A method of manufacturing a fork truck fork carriage assembly

Abstract

The application provides a manufacturing method of a forklift fork frame assembly, which comprises the following steps: step S1, vertical plate cross beam assembly assembling and welding: using a tool to clamp and position a lower cross beam, an upper cross beam, a right rib plate, a right vertical plate, a left vertical plate and a left rib plate, assembling and welding the vertical plate cross beam assembly; step S2, vertical plate cross beam assembly processing: after the vertical plate cross beam assembly is cooled to normal temperature after welding, a fitting surface for assembling with each roller seat is processed on the right vertical plate and the left vertical plate respectively; step S3, fork frame assembly assembling: assembling the processed vertical plate cross beam assembly with the right side plate, the left side plate and each roller seat into a fork frame assembly; and step S4, fork frame assembly welding: welding the assembled fork frame assembly. The application can effectively reduce the welding deformation of the fork frame assembly, and can also better ensure the position precision of each fitting surface, and the position precision of the left side plate, the right side plate and each roller seat is high, and the production efficiency is high.

Description

Technical Field

[0001] This invention belongs to the field of forklift manufacturing technology, specifically relating to a method for manufacturing a forklift fork carriage assembly. Background Technology

[0002] The fork carriage assembly is a crucial component of a forklift lifting system. Its manufacturing precision not only affects subsequent assembly with the backrest and inner mast but also its service life. A schematic diagram of an existing fork carriage is shown below. Figure 1 As shown in the diagram, a schematic of the existing fork carriage assembly is as follows: Figure 2 As shown, the fork carriage assembly includes a roller seat 15. Currently, there are two common methods for manufacturing fork carriage assemblies. The first method involves assembling the fork carriage, welding the fork carriage, aligning the fork carriage, assembling the fork carriage assembly, and welding the fork carriage assembly. The second method involves assembling the fork carriage, welding the fork carriage, assembling the fork carriage assembly, and welding the fork carriage assembly. During welding, a hydraulic cylinder is used to bend the upper crossbeam 12 and lower crossbeam 11 of the fork carriage assembly to allow for pre-setting a reverse deformation allowance.

[0003] However, whether it's the first method of post-weld correction or the second method of bending the upper crossbeam 12 and lower crossbeam 11 before welding to pre-set a counter-deformation allowance, both will result in significant deformation of the fork carriage assembly. This causes a substantial change in the relative positions of the left side plate 13 and right side plate 14 of the fork carriage assembly, making it difficult to install the backrest later. Therefore, how to reduce the deformation of the fork carriage assembly during manufacturing has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0004] The purpose of this invention is to provide a method for manufacturing a forklift fork carriage assembly to solve the aforementioned technical problems in the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A method for manufacturing a forklift fork carriage assembly, comprising the following steps: Step S1: Assembly and welding of the vertical plate and horizontal beam assembly: Using tooling, the lower crossbeam, upper crossbeam, right stiffening plate, right vertical plate, left vertical plate, and left stiffening plate are positioned and clamped one by one to assemble the vertical plate and crossbeam assembly; then the vertical plate and crossbeam assembly is welded. Step S2, Machining of the vertical plate and horizontal beam assembly: After the welded vertical plate and crossbeam assembly has cooled to room temperature, mating surfaces for assembling with the right middle roller seat, mating surfaces for assembling with the right upper roller seat, and mating surfaces for assembling with the right lower roller seat are machined on the right vertical plate. Machine the following mating surfaces on the left vertical plate: mating surface for pairing with the upper left roller seat assembly, mating surface for pairing with the middle left roller seat assembly, and mating surface for pairing with the lower left roller seat assembly. Step S3: Assemble the fork carriage assembly: The processed upright beam assembly is assembled with the right side plate, right middle roller seat, right upper roller seat, left upper roller seat, left middle roller seat, left side plate, left lower roller seat, and right lower roller seat to form the fork carriage assembly; Step S4, Welding of the fork carriage assembly: Welding is performed on the assembled fork carriage assembly.

[0006] Preferably, in step S1, during welding, the weld between the upper crossbeam and the left and right vertical plates is 5mm, and the weld between the lower crossbeam and the left and right vertical plates is 5mm.

