A full-welded formed front bumper assembly welding fixture and method

Abstract

The application discloses a full-welded forming front bumper assembly welding tool and method, relates to the technical field of welding tools and methods, and discloses a full-welded forming front bumper assembly welding tool which comprises a rack, a cross beam assembly clamping mechanism, a longitudinal beam front section clamping mechanism and a deformation control mechanism. The cross beam assembly clamping mechanism comprises vertical pressing components and horizontal positioning components arranged on the rack. The longitudinal beam front section clamping mechanism is divided into two groups and is arranged on opposite sides of the cross beam assembly clamping mechanism. The longitudinal beam front section clamping mechanism comprises vertical positioning components and horizontal pressing components arranged on the rack. The deformation control mechanism is arranged between the two groups of longitudinal beam front section clamping mechanisms. The deformation control mechanism comprises telescopic components and two groups of abutting pieces fixed on the two telescopic ends of the telescopic components. A full-welded forming front bumper assembly welding method is adopted.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding tooling and methods, and particularly relates to a full-welded forming front bumper assembly welding tooling and method. BACKGROUND

[0002] The front bumper assembly of a load-bearing military off-road vehicle is welded to the vehicle body, and the front bumper assembly is composed of a front bumper beam assembly, a left longitudinal beam front section assembly and a right longitudinal beam front section assembly, which are welded by manual gas arc welding. The longitudinal beam front section is composed of two irregular 5mm-thick groove-shaped inner and outer longitudinal beam pieces that are buckled and then welded. The front bumper beam assembly is composed of a 3mm-thick front bumper plate and a front bumper rear cover plate that are buckled and then welded. The deformation amount and relative position accuracy of the front bumper beam assembly determine the effect of power transmission dispersion and buffering during the impact process, and also affect the assembly posture and running effect of the front axle of the transfer case after final assembly.

[0003] To solve the above technical problem, a Chinese patent with the patent number CN201210453092.X discloses a welding method for an aluminum alloy bumper assembly for a vehicle. The aluminum alloy bumper assembly for a vehicle is composed of a beam, an energy-absorbing box and a bracket, which are welded in steps by using two sets of welding tooling. First, the energy-absorbing box and the bracket are welded, and then the welded energy-absorbing box and bracket are welded with the beam. The welding device can be adjusted and positioned according to the characteristics of the welding parts, and can realize fastening of the welding to avoid deformation after welding. The welding is performed by using an alternating current welding machine and manual tungsten inert gas arc welding (TIG). The process parameters such as welding wire material, welding current, welding speed and wire feeding speed are adjusted and optimized to avoid welding defects.

[0004] The welding method described above uses manual TIG welding by using an alternating current welding machine. Manual gas shielded arc welding is a process of uneven and rapid heating and cooling. During the welding process and after the welding, the welding components will be deformed. The irregular groove-shaped longitudinal beam structure and the open-type front bumper beam assembly structure are prone to twisting and deformation during the welding process, which leads to that the opening size of the left / right longitudinal beam front section assembly is too small or too large. If the opening size is too small, the front axle of the transfer case cannot be installed after the final assembly. If the opening size is too large, the threads are prone to wear and tear, and the bolts are prone to breakage after the front axle of the transfer case is installed. SUMMARY

[0005] Therefore, it is necessary to provide a full-welded forming front bumper assembly welding tooling and method to solve the technical problem that the welding method in the prior art is prone to twisting and deformation when welding the irregular groove-shaped longitudinal beam structure and the open-type front bumper assembly structure, and the opening size of the left / right longitudinal beam front section assembly is difficult to control.

[0006] To achieve the above technical purposes, the technical scheme of the present application provides a full-welded front bumper assembly forming welding tool, which comprises a rack, a cross beam assembly clamping mechanism, a longitudinal beam front section clamping mechanism and a deformation control mechanism, the cross beam assembly clamping mechanism comprises a vertical pressing assembly and a horizontal positioning assembly arranged on the rack, the vertical pressing assembly can be pressed on the upper and lower surfaces of the cross beam assembly to limit the vertical displacement of the cross beam assembly, and the horizontal positioning assembly can be vertically arranged in the cross beam assembly to limit the horizontal displacement of the cross beam assembly.

[0007] The longitudinal beam front section clamping mechanism is divided into two groups and arranged on the opposite sides of the cross beam assembly clamping mechanism, the longitudinal beam front section clamping mechanism comprises a vertical positioning assembly and a horizontal pressing assembly arranged on the rack, the vertical positioning assembly can be horizontally arranged in the left longitudinal beam front section assembly and the right longitudinal beam front section assembly to limit the vertical displacement of the left longitudinal beam front section assembly and the right longitudinal beam front section assembly, and the horizontal pressing assembly can be pressed on the two side surfaces of the left longitudinal beam front section assembly and the right longitudinal beam front section assembly to limit the outward expansion of the left longitudinal beam front section assembly and the right longitudinal beam front section assembly to cause the opening size to be too large.

[0008] The deformation control mechanism is arranged between the two groups of longitudinal beam front section clamping mechanisms, the deformation control mechanism comprises a telescopic assembly and two groups of abutting members fixedly arranged on the two telescopic ends of the telescopic assembly, the telescopic assembly can drive the two groups of abutting members to move relatively, and the two groups of abutting members are arranged on the opposite side surfaces of the left longitudinal beam front section assembly and the right longitudinal beam front section assembly clamped by the two groups of longitudinal beam front section clamping mechanisms respectively, so as to limit the inward twisting and shrinking of the left longitudinal beam front section assembly and the right longitudinal beam front section assembly to cause the opening size to be too small.

[0009] In one embodiment, the vertical pressing assembly comprises a bottom supporting member fixedly arranged on the rack for supporting the lower surface of the cross beam assembly, a linkage unit and a lower pressing member fixedly connected with the linkage unit, the linkage unit can drive the lower pressing member to be pressingly arranged on the upper surface of the cross beam assembly in an openable and closable manner, the horizontal positioning assembly comprises a first positioning pin, the first positioning pin is fixedly arranged on the rack, and the first positioning pin can be arranged in the cross beam assembly to limit the horizontal displacement of the cross beam assembly.

