A torsion beam production process

Abstract

The present application relates to a kind of torsion beam welding production line, including multiple welding workstations, welding workstations include pedestal, three-axis positioner, fixture tooling, mounting plate and at least one welding robot;Three-axis positioner is installed on pedestal, multiple welding workstations are sequentially arranged in the axial direction of three-axis positioner, three-axis positioner can also be rotatably provided with mounting seat;Fixture tooling is used to clamp workpiece, mounting plate is fixedly installed on fixture tooling, mounting plate can also be detachably connected on mounting seat, and make two working shafts of three-axis positioner all rotatably provided with fixture tooling;Welding robot is installed on pedestal, for welding workpiece.Each torsion beam is correspondingly configured with a set of fixture tooling, and the fixture tooling can be detachably installed on the three-axis positioner, so that the production line can be applied to the production of various models of torsion beam.A kind of torsion beam production process is applied to the torsion beam welding production line, so that the working time of each process is similar, the production rhythm can be balanced, and the production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of automotive parts manufacturing, specifically a torsion beam manufacturing process. Background Technology

[0002] Currently, traditional torsion beam welding production lines involve complex welding steps between various components of the torsion beam. Therefore, each model of torsion beam requires a dedicated production line, limiting production to specific vehicle types and resulting in low flexibility. When producing multiple vehicle models, multiple production lines are needed, leading to high costs. Furthermore, the existing torsion beam manufacturing process suffers from uneven welding time distribution across different processes, resulting in significant time differences between steps and overall low production efficiency. Summary of the Invention

[0003] (a) Technical problems to be solved

[0004] To address the above problems, this invention provides a torsion beam manufacturing process that can balance production cycle and improve production efficiency.

[0005] (II) Technical Solution

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A torsion beam manufacturing process is applied to a torsion beam welding production line, which includes multiple welding workstations. Each welding workstation includes a base, a three-axis positioner, a fixture, a mounting plate, and at least one welding robot.

[0008] The three-axis positioner is mounted on a base. It includes a horizontal central axis and two working axes parallel to the central axis. The front of the positioner is the preparation side, and the rear is the welding side. The two working axes are symmetrically positioned on both sides of the central axis and rotate around its axial direction, allowing the working axes to rotate from the preparation side to the welding side, or from the welding side to the preparation side. Multiple welding workstations are arranged sequentially along the axial direction of the central axis. A mounting base is also rotatably mounted on the three-axis positioner, with the working axes as its rotational axis.

[0009] The fixture includes a worktable and multiple clamping mechanisms mounted on the worktable, which are used to clamp the workpiece to be welded;

[0010] The mounting plate is fixedly mounted on the workbench with bolts. The mounting plate can also be detachably connected to the mounting base, and the two working axes of the three-axis positioner are equipped with rotatable fixtures.

[0011] The welding robot is mounted on the base and located on the welding side of the three-axis positioner. The welding robot is equipped with a welding torch, which is used to weld the workpiece.

[0012] There are four welding workstations, which are arranged and assembled along the three axes. They are the first workstation, the second workstation, the third workstation and the fourth workstation. The first and second workstations each have two welding robots, and the third and fourth workstations each have one welding robot.

[0013] The manufacturing process for this torsion beam includes the following steps:

[0014] OP1: Place the crossbeam, left and right longitudinal beams and left and right reinforcing plates on the preparation side workbench of the first workstation and fix them using multiple clamping mechanisms;

[0015] OP2: The three-axis positioner of the first workstation flips the central axis, causing the worktable on the preparatory side and the worktable on the working side to flip and exchange. The two welding robots weld the left longitudinal beam and the left reinforcing plate to the left side of the crossbeam, and weld the right longitudinal beam and the right reinforcing plate to the right side of the crossbeam, respectively, to obtain the first assembly.

[0016] OP3: The three-axis positioner of the first workstation flips the central axis again, so that the worktable loaded with the first assembly returns to the standby side, and the first assembly is unloaded manually.

