Adjustable positioning measurement and detection process for riveting

Abstract

The application provides an adjustable positioning measurement and detection process for riveting and welding, which designs a tool frame plate, a fixing nut and a screw, adopts a fixing nut and screw screwing cooperation mode to position the tool frame plate and the motor base cylinder radially, positions, measures and inspects the two side support side plates spliced with the motor base cylinder according to the scale marked on the tool frame plate; the application combines the design with the actual production site, makes a small invention and creation for the riveting and welding process, innovates the original production process, and solves the problem that the active part cannot be accurately positioned and measured according to the drawing size when the workshop is riveted and welded. Thus, the accurate control of the active part during riveting and welding is achieved to meet the drawing size requirement. The product qualification rate is improved, the rework and repair caused by the ineffective positioning and measurement is avoided, the production cost is reduced, the unnecessary waste of enterprise property is avoided, the labor intensity of the operator is reduced, the production efficiency is improved, the enterprise achieves and perfects the fine and standardized production.

Description

Technical Field

[0001] This invention relates to the field of riveting and welding technology for explosion-proof motor components, and particularly to an adjustable positioning measurement and testing process for riveting and welding. Background Technology

[0002] The development of mining machinery has led to changes in the coal mining industry, with the emergence of new products such as variable frequency integrated machines and variable frequency permanent magnet synchronous motors. This has improved the development level of coal mining machinery and forced enterprises to upgrade their machining capabilities and production processes. Technological innovation is explored through continuous problem identification and resolution, as well as the improvement and refinement of various processing equipment, tooling, and processing techniques. This project addresses an issue with the YJVFT-335M1-4 (400 / 3300) variable frequency integrated machine. During the welding of the machine base, the inability to accurately measure the horizontal and vertical positioning dimensions of the side support plates and the machine base cylinder during riveting and welding resulted in welding dimensions that did not meet the drawing requirements. This led to frequent rework and repairs, affecting product quality and causing economic waste for the enterprise. In past production of motors with this structure, design, process, quality assurance departments, workshop technicians, and operators brainstormed and continuously explored experiences, researching processes and tooling. A method was adopted to position the side support plates and the motor frame by spot-welding a steel frame together. However, this method has drawbacks: During production, the splicing and positioning rely on operator experience, using only a right-angle ruler. The tools and usage methods are prone to significant deviations, making effective dimensional measurement and positioning adjustments of the side support plates impossible to meet drawing requirements. Furthermore, this tooling is a one-time auxiliary riveting and welding method, not reusable, making it impossible to establish a production operation system and process flow, and failing to guarantee precise and controllable product quality. Moreover, since the tooling consists of separately spliced ​​and spot-welded steel frame strips, it is often carelessly placed on-site after use, easily lost, and re-fabricating it increases material waste and causes company property loss. Careless placement can also cause frame deformation, resulting in dimensional errors during riveting and welding, affecting product quality. Based on these factors, I designed an adjustable positioning, measuring, and testing fixture for riveting and welding to solve the positioning and measurement problems of the base welding of cylindrical motors and similar cylindrical structures such as variable frequency integrated machines and variable frequency permanent magnet synchronous motors. This fixture achieves precise and controllable positioning and convenient measurement of cylindrical components during the riveting and welding process. It is also reusable and can be used as a tool and method for inspecting the welding dimensions of products. Ultimately, using this fixture will enable standardized, serialized, and refined production in actual manufacturing. This fixture allows for free adjustment of the positioning dimensions within a certain radial range based on the outer diameter of the cylindrical component, thus providing broad coverage for the products being riveted and welded and saving costs. Furthermore, because the fixture uses a four-point positioning design, the screw dimensions can be adjusted according to the positioning scale. Therefore, this fixture can simultaneously perform three-axis dimensional positioning and measurement on irregularly symmetrical components on both sides of a cylindrical structure product, greatly meeting actual production needs and minimizing the equipment investment costs required for enterprise production. Summary of the Invention

[0003] In view of this, it is necessary to provide an adjustable positioning measurement and inspection process for riveting and welding.