[0010] In one embodiment, the cross beam assembly clamping mechanism further comprises a transverse clamping assembly, the transverse clamping assembly comprises a first clamping block and a first limiting block fixedly arranged on the rack and opposite to the first clamping block, the first clamping block is arranged on the rack through a first linear drive unit, the first linear drive unit can drive the first clamping block to move towards the first limiting block to clamp the front and rear end surfaces of the cross beam assembly.

[0011] In one of the embodiments, the front section clamping mechanism of the longitudinal beam further comprises a sliding member, which is slidingly arranged on the frame, and the sliding member is connected with the frame via a locking mechanism to switch the sliding connection state and the fixed connection state of the sliding member with the frame, and the vertical positioning assembly and the horizontal pressing assembly are fixedly connected with the sliding member.

[0012] In one of the embodiments, the vertical positioning assembly comprises a second positioning pin fixedly arranged on the sliding member, which is capable of penetrating the left front section assembly and the right front section assembly to limit the vertical displacement of the left front section assembly and the right front section assembly.

[0013] In one of the embodiments, the horizontal pressing assembly comprises a second clamping block and a second limiting block fixedly arranged on the sliding member and opposite to the second clamping block, and the second clamping block is arranged on the sliding member via a second linear driving unit, and the second linear driving unit is capable of driving the second clamping block to move towards the second limiting block to press the two side surfaces of the left front section assembly and the right front section assembly.

[0014] In one of the embodiments, the telescopic assembly comprises an adjusting screw, and the telescopic end comprises two groups of telescopic sleeves arranged at the two ends of the adjusting screw, one end of the two groups of telescopic sleeves is respectively screwed with the two ends of the adjusting screw, and the abutting members are respectively connected with the other end of the two groups of telescopic sleeves.

[0015] A welding method of a fully-welded formed front bumper assembly, which adopts the welding tool of the fully-welded formed front bumper assembly, and comprises the following steps:

[0016] S1. respectively weld the cross beam assembly, the left front section assembly and the right front section assembly, the cross beam assembly is provided with a first positioning hole, and the left front section assembly and the right front section assembly are respectively provided with a second positioning hole;

[0017] S2. press the upper and lower surfaces of the cross beam assembly via the vertical pressing assembly of the cross beam clamping mechanism, and position and clamp the cross beam assembly via the horizontal positioning assembly penetrating the first positioning hole of the cross beam assembly; position and clamp the left front section assembly and the right front section assembly via the vertical positioning assembly of the longitudinal beam front section clamping mechanism penetrating the second positioning hole of the left front section assembly and the right front section assembly, and press the two side surfaces of the left front section assembly and the right front section assembly via the horizontal pressing assembly to limit the outward expansion of the left front section assembly and the right front section assembly to cause the overlarge opening size;

[0018] S3. Placing the deformation control mechanism between the left front longitudinal beam assembly and the right front longitudinal beam assembly, and driving the two groups of abutting members to move relative to each other by adjusting the two telescopic ends of the telescopic assembly, so that the two groups of abutting members abut the opposite sides of the left front longitudinal beam assembly and the right front longitudinal beam assembly respectively, to limit the inward torsion and contraction of the left front longitudinal beam assembly and the right front longitudinal beam assembly, and cause the opening size to be too small.

[0019] S4. Butt welding the cross beam assembly, the left front longitudinal beam assembly and the right front longitudinal beam assembly.

[0020] In one of the embodiments, the cross beam assembly includes a cross beam inner sheet steel plate and a cross beam outer sheet steel plate, and the first positioning hole is a weight-reducing hole corresponding to the cross beam inner sheet steel plate and the cross beam outer sheet steel plate;

[0021] In the step S1, the step of butt welding the cross beam assembly includes the following steps: buckling the cross beam inner sheet steel plate and the cross beam outer sheet steel plate, welding by intermittent welding, symmetrically welding, and welding and fixing the cross beam inner sheet steel plate and the cross beam outer sheet steel plate to form the cross beam assembly.

[0022] In one of the embodiments, the left front longitudinal beam assembly and the right front longitudinal beam assembly each include a front longitudinal beam inner sheet steel plate, a front longitudinal beam outer sheet steel plate and a second bushing, the front longitudinal beam inner sheet steel plate and the front longitudinal beam outer sheet steel plate are provided with a second bushing hole corresponding to the inner hole of the second bushing, and the second positioning hole is the inner hole of the second bushing and the corresponding second bushing hole;

[0023] In the step S1, the step of butt welding the left front longitudinal beam assembly and the right front longitudinal beam assembly respectively includes the following steps: welding and fixing the second bushing at the second bushing hole of the front longitudinal beam outer sheet steel plate, and then buckling and welding the front longitudinal beam inner sheet steel plate and the front longitudinal beam outer sheet steel plate to form the left front longitudinal beam assembly and the right front longitudinal beam assembly.

[0024] Compared with the prior art, the present invention has the following beneficial effects: by setting longitudinal beam front section clamping mechanisms on opposite sides of the crossbeam assembly clamping mechanism, and by having the vertical positioning component of the longitudinal beam front section clamping mechanism pass horizontally through the left longitudinal beam front section assembly and the right longitudinal beam front section assembly, the vertical displacement of the left longitudinal beam front section assembly and the right longitudinal beam front section assembly is restricted; by having the horizontal pressing component press against the two sides of the left longitudinal beam front section assembly and the right longitudinal beam front section assembly, the horizontal displacement of the left longitudinal beam front section assembly and the right longitudinal beam front section assembly is restricted, and at the same time, the outward expansion of the left longitudinal beam front section assembly and the right longitudinal beam front section assembly is restricted, thus preventing the opening size from being too large; By setting a deformation control mechanism between the two sets of longitudinal beam front clamping mechanisms, the telescopic components of the deformation control mechanism drive the two sets of abutment parts to move relative to each other, so that the two sets of abutment parts abut against the opposite sides of the left longitudinal beam front assembly and the right longitudinal beam front assembly clamped in the two sets of longitudinal beam front clamping mechanisms, thereby limiting the inward twisting and shrinking of the left longitudinal beam front assembly and the right longitudinal beam front assembly, which would result in an excessively small opening size; thus, strict control of the opening size between the left longitudinal beam front assembly and the right longitudinal beam front assembly is achieved, avoiding the problem of the opening size between the left longitudinal beam front assembly and the right longitudinal beam front assembly being too small or too large during the welding process. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the welding fixture for the fully welded front bumper assembly of the present invention;

[0026] Figure 2 This is a schematic diagram of the present invention with the clamping mechanism at the front section of the longitudinal beam omitted.