[0017] OP4: Place the first assembly, along with the left and right spring seats, two hub mounting plates, and two shaft heads, onto the preparatory side workbench of the second workstation and secure them using the multiple clamping mechanisms on it;

[0018] OP5: The three-axis positioner of the second workstation flips the central axis, causing the worktable on the preparatory side and the worktable on the working side to flip and exchange. The two welding robots weld the left spring seat to the left side of the first assembly and the right spring seat to the right side of the first assembly to obtain the second assembly. Then, the two shaft heads are welded to the two hub mounting plates to obtain two hub sub-assemblies.

[0019] OP6: The three-axis positioner of the second workstation flips the central shaft again, so that the worktable loaded with the second sequence assembly and the wheel hub sub-assembly returns to the preparation side, and the first sequence assembly and the wheel hub sub-assembly are unloaded manually.

[0020] OP7: Place the second assembly, the left and right shock absorber mounting bases, and the left and right sleeves onto the preparation side workbench of the third workstation and fix them using the multiple clamping mechanisms on it;

[0021] OP8: The three-axis positioner of the third workstation flips the central axis, causing the worktable on the preparation side and the worktable on the working side to flip and exchange. The welding robot then welds the left and right shock absorber mounting seats and the left and right sleeves to the second assembly in sequence to obtain the third assembly.

[0022] OP9: The three-axis positioner of the third workstation flips the central axis again, so that the worktable loaded with the third assembly returns to the preparation side, and the third assembly is unloaded manually.

[0023] OP10: Place the third assembly and two wheel hub sub-assemblies on the preparation side workbench of the fourth workstation and fix them using multiple clamps on it;

[0024] OP11: The three-axis positioner of the fourth workstation flips the central shaft, causing the worktable on the preparatory side and the worktable on the working side to flip and exchange. The welding robot welds the two wheel hub sub-assemblies onto the third assembly to obtain the torsion beam assembly.

[0025] OP12: The three-axis positioner of the fourth workstation flips the central shaft again, so that the worktable loaded with the torsion beam assembly returns to the standby side, and the torsion beam assembly is unloaded manually.

[0026] The sum of the times of OP1, OP2 and OP3 is T1, the sum of the times of OP4, OP5 and OP6 is T2, the sum of the times of OP7, OP8 and OP9 is T3, and the sum of the times of OP10, OP11 and OP12 is T4. The difference between the maximum and minimum values ​​of T1, T2, T3 and T4 is less than 10% of their average value.

[0027] Preferably, after the preparatory worktable and the working worktable of OP2 are flipped and swapped, the crossbeam, left and right longitudinal beams, and left and right reinforcing plates are manually placed and clamped at the preparatory side of the three-axis positioner at this time; after the preparatory worktable and the working worktable of OP5 are flipped and swapped, the first assembly, left and right spring seats, two wheel hub mounting plates, and two shaft heads are manually placed and clamped at the preparatory side of the three-axis positioner at this time; after the preparatory worktable and the working worktable of OP8 are flipped and swapped, the second assembly, left and right shock absorber mounting seats, and left and right sleeves are manually placed and clamped at the preparatory side of the three-axis positioner at this time; after the preparatory worktable and the working worktable of OP11 are flipped and swapped, the third assembly and two wheel hub sub-assemblies are manually placed and clamped at the preparatory side of the three-axis positioner at this time.

[0028] Preferably, the mounting base is provided with a receiving boss perpendicular to the mounting base, and locking pins are rotatably provided on both sides of the receiving boss. The rotation plane of the locking pins is parallel to the mounting base. A pressure plate penetrates the locking pins, and the locking pins are also provided with threads and threadedly connected to the nut.

[0029] The mounting plate includes a fixed plate and a locking plate that is perpendicularly connected to the fixed plate. The fixed plate is fixedly connected to the workbench by bolts. The locking plate has locking notches on both sides, which extend toward the center of the locking plate.

[0030] The bottom surface of the locking plate can rest against the receiving protrusion, the locking pin can swing into the locking notch, and the rotating nut can cause the pressure plate to press against the top surface of the locking plate.

[0031] Preferably, the mounting base is further provided with a limiting boss on the receiving boss, and a limiting notch is provided on the locking plate. The limiting boss can be inserted into the limiting notch so that the locking notch corresponds to the position of the locking pin, so that the locking pin can swing into the locking notch.