[0007] Preferably, in step S1, during welding, the weld between the left stiffening plate, the right stiffening plate and the upper crossbeam is 6mm, and the weld between the left stiffening plate, the right stiffening plate and the lower crossbeam is 6mm.

[0008] Preferably, the tooling in step S1 is an integrated welding tooling.

[0009] Preferably, in step S1, a welding robot is used to weld the upright plate beam assembly.

[0010] Preferably, in step S2, each mating surface is machined using a milling machine.

[0011] Preferably, in step S3, assembly tooling is used to assemble the fork carriage assembly.

[0012] Preferably, in step S4, a welding robot is used to weld the assembled forklift assembly.

[0013] The beneficial effects of this invention are as follows: The manufacturing method of the forklift fork carriage assembly of the present invention involves first assembling and welding the lower crossbeam, upper crossbeam, right stiffener plate, right upright plate, left upright plate, and left stiffener plate into a plate crossbeam assembly. Then, the right side plate, right middle roller seat, right upper roller seat, left upper roller seat, left middle roller seat, left side plate, left lower roller seat, and right lower roller seat are assembled and welded to the plate crossbeam assembly to form the fork carriage assembly. This achieves step-by-step assembly and welding of the fork carriage assembly, prioritizing the assembly and welding of components with greater deformation, followed by components with less deformation. This effectively reduces welding deformation of the fork carriage assembly, facilitating the subsequent installation of the backrest. Furthermore, after the welded plate crossbeam assembly cools to room temperature, the mating surfaces for assembly with each roller seat are machined, effectively avoiding the effects of welding deformation and ensuring better positional accuracy of the mating surfaces. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly described below, and the specific embodiments of the present invention will be further described in detail with reference to the drawings, wherein... Figure 1 This is a schematic diagram of an existing fork carriage; Figure 2 This is a schematic diagram of an existing fork carriage assembly; Figure 3 A flowchart illustrating the manufacturing method of the forklift fork carriage assembly provided in an embodiment of the present invention; Figure 4 A schematic diagram of the vertical plate and crossbeam assembly provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the vertical plate and crossbeam assembly after processing, provided in an embodiment of the present invention; Figure 6 This is a schematic diagram of the fork carriage assembly provided in an embodiment of the present invention.

[0015] Marked in the attached diagram: 11. Lower crossbeam; 12. Upper crossbeam; 13. Left side plate; 14. Right side plate; 15. Roller seat; 21. Lower crossbeam, 22. Upper crossbeam, 31. Left vertical plate, 32. Right vertical plate. 33. The mating surface used for assembling with the right center roller seat. 34. The mating surface used for assembling with the upper right roller seat. 35. The mating surface for assembling with the lower right roller seat; 41. Left stiffening plate; 42. Right stiffening plate; 51. Left side panel; 52. Right side panel; 61. Right center roller seat; 62. Right upper roller seat. 63. Lower right roller seat; 71. Middle left roller seat; 72. Upper left roller seat. 73. Lower left roller seat. Detailed Implementation

[0016] To enable those skilled in the art to better understand the technical solution of the present invention, the present solution will be further described in detail below with reference to specific embodiments.

[0017] like Figures 3 to 6 As shown, this embodiment of the invention provides a method for manufacturing a forklift fork carriage assembly, which includes the following steps: Step S1: Assembly and welding of the vertical plate and horizontal beam assembly: Using tooling, the lower crossbeam 21, upper crossbeam 22, right stiffening plate 42, right vertical plate 32, left vertical plate 31, and left stiffening plate 41 are positioned and clamped one by one to assemble the vertical plate crossbeam assembly; then the vertical plate crossbeam assembly is welded. Step S2, Machining of the vertical plate and horizontal beam assembly: After the welded vertical plate and crossbeam assembly cools to room temperature, a mating surface 33 for assembling with the right middle roller seat, a mating surface 34 for assembling with the right upper roller seat, and a mating surface 35 for assembling with the right lower roller seat are machined on the right vertical plate 32. A mating surface for assembling with the upper left roller seat, a mating surface for assembling with the middle left roller seat, and a mating surface for assembling with the lower left roller seat are machined on the left vertical plate 31. Step S3: Assemble the fork carriage assembly: The processed upright beam assembly is assembled with the right side plate 52, right middle roller seat 61, right upper roller seat 62, left upper roller seat 72, left middle roller seat 71, left side plate 51, left lower roller seat 73, and right lower roller seat 63 to form a fork carriage assembly. Step S4, Welding of the fork carriage assembly: Welding is performed on the assembled fork carriage assembly.

