Aluminum alloy chassis subframe straightening method and tool for realizing straightening and detection

Abstract

This invention relates to the field of alignment tooling technology, specifically to an aluminum alloy chassis subframe alignment method and tooling for alignment and inspection. The advantages of this invention are: it achieves full-process monitoring of the product by designing alignment tooling, static tooling, and inspection tooling. First, through structural analysis, deformed areas are located, and then the extension and retraction of hydraulic cylinders are used to correct the deformed areas of the overall frame. Second, the blank is placed in a dedicated placement tray to release residual stress. Third, the blank is inspected using a gauge to check for springback. Products that spring back are returned for re-alignment, while those that do not continue to the next stage. This significantly improves the blank qualification rate, avoids waste of processing and casting resources due to product deformation, and greatly saves costs.

Description

Technical Field

[0001] This invention relates to the field of calibration tooling technology, specifically to a calibration method for aluminum alloy chassis subframes and tooling for calibration and testing. Background Technology

[0002] New energy is a major trend in the global automotive industry's transformation and upgrading, and green development; it is also a strategic choice for the leapfrog development of my country's automotive industry. Lightweight chassis is an inevitable choice for energy conservation and emission reduction. However, during the casting, placement, and subsequent heat treatment of integral aluminum alloy chassis castings, the overall frame is highly susceptible to deformation, and the deformation trend of each part is inconsistent, making detection and identification extremely difficult. When transferred to the machining process, deformed products exhibit issues such as thin bushing hole walls, hole misalignment, and lack of surface finish during processing, affecting processing efficiency and wasting processing costs. Through structural analysis, the deformed areas are located, and then the extension and retraction of hydraulic cylinders is used to correct the deformed areas of the overall frame. Currently, there is no universally accepted and effective process for correcting aluminum alloy chassis subframes in the industry. Methods include pressing parts together with a wooden hammer, using screw tightening mechanisms to press the deformed areas, and using hydraulic cylinders for correction. Summary of the Invention

[0003] The purpose of this invention is to provide a method for calibrating aluminum alloy chassis subframes and a tooling system for calibrating and inspecting them, addressing the aforementioned deficiencies. A complete calibrating tooling system for integral aluminum alloy chassis subframes is designed to ensure that the blanks sent to the machining process meet processing requirements, significantly improving product qualification rate and machining efficiency, and substantially reducing costs.

[0004] The present invention relates to a method for calibrating an aluminum alloy chassis subframe and the tooling for calibrating and inspecting it. The specific method is as follows:

[0005] A. Use aluminum alloy chassis subframe straightening fixtures to correct the deformed parts of the overall frame of the aluminum alloy chassis subframe;

[0006] B. Place it in the tray and let it stand for 1 hour to release residual stress;

[0007] C. Use the upper inspection tooling to inspect the aluminum alloy chassis subframe and check for springback. Products that spring back are returned for re-calibration, while products that do not spring back are moved down.

[0008] The calibration fixture includes a base plate, a pair of left-right calibration mechanisms, a pair of up-down calibration mechanisms, a pair of contouring calibration bending mechanisms, and a calibration frame structure mechanism.

[0009] The left and right adjustment mechanism includes a transverse hydraulic cylinder mounted on the base plate and a gauge bushing pull block located at its end;

[0010] The vertical adjustment mechanism includes a vertical hydraulic cylinder A installed below the base plate and a bushing hole push rod A located at its end. The bushing hole push rod A is located in the U-shaped groove of the gauge bushing pull block.

[0011] The contouring and bending mechanism includes a vertical hydraulic cylinder B installed below the middle of the base plate, a contouring block, a pressing support A, a middle pressing plate, and a pair of limiting blocks A at its end. The contouring block fixes the middle of the chassis subframe, the pair of limiting blocks A clamps the middle of the chassis subframe, and the middle pressing plate on the pressing support A presses and fixes the upper part of the chassis subframe.