[0032] Preferably, the receiving boss is also provided with a guide groove perpendicular to the mounting base, and the locking plate is provided with a guide post, which can slide in the guide groove.

[0033] Preferably, the worktable includes a fixed frame and a work plate. The mounting plate is detachably connected to the fixed frame, the work plate is installed inside the fixed frame, and the clamping mechanism is installed on the upper surface and / or lower surface of the work plate. The work plate is provided with a guide positioning rod for contacting and positioning with the workpiece. The work plate is also provided with a through welding hole through which the welding torch can pass.

[0034] (III) Beneficial Effects

[0035] The beneficial effects of this invention are as follows: A torsion beam welding production line includes multiple welding workstations. Each welding workstation includes a base, a three-axis positioner, a fixture, a mounting plate, and at least one welding robot. The three-axis positioner is mounted on the base, and the multiple welding workstations are arranged sequentially along the axial direction of the three-axis positioner. A mounting base can also be rotatably mounted on the three-axis positioner. The fixture is used to hold the workpiece, and the mounting plate is fixedly mounted on the fixture. The mounting plate can also be detachably connected to the mounting base, allowing the fixture to rotate on both working axes of the three-axis positioner. The welding robot is mounted on the base and used for welding the workpiece. Each torsion beam is equipped with a corresponding set of fixtures, which can be detachably mounted on the three-axis positioner. Therefore, this production line can be applied to the production of various types of torsion beams. A torsion beam production process, applied to a torsion beam welding production line, makes the working time of each process similar, which can balance the production cycle and improve production efficiency. Attached Figure Description

[0036] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention, but do not constitute a limitation thereof. In the drawings:

[0037] Figure 1 This is a structural schematic diagram of a welding workstation;

[0038] Figure 2 This is a schematic diagram of a three-axis positioner;

[0039] Figure 3 This is a structural schematic diagram of the fixture.

[0040] Figure 4 A schematic diagram of the connection structure between the mounting plate and the mounting base;

[0041] Figure 5 This is a schematic diagram showing the assembled state of the four welding workstations;

[0042] Figure 6 The product of four welding workstations shows the welding sequence of each part.

[0043] In the diagram: Welding workstation 1, base 11, three-axis positioner 12, fixture 13, mounting plate 14, welding robot 15, mounting seat 16, central shaft 121, working shaft 122, worktable 131, clamping mechanism 132, fixed frame 1311, working plate 1312, guide positioning rod 1313, welding hole 1314, fixed plate 141, locking plate 142, locking notch 1420, limiting notch 1421, guide column 1422, receiving boss 161, locking column 162, pressure plate 163, limiting boss 1610, guide groove 1611, first workstation 1001, second workstation 1002, third workstation 1003, fourth workstation 1004, first sequence assembly S10, second sequence assembly S20, third sequence assembly S30, torsion beam assembly S40, hub sub-assembly S21. Detailed Implementation

[0044] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0045] See appendix Figures 1 to 6 A torsion beam welding production line includes multiple welding workstations 1, each welding workstation 1 including a base 11, a three-axis positioner 12, a fixture 13, a mounting plate 14, and at least one welding robot 15.

[0046] The three-axis positioner 12 is mounted on a base 11. The three-axis positioner 12 includes a horizontal central axis 121 and two working axes 122 parallel to the central axis 121. The front side of the three-axis positioner 12 is the preparation side, and the rear side is the welding side. The two working axes 122 are symmetrically arranged on both sides of the central axis 121 and rotate around the axial direction of the central axis 121, allowing the working axes 122 to rotate from the preparation side to the welding side, or from the welding side to the preparation side. A mounting base 16 is also rotatably mounted on the three-axis positioner 12, with the working axes 122 as the axis of rotation. In other words, the three-axis positioner 12 has a rotating component that rotates around the central axis 121, with rotatable mounting plates on both sides of the rotating component. The three-axis positioner 12 has corresponding drive mechanisms for the central axis 121 and the working axes 122.

[0047] Multiple welding workstations 1 are arranged sequentially along the axial direction of the central shaft 121, and the bases 11 of the multiple welding workstations 1 are assembled sequentially.