[0027] Figure 3 for Figure 2 A magnified view of a portion of point A in the middle;

[0028] Figure 4 and Figure 5 This is a schematic diagram of the clamping mechanism for the front section of the longitudinal beam;

[0029] Figure 6 This is a cross-sectional view of the horizontally pressed assembly;

[0030] Figure 7 and Figure 8 This is a schematic diagram of the linkage unit and the pressing component;

[0031] Figure 9 and Figure 10 A schematic diagram of the horizontal positioning component;

[0032] Figure 11 and Figure 12 This is a schematic diagram of the lateral clamping assembly;

[0033] Figure 13 and Figure 14 This is a schematic diagram of the deformation control mechanism;

[0034] Figure 15 is a schematic view of a front bumper assembly;

[0035] Figure 16 is a schematic view of a cross beam assembly;

[0036] Figure 17 is a schematic view of a front section of a left side rail assembly; Figure 16 is an exploded view of

[0037] Figure 18 is a schematic view of a front section of a left side rail assembly;

[0038] Figure 19 is an exploded view of Figure 18

[0039] is a schematic view of a front section of a left side rail assembly using a C-type caliper gauge; Figure 20

[0040] Figure 21 is a schematic view of a C-type caliper gauge;

[0041] Figure 22 and Figure 23 are schematic views of a welding method for a fully-welded formed front bumper assembly of the present application;

[0042] Figure 24 is a partial enlarged view of B in Figure 22

[0043] is a partial enlarged view of C in Figure 25 Figure 22 is a partial enlarged view of D in

[0044] Figure 26 Figure 23 is a partial enlarged view of E in

[0045] Figure 27 is a V-V sectional view of Figure 26 DETAILED DESCRIPTION

[0046] The preferred embodiments of the present application will be described in detail below with reference to the attached drawings, which form a part of this application. The present application is illustrated by way of example and not limitation in the figures of the accompanying drawings in which like references indicate similar elements, and:

[0047] As shown in Figure 1 , the present application provides a welding tool for a fully-welded formed front bumper assembly, which includes a frame 1, a cross beam assembly clamping mechanism 2, a front section of a side rail clamping mechanism 3, and a deformation control mechanism 4, as shown in Figure 2 and Figure 3 ​​​​As shown, the beam assembly clamping mechanism 2 includes a vertical pressing assembly 22, a horizontal positioning assembly 23, a horizontal clamping assembly 24, a pin 26 and a vertical clamping assembly 27 arranged on the frame 1, the vertical pressing assembly 22 is capable of pressing on the upper and lower surfaces of the beam assembly 5 to limit the vertical displacement of the beam assembly 5, the horizontal positioning assembly 23 is capable of vertically penetrating the beam assembly 5 to limit the horizontal displacement of the beam assembly 5;

[0048] As shown, Figures 4 to 6 the longitudinal beam front section clamping mechanism 3 is divided into two groups and arranged on the opposite sides of the beam assembly clamping mechanism 2, the longitudinal beam front section clamping mechanism 3 includes a vertical positioning assembly 32, a horizontal pressing assembly 33 and a sliding member 31 arranged on the frame 1, the vertical positioning assembly 32 is capable of horizontally penetrating the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B to limit the vertical displacement of the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B, the horizontal pressing assembly 33 is capable of pressing on the two side surfaces of the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B to limit the horizontal displacement of the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B, and limit the outward expansion of the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B to cause the opening size to be too large;

[0049] As shown, Figure 13 and Figure 14 the deformation control mechanism 4 is arranged between the two groups of longitudinal beam front section clamping mechanisms 3, the deformation control mechanism 4 includes an extension assembly 41 and two groups of abutting members 42 respectively arranged on the two extension ends of the extension assembly 41, the extension assembly 41 is capable of driving the two groups of abutting members 42 to move relative to each other, and the two groups of abutting members 42 are respectively arranged on the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B clamped by the two groups of longitudinal beam front section clamping mechanisms 3 to limit the inward twisting and contraction of the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B to cause the opening size to be too small.

[0050] The full-welded formed front bumper assembly welding tool of the present application is used, the vertical pressing assembly 22 of the cross beam assembly clamping mechanism 2 is pressed on the upper and lower surfaces of the cross beam assembly 5, the vertical displacement of the cross beam assembly 5 is limited, the horizontal positioning assembly 23 is vertically penetrated in the cross beam assembly 5, the horizontal displacement of the cross beam assembly 5 is limited, and the cross beam assembly 5 is positioned and clamped. The longitudinal beam front segment clamping mechanism 3 is arranged on the opposite sides of the cross beam assembly clamping mechanism 2, the vertical positioning assembly 32 of the longitudinal beam front segment clamping mechanism 3 is horizontally penetrated in the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B, the vertical displacement of the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B is limited, the horizontal pressing assembly 33 is pressed on the two side surfaces of the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B, the horizontal displacement of the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B is limited, and the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B are prevented from expanding outward to cause the opening size to be too large; the deformation control mechanism 4 is arranged between the two groups of longitudinal beam front segment clamping mechanisms 3, the two groups of abutting pieces 42 are driven to relatively extend and retract by the telescopic assembly 41, the two groups of abutting pieces 42 are respectively abutted on the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B clamped on the two groups of longitudinal beam front segment clamping mechanisms 3, so as to limit the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B from being twisted and retracted inward to cause the opening size to be too small; and the opening size between the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B is strictly controlled, and the problems of the opening size between the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B being too small or too large in the welding process are avoided.

