A stainless steel rail vehicle door mechanism slideway assembly welding process

Abstract

The invention discloses a slide slot assembly welding process for a stainless steel rail vehicle door mechanism, which comprises the following steps: step S1: adjusting the slide slot assembly welding process of the door mechanism to the assembly process, and executing the process after the floor is installed; step S2: positioning the slide slot in the height direction; taking the upper surface of the floor as a reference, adopting a two-point positioning method for a slide slot, setting the marking point below the welding position, and making a height calibration ruler to mark the height; step S3: positioning the slide slot in the vehicle width direction; taking the outer surface of the door buckle iron as a reference, taking the extreme position difference of the slide slot in the vehicle width direction as another reference plane, and adjusting the positioning tolerance of the slide slot by adjusting the gap between the slide slot and the extreme position; step S4: verticality of the slide slot: taking the upper surface of the floor as a base plane; using a level ruler to detect the vertical installation surface of the slide slot, and adjusting the slide slot to make it perpendicular to the upper surface of the floor. The invention has the advantages of high slide slot assembly welding efficiency and high one-time qualified rate, and at the same time, can effectively avoid the safety hazard of being smashed during the assembly welding process.

Description

Technical Field

[0001] The invention relates to the technical field of rail transit vehicle body parts welding, and in particular to a stainless steel rail vehicle door mechanism slideway assembly welding process. Background Art

[0002] Most doors of stainless steel rail vehicles adopt built-in door structure, and the doors are installed inside the vehicle body. In order to meet the door installation requirements, it is necessary to weld and install the mounting seat for the door mechanism in the upper area of ​​the door inside the vehicle body steel structure. With the continuous optimization and improvement of the structure of stainless steel rail vehicles, the door mechanism installation mainly adopts the slide structure.

[0003] The door mechanism installation parts are composed of the lower slide and the upper hanger. The slide is generally a segmented groove structure, and the two vertical sides of the opening are connected to the reinforcement plate by arc welding. The door mechanism installation seat is welded in the vehicle body process, with the upper surface of the main crossbeam as the positioning reference, and the integral template is used for welding.

[0004] The flatness of the upper plane of the chassis steel structure after welding is 5mm / 3m. The floor is laid after the vehicle enters the assembly process. The flatness requirement for the floor is no more than 2mm / 4m. In order to meet the flatness standard, it is necessary to adjust by adding adjustment pads. When installing the door mechanism, the upper surface of the floor is used as the reference. After inspection, problems such as inconsistent slide height, inconsistent slide straightness, and excessive distance from the slide to the outer surface of the vehicle body were found. In order to ensure the installation of the door mechanism, it is necessary to correct it through on-site adjustment and cutting and matching, resulting in a large number of scrapped parts. At the same time, the heat generated by repeated cutting and welding affects the flatness of the door reinforcement plate, which in turn affects the flatness of the slide after welding. Welding and cutting also affect the flatness of the outer surface of the side wall.

[0005] The integral welding tooling used in the existing door mechanism slideway assembly welding process is made of aluminum alloy profiles to ensure lightweight and is connected by bolts. During use, fasteners are prone to loosening, resulting in dimensional deviation of the welded slideway. At the same time, the integral welding tooling is large in size and difficult to relocate and transport. There are also certain safety risks for operators during use.

[0006] In addition, the positioning datum of the door mechanism slideway welded by the existing process is inconsistent with the assembly, which cannot meet the assembly and installation requirements. There are also problems such as inconsistent slideway height, inconsistent slideway straightness, and excessive size of the slideway from the outer surface of the vehicle body. The rate of modification and rework is high, which seriously affects the quality of the vehicle and restricts the production progress.

[0007] Therefore, in view of the above problems, it is necessary for the present invention to provide a stainless steel rail vehicle door mechanism slideway welding process which has high slideway welding efficiency and high first-time qualified rate and can effectively avoid the safety hazard of being smashed during the welding process. Summary of the invention

[0008] The purpose of the present invention is to overcome the defects of the prior art and provide a stainless steel rail vehicle door mechanism slide welding process, adopt a new outer contour reverse positioning adjustment scheme, avoid the use of heavy integral welding tooling, improve the efficiency of door mechanism slide welding, improve the first-time pass rate of the door mechanism slide after welding, the height dimension, the flatness of the installation surface and the distance between the slide and the outer surface of the car body, avoid the safety hazard of being smashed during the welding process, avoid the scrapping of materials and the impact on the flatness of the car body surface.