[0048] The fixture 13 includes a worktable 131 and multiple clamping mechanisms 132 mounted on the worktable 131. The clamping mechanisms 132 are detachably connected to the worktable 131 by bolts. The positions of the clamping mechanisms 132 on the worktable 131 can be manually adjusted. The clamping mechanisms 132 are used to clamp the workpieces to be welded. The clamping mechanisms 132 clamp the workpieces electrically or by actuation. Each type of torsion beam is equipped with a corresponding fixture 13, and each fixture 13 differs only in its width or the positions of its clamping mechanisms 132.

[0049] Mounting plate 14 is bolted to the worktable 131. Mounting plate 14 can also be detachably connected to mounting base 16, and each of the two working axes 122 of the three-axis positioner 12 has the same fixture 13 rotating on it. All fixtures 13 are connected to the same mounting plate 14, so that the fixtures 13 of each welding workstation 1 can be changed in order or style according to the model of the torsion beam to be welded, and the matching fixtures 13 corresponding to the current torsion beam can be disassembled and replaced.

[0050] The welding robot 15 is mounted on the base 11 and located on the welding side of the three-axis positioner 12. The welding robot 15 is equipped with a welding torch, which is used to weld workpieces. The welding robot 15 adopts an existing multi-axis motion robotic arm, and the working end of the robotic arm is the welding torch. The welding torch can be moved to the welding table 131 of the three-axis positioner 12 to perform operations.

[0051] Specifically, since each fixture 13 of the torsion beam welding production line is detachable, each type of torsion beam is equipped with a set of fixtures 13. When it is necessary to change the production model, the torsion beam welding production line only needs to replace the fixtures 13 on each welding workstation 1. It is not necessary to have a production line for each type of torsion beam, which can save processing space. Therefore, the production line can be used for the production of multiple types of torsion beams.

[0052] Furthermore, regarding the detachable connection structure between the mounting plate 14 and the mounting base 16, in this embodiment, the mounting base 16 is provided with a receiving boss 161 perpendicular to the mounting base 16, and locking pins 162 are rotatably provided on both sides of the receiving boss 161. The rotation plane of the locking pins 162 is parallel to the mounting base 16, and a pressure plate 163 penetrates the locking pins 162. The locking pins 162 are also provided with threads and are threadedly connected to a nut.

[0053] Mounting plate 14 includes a fixing plate 141 and a locking plate 142 perpendicularly connected to the fixing plate 141. The fixing plate 141 is fixedly connected to the side frame of the workbench 131 by bolts. The locking plate 142 has locking notches 1420 on both sides, and both locking notches 1420 extend toward the center of the locking plate 142.

[0054] Initially, the locking pin 162 is located below the receiving boss 161. After the bottom surface of the locking plate 142 abuts against the receiving boss 161, the locking pin 162 can be swung to enter the locking notch 1420. Then, the nut is rotated to move the nut down and press the pressure plate 163 down. Finally, the pressure plate 163 presses against the top surface of the locking plate 142, thus realizing the fixing operation between the mounting base 16 and the mounting plate 14.

[0055] Further, see appendix. Figure 4 To facilitate the positioning of the locking notch 1420 and the locking pin 162, i.e. to complete the quick positioning between the mounting plate 14 and the mounting base 16, in this embodiment, the mounting base 16 is further provided with a limiting boss 1610 on the receiving boss 161, and a limiting notch 1421 is provided on the locking plate 142. The limiting boss 1610 can be inserted into the limiting notch 1421 so that the locking notch 1420 corresponds to the position of the locking pin 162, allowing the locking pin 162 to swing into the locking notch 1420.

[0056] Similarly, the receiving boss 161 is also provided with a guide groove 1611 perpendicular to the mounting base 16, and the locking plate 142 is provided with a guide post 1422, which can slide within the guide groove 1611. In this embodiment, the guide post 1422 is a threaded post that is threaded and penetrates the locking plate 142. The guide post 1422 and the guide groove 1611 are also provided to facilitate the positioning of the mounting plate 14 and the mounting base 16. Furthermore, when the guide post 1422 is inserted into the guide groove 1611, it can also prevent the mounting plate 14 from sliding in the length direction of the receiving boss 161. That is, after the guide post 1422 is inserted into the guide groove 1611 and slides to the deepest point, the limiting boss 1610 is inserted into the limiting notch 1421, thus achieving the positioning work.

