Railway freight car end wall flexible welding production line

Abstract

The application discloses a railway freight car end wall flexible welding production line and relates to the technical field of railway vehicle production equipment. The feeding group is used to complete the queuing and spot welding of end wall parts on the pressing spot welding station. Then, the welding of the front surface flat weld, the front surface vertical weld and the back surface flat weld of the end wall part is completed in sequence through different welding stations. Finally, the end wall part is stacked after manual repair welding. The chain conveying device and the transfer trolley are used for transportation between stations, so that the circulation of key materials is realized without human intervention. The setting of the buffer station solves the problems of the end wall stall type welding, large occupation area, high labor intensity, discontinuous production, low production efficiency, poor environment and the like, realizes the automatic welding of the end wall of the open wagon, and realizes the cost reduction and benefit increase and the quality risk reduction through the robot, automatic dust removal and automatic conveying and the like.

Description

Technical Field

[0001] This invention relates to the field of rail vehicle production equipment technology, and in particular to a flexible welding production line for the end walls of railway freight cars. Background Technology

[0002] Endwalls are a crucial component of railway freight cars, and endwall welding is a key process in their production, accounting for 70% of the total manufacturing cost. Currently, endwall welding primarily relies on a discrete, manual production method. Common practices include manual handling combined with overhead cranes for transporting endwall crossbands and end plates, along with manual assembly and spot welding. Product quality depends heavily on worker skill levels, leading to inconsistent quality. Furthermore, the use of a floor-based welding and placement system results in low automation, poor working conditions, and a large footprint. Other processes, such as assembly, conveying, stacking, and handling, require multiple workers, increasing labor costs. The welding station lacks buffering capabilities, resulting in long waiting times for loading and unloading, further extending the endwall production cycle. Summary of the Invention

[0003] To address the shortcomings of existing technologies, the purpose of this invention is to provide a flexible welding production line for railway freight car end walls. The entire production line has a high degree of automation and high production efficiency, and is compatible with the automated assembly and welding of end walls for various open wagon models, meeting the requirements of lean manufacturing. Through this technology, rapid production changeover and flexible manufacturing can be achieved, thereby increasing the production capacity of end walls.

[0004] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0005] A flexible welding production line for railway freight car end walls includes a gripping, positioning, and grinding station, a feeding, pressing, and spot welding station, a first buffer station, a first welding station, a second welding station, a second buffer station, a third welding station, a fourth welding station, a flipping station, a repair welding station, and a stacking station arranged sequentially along the welding production sequence.

[0006] The loading group is equipped with a flexible assembly jig for the pressing and spot welding station. The loading robot slides and grabs the end wall parts and places them on the flexible assembly jig. A welding robot is located above the flexible assembly jig for spot welding the end wall workpieces. A chain conveyor is provided from the flexible assembly jig to the second buffer station for conveying the workpieces.

[0007] The first and second welding stations are equipped with positioning mechanisms and welding robots for welding the flat welds on the front side of the end wall workpiece. The third welding station and the flipping station are equipped with flipping and lifting machines. The third welding station is used to convert the front vertical welds into front flat welds. The fourth welding station and the repair welding station are equipped with transfer vehicles. The fourth welding station is used to weld the back flat welds. The top of the transfer vehicle is connected to a lifting mechanism and a rotating mechanism to adjust the weld position. The flipping station is used to flip the end wall workpiece. The transfer vehicle of the repair welding station travels back and forth between the flipping station and the repair welding station.

[0008] As a further implementation, the gripping and positioning grinding station is equipped with a traveling track, on which a gripping device is slidably mounted. The gripping device is used to grip the cross strip and place it on the cross strip positioning grinding machine for grinding the cross strip.

[0009] As a further implementation, the feeding group is equipped with a feeding track for the pressing and welding station, the feeding robot slides in cooperation with the feeding track, the end of the feeding robot is equipped with a magnetic gripping fixture, one side of the feeding track is a gripping, positioning and grinding station, and the other side is a station for placing various parts of the end wall, and a flexible assembly is set at the end of the feeding track.

[0010] As a further implementation, the feeding group is equipped with walking tracks for the pressing spot welding station, the first welding station, the second welding station, the third welding station, and the fourth welding station. Walking trusses are slidably installed on the walking tracks of the five stations. The top of the walking truss is a crossbeam, and a welding robot is installed on the crossbeam. The feeding group is also equipped with pressing devices on the crossbeams of the pressing spot welding station and the second welding station.