[0009] In order to achieve the above object, the present invention provides the following technical solutions:

[0010] The present invention discloses a stainless steel rail vehicle door mechanism slideway assembly welding process, which comprises the following steps:

[0011] Step S1: Adjust the sliding groove assembly welding process of the door mechanism to the assembly process, which is performed after the floor is installed;

[0012] Step S2: Positioning the chute in height direction;

[0013] The upper surface of the floor is taken as the reference, which is also the reference for assembling and installing the door mechanism. The method of positioning a slide groove at two points is adopted. The marking points are set according to the number of slide grooves. Considering the influence of welding deformation on the slide groove, the marking points are set below the welding position, and a height calibration rod is made to mark the height.

[0014] Step S3: positioning the slide groove in the vehicle width direction;

[0015] Taking the outer surface of the door buckle iron as the reference and the limit position difference of the slide in the vehicle width direction as another reference surface, the positioning tolerance of the slide is adjusted by adjusting the gap between the slide and the limit position, making a bayonet sample to simulate the width of the slide, placing it on the vertical sample, cooperating with the upper horizontal ruler to simulate the positioning of the slide, and placing an adjustment gasket between the upper horizontal ruler and the slide to make the slide deviate from the limit tolerance;

[0016] Step S4: Verticality of chute:

[0017] The upper surface of the floor is taken as the base surface;

[0018] Use a level to check the vertical installation surface of the slide and adjust the slide to make it perpendicular to the upper surface of the floor.

[0019] Furthermore, in step S3.1, a negative tolerance zone is implemented in the thickness direction of the slide groove. When a gap appears between the slide groove and the reinforcement plate and affects the welding quality, a process connecting plate is added.

[0020] Furthermore, a notch is provided at the bottom of the bayonet sample block, and the notch is engaged with the height positioning block.

[0021] Furthermore, the height calibration ruler rod includes a rod body and a ruler head installed on the top of the rod body, and the height of the slide groove is positioned through the upper surface of the ruler head.

[0022] In the above technical solution, the present invention provides a stainless steel rail vehicle door mechanism slideway assembly welding process, which has the following beneficial effects:

[0023] The positioning of the slide assembly welding process is more in line with the installation needs of the door mechanism: the positioning reference is changed to the upper surface of the floor as the reference. The flatness of the floor is more stringent than the flatness of the upper surface of the chassis, which is consistent with the reference for door mechanism installation. It fully meets the needs of installing the door mechanism in the assembly process and avoids the problem of the door mechanism slide being low and tilted due to the influence of the flatness of the upper surface of the steel structure chassis on the floor paving height.

[0024] Reduced tooling costs: The door mechanism assembly welding tooling is cancelled. The door mechanism assembly welding device is based on the main crossbeam of the chassis. The deviation of the chassis flatness causes the door mechanism assembly welding tooling to tilt as a whole. After the assembly floor is installed, the present invention uses the sliding groove welding position as a marking point to measure and mark the height respectively, which can avoid the occurrence of tilting problems. The use of a simple height marking ruler and a lower flat ruler greatly reduces the labor intensity.

[0025] Precise size control: The vehicle width direction positioning adopts the extreme contour marking method, with the extreme tolerance of the slide positioning dimension in the vehicle width direction as the dimension contour. The extreme tolerance position of the slide is calibrated by the combination of the bayonet sample block simulating the slide, the horizontal ruler, and the width limit block. Then, by inserting an adjustment shim between the upper horizontal ruler and the slide at the simulated extreme position, the slide is deviated from the extreme positive tolerance position and close to the theoretical size. This solution can better control the size of the slide.