[0057] Furthermore, since the structure of each type of torsion beam is slightly different—for example, some torsion beams have a hollow stamped crossbeam, requiring a reinforcing plate to be welded to the bottom of the crossbeam to enhance its strength—the welding of the reinforcing plate necessitates flipping the crossbeam. This operation results in longer welding time and a more complex process. Therefore, in this embodiment, please refer to the appendix. Figure 3 The workbench 131 includes a fixed frame 1311 and a work plate 1312. The mounting plate 14 is detachably connected to the fixed frame 1311. The work plate 1312 is installed inside the fixed frame 1311, and the clamping mechanism 132 is installed on the upper surface and / or lower surface of the work plate 1312. The work plate 1312 is provided with a guide positioning rod 1313, which is used to contact and position the workpiece. The work plate 1312 is also provided with a through welding hole 1314, through which the welding torch can pass to weld the bottom surface of the workpiece. The workpiece only needs to be clamped and fixed once, without having to unload, flip and re-clamp the workpiece before welding, thus saving time.

[0058] Furthermore, to save equipment costs while ensuring production efficiency, the number of welding workstations 1 used on the production line should be minimized. Under this premise, because the parts requiring welding in the preceding process of welding the torsion beam are relatively larger and more numerous, the weld seams in the preceding process are longer, and the welding time needs to be correspondingly extended. Therefore, to balance the working time of each welding workstation 1, please refer to the appendix. Figure 5In one preferred embodiment of the torsion beam welding production line provided by this invention, there are four welding workstations 1, which are arranged and assembled along the three-axis transformation axis, namely, first workstation 1001, second workstation 1002, third workstation 1003, and fourth workstation 1004. First workstation 1001 and second workstation 1002 each have two welding robots 15, while third workstation 1003 and fourth workstation 1004 each have one welding robot 15. Adding a welding robot 15 to the first two processes improves their welding efficiency and balances the working time of the first two processes with that of the last two processes.

[0059] The torsion beam manufacturing process provided by the present invention, applied to the torsion beam welding production line in the above preferred embodiment, includes the following process steps:

[0060] OP1: Place the crossbeam, left and right longitudinal beams and left and right reinforcing plates on the preparation side workbench of the first workstation and fix them using multiple clamping mechanisms;

[0061] OP2: The three-axis positioner of the first workstation flips the central axis, causing the worktable on the preparatory side and the worktable on the working side to flip and exchange. The two welding robots weld the left longitudinal beam and the left reinforcing plate to the left side of the crossbeam, and weld the right longitudinal beam and the right reinforcing plate to the right side of the crossbeam, respectively, to obtain the first sequence assembly S10.

[0062] OP3: The three-axis positioner of the first workstation flips the central axis again, so that the worktable loaded with the first sequence assembly S10 returns to the standby side, and the first sequence assembly S10 is unloaded manually.

[0063] OP4: Place the first assembly S10, along with the left and right spring seats, two hub mounting plates, and two shaft heads, onto the preparatory side workbench of the second workstation and secure them using the multiple clamping mechanisms on it.

[0064] OP5: The three-axis positioner of the second workstation flips the central axis, causing the worktable on the preparatory side and the worktable on the working side to flip and exchange. The two welding robots weld the left spring seat to the left side of the first assembly S10 and the right spring seat to the right side of the first assembly S10, respectively, to obtain the second assembly S20. Then, the two shaft heads are welded to the two hub mounting plates, to obtain the two hub sub-assemblies S21.

[0065] OP6: The three-axis positioner of the second workstation flips the central shaft again, so that the worktable loaded with the second sequence assembly S20 and the hub sub-assembly S21 returns to the standby side, and the first sequence assembly S10 and the hub sub-assembly S21 are unloaded manually.