[0012] The calibration frame structure includes a calibration fixture positioning block mounted on the base plate, a clamping support seat B and an end pressure plate, a vertical cylinder C and a pull block set at its end, a pair of end limit blocks B, a vertical cylinder D mounted below the base plate and a bushing hole push rod B set at its end;

[0013] The inspection fixture includes a base plate.

[0014] The fixture base plate is equipped with a set of frame support columns, a set of clamping supports, a pair of lug contour positioning blocks, and a pair of front gear detection blocks.

[0015] The top of the frame support column is equipped with a detection bar for detecting the frame bushing holes, the top of the clamping support is equipped with a pressure plate for clamping the frame from above, the top of the lug contour positioning block is hinged with a lug detection block, and the top of the front opening detection block is equipped with a detection pin.

[0016] Furthermore, the clamping support B and the end plate press down and fix one end of the chassis subframe.

[0017] Furthermore, both the contour block and the pull block are U-shaped block structures, each with a pair of rod holes and a pull rod that can be inserted horizontally at the top. The chassis subframe is placed between the pull rod and the U-shaped block.

[0018] Furthermore, both bushing hole push rod A and bushing hole push rod B have annular grooves at their tops, and pull plates are inserted into the annular grooves.

[0019] Furthermore, a pair of end limit blocks B abut against the outer wall of the chassis subframe frame.

[0020] Furthermore, the bushing of the chassis subframe is placed in the U-shaped slot of the inspection tool bushing pull block.

[0021] Furthermore, one of the pair of frame support columns is equipped with a frame end limiting baffle.

[0022] Furthermore, the top of the clamping support has a fixing groove with a threaded hole, and the pressure plate has a through-bolt hole. The pressure plate is placed on the top of the clamping support, and the screw passes through the through-bolt hole and is screwed into the threaded hole of the clamping support to clamp and fix the pressure plate on the frame.

[0023] Further, a set of lug detection blocks are arranged on the fixture bottom plate, and the lug detection blocks are in a "convex" shape.

[0024] Further, a pin hole is opened at the top of the front opening block detection block, and the detection pin passes through the pin hole and abuts against the vehicle frame.

[0025] The advantages of the present invention are as follows: The present invention monitors the whole process of the product by designing a whole-process correction tooling, a static tooling, and a detection tooling. First, through structural analysis, the deformed parts are found, and then the telescopic movement of the hydraulic cylinder is used to correct the deformed parts of the overall frame; second, it is placed in a special placement tray and statically placed to release residual stress; third, the blank is detected by the inspection fixture to check whether there is springback. The products with springback are returned for re-shaping, and the products without springback are transferred downward. This can greatly improve the qualified rate of the product blanks, avoid waste of processing and casting resources due to product scrapping caused by deformation, and greatly save costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic structural diagram of the shaping tooling.

[0027] Figure 2 It is a schematic structural diagram of the bushing hole push rod at position A.

[0028] Figure 3 It is a schematic structural diagram under the bottom plate of the present invention.

[0029] Figure 4 It is a schematic structural diagram of the present invention for placing the chassis sub-frame.

[0030] Figure 5 It is a schematic structural diagram of the detection tooling.

[0031] Figure 6 It is a schematic structural diagram of the present invention when detecting the sub-frame. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0032] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. Usually, the components of the embodiments of the present invention described and illustrated herein can be arranged and designed in various different configurations.

[0033] Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the claimed present invention, but merely represents the selected embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0034] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0035] In the description of the embodiments of this invention, it should be noted that if terms such as "upper," "lower," "inner," or "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use, they are only for the convenience of describing the 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, and therefore should not be construed as a limitation of the invention. Furthermore, if terms such as "first" or "second" appear in the description of this invention, they are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0036] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set" and "connection" 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention based on the specific circumstances.