[0026] The qualified rate of one-time welding is higher: the chute process is adjusted to the assembly process, the vehicle is placed on a horse stool adjusted to a horizontal state, and the lower part of the vehicle body has been sprayed, avoiding the influence of painting, equipment hoisting, lower support and other factors on the horizontal state of the vehicle. The step-by-step assembly scheme and contour positioning method of the present invention avoid the deviation caused by one-time welding of the overall tooling assembly welding process and the problem of adjustment and re-welding after cutting.

[0027] Lower tooling costs and lower risks: Compared with the original integral welding process, the safety risk caused by the possible tipping of the integral welding device is avoided, the welding accuracy and efficiency are higher, and the problems caused by rework are avoided. The present invention uses a simple flat ruler and ruler rod, the tooling cost is lower, and no subsequent maintenance costs are required. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0029] Figure 1 It is a schematic diagram of slideway positioning of a slideway assembly welding process for a stainless steel rail vehicle door mechanism disclosed by the present invention;

[0030] Figure 2 It is a schematic diagram of slide slot height calibration in a slide slot assembly welding process for a stainless steel rail vehicle door mechanism disclosed by the present invention;

[0031] Figure 3 It is a schematic diagram of the calibration of the vehicle width profile of a slideway assembly welding process for a stainless steel rail vehicle door mechanism disclosed by the present invention;

[0032] Figure 4 It is a schematic diagram of a slideway assembly welding process for a slideway assembly welding of a stainless steel rail vehicle door mechanism disclosed in the present invention;

[0033] Figure 5 It is a schematic diagram of verticality detection of a slide groove installation surface in a stainless steel rail vehicle door mechanism slide groove assembly welding process disclosed in the present invention;

[0034] Figure 6 It is a schematic diagram of the upper level structure of a stainless steel rail vehicle door mechanism slideway assembly welding process disclosed by the present invention;

[0035] Figure 7 It is a schematic diagram of the lower flat ruler structure of a stainless steel rail vehicle door mechanism slideway assembly welding process disclosed by the present invention;

[0036] Figure 8 It is a schematic diagram of the structure of a bayonet sample block of a stainless steel rail vehicle door mechanism slideway assembly welding process disclosed by the present invention;

[0037] Fig. 9 The invention discloses a height calibration ruler structure schematic diagram of a stainless steel rail vehicle door mechanism slideway assembly welding process.

[0038] Description of reference numerals:

[0039] Lower level ruler 1; height calibration ruler rod 2; vertical sample block 3; bayonet sample block 4; upper level ruler 5; width limit block 6; level ruler 7; slide groove 8; adjustment gasket 9; process connection plate 10. DETAILED DESCRIPTION

[0040] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0041] See also Figure 1 As shown;

[0042] A stainless steel rail vehicle door mechanism slideway assembly welding process is invented, comprising:

[0043] Step S1: Adjust the welding process of the slide groove 8 of the door mechanism to the assembly process, which is performed after the floor is installed;

[0044] Step S2: Positioning the chute 8 in height direction;

[0045] Taking the upper surface of the floor as the reference, which is also the reference for assembling the door mechanism, a two-point positioning method of a slide slot 8 is adopted, and the marking points are set according to the number of slide slots 8. Considering the influence of welding deformation on the slide slot 8, the marking points are set below the welding position, and a height calibration ruler 2 is made for height marking.

[0046] Step S3: positioning the slide groove 8 in the vehicle width direction;

[0047] Taking the outer surface of the door buckle iron as the reference, and the limit position difference of the slide slot 8 in the vehicle width direction as another reference surface, the positioning tolerance of the slide slot 8 is adjusted by adjusting the gap between the slide slot 8 and the limit position, and the bayonet sample block 4 is made to simulate the width of the slide slot 8, and placed on the vertical sample block 3, and the positioning of the slide slot 8 is simulated with the upper horizontal ruler 5, and an adjustment gasket 9 is placed between the upper horizontal ruler 5 and the slide slot 8 to make the slide slot 8 deviate from the limit tolerance;

[0048] Step S4: Verticality of chute 8:

[0049] The upper surface of the floor is taken as the base surface;

[0050] The vertical installation surface of the slide groove 8 is detected by the level ruler 7, and the slide groove 8 is adjusted to be perpendicular to the upper surface of the floor. Specifically, a horse stool adjusted to a horizontal state is used when installing the floor in the assembly process. After the floor is installed in the assembly process, the slide groove 8 is welded, and the floor is more flat. The angle obtained by detecting the vertical installation surface of the slide groove 8 by the level ruler 7 is more accurate. The verticality can be adjusted by simple adjustment, and the angle measurement benchmark is also consistent with the door mechanism installation.

