting process method applied to the aluminum alloy chassis side beam 10 and the anti-roll mounting seat 20 includes the following implementation steps:

[0049] Clean and paint the riveted area of ​​the side beam, and continue with the subsequent process after the paint is dry;

[0050] Carry out rivet process test, such as Figure 3 As shown, in order to verify the equipment capacity of the rivet gun 80 and the quality of the rivet 30, it is necessary to simulate the actual product to conduct a riveting test, such as using test plate 1 to simulate the material and wall thickness of the edge beam profile, and test plate 2 to simulate the material and wall thickness of the casting. Rivet holes need to be pre-machined according to the required size of the riveting on test plates 1 and 2, and the two test plates are fixed tightly and then riveted with a rivet gun; after the riveting test is completed, the vehicle number, time, operator and other information are marked on the test plate to facilitate product quality traceability. After the rivet appearance and size inspection are passed, the formal product riveting operation can be carried out;

[0051] On the side beam 10, the anti-roll mounting seat 20 is marked with positioning dimensions according to the drawing dimensions, and the spacing dimensions of the anti-roll mounting seat casting are adjusted through shims according to the width dimensions of the chassis;

[0052] Match the rivet holes in the castings to the 40mm aluminum profile on the lower surface of the side beam, such as Figure 5 As shown, the anti-roll mounting seat 20 is placed on the lower surface 40 of the side beam according to the positioning size, and is clamped and fixed in the vertical direction by two F clamps 4; the machined support plate 3 is placed on the lower surface 40 of the side beam close to the casting, and is clamped and fixed in the vertical direction by two F clamps 4; the magnetic drill 8 is placed on the support plate 3, and after power is turned on, the magnetic drill 8 is adsorbed on the surface of the support plate 3 under the action of electromagnetic force, and the completion is completed. Figure 1 Two rivet holes are drilled in the area of ​​the lower surface 40 of the side beam as shown; then, the positioning holes of the lower surface 40 of the side beam are riveted in the clamped state of the F clamping rail 4. After the positioning riveting is completed, all the F clamping rails 4 clamped on the lower surface 40 of the side beam are removed;

[0053] Match the rivet holes in the casting to the inner slope of the side beam and drill positioning holes in the 50 aluminum profile, such as Figure 7 As shown, first, under the action of the positioning support block 7 and the F clamping bar 4, the anti-roll mounting seat 20 attached to the inner inclined surface 50 of the side beam is clamped and fixed to prevent the magnetic drill 8 from vibrating during the drilling process and resonating with the anti-roll mounting seat 20, thereby affecting the drilling accuracy; then, the support frame 6 is placed on the inner inclined surface 50 of the side beam, and the positioning support block 7 and the support frame 6 are clamped and fixed by two F clamping bars 4, and the magnetic drill 8 is placed on the support frame 6. After power is turned on, the magnetic drill 8 is adsorbed on the surface of the support frame 6 under the action of the electromagnetic force, as shown in FIG. Figure 1 The two rivet holes in the area of ​​the inner bevel 50 of the side beam are drilled as shown; finally, the rivet operation of the positioning hole of the inner bevel 50 of the side beam is performed in the clamping state of the F clamping rail 4;

[0054] Continue to match the casting rivet holes with the drilling holes in other areas of the aluminum profile on the inner bevel 50 of the side beam, the number is 4; after completing the riveting operation of the remaining holes on the inner bevel 50 of the side beam, disassemble the related auxiliary tooling;

[0055] Continue to match the casting rivet holes with the drilling holes in other areas of the aluminum profile 40 on the lower surface of the side beam, the number is 6; after completing the riveting operation of the remaining holes on the lower surface 40 of the side beam, disassemble the related auxiliary tooling;

[0056] After riveting, the rivets are inspected for size and looseness, and those that pass the inspection are transferred to the next process.

[0057] As described above, the auxiliary tooling and method for drilling and riveting the chassis side beams and castings described in this application proposes an auxiliary tooling structural design and connection method with strong practicality, high precision and high efficiency, and is designed according to the structural characteristics of the side beams and castings. The riveting process method implemented provides the necessary prerequisites for the accuracy of mechanical drilling by flexibly converting the positioning reference surface of the magnetic drill 8, using the inner bevel 50 of the side beam and the lower surface 40 of the side beam as positioning reference surfaces respectively; the use of the magnetic drill 8 to match the rivet holes of the castings to mechanically drill the side beam 10 profile avoids the influence of external uncertain interference factors compared to the previous manual drilling, ensures the accuracy of drilling, reduces the work intensity, and significantly improves production efficiency. The proposed process flow for drilling and riveting the side beam 10 and the casting clarifies the drilling and riveting operation steps, greatly guarantees the product quality, and avoids the rework of the physical product after riveting;

[0058] In summary, the auxiliary tooling is highly practical and flexible to operate, which greatly guarantees the requirements for drilling accuracy and position size; at the same time, this application provides certain experience reference for drilling and riveting of other similar components.

[0059] As described above, the contents of the solutions given in combination with the drawings and descriptions, as long as they do not deviate from the structural solutions of the present application, still belong to the protection scope of the solutions of the present application.

Claims

1. A riveting process for aluminum alloy chassis side beams and castings, characterized in that: The invention relates to a drilling and riveting auxiliary tooling comprising a support plate (3), an F-shaped clamping bar (4), a support frame (6), a positioning support block (7) and a magnetic drill (8), wherein the support plate (3) has a flat plate structure, the cross-sectional shape of the support frame (6) is L-shaped, and the positioning support block (7) has at least two continuous T-shaped structures connected as one. The supporting frame (6) is provided with a through groove (61) with a rectangular cross section between two right-angled edges, and the outer edge of the side beam (10) is inserted into the through groove (61); At the lower surface (40) of the side beam, the support plate (3) and the casting are respectively located on the lower surface (40) of the side beam, and the magnetic drill (8) is located on the support plate (3); at least one F-shaped clamp (4) is clamped and fixed on the upper surface of the support plate (3) and the vertical ends of the lower surface (40) of the side beam, and at least one F-shaped clamp (4) is clamped and fixed on the vertical ends of the casting and the lower surface (40) of the side beam; At the inner inclined surface (50) of the side beam, the positioning support block (7) and the casting are respectively located on the inner inclined surface (50) of the side beam, the magnetic drill (8) is located on the positioning support block (7), and the support frame (6) is located at the outer edge of the lower surface of the side beam (10); at least one F-shaped clamp (4) is clamped and fixed between the upper surface of the positioning support block (7) and the bottom surface of the support frame (6) in the vertical direction, and at least one F-shaped clamp (4) is clamped at both ends of the casting and the bottom surface of the support frame (6) in the vertical direction; The riveting process includes the following implementation steps: (1) Rivet pull riveting process test; (2) Marking the side beams to locate the dimensions of the castings; (3) Drill positioning holes and rivet positioning on the aluminum profile on the lower surface of the side beam to match the rivet holes of the casting; (4) Match the rivet holes of the casting to the aluminum profiles on the inner slope of the side beam and drill positioning holes and pull rivets for positioning; (5) Drill holes and rivet at other locations of the side beam aluminum profile to match the rivet holes in the casting.

2. The riveting process for aluminum alloy chassis side beams and castings according to claim 1 is characterized in that: Before riveting the actual product, the rivet process test is carried out on the rivet to verify the equipment capacity of the rivet gun and the quality of the rivets.

3. The riveting process for aluminum alloy chassis side beams and castings according to claim 2 is characterized in that: A magnetic drill (8) is used to mechanically drill holes in the side beam profile in accordance with the matching casting rivet holes.

Images