[0037] As shown in the attached diagram, the method for calibrating the aluminum alloy chassis subframe and the tooling for calibrating and inspecting it are as follows:

[0038] A. Use aluminum alloy chassis subframe straightening fixtures to correct the deformed parts of the overall frame of the aluminum alloy chassis subframe;

[0039] B. Place it in the tray and let it stand for 1 hour to release residual stress;

[0040] C. Use the upper inspection tooling to inspect the aluminum alloy chassis subframe and check for springback. Products that spring back are returned for re-calibration, while products that do not spring back are moved down.

[0041] The alignment fixture includes a base plate 1, a pair of alignment mechanisms for left and right directions, a pair of alignment mechanisms for up and down directions, a pair of alignment mechanisms for deformation and bending, and an alignment mechanism for the frame structure.

[0042] The left and right adjustment mechanism includes a transverse hydraulic cylinder 2 mounted on the base plate 1 and a gauge bushing pull block 3 located at its end;

[0043] The vertical adjustment mechanism includes a vertical hydraulic cylinder A4 installed below the base plate 1 and a bushing hole push rod A5 located at its end. The bushing hole push rod A5 is located in the U-shaped groove of the gauge bushing pull block 3.

[0044] The contouring and bending mechanism includes a vertical hydraulic cylinder B6 installed below the middle of the base plate 1, a contouring block 61, a pressing support A10, a middle pressing plate 7, and a pair of limiting blocks A8 at its end. The contouring block 61 fixes the middle of the chassis subframe 100, the pair of limiting blocks A8 clamp the middle of the chassis subframe 100, and the middle pressing plate 7 on the pressing support A10 presses and fixes the upper part of the chassis subframe 100.

[0045] The calibration frame structure includes a calibration fixture positioning block 9, a clamping support seat B11 and an end pressure plate 12, a vertical cylinder C13 and a pull block 14 at its end, a pair of end limit blocks B15, a vertical cylinder D16 installed below the base plate 1 and a bushing hole push rod B17 at its end.

[0046] The clamping support B11 and the end plate 12 press and fix one end of the chassis subframe 100.

[0047] Both the contour block 61 and the pull block 14 are U-shaped block structures, and each has a pair of rod holes and a pull rod 18 that can be inserted horizontally at the top. The chassis subframe 100 is placed between the pull rod 18 and the U-shaped block.

[0048] Both bushing hole push rod A5 and bushing hole push rod B17 have annular grooves 19 at their tops, and pull plates 20 are inserted into the annular grooves 19. The pull plates 20 pull the upper part of the chassis subframe 100 downwards.

[0049] A pair of end limit blocks B15 abut against the outer wall of the frame of the chassis subframe 100.

[0050] The bushing of the chassis subframe 100 is placed in the U-shaped slot of the bushing pull block 3 of the inspection tool.

[0051] Working method: The chassis subframe is calibrated using calibration fixtures. Based on the product structure analysis, the deformation and bending points of the chassis subframe are located, and multiple hydraulic cylinders are used to push and pull the chassis subframe at these points.

[0052] Left and right alignment: Left and right alignment is achieved by the transverse hydraulic cylinder 2 installed on the base plate 1 and the gauge bushing pull block 3 set at its end;

[0053] Vertical alignment: Vertical alignment is achieved by the vertical hydraulic cylinder A4 installed below the base plate 1 and the bushing hole push rod A5 located at its end;

[0054] Contouring and bending correction: The vertical hydraulic cylinder B6 installed in the lower middle of the base plate 1 and the contour block 61 set at its end are used to press the support seat A10 and the middle pressing plate 7 together;

[0055] Frame alignment structure: One end bushing of the chassis subframe is fixed by the alignment fixture positioning block 9 installed on the bottom plate 1 in cooperation with the pressing support seat B11 and the end pressing plate 12; the chassis subframe frame is aligned by the vertical oil cylinder C13, the pulling block 14 arranged at its end, a pair of end limiting blocks B15, the vertical oil cylinder D16 installed under the bottom plate 1 and the bushing hole push rod B17 arranged at its end.