[0051] Preferably, in order to control the tolerance by adding pad adjustment, a negative tolerance zone is implemented in the thickness direction of the slide groove 8 in step S3.1, and when a gap appears between the slide groove 8 and the reinforcement plate that affects the welding quality, a process connecting plate 10 is added.

[0052] Preferably, a notch is provided at the lower portion of the bayonet sample block 4, through which the bayonet sample block 4 engages with the height positioning block.

[0053] Preferably, the height calibration ruler rod 2 includes a rod body and a ruler head installed on the top of the rod body, and the height of the slide groove 8 is positioned by the upper surface of the ruler head. Specific embodiment:

[0055] When using this process for welding, perform the following steps:

[0056] Step S1: In the assembly process, after the vehicle is adjusted to a horizontal state and the inspection of the floor paving is completed, the levelness of the door area is rechecked using a level meter, and the chute 8 is welded in the assembly process;

[0057] Step S2: Positioning the chute 8 in height direction;

[0058] Protect the area around the chute 8 to avoid damage to other surrounding materials during the welding process. Place the lower ruler 1 on the upper surface of the floor in the door area and adjust the position to ensure that the lower ruler 1 is directly below the chute 8.

[0059] Using the center line of the door as a reference, mark the position of the weld of the chute 8, place the height calibration ruler 2 on the lower level ruler 1, calibrate the height of the weld of the chute 8, and calibrate at least 2 points for each chute 8. Refer to the calibrated mark group for the vertical sample block 3, at least 4 pieces for each door, use the upper level ruler 5 to check the overall flatness of the vertical sample block 3 and make appropriate adjustments, and the arc welding points are solid.

[0060] Step S3: positioning the slide groove 8 in the vehicle width direction;

[0061] Place the bayonet sample block 4 on the vertical sample block 3, place the upper level 5 on the outside of the bayonet sample block 4, place a plumb line on the upper roof side beam flange, make the plumb line close to the upper level 5 on the side close to the bayonet sample block 4, adjust the position of the upper level 5 so that its inner side surface coincides with the positive tolerance position contour of the slide groove 8. After adjusting the position of the upper level 5, weld the width limit block 6 on its outer side surface, and the two need to fit tightly.

[0062] Remove the bayonet sample 4, install the slide 8, place adjustment gaskets 9 of different thicknesses between the upper level 5 and the slide 8, adjust the gap between the slide 8 and the reinforcement plate, and tighten it after passing the test (tighten it above the slide 8).

[0063] Step S4: Verticality of chute 8:

[0064] After removing the upper level ruler 5, use the digital level ruler 7 to check the overall flatness of the mounting surface (vertical surface) of the chute 8, make appropriate adjustments as needed, and add fixed points at the bottom of the chute 8;

[0065] When the position where the flash gap of the chute 8 is large (exceeding the welding gap requirement) is connected using a process connecting plate 10, the connection is performed after spot fixing and welding.

[0066] The slide groove 8 is subjected to a secondary inspection (flatness and verticality), and the installation position is appropriately adjusted as required.

[0067] In the above technical solution, the present invention provides a stainless steel rail vehicle door mechanism slideway assembly welding process;

[0068] Beneficial effects:

[0069] The positioning of the slide assembly welding process is more in line with the installation needs of the door mechanism: the positioning reference is changed to the upper surface of the floor as the reference. The flatness of the floor is more stringent than the flatness of the upper surface of the chassis, which is consistent with the reference for door mechanism installation. It fully meets the needs of installing the door mechanism in the assembly process and avoids the problem of the door mechanism slide being low and tilted due to the influence of the flatness of the upper surface of the steel structure chassis on the floor paving height.