[0011] As a further implementation, welding platforms are set inside the tracks of the first welding station and the second welding station. The welding platforms and the flexible assembly are two support frames set on both sides of the chain conveyor. Multiple sets of cylinders are set on the support frames, and positioning blocks are set at the output end of the cylinders to achieve positioning of the end wall workpiece.

[0012] As a further implementation, the chain conveyor includes a frame, a support base at the bottom of the frame, a telescopic rod connecting the support base and the frame, a cylinder on the support base to support the frame, and two sets of chains arranged along the length of the frame. The two sets of chains move synchronously through a synchronous shaft and a drive motor.

[0013] As a further implementation, the second buffer station is also equipped with a transfer vehicle, which is located at the bottom of the chain conveyor and is used to transport the end wall of the second buffer station to the third welding station.

[0014] As a further implementation, the tilting and lifting machine includes two tilting frames, with a positioning frame rotatably connected to the opposite surfaces of the tilting frames. The two positioning frames are equipped with positioning mechanisms for positioning end wall workpieces, and the positioning frames are connected to a lifting motor at the top of the frame.

[0015] As a further implementation, the stacking station is also equipped with a walking track, a walking truss and a crossbeam. A magnetic gripping fixture is installed on the crossbeam, and the magnetic gripping fixture is connected to the crossbeam through a lifting mechanism and a rotating mechanism.

[0016] The stacking station is also equipped with a stacking rack, which is located below the crossbeam.

[0017] As a further implementation, welding fume hoods are installed on the outside of the first and second welding stations, and welding fume hoods are also installed on the outside of the first, third and fourth welding stations. The welding fume hoods are equipped with dust removal systems and electric roller shutters.

[0018] The beneficial effects of the present invention are as follows:

[0019] 1. This invention assembles and spots-welds end-wall components at the clamping and spot-welding station via a material loading group. Then, different welding stations sequentially complete the welding of the front flat weld, front vertical weld, and back flat weld of the end-wall components. Finally, manual finishing welds are applied before stacking. The workstations are transported via chain conveyors and transfer vehicles, enabling unmanned flow of critical materials. Combined with the buffer station setup, this invention effectively solves the problems of traditional open-field welding of end walls, such as large footprint, high labor intensity, inability to produce continuously, low production efficiency, and poor environmental conditions. It achieves automated welding of open-vehicle end walls, reducing costs and increasing efficiency while mitigating quality risks through robots, automatic dust removal, and automatic conveying.

[0020] 2. According to the position of the vertical weld seam of the workpiece, the transfer car at the second buffer station rotates the workpiece horizontally, and the tilting and lifting machine at the third welding station tilts the workpiece vertically. The two work together to convert the front vertical weld seam of the workpiece into the front flat weld seam, reducing the welding difficulty and improving the welding quality.

[0021] 3. The present invention is equipped with a stacking robot, which can rotate the workpiece horizontally according to the number of stacking layers and position of the workpiece, thereby reducing the stacking height and center of gravity of the workpiece, improving the safety of hoisting, and reducing the floor space occupied by the workpiece stacking.

[0022] 4. The transfer vehicle set in the fourth welding station of the present invention can adjust the position of the end wall workpiece by rotating, which is suitable for different end wall workpieces with different weld positions.

[0023] 5. The entire production line of this invention adopts integrated control by an industrial control computer, which can maximize the efficiency of end wall welding while ensuring stable operation and low failure rate of each workstation equipment; it is simple, convenient, safe and reliable to operate, and is suitable for welding a variety of end wall products in large batches. Attached Figure Description

[0024] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0025] Figure 1 This is a schematic diagram of the overall structure of the flexible welding production line for the end wall of railway freight cars in an embodiment of the present invention.

[0026] Figure 2 This is a schematic diagram of the horizontal gripping, positioning, and grinding station in an embodiment of the present invention.

[0027] Figure 3 This is a schematic diagram of the end wall workpiece in an embodiment of the present invention.

[0028] Figure 4 This is a schematic diagram of the material feeding group and the pressing spot welding station in an embodiment of the present invention.

[0029] Figure 5 This is a schematic diagram of the chain conveyor device in an embodiment of the present invention.

[0030] Figure 6 This is a schematic diagram of the first welding station in an embodiment of the present invention.

