Welding method for integral frame sidewall unit

Abstract

This invention relates to the field of welding technology and provides a welding method for an integral frame sidewall unit, comprising the following steps: determining the size and positioning of the clamping mold based on the layout of the beams, columns, and window frames in the sidewall unit; clamping and assembling the beams, columns, and window frames onto the clamping mold in the tack welding area; performing tack welding at the connections between the beams, columns, and window frames to form an integral frame; removing the integral frame from the clamping mold and transferring it to the forming welding area; laying the upper and lower wall panels on the integral frame and welding them to form the sidewall unit. This method ensures the accuracy of the formed integral frame and precise tack welding. Furthermore, separating the clamping mold from the integral frame after its formation facilitates the reuse of the clamping mold for welding within the same vehicle model.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and in particular to a welding method for an integral frame-type sidewall unit. Background Technology

[0002] The side wall units of rail vehicles are welded together from wall panels and beams. The existing welding methods have insufficient welding precision, which makes adjustment and maintenance more difficult, limits the elastic adjustment range of the side wall frame, and easily leads to low product consistency after manual adjustment. Summary of the Invention

[0003] This invention provides a welding method for an integral frame-type sidewall unit to solve the technical problem of insufficient welding precision in the prior art and achieve precise welding.

[0004] This invention provides a welding method for an integral frame-type sidewall unit, comprising the following steps:

[0005] The dimensions and positioning of the card template are determined based on the layout of the beams, columns and window frames in the side wall unit;

[0006] In the tack welding area, the crossbeam, the column and the window frame are snapped together and assembled into the snap-fit ​​mold. The connection between the crossbeam, the column and the window frame is tack welded to form an integral frame.

[0007] Remove the overall frame from the clamping mold, transfer the overall frame to the forming welding area, install the upper wall panel and lower wall panel on the overall frame, and weld them to form a side wall unit.

[0008] According to a welding method for an integral frame-type sidewall unit provided by the present invention, the step of determining the size positioning of the clamping mold based on the layout of the beams, columns, and window frames in the sidewall unit specifically includes:

[0009] Based on the number and spacing of the beams, columns, and window frames, several cross-shaped locking molds are provided, with the locking molds extending upward to form protrusions, and the protrusions being adapted to the beams, columns, and window frames.

[0010] According to a welding method for an integral frame-type side wall unit provided by the present invention, the clamping mold is adapted to be fixed to the tooling frame, and the crossbeam, the column and the window frame are laid on the clamping mold and clamped to the protrusion.

[0011] According to a welding method for an integral frame-type sidewall unit provided by the present invention, the window frame is connected to a beam body parallel to the direction of the crossbeam. The crossbeam, the column and the beam body are all configured as cap-shaped beams and form a slot, which is adapted to engage with the protrusion.

[0012] According to a welding method for an integral frame sidewall unit provided by the present invention, the height of the slot is higher than the height of the protrusion.

[0013] According to a welding method for an integral frame sidewall unit provided by the present invention, the step of laying the upper wall panel and the lower wall panel on the integral frame and welding them to form the sidewall unit specifically includes:

[0014] Determine whether the resulting overall skeleton meets the flatness requirements;

[0015] If the flatness requirement is met, the upper wall panel and the lower wall panel are installed on the overall frame and welded to form a side wall unit;

[0016] If the flatness requirement is not met, the flatness of the overall frame will be adjusted until the flatness requirement is met. Then, the upper wall panel and the lower wall panel will be installed on the overall frame and welded to form a side wall unit.

[0017] According to a welding method for an integral frame sidewall unit provided by the present invention, the step of laying the upper wall panel and the lower wall panel on the integral frame and welding them to form the sidewall unit specifically includes:

[0018] The upper wall panel and the lower wall panel are laid on the overall frame, and the upper wall panel and the lower wall panel overlap each other. The overlap of the upper wall panel and the lower wall panel and the connection between the upper wall panel and the lower wall panel and the overall frame are tack welded using a spot welding device. Then, the overlap of the upper wall panel and the lower wall panel and the connection between the upper wall panel and the lower wall panel and the overall frame are automatically welded using an automatic welding device.

[0019] According to a welding method for an integral frame sidewall unit provided by the present invention, the spot welding device performs single-sided spot positioning welding on the overlap of the upper wall panel and the lower wall panel, as well as the connection between the upper wall panel and the lower wall panel and the integral frame.

[0020] According to the welding method of the integral frame sidewall unit provided by the present invention, the welding path of the automatic welding device for automatically welding the overlap of the upper wall panel and the lower wall panel and the connection between the upper wall panel and the lower wall panel and the integral frame is a serpentine welding path.

