A manufacturing method of a diaphragm air spring cylinder block

Abstract

A manufacturing method of a diaphragm air spring cylinder block provided by the present invention relates to the technical field of air springs, and overcomes the technical defects of a large amount of material waste and environmental unfriendliness in the existing manufacturing. The manufacturing method of the diaphragm air spring cylinder block includes the following steps: S1: calculating the blank size according to the finished product size and cutting the material; S2: manufacturing a stamping die according to the finished product size; S3: installing the prefabricated stamping die in S2 on different punching presses; S4: placing the sheet material in S1 between the upper and lower dies in S3; S5: starting stamping forming; S6: including a partial welding process; S7: including a press-fitting process; S8: further including a riveting process; S9: including an overall welding process, welding each part into one body according to requirements. The manufacturing method of the present invention manufactures finished products through welding, press-fitting, and riveting processes, not only greatly saving materials, but also improving the rigidity of the air spring cylinder block and the product quality. The gas protection reduces the oxidation of the welding layer, and the punching press has high production and processing efficiency, being suitable for mass production.

Description

Technical Field

[0001] The present invention belongs to the technical field of air springs, and particularly relates to a manufacturing method of a diaphragm air spring cylinder block. Background Art

[0002] The present invention relates to an air spring for a commercial vehicle, which air spring comprises: a first connecting member in the form of a cover member in particular, a second connecting member in the form of a rolling piston, and a rolling airbag made of an elastic material, wherein a first end of the rolling airbag can be sealingly fastened to the first connecting member by means of a first fastening device, and a second end of the rolling airbag can be sealingly fastened to the rolling piston by means of a second fastening device.

[0003] Such air springs are known per se and are used in a wide range of commercial vehicles (for example in towing vehicles and trailers).

[0004] This rolling airbag itself consists of an elastic material, preferably made of rubber or a rubber-like plastic, and usually has a plurality of fastening bead rims at the ends.

[0005] The rolling airbag can be fastened or clamped to these connecting members by using a plurality of clamping rings in a form-fitting manner or simply by sliding these fastening bead rims of the rolling airbag onto a plurality of conical sealing surfaces. These fastening bead rims of the rolling airbag are usually reinforced by a plurality of embedded bead cores or annular bodies or piercing cores made of steel or steel wire with high tensile strength, and are sealingly supported on the associated conical seat surfaces of these connecting members under the action of the internal pressure of the rolling airbag.

[0006] The connection between the rolling airbag and these connecting members can also be produced by a clamp plate that can be screwed on, which fixes the rolling airbag to the corresponding connecting member, specifically on the rolling piston.

[0007] In this case of fastening, the internal volume of the rolling piston is used for this threaded connection, and thus this internal volume is no longer available for minimizing the natural frequency.

[0008] An air spring having such a connection between the rolling airbag and the rolling piston is not intended to be the subject of the present invention.

[0009] The connecting members can be additionally connected to the rolling airbag by means of a flange plate, wherein such a flange plate usually reaches around a corresponding fastening bead rim of the rolling airbag and is thus non-releasably, fixedly and in an airtight manner connected to the rolling airbag. Thereby, it is advantageously possible to transmit high tensile forces.

[0010] In addition, it is known that these connecting components (i.e., the roll-on pistons and / or the cover pieces or cover plates) are formed of plastic. As a result, these connecting components are protected from corrosion and advantageously have a much smaller weight compared to conventional metal connecting components.

[0011] This has the drawback that it has been found that such air springs are generally not airtight under temperature fluctuations. The Chinese patent document with the authorization announcement number CN102245926B and the name of air spring solves the airtightness problem. However, due to the shape and structure of the cylinder block, the rigidity is insufficient. How to improve the rigidity and toughness of the air spring cylinder block? In the prior art, for metal products with complex shapes, the casting method is mostly used. This method wastes a lot of materials and does not meet the current requirements of energy conservation and environmental protection. What method is used to manufacture a product that meets the above requirements? This is the technical problem that we need to solve currently. Summary of the Invention

[0012] The object of the present invention is to provide a manufacturing method for a diaphragm air spring cylinder block to solve the above technical problems existing in the prior art.

[0013] According to the above object, the basic technical solution of the present invention is: a manufacturing method for a diaphragm air spring cylinder block, the diaphragm air spring cylinder block includes an upper cover in a "concave" shape, the outer side of the upper cover is connected with a lower cover below, the lower cover is in a stepped cylindrical shape with different diameters, a gas guide pipe is provided on the side wall of the large cylinder of the lower cover, an annular groove is provided on the outer wall of the small cylinder of the lower cover, and a first bracket and a second bracket are provided at the bottom of the inner outer wall of the upper cover. The first bracket and the second bracket are arranged back to back relative to each other. The manufacturing method is characterized in that it includes the following steps:

[0014] S1: Calculate the blank size according to the finished product sizes of the upper cover, the lower cover, the first bracket and the second bracket and cut the material.