[0031] Figure 7 This is a schematic diagram of the second welding station in an embodiment of the present invention.

[0032] Figure 8 This is a schematic diagram of the second cache station in an embodiment of the present invention.

[0033] Figure 9 This is a schematic diagram of the third welding station in an embodiment of the present invention.

[0034] Figure 10 This is a schematic diagram of the fourth welding station in an embodiment of the present invention.

[0035] Figure 11 This is a schematic diagram of the tilting and lifting machine structure of the tilting station in an embodiment of the present invention.

[0036] Figure 12 This is a top view of the manual welding station in an embodiment of the present invention.

[0037] Figure 13 This is a schematic diagram of the stacking station in an embodiment of the present invention.

[0038] The diagram exaggerates the spacing or dimensions between parts to show their positions; the diagram is for illustrative purposes only.

[0039] Among them: G1, end wall workpiece; G1-1, first end plate; G1-2, second end plate; G1-3, upper end beam; G1-4, first corner column assembly; G1-5, cross band; G1-6, second corner column assembly.

[0040] B1. Gripping and positioning grinding station; B1-1. Horizontal belt storage rack; B1-2. Traveling track; B1-3. Column; B1-3-1. Slide plate; B1-4. Crossbeam; B1-5. Gripping robot; B1-5-1. Slide plate; B1-6. Gripping device; B1-7. Horizontal belt positioning grinding machine.

[0041] B2. Loading assembly for pressing and welding station; B2-1. Magnetic gripping fixture; B2-2. Loading robot; B2-3. Loading track; B2-4. Flexible assembly tire; B2-5. Walking truss; B2-5-1. Crossbeam; B2-6. Pressing device; B2-7. Welding robot.

[0042] T1, chain conveyor device; T1-2, chain; T1-3, drive motor; T1-4, frame; T1-5, synchronous shaft.

[0043] X1, First Cache Station.

[0044] X2, First welding station; X2-1, Welding platform; X2-2, Walking truss; X2-2-1, Crossbeam; X2-3, Welding robot.

[0045] X3, Second welding station; X3-1, Welding platform; X3-2, Walking truss; X3-2-1, Crossbeam; X3-3, Welding robot; X3-4, Clamping device.

[0046] X4, second cache station; X4-1, transfer vehicle.

[0047] X5, Third welding station; X5-1, Tilting elevator; X5-1-1, Frame; X5-1-2, Rotating frame; X5-1-3, Tilting motor; X5-1-4, Lifting motor; X5-2, Traveling truss; X5-2-1, Crossbeam; X5-3, Welding robot.

[0048] X6, Fourth Welding Station; X6-1, Welding Platform; X6-2, Walking Truss; X6-2-1, Crossbeam; X6-3, Welding Robot; X6-4, Transfer Vehicle.

[0049] X7, Tilting station; X7-1, Tilting elevator; X7-1-1, Frame; X7-1-2, Indexing frame; X7-1-3, Tilting motor; X7-1-4, Lifting motor.

[0050] X8, Repair welding station; X8-1, Welding platform; X8-2, Transfer vehicle.

[0051] X9, stacking station; X9-1, stacking rack; X9-2, traveling truss; X9-2-1, crossbeam; X9-3, stacking robot; X9-3-1, magnetic gripping fixture.

[0052] C1. Welding fume removal station. Detailed Implementation

[0053] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0054] like Figure 3 The diagram shows the structure of the end wall workpiece G1, which includes three horizontal bands G1-5, a first corner post assembly G1-4 and a second corner post assembly G1-6 at both ends of the horizontal bands, a first end plate G1-1 and a second end plate G1-2 on one side of the horizontal band G1-5, and an upper end beam G1-3 connecting one end of the corner post assembly.

[0055] Example 1

[0056] In a typical embodiment of the present invention, reference is made to Figure 1 As shown, a flexible welding production line for railway freight car end walls includes the following components in sequence according to the welding process flow of the end walls:

[0057] The gripping, positioning, and grinding station B1 is used for positioning and grinding of the cross belt G1-5. The loading, assembly, clamping, and spot welding station B2 is used for assembling and clamping the first end plate, second end plate, upper end beam, first corner column assembly, second corner column assembly, and cross belt. The first buffer station X1 is used for buffering the workpieces after the end wall components are assembled.