[0021] According to a welding method for an integral frame sidewall unit provided by the present invention, the crossbeam includes an upper window crossbeam, a window crossbeam, and a lower window crossbeam. The serpentine welding path is welded from the middle of the lower window crossbeam toward the end of the lower window crossbeam, and then serpentinely welded along the direction from the upper window crossbeam to the lower window crossbeam on the window crossbeam, and then welded from the middle of the upper window crossbeam toward the end of the upper window crossbeam.

[0022] The welding method for the integral frame sidewall unit provided in this invention determines the size and positioning of the clamping mold based on the layout of the beams, columns, and window frames. This allows the clamping mold to be designed based on the component layout. After the beams, columns, and window frames are clamped onto the clamping mold, they are positioned precisely according to the design. After the beams, columns, and window frames are assembled and positioned, the accuracy of the formed integral frame is ensured, guaranteeing precise positioning welding. Furthermore, the clamping mold is separated from the integral frame after its formation, facilitating the reuse of the clamping mold for welding within the same vehicle model. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This is a schematic flowchart of the welding method for the integral frame sidewall unit provided by the present invention;

[0025] Figure 2 This is a schematic diagram of the structure when the integral frame is installed in the clamping mold in the welding method of the integral frame side wall unit provided by the present invention;

[0026] Figure 3 This is a schematic diagram of the clamping mold structure in the welding method of the integral skeleton sidewall unit provided by the present invention;

[0027] Figure 4 This is a schematic diagram of the welding position for tack welding in the welding method of the integral frame sidewall unit provided by the present invention;

[0028] Figure 5 This is a welding path diagram for forming welding in the welding method of the integral frame sidewall unit provided by the present invention.

[0029] Figure label:

[0030] 110. Window top beam; 120. Window middle beam; 130. Window bottom beam; 20. Column; 30. Window frame components; 310. Beam body; 40. Mounting mold; 410. Protrusion; 50. Tooling frame. Detailed Implementation

[0031] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0032] In the description of the embodiments of the present invention, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of the present invention. In addition, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] In the description of the embodiments of the present invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of the present invention based on the specific circumstances.

[0034] In embodiments of the present invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0035] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0036] The following is combined with Figures 1-5 Embodiments of the present invention are described.

[0037] like Figure 1 As shown, the welding method for the integral frame sidewall unit in this embodiment includes the following steps:

[0038] S100, the size and positioning of the card template 40 are determined based on the layout of the beams, columns 20 and window frames 30 in the side wall unit.

[0039] S200. In the tack welding area, the beam, column 20 and window frame assembly 30 are snapped together and assembled on the clamping mold 40. Tack welding is performed at the connection between the beam, column 20 and window frame assembly 30 to form an integral skeleton.

[0040] S300. Remove the overall frame from the clamping mold 40, transfer the overall frame to the forming welding area, install the upper wall panel and lower wall panel on the overall frame, and weld them to form the side wall unit.

[0041] In this embodiment, the dimensions and positioning of the clamping mold 40 are determined based on the layout of the crossbeam, column 20, and window frame assembly 30. This allows the clamping mold 40 to be designed based on the component layout. After the crossbeam, column 20, and window frame assembly 30 are clamped onto the clamping mold 40, they are positioned precisely according to the design. After the crossbeam, column 20, and window frame assembly 30 are assembled and positioned by welding, the accuracy of the formed overall frame is ensured, guaranteeing precise positioning welding. Furthermore, after the overall frame is formed, the clamping mold 40 is separated from the overall frame, facilitating the reuse of the clamping mold 40 for welding within the same vehicle model.

[0042] After the beam, column 20, and window frame assembly 30 are assembled using the clamping mold 40, they are then tack welded to ensure precision and that all components are in the correct positions after forming. During the tack welding process, the clamping mold 40 continuously fixes the positions of the beam, column 20, and window frame assembly 30, ensuring that they do not move during welding and further guaranteeing the precision of the tack welding.

[0043] After the tack welding is completed, the overall frame formed by the tack welding is removed from the clamping mold 40. After the overall frame is transferred to the forming welding area, the upper wall panel and the lower wall panel are laid on the overall frame and welded to form the side wall unit.

[0044] The welding between the upper and lower wall panels and the overall frame includes tack welding and automatic welding. During the automatic welding process, no operator is required to monitor the welding operation, saving labor costs.

[0045] Specifically, the upper wall panel is installed at the location of the window frame assembly 30, and a window needs to be opened on the upper wall panel. When welding the upper wall panel and the window frame assembly 30 of the overall frame, the center of the window can be used as the positioning reference point, and welding can be carried out after positioning is completed.