[0070] Reduced tooling costs: The door mechanism assembly welding tooling is cancelled. The door mechanism assembly welding device is based on the main crossbeam of the chassis. The deviation of the chassis flatness causes the door mechanism assembly welding tooling to tilt as a whole. After the assembly floor is installed, the present invention uses the sliding groove welding position as a marking point to measure and mark the height respectively, which can avoid the occurrence of tilting problems. The use of a simple height marking ruler and a lower flat ruler greatly reduces the labor intensity.

[0071] Precise size control: The vehicle width direction positioning adopts the extreme contour marking method, with the extreme tolerance of the slide positioning dimension in the vehicle width direction as the dimension contour. The extreme tolerance position of the slide is calibrated by the combination of the bayonet sample block simulating the slide, the horizontal ruler, and the width limit block. Then, by inserting an adjustment shim between the upper horizontal ruler and the slide at the simulated extreme position, the slide is deviated from the extreme positive tolerance position and close to the theoretical size. This solution can better control the size of the slide.

[0072] The qualified rate of one-time welding is higher: the chute process is adjusted to the assembly process, the vehicle is placed on a horse stool adjusted to a horizontal state, and the lower part of the vehicle body has been sprayed, avoiding the influence of painting, equipment hoisting, lower support and other factors on the horizontal state of the vehicle. The step-by-step assembly scheme and contour positioning method of the present invention avoid the deviation caused by one-time welding of the overall tooling assembly welding process and the problem of adjustment and re-welding after cutting.

[0073] Lower tooling costs and lower risks: Compared with the original integral welding process, the safety risk caused by the possible tipping of the integral welding device is avoided, the welding accuracy and efficiency are higher, and the problems caused by rework are avoided. The present invention uses a simple flat ruler and ruler rod, the tooling cost is lower, and no subsequent maintenance costs are required.

[0074] The above description is only by way of illustration of certain exemplary embodiments of the present invention. It is undoubted that those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A stainless steel rail vehicle door mechanism slideway assembly welding process, characterized in that: The process includes the following steps: Step S1: adjusting the welding process of the slide groove (8) of the door mechanism to the assembly process, which is performed after the floor is installed; Step S2: Positioning the slideway (8) in height direction; Taking the upper surface of the floor as a reference, which is also the reference for assembling and installing the door mechanism, a two-point positioning method for a slide groove (8) is adopted, and marking points are set according to the number of slide grooves (8). Considering the influence of welding deformation on the slide groove (8), the marking points are set below the welding position, and a height calibration rod (2) is made to mark the height; Step S3: positioning the slide groove (8) in the vehicle width direction; Taking the outer surface of the door buckle iron as a reference and the limit position difference of the slide groove (8) in the vehicle width direction as another reference surface, the positioning tolerance of the slide groove (8) is adjusted by adjusting the gap between the slide groove (8) and the limit position, making a bayonet sample block (4) to simulate the width of the slide groove (8), and placing it on the vertical sample block (3), the bayonet sample block (4) and the upper horizontal ruler (5) cooperate to simulate the positioning of the slide groove (8), and an adjustment gasket (9) is placed between the upper horizontal ruler (5) and the slide groove (8) to make the slide groove (8) deviate from the limit tolerance; Step S4: Verticality of the chute (8): The upper surface of the floor is taken as the base surface; The vertical installation surface of the slide groove (8) is detected by using a level ruler (7), and the slide groove (8) is adjusted to be perpendicular to the upper surface of the floor.

2. A stainless steel rail vehicle door mechanism slideway assembly welding process according to claim 1, characterized in that ； Step S3.1: A negative tolerance zone is implemented in the thickness direction of the slide groove (8). When a gap appears between the slide groove (8) and the reinforcement plate, which affects the welding quality, a process connecting plate (10) is added.

3. A stainless steel rail vehicle door mechanism slideway assembly welding process according to claim 1, characterized in that ； The lower part of the bayonet sample block (4) is provided with a notch, and is engaged with the height positioning block through the notch.

4. A stainless steel rail vehicle door mechanism slideway assembly welding process according to claim 1, characterized in that ； The height calibration ruler rod (2) comprises a rod body and a ruler head mounted on the top end of the rod body, and the height of the slide groove (8) is positioned through the upper surface of the ruler head.

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