[0058] Following the first buffer station X1, there are sequentially the first welding station X2, the second welding station X3, the second buffer station X4, the third welding station X5, the fourth welding station X6, the flipping station X7, the manual repair welding station X8, and the stacking station X9.

[0059] A fume extraction station C1 is located outside the first welding station X2 and the second welding station X3, and another fume extraction station C1 is located outside the third welding station X5 and the fourth welding station X6. The fume extraction station C1 is primarily responsible for treating welding fumes from all four welding stations, ensuring a clean working environment and preventing workers from being harmed by welding fumes. The main body of the welding fume extraction station C1 is a hood used to cover the working area of ​​the welding stations. The hood is equipped with a dust removal system and an electric roller shutter door, and is connected to the production line scheduling system. The welding stations on the aforementioned end walls are arranged in a straight line. The electric roller shutter door is positioned in the direction of workpiece movement. The hood is equipped with proximity sensors, which automatically open the electric roller shutter door when a workpiece approaches it and automatically close it when the welding robot is welding, preventing welding fume leakage.

[0060] like Figure 2 As shown, the horizontal belt gripping and positioning grinding station B1 includes a horizontal belt storage rack B1-1, a traveling track B1-2, a column B1-3, a crossbeam B1-4, a gripping robot B1-5, a gripping device B1-6, a horizontal belt positioning grinding machine B1-7, and a sliding plate B1-5-1.

[0061] A walking track B1-2 is set on each side of the horizontal storage rack B1-1. The bottom of the column B1-3 is connected to the slide plate B1-3-1. The slide plate B1-3-1 is fitted onto the guide rail inside the walking track B1-2. The slide plate is connected to the drive motor. The drive motor drives the slide plate to move horizontally on the walking track, thereby driving the column to move.

[0062] Two uprights are connected to a crossbeam B1-4 at their tops. The crossbeam B1-4 is perpendicular to the walking track B1-2. A gripping robot B1-5 is mounted on the side of the crossbeam B1-4 and is slidably connected to the crossbeam B1-4 via a sliding plate B1-5-1, allowing the gripping robot B1-5 to move horizontally along the crossbeam B1-4. This is existing technology. The gripping robot B1-5 is slidably connected to the sliding plate B1-5-1 via a slider and can move vertically along the sliding plate B1-5-1 with the help of a drive motor. A gripping device B1-6 is fixedly connected to the end of the gripping robot B1-5 to grip the cross belt. A cross belt positioning and grinding machine B1-7 is mounted on a bracket on one side of the cross belt storage rack B1-1 and between the two walking tracks, used for positioning, pressing, and grinding the cross belt.

[0063] like Figure 4 As shown, the material loading and clamping spot welding station B2 includes a magnetic gripping fixture B2-1, a material loading robot B2-2, a material loading track B2-3, a flexible assembly tire B2-4, a traveling truss B2-5, a crossbeam B2-5-1, a clamping device B2-6, a welding robot B2-7, and a chain conveyor T1.

[0064] The front end of the loading track B2-3 is flush with the cross-belt storage rack B1-1, and the rear end is close to the flexible assembly tire B2-4. The loading robot B2-2 is set on the track, and its bottom slides along the track through a slider and a drive motor, moving back and forth between the cross-belt gripping, positioning and grinding station B1 and the loading, assembling, pressing and spot welding station B2. The loading robot B2-2 is equipped with a magnetic gripping fixture B2-1, which is used to grip the cross-belt and place it on the flexible assembly tire B2-4 for positioning and assembly.

[0065] One side of the front end of the loading track B2-3 is the horizontal gripping, positioning, and grinding station B1, and the other side is the station for placing corner column components, end plates, and upper crossbeams. The loading robot B2-2 uses the magnetic gripping fixture B2-1 to sequentially grip one of the required components for the end wall and place it on the flexible assembly jig B2-4 for positioning, clamping, and spot welding.

[0066] The loading robot B2-2 can move horizontally along the loading track B2-3 and can be adjusted in 7 degrees of freedom.

[0067] Understandably, the flexible assembly jig B2-4 consists of two support frames located on either side of the loading track B2-3, used to support the two ends of the workpiece for assembly. Each support frame of the flexible assembly jig B2-4 is equipped with multiple sets of cylinders, the output ends of which are connected to positioning blocks. The positioning blocks position and clamp the two ends of each part of the end wall to achieve automatic assembly.