[0018] The manufacturing method of the forklift fork carriage assembly provided in this embodiment of the invention first assembles and welds the lower crossbeam 21, upper crossbeam 22, right stiffening plate 42, right upright plate 32, left upright plate 31, and left stiffening plate 41 into a plate crossbeam assembly. Then, the right side plate 52, right middle roller seat 61, right upper roller seat 62, left upper roller seat 72, left middle roller seat 71, left side plate 51, left lower roller seat 73, and right lower roller seat 63 are assembled and welded with the plate crossbeam assembly to form the fork carriage assembly. This achieves step-by-step assembly and welding of the fork carriage assembly, that is, assembling and welding the parts with larger welding deformation first, and then assembling and welding the parts with smaller welding deformation. This can effectively reduce the welding deformation of the fork carriage assembly, thereby making the subsequent installation of the backrest rack more convenient. Meanwhile, after the welded vertical plate and horizontal beam assembly cools to room temperature, the mating surfaces for assembling with each roller seat are then machined. This effectively avoids the influence of welding deformation of the vertical plate and horizontal beam assembly and better ensures the positional accuracy of each mating surface.

[0019] Furthermore, in step S1, during welding, the weld between the upper crossbeam 22 and the left and right vertical plates 31 and 32 is 5mm, and the weld between the lower crossbeam 21 and the left and right vertical plates 31 and 32 is 5mm. By adopting this method, the weld between the upper and lower crossbeams and the left and right vertical plates is reduced from 8mm in the prior art to 5mm, thereby effectively reducing the bending deformation during welding of the upper and lower crossbeams.

[0020] Specifically, in step S1, during welding, the weld between the left stiffening plate 41, the right stiffening plate 42 and the upper crossbeam 22 is 6mm, and the weld between the left stiffening plate 41, the right stiffening plate 42 and the lower crossbeam 21 is 6mm. By adopting this scheme, the weld between the left and right stiffening plates and the upper and lower crossbeams is increased from 5mm in the prior art to 6mm, thereby better ensuring the overall strength.

[0021] Preferably, the tooling in step S1 is an integrated welding tooling.

[0022] Specifically, in step S1, a welding robot is used to weld the upright plate beam assembly, thereby ensuring the consistency of the welding.

[0023] It should be noted that in step S2, cooling the welded upright beam assembly to room temperature effectively releases the welding deformation of each component. Then, processing the mating surfaces that correspond to each roller seat ensures the positional accuracy of these mating surfaces. This results in smaller gaps and higher consistency between the roller seats when the left and right upright plates are assembled with each roller seat via their mating surfaces in step S3. Furthermore, since the welding deformation of the upright beam assembly has been released through cooling to room temperature, in step S4, after the forklift assembly is welded, the deformation of the left upright plate 31 and right upright plate 32 is minimal. The parallelism and coplanarity between the axes of the roller seats can be effectively controlled. Moreover, the right side plate 52 and left side plate 51 are only affected by their own welding deformation, no longer affected by the welding deformation of the upright beam assembly. This significantly reduces the amount of welding deformation on the left and right sides, ensuring the relative dimensions of the space and facilitating the later installation of the rack.

[0024] Specifically, in step S2, each mating surface is machined using a milling machine.

[0025] Preferably, in step S3, assembly tooling is used to assemble the fork carriage assembly.

[0026] Specifically, in step S4, a welding robot is used to weld the assembled fork carriage assembly, thereby ensuring better consistency in the welding.