[0015] S2: Make stamping dies according to the finished product sizes of the upper cover, the lower cover, the first bracket and the second bracket.

[0016] S3: Install the prefabricated stamping dies in step S2 on different punching presses.

[0017] S4: Place the sheet material cut in step S1 between the upper and lower dies of the stamping die on the punching press in step S3.

[0018] S5: Start the stamping operation button to stamp the sheet material in step S4 into the shape of the stamping die.

[0019] S6: Include a local welding process. Place the first bracket and the second bracket in step S5 on the welding equipment, start the welding switch, and weld the two parts of the first bracket and the second bracket into one body as required.

[0020] S7: It includes a press-fitting process. Install the first bracket, the second bracket assembly after welding in S6, and the upper cover in S5 on the press-fitting tooling, start the press-fitting switch, and press-fit the first bracket, the second bracket assembly and the upper cover together.

[0021] S8: It also includes a riveting process. Install the lower cover on the riveting tooling, put in the prefabricated reinforcing sleeve, start the riveting switch, and rivet the reinforcing sleeve inside the lower cover.

[0022] S9: It includes an overall welding process. Install the upper cover and the lower cover on the welding equipment, install the air duct on the lower cover, put the prefabricated stud on the upper cover, and then start the welding switch to weld all parts together as required.

[0023] Further, an inwardly concave arc block is provided on the inner side of the upper cover in S5. There are 4 such arc blocks, which are evenly spaced from the original inner circular wall, and the arc blocks are formed by one-time processing of the extension of the die-stamped sheet material.

[0024] Further, the stamping dies in S2 are divided into 4 sets, namely the upper cover stamping die, the lower cover stamping die, the first bracket stamping die and the second bracket stamping die, and each of the 4 sets of stamping dies is provided with its own number.

[0025] Further, in the partial welding process of S6, first fix the first bracket and the second bracket together as a whole through a detachable tooling, and then put them into the welding equipment for welding.

[0026] Further, in the press-fitting process of S7, an interference press-fitting connection is adopted between the whole of the first bracket and the second bracket and the upper cover. After press-fitting, if there is no damage deformation on the surface of the upper cover and it is difficult to remove by manual force, it is regarded as qualified.

[0027] Further, in the riveting process of S8, after riveting the reinforcing sleeve, there shall be no riveting burrs and cracking on its surface.

[0028] Further, in the overall welding process of S9, the welded product shall pass the first-piece product welding quality inspection before continuous welding production.

[0029] Even further, sampling inspection is also included in the continuous welding production, and the sampling inspection is carried out according to the national sampling standard.

[0030] Even further, the overall welding process is carried out by a gas shielded welding method.

[0031] Even further specifically, the gas shield is inert gas protection.

[0032] Advantages and beneficial effects of the present invention compared with the prior art:

[0033] 1. The product involved in the manufacturing method of the present invention uses a mold to form several parts through stamping, and then the parts are assembled into a product through welding, press-fitting, and riveting according to different overall distributions. This not only greatly saves materials, but also greatly improves the rigidity of the air spring cylinder body, greatly increases the supporting force on the upper end face stud, improves the overall product quality, and extends the service life of the air spring;

[0034] 2. In the manufacturing method of the present invention, an inert product is used for welding, reducing the oxidation of the welding layer and improving the welding quality;

[0035] 3. In the manufacturing method of the present invention, processing and production are carried out by making a stamping mold. Due to the high speed of the punching machine, the processing efficiency is high, which is suitable for mass production. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 is a three-dimensional structural schematic diagram of the product manufactured by the manufacturing method of the present invention;

[0037] Figure 2 is a top-view structural schematic diagram of the product manufactured by the manufacturing method of the present invention;

[0038] Figure 3 is Figure 2 the H-H cross-sectional structural schematic diagram of;