[0068] The flexible assembly jig B2-4 has walking tracks on both sides, and a walking truss B2-5 is mounted on the tracks. The walking truss includes two columns, the bottom of which slides with the walking tracks via sliders and drive motors. The two main tops are connected by a crossbeam located on top of the flexible assembly jig B2-4. A clamping device, consisting of a cylinder and a stop, is located below the crossbeam B2-5-1, used to clamp the top of the end wall workpiece on the flexible assembly jig B2-4. The welding robot B2-7 is positioned on the side of the crossbeam B2-5-1 of the walking truss B2-5 for automatic spot welding of the workpiece.

[0069] The chain conveyor T1 is positioned below and passes through the flexible assembly tire B2-4. Specifically, T1 is located between two support frames and can transport the spot-welded workpiece to the next station. The next station is the first buffer station. In this embodiment, after the end wall components are clamped, positioned, and assembled, spot welding is performed. The spot-welded end wall workpiece is placed in the first buffer station for subsequent welding work.

[0070] Reference Figure 5As shown, the top of the chain conveyor T1 is a frame, which is a rectangular frame. The chain conveyor T1 includes four support seats, and the top of the support seats is equipped with a telescopic rod. The top of the telescopic rod supports the rectangular frame. A cylinder T1-1 is installed on the support seat, and the output end of the cylinder supports the frame through a fixed block. When the cylinder extends, it moves the telescopic rod upward, and the cylinder can raise and lower the rectangular frame. When raised, the end wall workpiece can be lifted from the flexible assembly jig. After the end wall workpiece is conveyed to the first buffer station, the chain conveyor descends and places the end wall workpiece on the first buffer station.

[0071] The frame includes two crossbeams along its length, each with a set of chains T1-2. A chain conveyor T1 is equipped with a drive motor T1-3 to drive the chains T1-2 horizontally. The chain conveyor T1 also has a frame T1-4 to support the drive motor T1-3. The two sets of chains T1-2 are connected by a synchronous shaft to achieve synchronized movement. The chain movement transports the workpiece from the loading group's pressing and spot welding station B2 to the first buffer station. It is understood that the fixed block supporting the frame in this embodiment does not affect the chain transmission; the fixed block supports both sides of the frame.

[0072] Reference Figure 6 As shown, the first welding station includes a welding platform X2-1, a traveling truss X2-2, a welding robot X2-3 for the first welding station, and a chain conveyor T1.

[0073] The welding platform X2-1 can achieve positioning and clamping of the end wall by means of multiple sets of cylinders and positioning blocks set on the welding platform X2-1. The welding platform also has two support frames, which are set on both sides of the chain conveyor T1. The cylinders and positioning blocks on the support frames clamp the two ends of the end wall workpiece after spot welding. The setting method is the same as the cylinder setting on the flexible assembly tire B2-4.

[0074] The traveling truss X2-2 is set above the welding platform X2-1 and can move horizontally. The two ends of the traveling truss are columns, and the top is a crossbeam connected to the columns. The bottom of the columns also moves horizontally along the track. This part is set up in the same way as the material loading group for the clamping spot welding station, so it will not be described again here.

[0075] Welding robot X2-3 is positioned on the side of the crossbeam X2-2-1 of the traveling truss X2-2 for automatic workpiece welding. The welding robot at the first welding station is used to weld the front weld of the end wall workpiece. Chain conveyor T1 is positioned below, in the middle of, and through the welding platform X2-1 to transport the welded workpiece to the next station.

[0076] The first buffer station in this embodiment also consists of two support frames, used to support both ends of the end wall workpiece.

[0077] Furthermore, such as Figure 7 The second welding station is shown. The chain conveyor T1 is distributed at both the first and second welding stations, and sends the end wall workpiece on the first welding station to the second welding station. The second welding station X3 includes a welding platform X3-1, a traveling truss X3-2, a welding robot X3-3, a chain conveyor T1, and a clamping device X3-4.

[0078] The positioning and clamping of the end wall can be achieved by multiple sets of cylinders and positioning blocks installed on the welding platform X3-1. The cylinders and positioning blocks have the same structural configuration as the welding platform on the first welding station. The traveling truss X3-2 is installed above the welding platform X3-1 and can move horizontally. The traveling truss X3-2 also has the same structural configuration as the corresponding one on the first welding station.

