Welding method for a side wall unit of a railway vehicle

Abstract

This invention relates to the field of welding technology and provides a welding method for a side wall unit of a rail vehicle, specifically including the following steps: determining the size and positioning of the clamping mold based on the layout of the beams and columns in the side wall unit; sequentially clamping the beams and columns onto the clamping mold, and fixing at least some of the beams and columns to the clamping mold through a clamping mechanism; performing tack welding on the welding points between the beams and columns to form a side wall frame; laying the upper wall panel and lower wall panel on the side wall frame and welding them to form the side wall unit. Determining the size and positioning of the clamping mold based on the beam and column layout allows the clamping mold to be designed based on the beam and column layout. After the beams and columns are clamped onto the clamping mold, they will be in the precise design position. After the beams and columns are tack welded, the accuracy of the formed side wall frame can be ensured, ensuring precise tack welding. After welding is completed, there is no need to adjust the beams and columns, reducing operation time and improving product consistency.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and in particular to a welding method for a side wall unit of a rail vehicle. Background Technology

[0002] During the welding process of the side wall unit of the rail vehicle, welding equipment is used to support and fix the side wall unit. The current welding method limits the elastic adjustment of the side wall frame, increases the difficulty of frame adjustment, and is prone to local plastic deformation of beams and columns after adjustment. The outline will also bulge outward due to welding deformation, resulting in low consistency of the side wall unit. Summary of the Invention

[0003] This invention provides a welding method for side wall units of rail vehicles, which solves the problem in the prior art that the side wall frame needs to be adjusted after welding, which can easily cause beam and column deformation and result in low consistency of the side wall units, thereby improving product consistency.

[0004] This invention provides a welding method for a side wall unit of a rail vehicle, comprising:

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

[0006] The beams and columns are sequentially snapped into the clamping mold, and at least a portion of the beams and columns are fixed to the clamping mold by a clamping mechanism;

[0007] The welding points between the beams and columns are tack welded to form the side wall frame;

[0008] The upper and lower wall panels are laid on the side wall frame and welded together to form a side wall unit.

[0009] According to a welding method for a side wall unit of a rail vehicle provided by the present invention, the step of determining the size positioning of the clamping mold based on the layout of beams and columns in the side wall unit specifically includes:

[0010] Based on the number and position of the window pillars, upper window beams, lower window beams, upper window side beams, lower window side beams, upper window pillars, lower window pillars, door pillars, sub-beams, lower side beams, window frames, and connecting plates in the side wall unit, several intersecting locking molds are set up, so that the locking molds extend upward to form protrusions, and the protrusions are adapted to the window pillars, upper window beams, lower window beams, upper window side beams, lower window side beams, upper window pillars, lower window pillars, door pillars, sub-beams, lower side beams, window frames, and connecting plates.

[0011] According to a welding method for a side wall unit of a rail vehicle provided by the present invention, the step of determining the size positioning of the clamping mold based on the layout of beams and columns in the side wall unit further includes:

[0012] Based on the assembly relationship between the beam / column and the clamping mold, an anti-deformation zone is designed in the clamping mold;

[0013] The anti-deformation zone includes the column contour anti-deformation zone and the door column anti-deformation zone.

[0014] According to a welding method for a side wall unit of a rail vehicle provided by the present invention, the step of sequentially snapping the beams and columns into the snap-fit ​​mold specifically includes:

[0015] The window pillars, upper window beams, lower window beams, upper window side beams, lower window side beams, upper window pillars, lower window pillars, door pillars, side beams, lower side beams, window frames, and connecting plates of the side wall unit are sequentially snapped together and assembled into the snap-fit ​​mold.

[0016] According to a welding method for a side wall unit of a rail vehicle provided by the present invention, the clamping mold is adapted to be fixed to a tooling frame, the tooling frame is provided with a clamping mechanism, and the clamping mechanism is used to press the beam and column tightly against the clamping mold.

[0017] According to a welding method for a side wall unit of a rail vehicle provided by the present invention, the clamping mechanism includes:

[0018] The mounting base is C-shaped, with one end of the mounting base rotatably connected to the tooling frame and the other end of the mounting base having an assembly hole.

[0019] A clamping rod is inserted through the mounting hole. One end of the clamping rod is located inside the mounting base and is connected to a clamping part. The other end of the clamping rod is located outside the mounting base and is connected to a gripping part.