[0046] The positioning reference for the 30 formed by the card-mounted mold 40, the crossbeam, the column 20, and the window frame is that the edges of the 30 formed by the card-mounted mold 40, the crossbeam, the column 20, and the window frame are flush.

[0047] In this method, the side wall unit is welded in the above manner, and the facade of column 20 does not need to be tack welded, which eliminates the need for post-weld grinding of the facade of column 20, and significantly reduces labor costs and the cost of using ventilation, gas and water.

[0048] According to the welding method for the integral frame sidewall unit provided by the present invention, the step of determining the size positioning of the clamping mold 40 based on the layout of the beams, columns 20 and window frames 30 in the sidewall unit specifically includes:

[0049] Based on the number and spacing of the beams, columns 20 and window frames 30, several cross-shaped locking molds 40 are set up so that the locking molds 40 extend upward to form protrusions 410, and the protrusions 410 are adapted to the beams, columns 20 and window frames 30.

[0050] like Figure 2 and Figure 3As shown, several cross-shaped clamping molds 40 form clamping fixtures. Based on the clamping fixtures, the cross beams, columns 20 and window frame assembly 30 are clamped and fixed. The cross-shaped clamping fixtures can reserve space for spot welding operations, which facilitates positioning welding between the cross beams, columns 20 and window frame assembly 30, and realizes direct assembly spot welding. Moreover, the structure based on the clamping fixtures can improve welding accuracy and the overall skeleton has good consistency.

[0051] The cross-shaped template fixture can respectively snap and fix the beam, column 20 and window frame assembly 30, so that the beam, column 20 and window frame assembly 30 can be fixed on the template fixture respectively without interference between them.

[0052] The protrusion 410 can be integrally formed on the clamping mold 40, or it can be fixed to the clamping mold 40 by welding, bolt connection or other means.

[0053] In this embodiment, the clamping mold 40 is adapted to be fixed to the tooling frame 50. The crossbeam, column 20, and window frame assembly 30 are laid on the clamping mold 40 and clamped to the protrusion 410. The protrusion 410 enables the clamping mold 40 to achieve an installation accuracy of 1 mm, realizing precise welding. The position of the protrusion 410 matches the designed forming position of the crossbeam, column 20, and window frame assembly 30, thereby enabling precise assembly of the crossbeam, column 20, and window frame assembly 30 after being clamped and fixed by the clamping mold 40.

[0054] The allowance for the dimensions of the upper wall panel at the window is +1mm, and the allowance for the dimensions of the window in the 30 window frames is +2mm.

[0055] The tooling frame 50 includes at least a first support portion and a second support portion, which are respectively supported on both sides of the template tooling. A support seat is rotatably mounted on the upper surface of the first support portion and / or the second support portion. This rotatable support seat allows the template tooling to be flipped, facilitating the removal of the welded integral frame from the mold. It should be noted that a fixing mechanism is required during the flipping and removal process to clamp and secure the template tooling to the integral frame, preventing them from detaching.

[0056] The window frame assembly 30 is connected to a beam 310 parallel to the direction of the horizontal beam. The horizontal beam, column 20, and beam 310 are all designed as cap-shaped beams and form a slot, which is suitable for engaging with the protrusion 410. The slot is formed by the cap-shaped beam, with the slot facing the protrusion 410, so that the cap-shaped beam can engage with the protrusion 410 through the slot, realizing the assembly between the horizontal beam, column 20, and beam 310 and the engagement mold 40.

[0057] The height of the slot is higher than the height of the protrusion 410. Specifically, the height of the protrusion 410 is 2mm less than the height of the slot, thus preventing the protrusion 410 from lifting the cap-shaped beam, i.e., preventing the clamping mold 40 from lifting the crossbeam, column 20, or window frame assembly 30 and affecting the flatness. Furthermore, the end of the protrusion 410 facing the slot is tapered, meaning that the opposite sides of the protrusion 410 have beveled surfaces with a bevel extension of 0.2mm, to facilitate clamping and improve assembly accuracy.

[0058] In this embodiment, the steps of installing the upper and lower wall panels onto the overall frame and welding them to form side wall units specifically include:

[0059] Determine whether the overall skeleton formed meets the flatness requirements.

[0060] If the flatness requirements are met, the upper and lower wall panels will be installed with the overall frame and welded to form side wall units.

[0061] If the flatness requirement is not met, the flatness of the overall frame will be adjusted until it is met. Then, the upper and lower wall panels will be installed on the overall frame and welded to form the side wall unit.

[0062] Understandably, insufficient flatness of the overall frame will make it difficult to ensure the installation accuracy of the upper and lower wall panels. Assessing the flatness of the overall frame can improve the consistency of the side wall units after welding.