[0079] Welding robot X3-3 is mounted on the side of the crossbeam X3-2-1 of the traveling truss X3-2 for automatic workpiece welding. Chain conveyor T1 is positioned below and passes through the welding platform X3-1, enabling the transport of welded workpieces to the next workstation. Clamping device X3-4 is located below the crossbeam X3-2-1 of the traveling truss X3-2 for clamping the workpieces on the welding platform X3-1. The clamping device and the loading group have the same structural configuration for clamping the spot welding stations.

[0080] In this embodiment, the second welding station is equipped with a clamping device compared to the first welding station. The first welding station is used to weld the first part of the weld on the front of the end wall workpiece, and the second welding station is used to weld the remaining part of the weld on the front. The setting of the first welding station and the second welding station realizes the welding of the weld on the front of the end wall workpiece.

[0081] A fume extraction station C1 is set up outside the first welding station X2 and the second welding station X3. It is mainly responsible for the treatment of welding fumes at the welding stations, ensuring a clean working environment and preventing workers from being harmed by welding fumes.

[0082] Furthermore, such as Figure 8 As shown, the second buffer station is equipped with a chain conveyor T1 and a transfer car X4-1. The chain conveyor T1 can buffer the workpieces transported from the previous station. The functions that the chain conveyor T1 can perform are as described above, and will not be repeated here.

[0083] The transfer car X4-1 is positioned below the chain conveyor T1 and moves horizontally. The transfer car X4-1 is equipped with a lifting device and a horizontal rotation device to realize the lifting and horizontal rotation of the workpiece. The transfer car X4-1 can transport the workpiece conveyed by the chain conveyor T1 to the next work station.

[0084] The transfer cart is equipped with wheels at the bottom for horizontal movement. The lifting device is a cylinder installed inside the transfer cart frame, used to raise and lower the top surface of the frame. The horizontal rotation device is a rotating shaft located at the center of the top surface of the transfer cart frame. The top of the shaft engages with a worktable; rotation of the shaft drives the worktable to rotate, thereby rotating the end-wall workpiece. It is understood that the chain conveyor T1 in this embodiment does not affect the movement of the transfer cart. Those skilled in the art can remove the crossbeam at the end of the chain conveyor T1 as needed to prevent obstruction of the transfer cart's movement. The second buffer station is used to buffer the end-wall workpieces that have been welded on the front side.

[0085] Furthermore, such as Figure 9 As shown, the third welding station includes a tilting elevator X5-1, a traveling truss X5-2, and a welding robot X5-3. The tilting elevator X5-1 can rotate along the horizontal axis and move vertically to position and clamp the end wall. The traveling truss X5-2 is positioned above the tilting elevator X5-1 and can move horizontally. The structure of the traveling truss is the same as the corresponding structure described above. The welding robot X5-3 is positioned on the side of the crossbeam X5-2-1 of the traveling truss X5-2 for automatically welding workpieces.

[0086] Specifically, the tilting and lifting machine X5-1 is equipped with a frame X5-1-1, a rotation frame X5-1-2, a tilting motor X5-1-3, and a lifting motor X5-1-4 located on both sides. The rotation frame X5-1-2 is supported on the opposite sides of the frame X5-1-1. The tilting motor X5-1-3 and the lifting motor X5-1-4 are supported on the frame.

[0087] The frame includes two columns with slide rails on their opposite surfaces. The slider slides along the two slide rails. A tilting motor X5-1-3 is located at the center of the slider's back side, and a rotary table X5-1-2 connected to the output of the tilting motor X5-1-3 is located on the front of the slider. A lifting motor X5-1-4 is located at the top of the frame, with its output passing through the top of the frame and connecting to the top of the slider, thus driving the slider and the rotary table X5-1-2 to rise and fall.

[0088] The indexing frame X5-1-2 can be positioned and clamped against the end wall by multiple sets of cylinders and positioning blocks set on the indexing frame X5-1-2. The positioning blocks can clamp the end of the end wall. The indexing frame X5-1-2 can be rotated along the horizontal axis by gear meshing with the flip motor X5-1-3. The lifting motor X5-1-4 can be raised and lowered in the vertical direction by lead screw and slider.