[0027] The manufacturing method of the forklift fork carriage assembly of the present invention not only eliminates the calibration process, which is difficult to control in terms of precision and efficiency, in the prior art, but also has the following beneficial effects: (1) The welding deformation of the upper and lower crossbeams is small: The deformation of the upper and lower crossbeams is mainly caused by the large welds between the left and right uprights and the upper and lower crossbeams. This invention reduces the weld deformation of the upper and lower crossbeams without reducing the strength of the forklift assembly by reducing the welds between the left and right uprights and the upper and lower crossbeams, while increasing the welds between the upper and lower crossbeams and the left and right stiffening plates. This ensures the parallelism between the two left and right uprights and the perpendicularity between the left and right uprights and the upper and lower crossbeams.

[0028] (2) The left and right side plates and each roller seat have high positional accuracy: This invention first assembles and welds the upright plate and crossbeam assembly to release welding deformation in advance. Then, the countersunk surface, i.e. the mating surface, is processed to ensure its parallelism. Finally, the fork carriage assembly is assembled and welded, so that the left and right side plates are only affected by their own welds, greatly improving the positional accuracy. The gaps between each roller seat are uniform during assembly, and are only affected by their own welds, resulting in small deformation after welding and greatly improving the positional accuracy. This makes the axes of each roller seat parallel and in the same plane, which facilitates the assembly of each roller later. At the same time, it also makes the rollers less prone to wear during operation, extending the service life of the rollers.

[0029] (3) High production efficiency: This invention can improve product precision, reduce rework frequency, and thus improve production efficiency.

[0030] The above are merely preferred embodiments of the present invention. It should be noted that these embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention. Moreover, after reading the contents of the present invention, those skilled in the art can make various modifications or alterations to the present invention, and these equivalent forms also fall within the scope defined by the appended claims.

Claims

1. A method for manufacturing a forklift fork carriage assembly, characterized in that, It includes the following steps: Step S1: Assembly and welding of the vertical plate and horizontal beam assembly: Using tooling, the lower crossbeam, upper crossbeam, right stiffening plate, right vertical plate, left vertical plate, and left stiffening plate are positioned and clamped one by one to assemble the vertical plate and crossbeam assembly; then the vertical plate and crossbeam assembly is welded. Step S2, Machining of the vertical plate and horizontal beam assembly: After the welded vertical plate and crossbeam assembly has cooled to room temperature, mating surfaces for assembling with the right middle roller seat, mating surfaces for assembling with the right upper roller seat, and mating surfaces for assembling with the right lower roller seat are machined on the right vertical plate. Machine the following mating surfaces on the left vertical plate: mating surface for pairing with the upper left roller seat assembly, mating surface for pairing with the middle left roller seat assembly, and mating surface for pairing with the lower left roller seat assembly. Step S3: Assemble the fork carriage assembly: The processed upright beam assembly is assembled with the right side plate, right middle roller seat, right upper roller seat, left upper roller seat, left middle roller seat, left side plate, left lower roller seat, and right lower roller seat to form the fork carriage assembly; Step S4, Welding of the fork carriage assembly: Welding is performed on the assembled fork carriage assembly.

2. The method for manufacturing the forklift fork carriage assembly according to claim 1, characterized in that, In step S1, during welding, the weld between the upper crossbeam and the left and right vertical plates is 5mm, and the weld between the lower crossbeam and the left and right vertical plates is 5mm.

3. The method for manufacturing the forklift fork carriage assembly according to claim 2, characterized in that, In step S1, during welding, the weld between the left stiffening plate, the right stiffening plate and the upper crossbeam is 6mm, and the weld between the left stiffening plate, the right stiffening plate and the lower crossbeam is 6mm.

4. The method for manufacturing the forklift fork carriage assembly according to claim 1, characterized in that, The tooling in step S1 is an integrated welding tooling.

5. The method for manufacturing the forklift fork carriage assembly according to claim 1, characterized in that, In step S1, a welding robot is used to weld the vertical plate beam assembly.

6. The method for manufacturing the forklift fork carriage assembly according to claim 1, characterized in that, In step S2, each mating surface is machined using a milling machine.

7. The method for manufacturing the forklift fork carriage assembly according to claim 1, characterized in that, In step S3, the fork carriage assembly is assembled using assembly tooling.

8. The method for manufacturing a forklift fork carriage assembly according to any one of claims 1 to 7, characterized in that, In step S4, a welding robot is used to weld the assembled forklift assembly.

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