[0051] In one embodiment, the vertical pressing assembly 22 includes a bottom support 21 fixed to the rack 1 for abutting the lower surface of the cross beam assembly 5, a linkage unit 221, a lower pressing piece 222 fixed to the linkage unit 221, and a pressing block 223. The linkage unit 221 can drive the lower pressing piece 222 to pressably arranged on the upper surface of the cross beam assembly 5. The horizontal positioning assembly 23 includes a first positioning pin 231 and a third support 232. The first positioning pin 231 is fixed to the rack 1 and can penetrate the cross beam assembly 5 to limit the horizontal displacement of the cross beam assembly 5. The pressing block 223 is fixed to the linkage unit 221 and is provided with a positioning column 224. The linkage unit 221 can drive the pressing block 223 to press the wire harness fixing bracket 56 on the upper surface of the cross beam assembly 5 and position the wire harness fixing bracket 56 to penetrate the bracket hole 561 of the wire harness fixing bracket 56 through the positioning column 224.

[0052] The linkage unit 221 can drive the pressing block 223 to act, and the wire harness fixing bracket 56 is positioned and fixed on the positioned and clamped cross beam assembly 5, which facilitates the welding of the wire harness fixing bracket 56 and the cross beam assembly 5.

[0053] The specific structure of the linkage unit 221 is as follows: as shown in Figure 7 The linkage unit 221 is a quick clamp, which is a mature product on the market and belongs to the prior art in the field, and its structure does not need to be described in detail here.

[0054] The specific structure of the first positioning pin 231 is as follows: as shown in Figure 9 and Figure 10 The first positioning pin 231 includes a lower positioning portion 2321 and an upper positioning portion 2312, the third support 232 is fixedly arranged on the rack 1, the lower positioning portion 2321 is fixedly connected with the third support 232, the lower positioning portion 2321 is provided with a third screw rod 2313, the upper positioning portion 2312 is provided with a third screw hole 2314, the upper positioning portion 2312 is screwed with the third screw rod 2313 through the third screw hole 2314, and the upper positioning portion 2312 is provided with a stepped surface 2315 for abutting against the upper surface of the beam assembly 5.

[0055] The beam assembly 5 can be supported by the bottom support 21, and when the beam assembly 5 is placed on the bottom support 21, the lower pressing member 222 is actuated by the linkage unit 221 to be pressed on the upper surface of the beam assembly 5, so as to limit the vertical displacement of the beam assembly 5, and the first positioning pin 231 can be vertically arranged in the beam assembly 5, so as to limit the horizontal displacement of the beam assembly 5, and thus the beam assembly 5 can be completely positioned and fixed on the rack 1.

[0056] As shown in Figure 11 and Figure 12 In one embodiment, the lateral clamping assembly 24 includes a first clamping block 241 and a first limiting block 242 fixedly arranged on the rack 1 and opposite to the first clamping block 241, and more specifically, the first limiting block 242 is fixedly arranged on the linkage unit 221, and the first clamping block 241 is arranged on the rack 1 via a first linear drive unit, and the first linear drive unit can drive the first clamping block 241 to move towards the first limiting block 242 to clamp the front and rear end surfaces of the beam assembly 5.

[0057] The first linear drive unit includes a first support 251, a first screw rod 252 and a first locking nut 253, the first support 251 is fixedly arranged on the rack 1, the first support 251 is provided with a first screw hole 254, the first screw rod 252 is screwed with the first screw hole 254 of the first support 251, and the first locking nut 253 is screwed with the first screw rod 252, the first locking nut 253 can abut against the first support 251, and the first screw rod 252 is fixedly connected with the first support 251, one end of the first clamping block 241 is connected with the first screw rod 252, and the other end of the first screw rod 252 is provided with a first handle 255.

[0058] The specific connection relationship between the first clamping block 241 and the first screw rod 252 is as follows: the first screw rod 252 is provided with a first connecting plate 256, the first clamping block 241 is provided with a first limiting groove 257, and the first screw rod 252 is rotatably clamped in the first limiting groove 257 through the first connecting plate 256.

[0059] The first screw rod 252 can be rotated through the first handle 255 of the transverse clamping assembly 24, thereby driving the first clamping block 241 to move towards the first limiting block 242, so that the first clamping block 241 and the first limiting block 242 are clamped on the front and rear end faces of the beam assembly 5, the front and rear end faces of the beam assembly 5 are limited, and deformation during welding is prevented.

[0060] As shown in the drawings, in one embodiment, the first connecting plate 256 of the first screw rod 252 is clamped in the first limiting groove 257 of the first clamping block 241. Figure 24 The relative positions of the first lining pipe 53, the inner plate steel sheet 51 and the outer plate steel sheet 52 of the beam assembly 5 can be fixed through the bolt 26, so that the position of the first lining pipe 53 is prevented from being deviated due to the deformation of the inner plate steel sheet 51 and the outer plate steel sheet 52 of the beam assembly 5 during welding.

[0061] As shown in the drawings, in one embodiment, the longitudinal clamping assembly 27 includes a longitudinal clamping block 272 and a pad block 273, and the vertical pressing assembly 22 further includes an end supporting block 271 fixed to the sliding member 31 and used for supporting the lower surfaces of the two ends of the beam assembly 5, the longitudinal clamping block 272 is fixed to the sliding member 31 and clamped on the left and right end faces of the beam assembly 5, and the pad block 273 can be clamped in the interval 58 between the inner plate steel sheet end face 511 and the outer plate steel sheet end face 521 of the beam assembly 5, so as to support the inner plate steel sheet end face 511 and the outer plate steel sheet end face 521 when the longitudinal clamping block 272 is clamped on the left and right end faces of the beam assembly 5.