[0089] Furthermore, the aforementioned tilting and lifting machine X5-1 is used for tilting and lifting the workpiece from -90° to +90°. After the material is loaded, the tilting and lifting machine X5-1 rotates -90° and lifts to a suitable position to achieve accessibility of the left weld seam during automated welding of the workpiece. After the left weld seam is welded, the tilting and lifting machine X5-1 rotates +90° and lifts to a suitable position to achieve accessibility of the right weld seam during automated welding of the workpiece. This method can convert vertical weld seams into horizontal weld seams for automated welding, improving work efficiency and welding quality.

[0090] Furthermore, such as Figure 10 As shown, the fourth welding station includes a welding platform X6-1, a traveling truss X6-2, a welding robot X6-3, and a transfer vehicle X6-4. The structural configurations of the welding platform X6-1, the traveling truss X6-2, and the welding robot X6-3 are the same as the corresponding structures mentioned above. The fourth welding station is used to weld the back flat weld of the end wall workpiece. The tilting and lifting machine of the third welding station can tilt the end wall workpiece and then transport it to the fourth welding station via the transfer vehicle X6-4 for welding the back flat weld.

[0091] The welding platform X6-1, equipped with multiple sets of cylinders and positioning blocks, can position and clamp the end wall. The traveling truss X6-2 is positioned above the welding platform X6-1 and can move horizontally. The welding robot X6-3 is positioned on the side of the crossbeam X6-2-1 of the traveling truss X6-2 for automatic workpiece welding. The transfer cart X6-4 is positioned below and in the middle of the welding platform X6-1 and moves horizontally. Equipped with lifting and horizontal rotation devices, the transfer cart X6-4 can lift and rotate the workpiece horizontally, transporting the workpiece from the welding platform X6-1 to the next workstation. Further details about the transfer cart are omitted here.

[0092] The transfer vehicle travels back and forth between the third and fourth welding stations, delivering the end wall workpieces from the third welding station to the fourth welding station.

[0093] Furthermore, such as Figure 11As shown, the tilting station is equipped with a tilting elevator X7-1. The tilting elevator X7-1 has the same structural configuration as the tilting elevator X5-1 mentioned above. The tilting elevator X7-1 is equipped with a frame X7-1-1, a rotation frame X7-1-2, a tilting motor X7-1-3, and a lifting motor X7-1-4. The frame X7-1-1 supports the rotation frame X7-1-2, the tilting motor X7-1-3, and the lifting motor X7-1-4. The rotation frame X7-1-2 can be positioned and clamped against the end wall by multiple sets of cylinders and positioning blocks set on the rotation frame X7-1-2. The rotation frame X7-1-2 can rotate along the horizontal axis by meshing with the tilting motor X7-1-3 through gears. The lifting motor X7-1-4 is connected to the rotation frame X7-1-2 through a lead screw, which can make the rotation frame X7-1-2 rise and fall in the vertical direction.

[0094] Furthermore, unlike the X5-1 tilting elevator, the X7-1 tilting elevator is used for tilting and lifting workpieces from 0 to 180°. After loading, the X7-1 tilting elevator is lifted to a suitable position and tilted 180°. This method can realize the automatic 180° tilting of workpieces, which is convenient for manual welding at the next station, and also convenient for flipping the workpieces at the fourth welding station to the front for subsequent stacking.

[0095] Furthermore, such as Figure 12 As shown, the manual welding station X8 includes a welding platform X8-1 and a transfer vehicle X8-2. The welding platform X8-1 can be positioned and clamped against the end wall by multiple sets of cylinders and positioning blocks. The transfer vehicle X8-2 is located below the welding platform X8-1 and moves horizontally. The transfer vehicle X8-2 is equipped with a lifting device to lift the workpiece. The transfer vehicle X8-2 can transport the workpiece on the indexing frame X7-1-2 to the manual welding station X8.

[0096] Furthermore, such as Figure 13 As shown, the stacking station X9 includes a stacking rack X9-1, placed near the welding station. A traveling truss X9-2 is located at both ends of the rack and travels along a track. A stacking robot X9-3 is mounted on the crossbeam of the traveling truss X9-2. The stacking rack X9-1 stores workpieces. The traveling truss X9-2 is positioned above the stacking rack X9-1 and can move horizontally. The stacking robot X9-3 is positioned on the side of the crossbeam X9-2-1 of the traveling truss X9-2 and can achieve lifting, lowering, and horizontal rotation. It is understood that the lifting and horizontal rotation functions of the stacking robot are existing technologies, achieved through a rotating motor, a lifting motor, a track, a slider, and a rotating shaft. The stacking robot X9-3 is equipped with a magnetic gripping fixture X9-3-1 for gripping workpieces from the welding platform X8-1 and placing them onto the stacking rack X9-1.