[0056] After measuring with a precision ruler to control the dimensions, the chassis subframe is aligned to the theoretical position.

[0057] The inspection tooling includes a fixture bottom plate 101.

[0058] A set of vehicle frame support columns 102, a set of pressing supports 103, a pair of ear-shaped profiling positioning blocks 104 and a pair of front opening block detection blocks 105 are arranged on the fixture bottom plate 101.

[0059] At the top of the vehicle frame support column 102, there is a detection rod 106 for detecting the vehicle frame bushing hole. At the top of the pressing support 103, there is a pressing plate 107 for pressing the vehicle frame from above. At the top of the ear-shaped profiling positioning block 104, there is an ear-shaped detection block 108 hinged. At the top of the front opening block detection block 105, there is a detection pin 109.

[0060] On one pair of vehicle frame support columns 102, there are vehicle frame end limiting baffles 1010.

[0061] At the top of the pressing support 103, there is a fixing groove, and a threaded hole is opened in the fixing groove. A through-hole for a pin is opened on the pressing plate 107. The pressing plate 107 is placed on the top of the pressing support 103, and a screw passes through the through-hole for a pin and is screwed into the threaded hole of the pressing support 103 to press and fix the pressing plate 107 on the vehicle frame.

[0062] A set of ear-shaped detection blocks 1011 are arranged on the fixture bottom plate​​​​​​​​​​​​​​Example 1: The operator places the frame 100 on a set of frame support columns 102. The detection rod 106 is located in the bushing hole of the frame 100. One end of the frame 100 abuts against the end limit baffle 1010 of the frame. The pressure plate 107 is installed on the clamping support 103 with screws, and the frame 100 is pressed from above to complete the positioning. The upper part of the ear plate detection block 1011 is located in the ear plate on the side of the frame 100. The ear plate detection block 108 is flipped so that it is located in the ear plate at the top of the frame 100. Since the ear plate detection block 108 is "+" shaped, it can detect whether the length of the ear plate is qualified. The detection pin 109 is inserted into the pin hole of the front opening detection block 105. Then, the end of the detection pin 109 abuts against the front opening position of the frame 100 to check whether it is qualified. When the frame 100 can be smoothly placed into each of the testing components, it indicates that the frame 100 is qualified. If some testing components cannot be placed in the designated position or are offset, it indicates that the frame 100 has been deformed and needs to be reshaped.

[0068] The above embodiments are only for illustrating the technical solutions and features of the present invention, and are intended to enable those skilled in the art to implement them better. They should not be used to limit the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention are within the scope of protection of the present invention. The parts not described in detail are prior art.

