A bonding and straightening process for aluminum side panels of passenger buses

Abstract

This invention discloses a bonding and straightening process for aluminum skin on the side of a bus, comprising the following steps: (1) welding multiple positioning blocks onto the lower edge steel of the side window glass, with the upper surfaces of the multiple positioning blocks located on the same plane and the flatness deviation ≤0.5mm; (2) cutting the nozzle of the adhesive into an inverted triangle shape; (3) cleaning the aluminum skin and the side frame, and brushing an activator and a primer onto the bonding surface on the frame, and then applying the adhesive; (4) hanging the aluminum skin on the positioning blocks and pressing the upper edge of the aluminum skin, and straightening the middle and lower part of the aluminum skin; (5) adjusting the surface difference between two adjacent aluminum skin sections so that the surface difference is ≤0.5mm; This invention limits the process parameters and straightening methods for skin bonding, which is beneficial to controlling the flatness of the skin and the consistency of the width of the side window glue joint, and improves the bonding effect of the aluminum skin and the flatness of the side skin of the bus body.

Description

Technical Field

[0001] This invention relates to the field of bus manufacturing technology, specifically to a bonding and shaping process for aluminum side panels of buses. Background Technology

[0002] The information disclosed in this background section is intended only to enhance understanding of the overall background of the invention and is not necessarily to be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art.

[0003] Currently, most domestic buses use galvanized iron sheet for their side panels, employing CO2 gas shielded welding or resistance welding processes. Aluminum panels are rarely used, as their bonding and shaping processes significantly impact conventional production cycles, requiring advanced skills and experience. Incomplete processes can easily lead to rework or defects such as poor flatness after bonding. While existing adhesive-bonded panel production processes improve flatness, the panels are prone to peeling. Under extreme operating conditions, the paint at the panel joints is susceptible to cracking, and even panel detachment can occur. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a bonding and shaping process for aluminum side panels of buses. By controlling the dimensions and correcting the flatness during the bonding process of the aluminum side panels, the flatness of the bus body side panels is improved.

[0005] The technical solution of the present invention is as follows:

[0006] In a first aspect of the present invention, a bonding and shaping process for aluminum side panels of a passenger vehicle is provided, comprising the following steps:

[0007] (1) Weld multiple positioning blocks onto the lower edge steel of the side window glass, with the upper surfaces of the multiple positioning blocks located on the same plane and the flatness deviation ≤0.5mm;

[0008] (2) Cut the nozzle of the adhesive into an inverted triangle shape:

[0009] (3) Clean the aluminum skin and side frame, and apply activator and primer to the bonding surface on the frame, and then apply adhesive.

[0010] (4) Hang the aluminum skin on the positioning block and press the upper edge of the aluminum skin to straighten the middle and lower part of the aluminum skin.

[0011] (5) Adjust the surface difference between two adjacent aluminum skin sections so that the surface difference is ≤0.5mm.

[0012] In some embodiments of the present invention, in step (1), the difference between the upper surface of the first positioning block and the last positioning block and the lower surface of the skin drainage channel on the side window is ≤3mm, and both are greater than the sum of the design values ​​of the side window glass, the glue seam and the aluminum skin thickness, with a deviation between 0-5mm.

[0013] In some embodiments of the present invention, in step (2), the width of the bottom of the triangle is greater than 10 mm, and the height of the triangle is greater than the design gap between the aluminum skin and the skeleton by more than 5 mm.

[0014] In some embodiments of the present invention, in step (3), when applying adhesive, the height of the adhesive is greater than the gap between the aluminum skin and the skeleton, and the outermost adhesive seam is continuous from beginning to end.

[0015] In some embodiments of the present invention, in step (4), the upper edge of the aluminum skin is folded and then attached to the side waist beam steel so that the upper folded edge is close to the side waist beam steel and is fixed with tape.

[0016] In some embodiments of the present invention, in step (4), an F-type clamp is used to clamp the upper edge of the aluminum skin, and the distance from the F-type clamp to the edge of the skin does not exceed 400mm.

[0017] In some embodiments of the present invention, step (4) includes the correction process of the lower part of the aluminum skin, which involves slowly applying pressure from top to bottom to press the lower part of the aluminum skin with a straight rod with a straightness of ≤0.5mm.

[0018] In some embodiments of the present invention, during the pressing process, the gap between the aluminum skin and the skeleton is measured and must not exceed the designed gap of 0-2mm.

[0019] In some embodiments of the present invention, multiple leveling clamps are provided at the gaps between two adjacent aluminum skin sections to adjust the surface difference.

[0020] In some embodiments of the present invention, the distance between two adjacent positioning blocks is less than 1m.

[0021] One or more technical solutions of the present invention have the following beneficial effects:

[0022] (1) The bonding and straightening process of the aluminum skin of the bus side panel provided by the present invention limits the process parameters and straightening method of the skin bonding, which is conducive to controlling the flatness of the skin and the consistency of the width of the side window glue joint, improving the bonding effect of the aluminum skin and the flatness of the bus body side panel skin. The tooling and fixtures used in the bonding process are low in cost and easy to obtain.