[0097] The automated welding production method for the end walls of the truck described above can reduce labor intensity, improve production efficiency, and ensure welding quality. The outer diameter of each workpiece is basically the same, and the process is basically the same, so it will not be described in detail here.

[0098] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A flexible welding production line for the end walls of railway freight cars, characterized in that, The welding process includes, in sequence, the gripping, positioning and grinding station, the feeding group pressing and spot welding station, the first buffer station, the first welding station, the second welding station, the second buffer station, the third welding station, the fourth welding station, the flipping station, the repair welding station, and the stacking station. The loading group is equipped with a flexible assembly jig for the pressing and spot welding station. The loading robot slides and grabs the end wall parts and places them on the flexible assembly jig. A welding robot is located above the flexible assembly jig for spot welding the end wall workpieces. A chain conveyor is provided from the flexible assembly jig to the second buffer station for conveying the workpieces. The first and second welding stations are equipped with positioning mechanisms and welding robots for welding the flat welds on the front side of the end wall workpiece; the third welding station and the flipping station are equipped with flipping and lifting machines, with the third welding station used for converting the front vertical welds into front flat welds; the fourth welding station and the repair welding station are equipped with transfer vehicles, with the fourth welding station used for welding the back flat welds, and the top of the transfer vehicle connected to a lifting mechanism and a rotating mechanism to adjust the weld position; the flipping station is used to flip the end wall workpiece, and the transfer vehicle at the repair welding station travels back and forth between the flipping station and the repair welding station; The gripping and positioning grinding station is equipped with a walking track, on which a gripping device is slidably mounted. The gripping device is used to grip the cross strip and place it on the cross strip positioning grinding machine for grinding the cross strip. The feeding group is equipped with a feeding track for the pressing spot welding station. The feeding robot slides in conjunction with the feeding track. The end of the feeding robot is equipped with a magnetic gripping fixture. One side of the feeding track is a gripping, positioning and grinding station, and the other side is a station for placing various parts of the end wall. The flexible assembly is located at the end of the feeding track. The feeding group is equipped with walking tracks for the pressing spot welding station, the first welding station, the second welding station, the third welding station, and the fourth welding station. A walking truss is slidably installed on the walking tracks of the five stations. The top of the walking truss is a crossbeam, and a welding robot is installed on the crossbeam. The feeding group is also equipped with a pressing device on the crossbeam of the pressing spot welding station and the second welding station. Welding platforms are installed on the inner sides of the tracks of the first welding station and the second welding station. The welding platform and the flexible assembly jig are two support frames located on both sides of the chain conveyor. Multiple sets of cylinders are installed on the support frames, and positioning blocks are installed at the output end of the cylinders to achieve positioning of the workpiece on the end wall. The chain conveyor includes a frame, a support base at the bottom of the frame, a telescopic rod connecting the support base and the frame, a cylinder on the support base to support the frame, and two sets of chains along the length of the frame. The two sets of chains move synchronously through a synchronous shaft and a drive motor. The second buffer station is also equipped with a transfer vehicle, which is located at the bottom of the chain conveyor and is used to transport the end wall of the second buffer station to the third welding station. The tilting and lifting machine includes two tilting frames, with a rotating frame rotatably connected to the opposite surfaces of the tilting frames. The two rotating frames are equipped with positioning mechanisms for positioning end wall workpieces. The rotating frames are connected to a lifting motor at the top of the frame.

2. The flexible welding production line for railway freight car end walls according to claim 1, characterized in that, The stacking station is also equipped with a walking track, a walking truss and a crossbeam. A magnetic gripping fixture is installed on the crossbeam, and the magnetic gripping fixture is connected to the crossbeam through a lifting mechanism and a rotating mechanism. The stacking station is also equipped with a stacking rack, which is located below the crossbeam.

3. The flexible welding production line for railway freight car end walls according to claim 1, characterized in that, Welding fume hoods are installed on the outside of the first and second welding stations, and welding fume hoods are also installed on the outside of the third and fourth welding stations. The welding fume hoods are equipped with dust removal systems and electric roller shutters.

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