[0062] Figure 25 The left and right end faces of the beam assembly 5 can be clamped and limited through the longitudinal clamping block 272 and the pad block 273, so that deformation during welding is prevented.

[0063] In one embodiment, the sliding member 31 is slidingly arranged in the rack 1, the sliding member 31 is connected with the rack 1 through a locking mechanism, the sliding connection state and the fixed connection state of the sliding member 31 and the rack 1 are switched, and the vertical positioning assembly 32 and the horizontal pressing assembly 33 are respectively fixed to the sliding member 31.

[0064] In one embodiment, the sliding member 31 is slidingly arranged in the rack 1, the sliding member 31 is connected with the rack 1 through a locking mechanism, the sliding connection state and the fixed connection state of the sliding member 31 and the rack 1 are switched, and the vertical positioning assembly 32 and the horizontal pressing assembly 33 are respectively fixed to the sliding member 31.

[0065] ​The specific connection relationship of the sliding member 31, the locking mechanism and the rack 1 is as follows: the rack 1 is provided with a guide rail 34, the bottom of the sliding member 31 is provided with a sliding block 312, and the sliding member 31 is slidably clamped on the guide rail 34 through the sliding block 312. The locking mechanism comprises a locking pin 35, the rack 1 is provided with a vertical positioning hole 36, the sliding member 31 is provided with a limiting hole 313, and the locking pin 35 is detachably arranged in the limiting hole 313 and the vertical positioning hole 36, so as to switch the sliding connection state and the fixed connection state of the sliding member 31 and the rack 1.

[0066] The vertical positioning assembly 32 and the horizontal pressing assembly 33 are slidably arranged in the rack 1 through the sliding member 31 and the guide rail 34, so that the vertical positioning assembly 32 and the horizontal pressing assembly 33 can be slid along the guide rail 34, so as to facilitate the longitudinal beam front section clamping mechanism 3 to position and clamp the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B.

[0067] In one embodiment, the vertical positioning assembly 32 comprises a second positioning pin 321 fixedly arranged on the sliding member 31, and the second positioning pin 321 can be arranged in the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B, so as to limit the vertical displacement of the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B.

[0068] In one embodiment, the horizontal pressing assembly 33 comprises a second clamping block 331 and a second limiting block 332 fixedly arranged on the sliding member 31 and opposite to the second clamping block 331, the second clamping block 331 is arranged on the sliding member 31 through a second linear driving unit, and the second linear driving unit can drive the second clamping block 331 to move towards the second limiting block 332, so as to be pressed on both side surfaces of the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B, while limiting the outward expansion of the left longitudinal beam front section assembly 6A and the right longitudinal beam front section assembly 6B to cause the size of the opening to be too large.

[0069] The specific structure of the second linear driving unit is as follows: the second linear driving unit comprises a second support 333, a second screw rod 334, a second locking nut 335, and a locking pin 3311; the second support 333 is hingedly connected to the sliding piece 31 through a pivot 3310, the sliding piece 31 and the second support 333 are provided with corresponding pin holes, and the locking pin 3311 is plug-inly arranged in the pin holes of the sliding piece 31 and the second support 333 to switch the rotating state and the fixed state of the second support 333 and the sliding piece 31; the second support 333 is provided with a second screw hole 336, the second screw rod 334 is screwed with the second screw hole 336 of the second support 333, the second locking nut 335 is screwed with the second screw rod 334, the second locking nut 335 can abut against the second support 333, the second screw rod 334 is fixed to the second support 333, the second clamping block 331 is connected to one end of the second screw rod 334, and the other end of the second screw rod 334 is provided with a second handle 337.

[0070] The specific connection relationship between the second clamping block 331 and the second screw rod 334 is as follows: the second screw rod 334 is provided with a second connecting plate 338, the second clamping block 331 is provided with a second limiting groove 339, and the second screw rod 334 is rotationally clamped in the second limiting groove 339 through the second connecting plate 338.

[0071] The second handle 337 of the horizontal pressing assembly 33 can rotate the second screw rod 334, the second clamping block 331 can be driven by the second screw rod 334 to move towards the second limiting block 332, and the second clamping block 331 and the second limiting block 332 can be clamped and pressed on the two side surfaces of the left longitudinal beam front assembly 6A and the right longitudinal beam front assembly 6B to limit the horizontal displacement of the left longitudinal beam front assembly 6A and the right longitudinal beam front assembly 6B, and to limit the outward expansion of the left longitudinal beam front assembly 6A and the right longitudinal beam front assembly 6B to prevent the size of the opening from being too large.

[0072] In one embodiment, the telescopic assembly 41 comprises an adjusting screw rod 412, the telescopic end comprises two groups of telescopic sleeves 411 arranged at two ends of the adjusting screw rod 412, one end of each group of telescopic sleeves 411 is provided with a screw sleeve 4112, and each group of telescopic sleeves 411 is screwed with the two ends of the adjusting screw rod 412 through the screw sleeve 4112, and the abutting piece 42 is connected to the other end of each group of telescopic sleeves 411.

[0073] The telescopic sleeve 411 is provided with a slot hole 4111 for the screwing tool 4113 to pass through and screw the telescopic sleeve 411, the adjusting screw 412 is provided with a limiting groove 4121, when the screwing tool 4113 passes through the slot hole 4111 to screw the telescopic sleeve 411, a clamp or other tool is clamped in the limiting groove 4121 to limit the rotation of the adjusting screw 412 with the telescopic sleeve 411, and the screwing tool 4113 can be a common cylindrical rod.

[0074] The specific connection relationship between the abutting piece 42 and the telescopic sleeve 411 is as follows: the other end of the two groups of telescopic sleeves 411 is respectively fixedly provided with a connecting rod 413, the connecting rod 413 is provided with a third connecting plate 4131, the abutting piece 42 is provided with a third limiting groove 421, and the connecting rod 413 is rotatably clamped in the third limiting groove 421 through the third connecting plate 4131.