[0039] In the figure: 1. upper cover; 2. lower cover; 3. middle through hole; 4. first bracket; 5. second bracket; 6. stud; 7. air duct; 8. thread; 9. reinforcing sleeve; 10. annular groove; 11. concave arc block. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0040] Combined with Figures 1 to 3 , which is a structural schematic diagram of the product manufactured by the embodiment of the manufacturing method of a diaphragm air spring cylinder body of the present invention. The diaphragm air spring cylinder body includes an upper cover 1 in a "concave" shape. The lower part of the outer side of the upper cover 1 is connected with a lower cover 2. The lower cover 2 is in the shape of a stepped cylinder with different diameters. An air duct 7 is provided on the side wall of the large cylinder of the lower cover 2, and an annular groove 10 is provided on the outer wall of the small cylinder of the lower cover 2. A first bracket 4 and a second bracket 5 are provided at the bottom of the inner outer wall of the upper cover 1. The first bracket 4 and the second bracket 5 are arranged back to back. The manufacturing method includes the following steps:

[0041] S1: Calculate the blank size according to the finished product sizes of the upper cover 1, the lower cover 2, the first bracket 4 and the second bracket 5 and cut the material;

[0042] S2: Make a stamping mold according to the finished product sizes of the upper cover 1, the lower cover 2, the first bracket 4 and the second bracket 5;

[0043] S3: Install the prefabricated stamping die in S2 on different punching presses;

[0044] S4: Place the sheet material after blanking in S1 between the upper and lower dies of the stamping die on the punching press in S3;

[0045] S5: Start the stamping operation button to stamp the sheet material in S4 into the shape of the stamping die;

[0046] S6: Include a partial welding process. Place the first bracket 4 and the second bracket 5 in S5 on the welding equipment, start the welding switch, and weld the two parts of the first bracket 4 and the second bracket 5 into one body as required;

[0047] S7: Include a press-fitting process. Install the assembled first bracket 4 and second bracket 5 in S6 and the upper cover 1 in S5 on the press-fitting tooling, start the press-fitting switch, and press-fit the assembled first bracket 4 and second bracket 5 with the upper cover 1 together;

[0048] S8: Also include a riveting process. Install the lower cover 2 on the riveting tooling, place the prefabricated reinforcing sleeve 9, start the riveting switch, and rivet the reinforcing sleeve 9 inside the lower cover 2.

[0049] S9: Include an overall welding process. Install the upper cover 1 and the lower cover 2 on the welding equipment, install the air duct 7 on the lower cover 2, place the prefabricated stud 6 on the upper cover 1, and then start the welding switch to weld each part into one body as required;

[0050] Inside the upper cover 1 in the above S5, there are concave arc blocks 11 recessed inward. There are 4 of the concave arc blocks 11, which are arranged at equal intervals with the original inner circular wall. The concave arc blocks 11 are formed by one-time processing of the extension of the stamping sheet material through a die.

[0051] The stamping dies in the above S2 are divided into 4 sets, namely the stamping die for the upper cover 1, the stamping die for the lower cover 2, the stamping die for the first bracket 4, and the stamping die for the second bracket 5. Each of the 4 sets of stamping dies is provided with its own number.

[0052] In the partial welding process of the above S6, first fix the first bracket 4 and the second bracket 5 together as one body through a detachable tooling combination, and then place them in the welding equipment for welding.

[0053] In the press-fitting process of the above S7, the overall of the first bracket 4 and the second bracket 5 and the upper cover 1 are connected by interference press-fitting. After press-fitting, the surface of the upper cover 1 does not undergo damage deformation and it is difficult to remove by manual force as the qualified standard.

[0054] In the riveting process of the above S8, after riveting the reinforcing sleeve 9, there shall be no riveting burrs and cracking on its surface.

[0055] In the overall welding process of the above S9, the welded product shall undergo the first-piece product welding quality inspection and only after passing the inspection can continuous welding production be carried out. Sampling inspection is also included in the continuous welding production, and the sampling inspection is carried out in accordance with the national sampling standards. The overall welding process is carried out by means of gas shielded welding, and the gas shield is inert gas shield.

[0056] The specific embodiments described herein are merely illustrative of the spirit of the present invention. Those skilled in the art to which the present invention pertains may make various modifications or supplements to the described specific embodiments or use similar ways for substitution, but will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

[0057] Although the terms such as 1. upper cover; 2. lower cover; 3. middle through hole; 4. first bracket; 5. second bracket; 6. stud; 7. air duct; 8. thread; 9. reinforcing sleeve; 10. annular groove; 11. concave arc block are used more frequently in this article, the possibility of using other terms is not excluded. The use of these terms is only for more conveniently describing and explaining the essence of the present invention; interpreting them as any additional limitation is contrary to the spirit of the present invention.