[0066] OP7: Place the second assembly S20, the left and right shock absorber mounting bases, and the left and right sleeves onto the preparation side workbench of the third workstation and fix them using the multiple clamping mechanisms on it;

[0067] OP8: The three-axis positioner of the third workstation flips the central axis, causing the worktable on the preparation side and the worktable on the working side to flip and exchange. The welding robot then welds the left and right shock absorber mounting seats and the left and right sleeves to the second assembly S20 in sequence to obtain the third assembly S30.

[0068] OP9: The three-axis positioner of the third workstation flips the central axis again, so that the worktable loaded with the third assembly S30 returns to the preparation side, and the third assembly S30 is unloaded manually.

[0069] OP10: Place the third assembly S30 and the two wheel hub sub-assemblies S21 on the preparation side workbench of the fourth work station and fix them using the multiple clamps on it;

[0070] OP11: The three-axis positioner of the fourth workstation flips the central shaft, causing the worktable on the preparatory side and the worktable on the working side to flip and exchange. The welding robot welds the two wheel hub sub-assemblies S21 onto the third assembly S30 respectively, to obtain the torsion beam assembly S40.

[0071] OP12: The three-axis positioner of the fourth workstation flips the central shaft again, so that the worktable loaded with the torsion beam assembly S40 returns to the standby side, and the torsion beam assembly S40 is unloaded manually.

[0072] The sum of the times for OP1, OP2, and OP3 is T1; the sum of the times for OP4, OP5, and OP6 is T2; the sum of the times for OP7, OP8, and OP9 is T3; and the sum of the times for OP10, OP11, and OP12 is T4. The difference between the maximum and minimum values ​​among T1, T2, T3, and T4 is less than 10% of their average. Furthermore, material transfer between welding workstations can be done manually or using a crane. Furthermore, after the preparatory worktable and the working worktable of OP2 are flipped and swapped, the operator then manually places and clamps the crossbeam, left and right longitudinal beams, and left and right reinforcing plates at the preparatory side of the three-axis positioner. After the preparatory worktable and the working worktable of OP5 are flipped and swapped, the operator then manually places and clamps the first assembly S10, left and right spring seats, two wheel hub mounting plates, and two shaft heads at the preparatory side of the three-axis positioner. After the preparatory worktable and the working worktable of OP8 are flipped and swapped, the operator then manually places and clamps the second assembly S20, left and right shock absorber mounting seats, and left and right sleeves at the preparatory side of the three-axis positioner. After the preparatory worktable and the working worktable of OP11 are flipped and swapped, the operator then manually places and clamps the third assembly S30 and two wheel hub sub-assemblies S21 at the preparatory side of the three-axis positioner, thereby achieving continuous production without stopping the machine.

[0073] See appendix Figure 6 In this torsion beam manufacturing process, the welding sequence of each component is from the inside out. First, the main structural crossbeam and left and right longitudinal beams are welded; then the innermost left and right reinforcing ribs are welded; followed by the left and right spring seats, left and right shock absorber mounting seats, wheel hub sub-assembly S21, and left and right sleeves. Considering factors such as the size of each component, weld length, loading and unloading time, and welding difficulty at different weld locations, the crossbeam and longitudinal beam welds are long but easy to install, while the wheel hub sub-assembly S21 is more difficult to weld to the longitudinal beams. Therefore, the wheel hub sub-assembly S21 is assigned to the second welding workstation, and the left and right sleeves are assigned to the third workstation. This results in the torsion beam manufacturing process provided by this invention, which makes the working time of the four welding workstations more consistent, adjusts the production line's production rhythm, and ensures that all equipment is continuously working, thus improving production efficiency. The welding sequence adopted in this torsion beam manufacturing process allows the welding work of each component to be distributed across various processes, resulting in a relatively small number of workpieces welded at one time, minimal deformation during welding, easier control, and higher finished product quality.

[0074] Regarding the manufacturing process of this torsion beam, this invention provides a set of actual data:

[0075] The working time of the first workstation is as follows: loading and unloading time 39 seconds, positioner rotation time 12 seconds, fixture rotation time 10 seconds, weld length 1274 mm, welding time 64 seconds, welding machine jump time 27 seconds, and total time 152 seconds.