[0075] By passing the screwing tool 4113 into the slot hole 4111, the telescopic sleeve 411 can be rotated, and under the interaction of the screw sleeve 4112 and the adjusting screw 412, the telescopic sleeve 411 and the adjusting screw 412 can be driven to axially relatively telescopic move, so that the two groups of abutting pieces 42 are respectively abutted on the left front longitudinal beam assembly 6A and the right front longitudinal beam assembly 6B clamped on the two groups of front longitudinal beam clamping mechanisms 3, to limit the left front longitudinal beam assembly 6A and the right front longitudinal beam assembly 6B from being twisted and contracted inwardly to cause the opening size to be too small.

[0076] As shown in Figures 22 to 26 , a full-welded formed front bumper assembly welding method adopts the full-welded formed front bumper assembly welding tool, and includes the following steps:

[0077] S1. respectively weld the cross beam assembly 5, the left front longitudinal beam assembly 6A and the right front longitudinal beam assembly 6B, the cross beam assembly 5 is provided with a first positioning hole 54, and the left front longitudinal beam assembly 6A and the right front longitudinal beam assembly 6B are respectively provided with a second positioning hole;

[0078] As shown in Figure 16 and Figure 17 , the cross beam assembly 5 includes a cross beam inner sheet steel plate 51, a cross beam outer sheet steel plate 52, a first lining pipe 53 and a wire harness fixing support 56, the cross beam inner sheet steel plate 51 and the cross beam outer sheet steel plate 52 are provided with a first lining pipe hole 55 corresponding to the inner hole of the first lining pipe 53, the first positioning hole 54 is a weight-reducing hole provided on the cross beam inner sheet steel plate 51 and the cross beam outer sheet steel plate 52 and corresponding to each other, and the cross beam inner sheet steel plate 51 is provided with an assembly groove 57 for the left front longitudinal beam assembly 6A and the right front longitudinal beam assembly 6B to be inserted and combined with the cross beam assembly 5;

[0079] In the step S1, the welding of the cross beam assembly 5 includes the following steps: first, using a positioning tool (such as a cylindrical pin) to position the first liner pipe 53, so that the first liner pipe 53 is coaxial with the first liner pipe hole 55 of the cross beam outer sheet steel plate 52, then using three-point spot welding to fix the first liner pipe 53 to the cross beam outer sheet steel plate 52, then buckling the cross beam inner sheet steel plate 51 with the cross beam outer sheet steel plate 52, and making the first liner pipe hole 55 of the cross beam inner sheet steel plate 51 coaxial with the first liner pipe 53, then using intermittent welding to weld symmetrically, and controlling the welding speed at 0.28m / min-0.3m / min, to weld and fix the cross beam inner sheet steel plate 51 with the cross beam outer sheet steel plate 52, to form the cross beam assembly 5, and the cross beam assembly 5 after welding has a gap 58 between the end face 511 of the cross beam inner sheet steel plate and the end face 521 of the cross beam outer sheet steel plate.

[0080] As shown in Figure 18 and Figure 19 , the left front longitudinal beam assembly 6A and the right front longitudinal beam assembly 6B respectively include a front longitudinal beam inner sheet steel plate 61, a front longitudinal beam outer sheet steel plate 62 and a second liner pipe 63, the front longitudinal beam inner sheet steel plate 61 and the front longitudinal beam outer sheet steel plate 62 are provided with a second liner pipe hole 64 corresponding to the inner hole of the second liner pipe 63, and the second positioning hole is the inner hole of the second liner pipe 63 and the corresponding second liner pipe hole 64.

[0081] In the step S1, the welding of the left front longitudinal beam assembly 6A and the right front longitudinal beam assembly 6B respectively includes the following steps: first, using a positioning tool (such as a cylindrical pin) to position the second liner pipe 63, so that the second liner pipe 63 is coaxial with the second liner pipe hole 64 of the front longitudinal beam outer sheet steel plate 62, then using three-point spot welding to fix the second liner pipe 63 to the second liner pipe hole 64 of the front longitudinal beam outer sheet steel plate 62, then buckling and welding the front longitudinal beam inner sheet steel plate 61 with the front longitudinal beam outer sheet steel plate 62, to form the left front longitudinal beam assembly 6A and the right front longitudinal beam assembly 6B.

[0082] When the front longitudinal beam inner sheet steel plate 61 and the front longitudinal beam outer sheet steel plate 62 are buckled and welded, first, the front longitudinal beam inner sheet steel plate 61 and the front longitudinal beam outer sheet steel plate 62 are buckled and fixed by spot welding, and then full welding is performed by segmental back welding, from inside to outside.

[0083] As shown in Figure 20 and Figure 21 , after the front longitudinal beam inner sheet steel plate 61 and the front longitudinal beam outer sheet steel plate 62 are buckled and welded, a C-type caliper 7 is used to detect the passability of the left front longitudinal beam assembly 6A and the right front longitudinal beam assembly 6B, and the appearance of the weld is visually inspected for welding defects such as undercut, weld tumor, burn-through, cracks, pores, etc., and the qualified parts are retained.

[0084] S2. The horizontal positioning assembly 23 is used to position the cross beam assembly 5 by penetrating the first positioning hole 54 of the cross beam assembly 5, and the vertical pressing assembly 22 of the cross beam clamping mechanism 2 is used to press the upper and lower surfaces of the cross beam assembly 5, so as to clamp the cross beam assembly 5; the vertical positioning assembly 32 of the longitudinal beam front segment clamping mechanism 3 is used to penetrate the second positioning hole of the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B, and the horizontal pressing assembly 33 is used to press the two side surfaces of the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B, so as to clamp the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B and limit the outward expansion of the left longitudinal beam front segment assembly 6A and the right longitudinal beam front segment assembly 6B to cause the size of the opening to be too large.