[0063] In this embodiment, the steps of installing the upper and lower wall panels onto the overall frame and welding them to form side wall units specifically include:

[0064] The upper and lower wall panels are laid on the overall frame and overlapped with each other. Spot welding equipment is used to perform positioning welding on the overlap of the upper and lower wall panels and the connection between the upper and lower wall panels and the overall frame. Then, an automatic welding equipment is used to automatically weld the overlap of the upper and lower wall panels and the connection between the upper and lower wall panels and the overall frame.

[0065] The spot welding device performs single-sided spot welding at the overlap of the upper and lower wall panels, as well as at the connection between the upper and lower wall panels and the overall frame. For example... Figure 4 The image shows the location for single-sided spot welding to ensure the reliability of the spot welding.

[0066] In this embodiment, the crossbeams include an upper window crossbeam 110, a middle window crossbeam 120, and a lower window crossbeam 130, as shown below. Figure 5 As shown, the automatic welding device uses a serpentine welding path for automatically welding the overlaps of the upper and lower wall panels, as well as the connections between the upper and lower wall panels and the overall frame. This ensures the reliability and strength of the welds after automatic welding and facilitates the movement of the automated welding equipment.

[0067] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A welding method for an integral frame-type sidewall unit, characterized in that, Includes the following steps: The dimensions and positioning of the card template are determined based on the layout of the beams, columns and window frames in the side wall unit; In the tack welding area, the crossbeam, the column and the window frame are snapped together and assembled into the snap-fit ​​mold. The connection between the crossbeam, the column and the window frame is tack welded to form an integral frame. Remove the overall frame from the card mold, transfer the overall frame to the forming welding area, lay the upper wall panel and lower wall panel on the overall frame, and weld them to form a side wall unit; The steps for determining the size positioning of the card template based on the layout of the beams, columns, and window frames in the side wall unit specifically include: Based on the number and spacing of the beams, columns, and window frames, several cross-shaped locking molds are provided, with each locking mold extending upward to form a protrusion that is adapted to fit the beams, columns, and window frames. The locking molds are suitable for fixing to the tooling frame, and the beams, columns, and window frames are laid on the locking molds and locked onto the protrusions.

2. The welding method for the integral frame sidewall unit according to claim 1, characterized in that, The window frame is connected to a beam parallel to the direction of the horizontal beam. The horizontal beam, the column, and the beam are all configured as cap-shaped beams and form a slot, which is adapted to engage with the protrusion.

3. The welding method for the integral frame sidewall unit according to claim 2, characterized in that, The height of the slot is higher than the height of the protrusion.

4. The welding method for the integral frame sidewall unit according to any one of claims 1-3, characterized in that, The step of installing the upper and lower wall panels onto the overall frame and welding them to form side wall units specifically includes: Determine whether the resulting overall skeleton meets the flatness requirements; If the flatness requirement is met, the upper wall panel and the lower wall panel are installed on the overall frame and welded to form a side wall unit; If the flatness requirement is not met, the flatness of the overall frame will be adjusted until the flatness requirement is met. Then, the upper wall panel and the lower wall panel will be installed on the overall frame and welded to form a side wall unit.

5. The welding method for the integral frame sidewall unit according to claim 4, characterized in that, The step of installing the upper and lower wall panels onto the overall frame and welding them to form side wall units specifically includes: The upper wall panel and the lower wall panel are laid on the overall frame, and the upper wall panel and the lower wall panel overlap each other. The overlap of the upper wall panel and the lower wall panel and the connection between the upper wall panel and the lower wall panel and the overall frame are tack welded using a spot welding device. Then, the overlap of the upper wall panel and the lower wall panel and the connection between the upper wall panel and the lower wall panel and the overall frame are automatically welded using an automatic welding device.

6. The welding method for the integral frame sidewall unit according to claim 5, characterized in that, The spot welding device performs single-sided spot positioning welding on the overlap of the upper wall panel and the lower wall panel, as well as the connection between the upper wall panel and the lower wall panel and the overall frame.

7. The welding method for the integral frame sidewall unit according to claim 5, characterized in that, The automatic welding device performs automatic welding at the overlap of the upper wall panel and the lower wall panel, as well as at the connection between the upper wall panel and the lower wall panel and the overall frame, using a serpentine welding path.

8. The welding method for the integral frame sidewall unit according to claim 7, characterized in that, The crossbeam includes an upper window crossbeam, a middle window crossbeam, and a lower window crossbeam. The serpentine welding path is welded from the middle of the lower window crossbeam toward the end of the lower window crossbeam, and then serpentinely welded along the direction from the upper window crossbeam to the lower window crossbeam on the middle window crossbeam, and then welded from the middle of the upper window crossbeam toward the end of the upper window crossbeam.

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