[0076] The working time of the second workstation is as follows: loading and unloading time 45 seconds, positioner rotation time 12 seconds, fixture rotation time 10 seconds, weld length 1380 mm, welding time 69 seconds, welding machine jump time 14 seconds, and total time 150 seconds.

[0077] The working time of the third workstation is as follows: loading and unloading time 36 seconds, positioner rotation time 12 seconds, fixture rotation time 10 seconds, weld length 794 mm, welding time 79 seconds, welding machine jump time 19 seconds, and total time 157 seconds.

[0078] The working time of the fourth workstation is as follows: loading and unloading time 44 seconds, positioner rotation time 12 seconds, fixture rotation time 10 seconds, weld length 568 mm, welding time 57 seconds, welding machine jump time 24 seconds, and total time 147 seconds.

[0079] The longest working time was 157 seconds for the third workstation, and the shortest was 147 seconds for the fourth workstation, a difference of 10 seconds. The average working time across the four workstations was 151 seconds, and 10% of that average is 15 seconds. Therefore, the difference between the maximum and minimum working times given here is within 10% of this average working time.

[0080] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. Although embodiments of the invention have been shown and described, those skilled in the art will recognize that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for a torsion beam, characterized in that, It is applied to a torsion beam welding production line, which includes multiple welding workstations, each of which includes a base, a three-axis positioner, a fixture, a mounting plate, and at least one welding robot. The three-axis positioner is mounted on a base. The three-axis positioner includes a horizontal central axis and two working axes parallel to the central axis. The front side of the three-axis positioner is the preparation side, and the rear side is the welding side. The two working axes are symmetrically arranged on both sides of the central axis and rotate around the central axis's axis, allowing the working axes to rotate from the preparation side to the welding side, or from the welding side to the preparation side. Multiple welding workstations are arranged sequentially along the central axis. A mounting base is also rotatably mounted on the three-axis positioner, with the working axes as the rotation axis. The fixture includes a worktable and multiple clamping mechanisms mounted on the worktable, the multiple clamping mechanisms being used to clamp the workpiece to be welded; The mounting plate is fixedly mounted on the workbench by bolts. The mounting plate can also be detachably connected to the mounting base, and both working axes of the three-axis positioner are equipped with rotatable fixtures. The welding robot is mounted on the base and located on the welding side of the three-axis positioner. The welding robot is equipped with a welding torch, which is used to weld the workpiece. The welding workstation has four stations, which are arranged and assembled along the axis of the three-axis transformation, namely the first station, the second station, the third station and the fourth station. The first station and the second station each have two welding robots, and the third station and the fourth station each have one welding robot. The manufacturing process for this torsion beam includes the following steps: OP1: Place the crossbeam, left and right longitudinal beams and left and right reinforcing plates on the preparation side workbench of the first workstation and fix them using multiple clamping mechanisms; OP2: The three-axis positioner of the first workstation flips the central axis, causing the worktable on the preparatory side and the worktable on the working side to flip and exchange. The two welding robots weld the left longitudinal beam and the left reinforcing plate to the left side of the crossbeam, and weld the right longitudinal beam and the right reinforcing plate to the right side of the crossbeam, respectively, to obtain the first assembly. OP3: The three-axis positioner of the first workstation flips the central axis again, so that the worktable loaded with the first assembly returns to the standby side, and the first assembly is unloaded manually. OP4: Place the first assembly, along with the left and right spring seats, two hub mounting plates, and two shaft heads, onto the preparatory side workbench of the second workstation and secure them using the multiple clamping mechanisms on it; OP5: The three-axis positioner of the second workstation flips the central axis, causing the worktable on the preparatory side and the worktable on the working side to flip and exchange. The two welding robots weld the left spring seat to the left side of the first assembly and the right spring seat to the right side of the first assembly to obtain the second assembly. Then, the two shaft heads are welded to the two hub mounting plates to obtain two hub sub-assemblies. OP6: The three-axis positioner of the second workstation flips the central shaft again, so that the worktable loaded with the second sequence assembly and the wheel hub sub-assembly returns to the preparation side, and the first sequence assembly and the wheel hub sub-assembly are unloaded manually. OP7: Place the second assembly, the left and right shock absorber mounting bases, and the left and right sleeves onto the preparation side workbench of the third workstation and fix them using the multiple clamping mechanisms on it; OP8: The three-axis positioner of the third workstation flips the central axis, causing the worktable on the preparation side and the worktable on the working side to flip and exchange. The welding robot then welds the left and right shock absorber mounting seats and the left and right sleeves to the second assembly in sequence to obtain the third assembly. OP9: The three-axis positioner of the third workstation flips the central axis again, so that the worktable loaded with the third assembly returns to the preparation side, and the third assembly is unloaded manually. OP10: Place the third assembly and two wheel hub sub-assemblies on the preparation side workbench of the fourth workstation and fix them using multiple clamps on it; OP11: The three-axis positioner of the fourth workstation flips the central shaft, causing the worktable on the preparatory side and the worktable on the working side to flip and exchange. The welding robot welds the two wheel hub sub-assemblies onto the third assembly to obtain the torsion beam assembly. OP12: The three-axis positioner of the fourth workstation flips the central shaft again, so that the worktable loaded with the torsion beam assembly returns to the standby side, and the torsion beam assembly is unloaded manually. The sum of the times of OP1, OP2 and OP3 is T1, the sum of the times of OP4, OP5 and OP6 is T2, the sum of the times of OP7, OP8 and OP9 is T3, and the sum of the times of OP10, OP11 and OP12 is T4. The difference between the maximum and minimum values ​​of T1, T2, T3 and T4 is less than 10% of their average value.