[0085] More specifically, the upper positioning part 2312 of the first positioning pin 231 is first detached from the third screw 2313, as shown in the figure, the cross beam assembly 5 welded in step S1 is sleeved on the lower positioning part 2321 of the first positioning pin 231 through the first positioning hole 54 on the cross beam outer sheet steel plate 52 and is placed on the bottom support 21, then the upper positioning part 2312 is screwed with the third screw 2313, so that the upper positioning part 2312 penetrates the first positioning hole 54 of the cross beam inner sheet steel plate 51 of the cross beam assembly 5, and the stepped surface 2315 of the upper positioning part 2312 abuts against the upper surface of the cross beam inner sheet steel plate 51, so as to limit the horizontal displacement of the cross beam assembly 5. Figure 27

[0086] The linkage unit 221 of the vertical pressing assembly 22 is operated to drive the lower pressing piece 222 to press against the upper surface of the cross beam inner sheet steel plate 51 of the cross beam assembly 5, so as to limit the vertical displacement of the cross beam assembly 5, thereby achieving the positioning and clamping of the cross beam assembly 5. The linkage unit 221 of one set of vertical pressing assemblies 22 is operated to drive the pressing block 223 to act, so as to press and fix the wire harness fixing bracket 56 on the upper surface of the cross beam assembly 5, and the positioning column 224 is used to penetrate the bracket hole 561 of the wire harness fixing bracket 56.

[0087] The first handle 255 of the transverse clamping assembly 24 is rotated to drive the first screw 252 to move the first clamping block 241 towards the first limiting block 242, so that the first clamping block 241 and the first limiting block 242 clamp the front and rear end surfaces of the cross beam assembly 5, thereby limiting the front and rear end surfaces of the cross beam assembly 5 to prevent deformation during welding.

[0088] ​The lower end of the left and right front longitudinal beam assemblies 6A and 6B is inserted into the assembly groove 57 of the cross beam assembly 5, then the sliding member 31 is slid along the guide rail 34 to a predetermined position, and the locking pin 35 is inserted into the limiting hole 313 and the vertical positioning hole 36 for locking, so that the second positioning pin 321 can be inserted into the second positioning hole of the left and right front longitudinal beam assemblies 6A and 6B to limit the vertical displacement of the left and right front longitudinal beam assemblies 6A and 6B, and the left and right end faces of the cross beam assembly 5 are clamped and limited by the longitudinal clamping block 272 and the spacer 273 in the space 58 between the inner plate end face 511 and the outer plate end face 521 of the cross beam assembly 5, so as to prevent deformation during welding. Then the second handle 337 is rotated to move the second clamping block 331 towards the second limiting block 332 by the second screw rod 334, and the left and right front longitudinal beam assemblies 6A and 6B are clamped and pressed by the second clamping block 331 and the second limiting block 332, so as to limit the horizontal displacement of the left and right front longitudinal beam assemblies 6A and 6B and prevent the left and right front longitudinal beam assemblies 6A and 6B from expanding outward to cause the opening size to be too large.

[0089] S3. The deformation control mechanism 4 is arranged between the left and right front longitudinal beam assemblies 6A and 6B, the two telescopic ends of the telescopic assembly 41 are adjusted to drive the two groups of abutting members 42 to move relatively and telescopically, so that the two groups of abutting members 42 abut against the opposite two side faces of the left and right front longitudinal beam assemblies 6A and 6B, respectively, to limit the left and right front longitudinal beam assemblies 6A and 6B from being twisted and contracted inward to cause the opening size to be too small.

[0090] More specifically, the telescopic sleeve 411 is rotated by inserting the twisting tool 4113 into the slot hole 4111 of the telescopic sleeve 411, and the telescopic sleeve 411 and the adjusting screw rod 412 move axially and telescopically relative to each other under the interaction of the screw sleeve 4112 and the adjusting screw rod 412, so that the two groups of abutting members 42 abut against the opposite two side faces of the left and right front longitudinal beam assemblies 6A and 6B clamped by the two groups of front longitudinal beam clamping mechanisms 3, respectively.

[0091] S4. The cross beam assembly 5, the left and right front longitudinal beam assemblies 6A and 6B are spot-welded, and during the spot-welding process, short welds are welded first and then long welds are welded, transverse welds are welded first and then longitudinal welds are welded, full penetration welding is adopted at the spot-welding position, and the welding is performed from inside to outside in sections.

[0092] The above merely describes preferred specific embodiments of the present application, but the protection scope of the present application is not limited thereto, and any person skilled in the art can easily think of changes or replacements within the technical scope disclosed by the present application, which should be covered within the protection scope of the present application.

Claims

1. A fully welded formed front bumper assembly welding fixture, characterized by, The rack, the cross beam assembly clamping mechanism, the longitudinal beam front section clamping mechanism and the deformation control mechanism, the cross beam assembly clamping mechanism comprises vertical pressing assembly and horizontal positioning assembly arranged on the rack, the vertical pressing assembly can be pressed on the upper and lower surfaces of the cross beam assembly to limit the vertical displacement of the cross beam assembly, the horizontal positioning assembly can be vertically arranged in the cross beam assembly to limit the horizontal displacement of the cross beam assembly; The longitudinal beam front section clamping mechanism is divided into two groups and arranged on the opposite sides of the cross beam assembly clamping mechanism, the longitudinal beam front section clamping mechanism comprises vertical positioning assembly and horizontal pressing assembly arranged on the rack, the vertical positioning assembly can be horizontally arranged in the left and right longitudinal beam front section assemblies to limit the vertical displacement of the left and right longitudinal beam front section assemblies, the horizontal pressing assembly can be pressed on the two side surfaces of the left and right longitudinal beam front section assemblies to limit the outward expansion of the left and right longitudinal beam front section assemblies to cause the opening size to be too large. The deformation control mechanism is arranged between the two groups of longitudinal beam front section clamping mechanisms, the deformation control mechanism comprises telescopic assembly and two groups of abutting members fixed on the two telescopic ends of the telescopic assembly, the telescopic assembly can drive the two groups of abutting members to move relatively, the two groups of abutting members are arranged on the opposite sides of the left and right longitudinal beam front section assemblies clamped by the two groups of longitudinal beam front section clamping mechanisms to limit the inward twisting and shrinking of the left and right longitudinal beam front section assemblies to cause the opening size to be too small, the telescopic assembly comprises adjusting screw, the telescopic end comprises two groups of telescopic sleeves arranged on the two ends of the adjusting screw, one end of the two groups of telescopic sleeves is screwed with the two ends of the adjusting screw, the abutting member is connected with the other end of the two groups of telescopic sleeves, the telescopic sleeve is provided with a slot for the penetrating and turning of the turning tool, the adjusting screw is provided with a limiting groove, when the turning tool penetrates the slot to turn the telescopic sleeve, the spanner tool is arranged in the limiting groove to limit the rotation of the adjusting screw with the telescopic sleeve.