[0023] (2) The bonding and straightening process of the aluminum skin for the side panel of the bus provided by this invention improves the bonding process and straightening process of the side panel of the bus. By welding the positioning blocks, the straightness of the upper edge of the skin and the consistency of the width of the side window glue joint can be ensured. After the upper edge of the aluminum skin is clamped, the straightness of the upper edge of the skin can be ensured. Applying pressure with straight rods in the lower part of the skin can avoid skin dents caused by local stress. The leveling step of adjacent skins can ensure that each section of the skin is coplanar after bonding. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the side aluminum skin bonding and straightening process of the present invention;

[0025] Figure 2 This is a schematic diagram of the welding of the positioning block of the present invention;

[0026] Figure 3 This is a schematic diagram of the aluminum skin being pressed along its upper edge according to the present invention;

[0027] Figure 4 This is a schematic diagram of the leveling fixture used in this invention.

[0028] In the diagram: 1-1, First tape; 1-2, Second tape; 1-3, Third tape; 1-4, Fourth tape; 2-1, First F-type clamp; 2-2, Second F-type clamp; 2-3, Third F-type clamp; 2-4, Fourth F-type clamp; 3-1, First long rod; 3-2, Second long rod; 4-1, First aluminum skin; 4-2, Second aluminum skin; 5, Straight rod; 6-1, First leveling clamp; 6-2, Second leveling clamp; 6-3, Third leveling clamp; 7, Drainage channel; 8, Upper edge adhesive joint of glass; 9, Side window glass; 10, Lower edge adhesive joint of glass; 11-1, First positioning block; 11-2, Second positioning block; 11-3, Third positioning block; 11-4, Fourth positioning block; 12, Waist beam steel; 13, Side frame. Detailed Implementation

[0029] 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 herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0030] Example 1

[0031] In a typical embodiment of the present invention, a bonding and shaping process for aluminum side panels of a passenger bus is proposed, such as... Figure 1-4The image shows the bonding and straightening process of two aluminum skin sections of a passenger bus, including welding of the side skin positioning blocks, cutting of the glue nozzles, cleaning of the aluminum skin and frame, attaching of skin 4-1, clamping of the upper edge of skin 4-1, straightening of the middle and lower part of skin 4-1, and adjustment of the surface difference between adjacent skins 4-1 and 4-2.

[0032] Specifically, it includes the following steps:

[0033] (1) The side panel positioning blocks are welded to the waist beam steel 12 at the lower edge of the side window glass 9. The upper surfaces of the first positioning block 11-1, the second positioning block 11-2, the third positioning block 11-3, and the fourth positioning block 11-4 are located on the same plane with a flatness deviation of ≤0.5mm. The difference between the upper surfaces of the first positioning block 11-1 and the fourth positioning block 11-4 and the lower surface of the upper edge panel water channel 7 of the side window glass 9 is ≤3mm, and both are greater than the sum of the design values ​​of the side window glass 9, the upper edge glue joint 8, the lower edge glue joint 10, and the panel thickness, with a deviation between 0-5mm.

[0034] When welding the positioning blocks, the first positioning block 11-1 and the fourth positioning block 11-4 can be welded first. The second positioning block 11-2 and the third positioning block 11-3 should be leveled with the positioning blocks at the front and rear ends using a laser level or cotton thread. Each section of aluminum skin should have at least two positioning blocks. When the width of the aluminum skin is large, multiple positioning blocks can be set according to the specific situation. The distance between two adjacent positioning blocks should be less than 1m to ensure that the positioning blocks have a good supporting effect on the aluminum skin and to avoid the aluminum skin from collapsing due to the distance between the two positioning blocks.

[0035] (2) Cut the nozzle of the adhesive into an inverted triangle shape to improve the coating effect and make the adhesive better support and bond the skin. The width of the bottom of the triangle is greater than 10mm and the height of the triangle is greater than the design gap between the aluminum skin and the skeleton by more than 5mm.

[0036] (3) Clean the aluminum skin and side frame. First, roughen the bonding area with sandpaper, then wipe the bonding area with a cloth, then brush the activator and primer on the bonding surface of the frame, and then apply the adhesive. When applying the adhesive, the height of the adhesive should be greater than the gap between the aluminum skin and the frame, and the outermost adhesive seam should be continuous from beginning to end.