[0020] The beam and column are adapted to be pressed and fixed to the clamping mold by the pressing part.

[0021] According to a welding method for a side wall unit of a rail vehicle provided by the present invention, the clamping mechanism further includes:

[0022] An elastic element is sleeved on the clamping rod, and the two ends of the elastic element abut against the clamping part and the mounting base, respectively.

[0023] According to a welding method for a side wall unit of a rail vehicle provided by the present invention, the beam-column includes a cap-shaped beam, and a groove is formed on the side of the cap-shaped beam facing the clamping mold, the groove engaging with the protrusion.

[0024] The height of the slot is higher than the height of the protrusion.

[0025] According to a welding method for a side wall unit of a rail vehicle provided by the present invention, the clamping mold includes a horizontal section and an inclined section arranged at an angle.

[0026] According to a welding method for a side wall unit of a rail vehicle provided by the present invention, the step of performing tack welding on the welding points between the beams and columns to form a side wall frame specifically includes:

[0027] The welding points between the beams and columns are spot-welded on one side along a preset welding path to form a side wall frame.

[0028] The welding method for the side wall unit of a rail vehicle provided in this invention determines the size and positioning of the clamping mold based on the beam and column layout. This allows the clamping mold to be designed based on the beam and column layout, ensuring that the beams and columns are precisely positioned after being clamped into the clamping mold. After the beams and columns are positioned and welded, the accuracy of the formed side wall frame is ensured, guaranteeing precise positioning welding. No adjustments to the beams and columns are required after welding, reducing operation time and improving product consistency. Attached Figure Description

[0029] 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.

[0030] Figure 1 This is a schematic flowchart of the welding method for the side wall unit of a rail vehicle provided by the present invention;

[0031] Figure 2 This is a side view of the clamping mold set on the tooling frame in the welding method of the rail vehicle side wall unit provided by the present invention;

[0032] Figure 3 This is a schematic diagram of the clamping mechanism in the welding method for the side wall unit of a rail vehicle provided by the present invention;

[0033] Figure 4 This is a schematic diagram of the welding path in the welding method for the side wall unit of a rail vehicle provided by the present invention.

[0034] Figure label:

[0035] 10. Beams and columns; 20. Clamping mold; 210. Protrusion; 220. Horizontal section; 230. Inclined section; 30. Clamping mechanism; 310. Mounting base; 320. Clamping rod; 330. Elastic element; 340. Clamping part; 350. Holding part; 40. Tooling frame. Detailed Implementation

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] The following is combined Figures 1-4 Embodiments of the present invention are described.

[0042] like Figure 1 As shown, the welding method for the rail vehicle sidewall unit in this embodiment includes the following steps:

[0043] S100. Determine the size and positioning of the card template 20 based on the layout of the beams and columns 10 in the side wall unit.

[0044] S200, sequentially snap the beams and columns 10 into the clamping mold 20, and fix at least a portion of the beams and columns 10 to the clamping mold 20 through the clamping mechanism 30.

[0045] S300, perform tack welding on the welding points between beams and columns 10 to form the side wall frame.

[0046] S400. Install the upper and lower wall panels onto the side wall frame and weld them together to form a side wall unit.

[0047] The dimensions and positioning of the clamping mold 20 are determined based on the layout of the beams and columns 10, allowing the clamping mold 20 to be designed according to the layout of the beams and columns 10. After the beams and columns 10 are clamped into the clamping mold 20, they will be in the precise design position. After the beams and columns 10 are positioned and welded, the accuracy of the formed side wall frame can be ensured, ensuring precise positioning welding. After welding is completed, there is no need to adjust the beams and columns 10, reducing operation time and improving product consistency.

[0048] After the tack welding is completed, the side wall frame formed by the tack welding is removed from the clamping mold 20. After the side wall frame is transferred to the forming welding area, the upper wall panel and the lower wall panel are laid on the side wall frame and welded to form a side wall unit.

[0049] The welding between the upper and lower wall panels and the side wall frame includes tack welding and automatic welding. During the automatic welding process, no operator is required to monitor the welding operation, saving labor costs.

[0050] Specifically, the upper wall panel is installed at the location of the window frame, and a window needs to be opened on the upper wall panel. When welding the upper wall panel and the window frame of the side wall frame, the center of the window can be used as a positioning reference point, and welding can be carried out after positioning is completed.