2. The fully welded formed front bumper assembly welding fixture of claim 1, wherein, The vertical pressing assembly comprises bottom support member fixed on the rack for supporting the lower surface of the cross beam assembly, linkage unit and lower pressing member fixed with the linkage unit, the linkage unit can drive the lower pressing member to be pressingly arranged on the upper surface of the cross beam assembly, the horizontal positioning assembly comprises first positioning pin, the first positioning pin is fixed on the rack, the first positioning pin can be arranged in the cross beam assembly to limit the horizontal displacement of the cross beam assembly.

3. The fully welded formed front bumper assembly welding fixture of claim 1, wherein, The cross beam assembly clamping mechanism further comprises transverse clamping assembly, the transverse clamping assembly comprises first clamping block and first limiting block fixed on the rack and opposite to the first clamping block, the first clamping block is arranged on the rack through the first linear drive unit, the first linear drive unit can drive the first clamping block to move towards the first limiting block to clamp the front and rear end surfaces of the cross beam assembly.

4. The fully welded formed front bumper assembly welding fixture of claim 1, wherein, The front section clamping mechanism further comprises a sliding member, which is slidingly arranged on the rack, and the sliding member is connected with the rack via a locking mechanism to switch the sliding connection state and the fixed connection state of the sliding member and the rack, and the vertical positioning assembly and the horizontal pressing assembly are fixedly connected with the sliding member.

5. A full weld formed front bumper assembly welding fixture according to claim 4, wherein, The vertical positioning assembly comprises a second positioning pin fixedly arranged on the sliding member, and the second positioning pin is capable of penetrating the left front section assembly and the right front section assembly to limit the vertical displacement of the left front section assembly and the right front section assembly.

6. A full weld formed front bumper assembly welding fixture according to claim 4, wherein, The horizontal pressing assembly comprises a second clamping block and a second limiting block fixedly arranged on the sliding member and opposite to the second clamping block, the second clamping block is arranged on the sliding member via a second linear driving unit, and the second linear driving unit is capable of driving the second clamping block to move towards the second limiting block to press the two side surfaces of the left front section assembly and the right front section assembly.

7. A method of welding a full-welded formed front bumper assembly, characterized by, The full-welded formed front bumper assembly welding tool according to any one of claims 1-6 comprises the following steps: S1. separately welding the cross beam assembly, the left front section assembly and the right front section assembly, the cross beam assembly is provided with a first positioning hole, and the left front section assembly and the right front section assembly are respectively provided with a second positioning hole; S2. the vertical pressing assembly of the cross beam assembly clamping mechanism is pressed on the upper and lower surfaces of the cross beam assembly, the first positioning hole of the cross beam assembly is penetrated by the horizontal positioning assembly to position and clamp the cross beam assembly; the second positioning hole of the left front section assembly and the right front section assembly is penetrated by the vertical positioning assembly of the front section clamping mechanism, and the two side surfaces of the left front section assembly and the right front section assembly are pressed by the horizontal pressing assembly to position and clamp the left front section assembly and the right front section assembly, and meanwhile, the outward expansion of the left front section assembly and the right front section assembly is limited to prevent the opening size from being too large; S3. the deformation control mechanism is arranged between the left front section assembly and the right front section assembly, the two telescopic ends of the telescopic assembly are adjusted to drive the two groups of abutting members to relatively move and abut on the opposite two side surfaces of the left front section assembly and the right front section assembly, so as to limit the inward torsion and contraction of the left front section assembly and the right front section assembly to prevent the opening size from being too small; S4. the cross beam assembly, the left front section assembly and the right front section assembly are subjected to tailor welding.

8. The method of claim 7, wherein, The cross beam assembly comprises a cross beam inner sheet steel plate and a cross beam outer sheet steel plate, and the first positioning hole is a weight-reducing hole arranged on the cross beam inner sheet steel plate and the cross beam outer sheet steel plate and corresponding to each other; In the step S1, the welding of the cross beam assembly comprises the following steps: the cross beam inner sheet steel plate is buckled with the cross beam outer sheet steel plate, intermittent welding is adopted, and the cross beam inner sheet steel plate and the cross beam outer sheet steel plate are fixedly welded to form the cross beam assembly.

9. The method of claim 7, wherein, The left front section assembly and the right front section assembly respectively comprise a front section inner sheet steel plate, a front section outer sheet steel plate and a second lining pipe, the front section inner sheet steel plate and the front section outer sheet steel plate are provided with a second lining pipe hole corresponding to the inner hole of the second lining pipe, and the second positioning hole is the inner hole of the second lining pipe and the corresponding second lining pipe hole. In the step S1, the welding of the left longitudinal beam front segment assembly and the right longitudinal beam front segment assembly respectively comprises the following steps: welding and fixing the second liner tube at the second liner tube hole of the longitudinal beam front segment outer sheet steel plate, and then welding the longitudinal beam front segment inner sheet steel plate and the longitudinal beam front segment outer sheet steel plate to form the left longitudinal beam front segment assembly and the right longitudinal beam front segment assembly.

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