[0037] (4) Hang the aluminum skin on the positioning block and press the upper edge of the aluminum skin to straighten the middle and lower part of the aluminum skin; specifically, the first aluminum skin 4-1 is hung by hanging the folded edge of the skin on the upper surface of the first positioning block 11-1 and the second positioning block 11-2, and the first aluminum skin 4-1 is pressed lightly by hand so that the upper folded edge is close to the side waist beam steel 12, and the first tape 1-1 and the second tape 1-2 are used to bond with the waist beam steel 12 to prevent it from falling off; the clamping of the upper edge of the first aluminum skin 4-1 refers to clamping the upper edge of the first skin 4-1 with the first F-type clamp 2-1 and the second F-type clamp 2-2. The distance from the clamp to the edge of the skin does not exceed 400mm, and the first long rod 3-1 is placed between the first F-type clamp 2-1, the second F-type clamp 2-2 and the first aluminum skin 4-1. The length of the first long rod 3-1 is slightly less than the length of the skin, and the straightness deviation of the first long rod 3-1 is ≤0.5mm.

[0038] The straightening of the lower part of the first aluminum skin 4-1 involves slowly applying pressure from top to bottom to the lower part of a straight rod 5 with a length of not less than 2 meters and a straightness of ≤0.5 mm, pressing the first aluminum skin 4-1 into full contact with the adhesive. During the pressing process, the gap between the skin and the frame is measured and must not exceed the designed gap of 0-2 mm.

[0039] The second aluminum skin 4-2 was bonded and shaped using the same aluminum skin bonding and shaping process described above.

[0040] (5) Adjust the surface difference between two adjacent aluminum skin sections, namely the first aluminum skin and the second aluminum skin, so that the surface difference is ≤0.5mm. Specifically, set the first leveling clamp 6-1, the second leveling clamp 6-2, and the third leveling clamp 6-3 at the gap between the two adjacent aluminum skin sections to adjust the surface difference.

[0041] The bonding and straightening process for the aluminum side panel of a bus provided in this embodiment improves the bonding process and straightening technique for the side panel. By welding the positioning blocks, the straightness of the upper edge of the panel and the consistency of the width of the side window sealant joint can be ensured. After clamping the upper edge of the aluminum panel, the straightness of the upper edge of the panel can be ensured. Applying pressure with straight rods to the lower part of the panel can avoid panel dents caused by local stress. The leveling steps of adjacent panels can ensure that all sections of the panel are coplanar after bonding.

[0042] The embodiments described above provide a detailed explanation of the technical solution of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, additions, or similar substitutions made within the scope of the principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A process for bonding and straightening an aluminum skin of a side wall of a passenger car, characterized in that, The method comprises the following steps: (1) welding a plurality of positioning blocks on the lower edge profile of the side window glass, the upper surfaces of the plurality of positioning blocks being located on the same plane, and the flatness deviation being less than or equal to 0.5 mm; (2) cutting the glue nozzle of the adhesive into an inverted triangular shape; (3) cleaning the aluminum skin and the side wall framework, brushing the adhesive surface on the framework with an activator and a primer, and then applying the adhesive; (4) hanging the aluminum skin on the positioning blocks and pressing the upper edge of the aluminum skin, and correcting the middle and lower parts of the aluminum skin; (5) adjusting the surface difference between the two adjacent aluminum skins, so that the surface difference of the skin is less than or equal to 0.5 mm.

2. The process of claim 1 wherein, In step (1), the distance from the upper surface of the first positioning block to the lower surface of the skin gutter on the side window is less than or equal to 3 mm, and is greater than the sum of the design values of the side window glass, the glue joint and the aluminum skin thickness, with a deviation of 0-5 mm.

3. The process of claim 1 wherein, In step (2), the base width of the triangle is greater than 10 mm, and the height of the triangle is greater than 5 mm more than the design gap between the aluminum skin and the framework.

4. The process of claim 1 wherein, In step (3), when applying the adhesive, the height of the adhesive is greater than the gap between the aluminum skin and the framework, and the outermost circle of the glue joint is continuous.

5. The process of claim 1 wherein, In step (4), the upper edge of the aluminum skin is folded and then hung, so that the upper folded edge is tightly attached to the side waist beam profile, and is fixed by using adhesive tape.

6. The process for bonding and fairing of aluminum side skin of a transit vehicle as claimed in claim 1 wherein, In step (4), the F-shaped clamp is used to clamp the upper edge of the aluminum skin, and the distance from the F-shaped clamp to the edge of the skin is not more than 400 mm.

7. The process of claim 1 wherein, In step (4), the correction process of the middle and lower parts of the aluminum skin includes slowly applying pressure from top to bottom to the middle and lower parts of the aluminum skin by using a straight rod with a straightness of less than or equal to 0.5 mm.

8. The process of claim 7, wherein the adhesive is applied to the aluminum skin in a pattern that is substantially continuous along the length of the side wall of the bus. 5 During the pressing process, the gap between the aluminum skin and the framework is measured and should not exceed the design gap of 0-2 mm.

9. The process of claim 1 wherein, In step (5), a plurality of leveling clamps are arranged at the joint gap between the two adjacent aluminum skins to adjust the surface difference.

10. The process of claim 1 wherein, The distance between the two adjacent positioning blocks is less than 1 m.

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