[0051] The steps for determining the size positioning of the template 20 based on the layout of the beams and columns 10 in the side wall unit specifically include:

[0052] Based on the number and position of window pillars, upper window beams, lower window beams, upper window side beams, lower window side beams, upper window pillars, lower window pillars, door pillars, sub-beams, lower edge beams, window frames, and connecting plates in the side wall unit, several intersecting locking molds 20 are set up, so that the locking molds 20 extend upward to form protrusions 210, and the protrusions 210 are adapted to the window pillars, upper window beams, lower window beams, upper window side beams, lower window side beams, upper window pillars, lower window pillars, door pillars, sub-beams, lower edge beams, window frames, and connecting plates.

[0053] The cross-shaped clamping molds 20 can form a clamping fixture. The cross-shaped clamping fixture can clamp and fix the window pillars, window upper beam, window lower beam, window side upper beam, window side lower beam, window upper pillar, window lower pillar, door pillar, sub-beam, bottom beam, window frame, and connecting plate respectively, so that the window pillars, window upper beam, window lower beam, window side upper beam, window side lower beam, window upper pillar, window lower pillar, door pillar, sub-beam, bottom beam, window frame, and connecting plate can be fixed on the clamping fixture respectively without interference between them.

[0054] The cross-shaped template fixture can also reserve space for spot welding operations, which facilitates positioning welding between window pillars, upper window beams, lower window beams, upper window side beams, lower window side beams, upper window pillars, lower window pillars, door pillars, sub-beams, lower side beams, window frames, and connecting plates, enabling direct assembly spot welding. Furthermore, the structure based on the template fixture can improve welding accuracy and ensure good consistency of the overall skeleton.

[0055] The cross-shaped template fixture allows for direct assembly and spot welding of the side wall frame, saving space. It changes the previous method of pre-assembly jig + spot welding jig to a frame assembly and welding jig, reducing the working area by 20m². 2 (square meters).

[0056] The protrusion 210 can be integrally formed on the clamping mold 20, or it can be fixed to the clamping mold 20 by welding, bolt connection or other means.

[0057] In this embodiment, the locking mold 20 is suitable for fixing to the tooling frame 40. Window pillars, upper window beams, lower window beams, upper window side beams, lower window side beams, upper window pillars, lower window pillars, door pillars, side beams, lower edge beams, window frames, and connecting plates are laid on the locking mold 20 and locked to the protrusion 210. The protrusion 210 enables the installation accuracy of the locking mold 20 to reach 1mm, achieving precise welding. The position of the protrusion 210 matches the design and forming position of the window pillar, upper window beam, lower window beam, upper window side beam, lower window side beam, upper window pillar, lower window pillar, door pillar, sub-beam, lower edge beam, window frame, and connecting plate. This allows for precise assembly of the window pillar, upper window beam, lower window beam, upper window side beam, lower window side beam, upper window pillar, lower window pillar, door pillar, sub-beam, lower edge beam, window frame, and connecting plate after they are snapped together by the snap-fit ​​mold 20.

[0058] The steps for determining the size positioning of the template 20 based on the layout of the beams and columns 10 in the side wall unit also include:

[0059] Based on the assembly relationship between beam-column 10 and clamping mold 20, an anti-deformation zone is designed in clamping mold 20.

[0060] The anti-deformation zone includes the column outline anti-deformation zone and the door column anti-deformation zone.

[0061] The anti-deformation zones for the column profiles include those for window columns, upper window columns, lower window columns, and door columns, with each zone having a pre-fabricated 2mm anti-deformation radius. The door column anti-deformation zone is a 2mm anti-deformation formed in the installation area of ​​the door column. This anti-deformation design can accommodate the deformation of beams and columns 10 during welding, ensuring that no adjustments to beams and columns 10 are needed after welding, and ensuring the flatness of the side wall frame and its consistency.

[0062] The design based on the anti-deformation zone can avoid external bulging deformation during the welding process, significantly reducing labor, ventilation, gas and electricity costs.

[0063] The steps of sequentially snapping the beams and columns 10 onto the clamping mold 20 specifically include:

[0064] The window pillars, upper and lower horizontal beams, upper and lower horizontal beams, upper and lower horizontal beams, upper and lower pillars, door pillars, side beams, lower side beams, window frames, and connecting plates in the side wall unit are sequentially snapped together and assembled into the snap-fit ​​mold 20.