2. The torsion beam manufacturing process according to claim 1, characterized in that, After the preparatory worktable and the working worktable of OP2 are flipped and swapped, the crossbeam, left and right longitudinal beams, and left and right reinforcing plates are manually placed and clamped at the preparatory side of the three-axis positioner. After the preparatory worktable and the working worktable of OP5 are flipped and swapped, the first assembly, left and right spring seats, two wheel hub mounting plates, and two shaft heads are manually placed and clamped at the preparatory side of the three-axis positioner. After the preparatory worktable and the working worktable of OP8 are flipped and swapped, the second assembly, left and right shock absorber mounting seats, and left and right sleeves are manually placed and clamped at the preparatory side of the three-axis positioner. After the preparatory worktable and the working worktable of OP11 are flipped and swapped, the third assembly and two wheel hub sub-assemblies are manually placed and clamped at the preparatory side of the three-axis positioner.

3. The manufacturing process for a torsion beam according to claim 1, characterized in that, The mounting base is provided with a receiving boss perpendicular to the mounting base. Locking pins are rotatably provided on both sides of the receiving boss. The rotation plane of the locking pins is parallel to the mounting base. A pressure plate penetrates the locking pins. The locking pins are also provided with threads and are threadedly connected to a nut. The mounting plate includes a fixing plate and a locking plate perpendicularly connected to the fixing plate. The fixing plate is fixedly connected to the workbench by bolts. The locking plate has locking notches on both sides, and the locking notches extend toward the center of the locking plate. The bottom surface of the locking plate can abut against the receiving protrusion, the locking pin can swing into the locking notch, and rotating the nut can cause the pressure plate to press against the top surface of the locking plate.

4. The torsion beam manufacturing process according to claim 3, characterized in that, The mounting base is further provided with a limiting boss on the receiving boss, and a limiting notch is provided on the locking plate. The limiting boss can be inserted into the limiting notch so that the locking notch corresponds to the position of the locking pin, allowing the locking pin to swing into the locking notch.

5. The torsion beam manufacturing process according to claim 4, characterized in that, The receiving boss is also provided with a guide groove perpendicular to the mounting base, and the locking plate is provided with a guide post, which can slide in the guide groove.

6. The torsion beam manufacturing process according to claim 5, characterized in that, The workbench includes a fixed frame and a work plate. The mounting plate is detachably connected to the fixed frame. The work plate is installed inside the fixed frame. The clamping mechanism is installed on the upper and / or lower surface of the work plate. The work plate is provided with a guide positioning rod for contacting and positioning the workpiece. The work plate is also provided with a through welding hole through which the welding torch can pass.

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