Claims

1. A method for calibrating an aluminum alloy chassis subframe, characterized in that... The specific method is as follows: A. Use aluminum alloy chassis subframe straightening fixtures to correct the deformed parts of the overall frame of the aluminum alloy chassis subframe; B. Place it in a tray and let it stand for one hour to release residual stress; C. Use the upper inspection tooling to inspect the aluminum alloy chassis subframe and check for springback. Products that spring back are returned for re-calibration, while products that do not spring back are moved down. The alignment fixture includes a base plate (1), a pair of alignment mechanisms for left and right directions, a pair of alignment mechanisms for up and down directions, a pair of alignment mechanisms for bending and deformation correction, and an alignment frame structure mechanism. The left and right adjustment mechanism includes a transverse hydraulic cylinder (2) mounted on the base plate (1) and a gauge bushing pull block (3) located at its end; The vertical adjustment mechanism includes a vertical cylinder A (4) installed below the base plate (1) and a bushing hole push rod A (5) located at its end. The bushing hole push rod A (5) is located in the U-shaped slot of the gauge bushing pull block (3). The contouring and bending mechanism includes a central clamping plate (7), a pair of limiting blocks A (8), a clamping support A (10), a vertical cylinder B (6) installed below the center of the base plate (1), and a contouring block (61) set at the end of the vertical cylinder B (6). The contouring block (61) fixes the center of the chassis subframe (100), the pair of limiting blocks A (8) clamps the center of the chassis subframe (100), and the central clamping plate (7) on the clamping support A (10) presses and fixes the upper part of the chassis subframe (100). The calibration frame structure includes a calibration fixture positioning block (9), a clamping support seat B (11), and an end pressure plate (12) mounted on the base plate (1), a vertical cylinder C (13), a pull block (14) set at the end of the vertical cylinder C (13), a pair of end limit blocks B (15), a vertical cylinder D (16) mounted below the base plate (1), and a bushing hole push rod B (17) set at the end of the vertical cylinder D (16); The chassis subframe bushing is fixed by the positioning block (9) of the calibration fixture installed on the base plate (1) in conjunction with the clamping support seat B (11) and the end pressure plate (12); the chassis subframe frame is shaped by the vertical cylinder C (13) and the pull block (14) set at its end, a pair of end limit blocks B (15), the vertical cylinder D (16) installed below the base plate (1) and the bushing hole push rod B (17) set at the end of the vertical cylinder D (16); The fixture base plate (101) is provided with a set of frame support columns (102), a set of clamping supports (103), a pair of lug contour positioning blocks (104), and a pair of front opening detection blocks (105). The inspection fixture includes a fixture base plate (101). The top of the frame support column (102) is provided with a detection rod (106) for detecting the frame bushing hole, the top of the clamping support (103) is provided with a pressure plate (107) for pressing the frame from above, the top of the lug contour positioning block (104) is hinged with a lug detection block (108), and the top of the front opening detection block (105) is provided with a detection pin (109).

2. The aluminum alloy chassis subframe calibration method according to claim 1, characterized in that... The profiling block (61) and the pulling block (14) are both U-shaped block structures. A pair of rod holes are provided at the top of each of them, and a pulling rod (18) that can be horizontally inserted into the rod holes is provided. The chassis sub-frame (100) is placed between the pulling rod (18) and the U-shaped block structure.

3. The aluminum alloy chassis subframe calibration method according to claim 1, characterized in that... Annular grooves (19) are provided at the tops of the bushing hole push rod A (5) and the bushing hole push rod B (17). A pulling plate (20) is inserted into the annular grooves (19).

4. The aluminum alloy chassis subframe calibration method according to claim 1, characterized in that... A pair of end limit blocks B (15) are in contact with the outer wall of the frame of the chassis sub-frame (100).

5. The aluminum alloy chassis subframe calibration method according to claim 1, characterized in that... The bushing of the chassis sub-frame (100) is placed in the U-shaped card slot of the gauge bushing pulling block (3).

6. The aluminum alloy chassis subframe calibration method according to claim 1, characterized in that, A frame end limit baffle (1010) is provided on one of the pair of frame support columns (102).

7. The aluminum alloy chassis subframe calibration method according to claim 1, characterized in that, A fixing groove is provided at the top of the pressing support (103), and a threaded hole is provided in the fixing groove. A through-pin hole is provided on the pressing plate (107). The pressing plate (107) is placed on the top of the pressing support (103). A screw passes through the through-pin hole and is screwed into the threaded hole of the pressing support (103) to press and fix the pressing plate (107) on the aluminum alloy chassis sub-frame.

8. The method for calibrating an aluminum alloy chassis subframe according to claim 1, characterized in that, A group of earpiece detection blocks (1011) are provided on the gauge bottom plate (101), and the earpiece detection blocks (1011) are "convex" in shape.

9. The method for calibrating an aluminum alloy chassis subframe according to claim 1, characterized in that, A pin hole is provided at the top of the front opening detection block (105), and the detection pin (109) passes through the pin hole and abuts against the aluminum alloy chassis sub-frame.

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