[0065] Based on the above assembly method, each component is sequentially snapped into the clamping mold 20, achieving compact assembly while ensuring the most reasonable and convenient equipment process.

[0066] The assembly order of the upper and lower horizontal beams of the window can be replaced, the assembly order of the upper and lower horizontal beams of the window side can be replaced, and the assembly order of the upper and lower vertical pillars of the window can be replaced.

[0067] The clamping mold 20 is suitable for fixing to the tooling frame 40. The tooling frame 40 is provided with a clamping mechanism 30, which is used to clamp the beam and column 10 to the clamping mold 20. The clamping mechanism 30 clamps the beam and column 10 to the clamping mold 20, ensuring the stable installation of the beam and column 10.

[0068] like Figure 3 As shown, the clamping mechanism 30 includes a mounting base 310 and a clamping rod 320. The mounting base 310 is C-shaped, with one end rotatably connected to the tooling frame 40 and the other end having an assembly hole. The clamping rod 320 passes through the assembly hole, with one end inside the mounting base 310 and connected to a clamping part 340, and the other end outside the mounting base 310 and connected to a gripping part 350. The beam / column 10 is adapted to be clamped and fixed to the clamping mold 20 by the clamping part 340.

[0069] The beam-column 10 is clamped and fixed by the C-shaped mounting base 310 in conjunction with the clamping rod 320. Specifically, the mounting base 310 is rotated so that it is perpendicular to the clamping mold 20, and the other end of the mounting base 310 is parallel to the clamping mold 20. The assembly hole is aligned with the beam-column 10 and the clamping mold 20. The position of the clamping part 340 is adjusted by the gripping part 350 so that the clamping part 340 abuts against the edge of the beam-column 10 and fixes the beam-column 10 and the clamping mold 20 to each other, ensuring the reliable fixation of the beam-column 10.

[0070] The clamping mechanism 30 also includes an elastic element 330, sleeved on the clamping rod 320, with both ends of the elastic element 330 abutting against the clamping part 340 and the mounting base 310, respectively. The elastic force of the elastic element 330 allows the clamping part 340 to be better clamped against the beam / column 10 and the locking mold 20, ensuring a secure fixation between the beam / column 10 and the locking mold 20.

[0071] The clamping rod 320 can be threaded into the mounting hole. The distance between the clamping part 340 and the beam / column 10 can be adjusted by rotating the gripping part 350, and the elastic abutment of the elastic element 330 ensures a secure fixation between the beam / column 10 and the locking mold 20. Alternatively, the clamping rod 320 can be slidably mounted to the mounting hole. Pulling the gripping part 350 adjusts the distance between the clamping part 340 and the beam / column 10, and the elastic abutment of the elastic element 330 ensures reliable contact between the clamping part 340, the beam / column 10, and the locking mold 20, guaranteeing a secure fixation between them.

[0072] The tooling frame 40 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.

[0073] The tooling frame 40 is also equipped with a lifting and adjusting mechanism, which includes a lifting nut and a guide column to adjust the height of the tooling frame 40.

[0074] The beam-column 10 includes a cap-shaped beam, with a groove formed on the side of the cap-shaped beam facing the clamping mold 20. The groove engages with the protrusion 210. The height of the groove is higher than the height of the protrusion 210. Specifically, the height of the protrusion 210 is 2mm less than the height of the groove, thus preventing the protrusion 210 from lifting the cap-shaped beam, and consequently preventing the clamping mold 20 from lifting the window pillars, upper window beams, lower window beams, upper side window beams, lower side window beams, upper window pillars, lower window pillars, door pillars, purlins, lower edge beams, window frames, and connecting plates, thereby affecting flatness. Furthermore, the end of the protrusion 210 facing the groove is tapered, meaning that the opposite sides of the protrusion 210 have beveled surfaces with a bevel extension of 0.2mm, facilitating engagement and improving assembly accuracy.

[0075] like Figure 2 As shown, the card mold 20 includes a horizontal section 220 and an inclined section 230 set at an angle. The angle between the inclined section 230 and the vertical plane is 97°. This small inclination angle design facilitates mold release and improves welding efficiency.

[0076] The steps for performing tack welding on the weld points between beams and columns 10 to form the side wall frame specifically include:

[0077] The welding points between beams and columns 10 are spot welded on one side along a preset welding path to form a side wall frame.