[0058] The manufacturing method of the diaphragm air spring cylinder body provided by the present invention has been introduced above. In this introduction, specific preferred embodiments are used to elaborate on the principle and implementation manner of the present invention. These embodiments are only used to help understand the principle and core idea of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the design idea of the present invention, the implementation schemes in the above embodiments can be further combined or substituted, and several improvements and modifications can be made to the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A manufacturing method of a diaphragm air spring cylinder block, the diaphragm air spring cylinder block includes an upper cover (1) in a "concave" shape, the lower side of the outer side of the upper cover (1) is connected with a lower cover (2), the lower cover (2) is in a stepped cylindrical shape with different diameters, an air guide pipe (7) is arranged on the side wall of the large cylinder of the lower cover (2), an annular groove (10) is arranged on the outer wall of the small cylinder of the lower cover (2), and a first bracket (4) and a second bracket (5) are arranged at the bottom of the inner outer wall of the upper cover (1), and the first bracket (4) and the second bracket (5) are arranged back to back relative to each other, and it is characterized in that: The manufacturing method described above includes the following steps: S1: Calculate the blank size according to the finished product sizes of the upper cover (1), lower cover (2), first bracket (4) and second bracket (5), and cut the material. S2: Manufacture stamping dies according to the finished product sizes of the upper cover (1), lower cover (2), first bracket (4) and second bracket (5). S3: Install the prefabricated stamping dies in step S2 on different punching presses. S4: Place the sheet material cut in step S1 between the upper and lower dies of the stamping die on the punching press in step S3. S5: Start the stamping operation button to stamp the sheet material in step S4 into the shape of the stamping die. S6: Include a partial welding process. Place the first bracket (4) and second bracket (5) in step S5 on the welding equipment, start the welding switch, and weld the two parts of the first bracket (4) and second bracket (5) into one body as required. S7: Include a press-fitting process. Install the assembled first bracket (4) and second bracket (5) after welding in step S6 and the upper cover (1) in step S5 on the press-fitting tooling, start the press-fitting switch, and press-fit the first bracket (4) and second bracket (5) assembly with the upper cover (1). S8: Also include a riveting process. Install the lower cover (2) on the riveting tooling, place the prefabricated reinforcement sleeve (9) in it, start the riveting switch, and rivet the reinforcement sleeve (9) inside the lower cover (2). S9: Include an overall welding process. Install the upper cover (1) and lower cover (2) on the welding equipment, install the air duct (7) on the lower cover (2), place the prefabricated stud (6) on the upper cover (1), and then start the welding switch to weld each part into one body as required.

2. The manufacturing method of the diaphragm air spring cylinder according to claim 1, characterized in that: On the inner side of the upper cover (1) in step S5, there are inwardly recessed concave arc blocks (11). There are 4 concave arc blocks (11), which are arranged at equal intervals from the original inner circular wall. The concave arc blocks (11) are formed by one-time processing of the extension of the sheet material through die stamping.

3. The manufacturing method of the diaphragm air spring cylinder according to claim 1, characterized in that: The stamping dies in step S2 are divided into 4 sets, namely the upper cover (1) stamping die, lower cover (2) stamping die, first bracket (4) stamping die and second bracket (5) stamping die. Each of the 4 sets of stamping dies is provided with its own number.

4. The manufacturing method of the diaphragm air spring cylinder according to claim 1, characterized in that: In the partial welding process in step S6, first fix the first bracket (4) and second bracket (5) together as one body through a detachable tooling combination, and then place them in the welding equipment for welding.

5. The manufacturing method of the diaphragm air spring cylinder according to claim 1, characterized in that: In the press-fitting process in step S7, the overall connection between the first bracket (4) and second bracket (5) and the upper cover (1) is an interference press-fitting connection. After press-fitting, if there is no damage deformation on the surface of the upper cover (1) and it is difficult to remove by manual force, it is considered qualified.

6. The manufacturing method of the diaphragm air spring cylinder body according to claim 1, characterized in that: In the riveting process in step S8, after riveting the reinforcement sleeve (9), there shall be no riveting burrs and cracking on its surface.

7. The manufacturing method of the diaphragm air spring cylinder according to claim 1, characterized in that: In the overall welding process in step S9, the welded product shall pass the first-piece product welding quality inspection before continuous welding production is carried out.

8. The manufacturing method of the diaphragm air spring cylinder according to claim 7, characterized in that: Sampling inspection is also included in the continuous welding production, and the sampling inspection is carried out according to the national sampling standard.

9. The manufacturing method of the diaphragm air spring cylinder according to claim 7, characterized in that: The overall welding process is carried out by a gas shielded welding method.

10. The manufacturing method of the diaphragm air spring cylinder body according to claim 9, characterized in that: The gas shield is inert gas shield.

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