[0078] like Figure 4 As shown, the arrow indicates the welding path, which is approximately U-shaped. An automatic welding device is used to perform automatic positioning welding along this path, and single-sided spot welding is used to ensure the firmness of the positioning weld.

[0079] By using the above welding method to form the side wall frame and side wall units, the tack welding inside the beams and columns can be eliminated, eliminating the need for post-weld cleaning and grinding. Once the side wall frame is completed, no adjustments are required, significantly reducing labor, ventilation, gas, and electricity costs. This results in savings of 200 yuan per vehicle for tack welding; 200 yuan per vehicle for weld cleaning; and 800 yuan per vehicle per shift for energy (ventilation, water, gas, electricity, etc.), totaling a cost reduction of 1200 yuan per vehicle.

[0080] 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 a side wall unit of a rail vehicle, characterized in that, Includes the following steps: The dimensions and positioning of the card template are determined based on the layout of beams and columns in the side wall unit; The beams and columns are sequentially snapped into the clamping mold, and at least a portion of the beams and columns are fixed to the clamping mold by a clamping mechanism; The welding points between the beams and columns are tack welded to form the side wall frame; The upper and lower wall panels are laid on the side wall frame and welded to form a side wall unit; The steps for determining the size positioning of the template based on the layout of beams and columns in the side wall unit specifically include: Based on the number and position of the window pillars, upper window beams, lower window beams, upper window side beams, lower window side beams, upper window pillars, lower window pillars, door pillars, sub-beams, lower edge beams, window frames, and connecting plates in the side wall unit, several intersecting locking molds are set up, so that the locking molds extend upward to form protrusions, and the protrusions are adapted to the window pillars, upper window beams, lower window beams, upper window side beams, lower window side beams, upper window pillars, lower window pillars, door pillars, sub-beams, lower edge beams, window frames, and connecting plates; The beam-column includes a cap-shaped beam, and a groove is formed on the side of the cap-shaped beam facing the locking mold, and the groove engages with the protrusion. The height of the slot is higher than the height of the protrusion.

2. The welding method for the side wall unit of a rail vehicle according to claim 1, characterized in that, The step of determining the size positioning of the template based on the layout of beams and columns in the side wall unit further includes: Based on the assembly relationship between the beam / column and the clamping mold, an anti-deformation zone is designed in the clamping mold; The anti-deformation zone includes the column contour anti-deformation zone and the door column anti-deformation zone.

3. The welding method for the side wall unit of a rail vehicle according to claim 1, characterized in that, The step of sequentially snapping the beams and columns into the clamping mold specifically includes: The window pillars, upper window beams, lower window beams, upper window side beams, lower window side beams, upper window pillars, lower window pillars, door pillars, side beams, lower side beams, window frames, and connecting plates of the side wall unit are sequentially snapped together and assembled into the snap-fit ​​mold.

4. The welding method for the side wall unit of a rail vehicle according to claim 1, characterized in that, The clamping mold is adapted to be fixed to the tooling frame, and the tooling frame is provided with a clamping mechanism, which is used to press the beam and column tightly against the clamping mold.

5. The welding method for the side wall unit of a rail vehicle according to claim 4, characterized in that, The clamping mechanism includes: The mounting base is C-shaped, with one end of the mounting base rotatably connected to the tooling frame and the other end of the mounting base having an assembly hole. A clamping rod is inserted through the mounting hole. One end of the clamping rod is located inside the mounting base and is connected to a clamping part. The other end of the clamping rod is located outside the mounting base and is connected to a gripping part. The beam and column are adapted to be pressed and fixed to the clamping mold by the pressing part.

6. The welding method for the side wall unit of a rail vehicle according to claim 5, characterized in that, The clamping mechanism further includes: An elastic element is sleeved on the clamping rod, and the two ends of the elastic element abut against the clamping part and the mounting base, respectively.

7. The welding method for the side wall unit of a rail vehicle according to claim 1, characterized in that, The card slot includes a horizontal section and an inclined section set at an angle.

8. The welding method for the side wall unit of a rail vehicle according to any one of claims 1-7, characterized in that, The step of performing tack welding on the welding points between the beams and columns to form the sidewall frame specifically includes: The welding points between the beams and columns are spot-welded on one side along a preset welding path to form a side wall frame.

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