[0004] An adjustable positioning measurement and inspection process for riveting and welding includes the following steps: Step 1: Design the tooling frame, fixing nuts, and screws. After cutting the tooling frame, flatten the surface and level it. Strictly inspect the workpiece according to the drawing requirements. Mark the welding points of the fixing nuts. Place the outer surface of the fixing nuts on the surface of the tooling frame, align with the marking lines, and then spot weld. Weld the four fixing nuts securely in this way. After welding, perform aging treatment. Step two: After aging treatment, measure and mark the scale according to the drawing requirements, and then inspect according to the drawing after completion; Step 3: Use a combination of fixing nuts and screws to radially position the tooling frame plate and the motor base cylinder. Based on the scale marked on the tooling frame plate, position, measure, and inspect the two support side plates that are spliced ​​with the base cylinder. Step 4: Fit the tooling frame plate onto the machine base cylinder from the rear end of the machine base. At this time, the bottom of the tooling frame plate is flush with the support base of the frequency converter integrated machine, and the center height of the machine base and the tooling frame plate are the same. Step 5: Screw in 4 screws according to the scale marked on the tooling frame. According to the inner hole size of the tooling frame and the outer diameter of the machine base cylinder, we can get: (inner hole size of tooling frame - outer diameter of machine base cylinder) / 2 = A. The 4 screws on the tooling frame should be screwed in A mm respectively. Use these 4 screws to clamp and position the tooling frame and the machine base cylinder. At this time, use a measuring tool to measure the distance from the rear end face of the machine base cylinder to the tooling to ensure that the axial dimension of the tooling is accurately positioned. Step six: Then, according to the dimensions in the drawing, refer to the scale marked on the tooling to position and measure the support side plates on both sides of the frequency converter. After adjustment and calibration, proceed with riveting and welding. After completion, the operator and product inspector can use this tooling frame to inspect the workpiece. Once the dimensions of the workpiece meet the requirements of the drawing, the tooling frame can be removed to carry out subsequent production work.

[0005] Preferably, a spacer is added at the position where the fixing nut is welded to the tooling frame plate.

[0006] Preferably, the tooling frame plate has an inner hole size of φ774±1mm, and the distance from the center of the inner hole to the bottom center of the tooling frame plate is 475mm. The outer diameter of the base cylinder of the YJVFT-355M1-4(400 / 3300) frequency converter is φ674mm. (774-674) / 2=50. The four screws of the tooling should be screwed in 50mm respectively. The tooling and the base cylinder are clamped and positioned by these four screws. At this time, the distance from the rear end face of the base cylinder to the tooling should be measured by measuring tools such as a right angle ruler, tape measure, and caliper.

[0007] Preferably, the fixing nut is M12, the screw is 4 M12*110 internal hex screws, the pad is a cube structure, and there are 4 pads.

[0008] Because new products such as frequency converters have only been on the market for a short time and their structures differ from traditional motors, the manufacturing process and tooling have also evolved accordingly. The key challenge in implementing this project lies in ensuring the accuracy of the markings on the tooling. Therefore, the tooling frame plates must be made flat, all cutting dimensions inspected, and after welding, aging treatment performed to release stress. After this process, markings must be made appropriately and then inspected.

[0009] To ensure the welding strength between the tooling frame and the fixing nut, the outer side of the fixing nut was fitted tightly against the tooling frame. However, this restricted the operating space when using an Allen wrench to tighten the screw, hindering operation. In subsequent improvements, a 10*10*5 shim was added to the tooling frame where the fixing nut was welded. The fixing nut was then welded after the initial welding, resolving the issue of limited operating space caused by the excessive fit between the tooling frame and the fixing nut, and the problem of the screw scraping against the tooling frame during tightening.

[0010] Beneficial effects: This invention, through a combination of design and practical production site considerations, makes a small innovation in the riveting and welding process, revolutionizing the original production process and solving the problem of inaccurate positioning and measurement of dimensions required by drawings when riveting and welding such parts in the workshop. This achieves precise and controllable control of the parts during riveting and welding to meet the dimensional requirements of the drawings. It improves the product qualification rate, avoids rework and repairs caused by ineffective positioning and measurement, reduces production costs and avoids unnecessary waste of company assets, reduces the labor intensity of operators, improves production efficiency, and enables the company to achieve and perfect refined and standardized production.

[0011] This invention features a simple and practical structure that is reusable; it is adjustable and has a wide coverage, meeting the needs of positioning and measuring workpieces during the riveting and welding of machine casing cylinders within a certain outer diameter range; it innovatively incorporates self-made scale lines, which further ensures accurate clamping and positioning measurement of workpieces during production operations.

[0012] Before the implementation of this invention, precise and effective positioning and measurement were impossible when riveting and welding such cylindrical components in the actual production process of the workshop, often resulting in uneven subsequent processing. The inability to process these components led to rework and repairs, wasting materials, labor, and time, and causing direct or indirect waste to the company's property. After the implementation of this invention, product quality can be effectively guaranteed, thereby minimizing material waste and property losses to the company caused by rework and repairs, as well as defective products. It also effectively improves operator productivity. Because this invention is adjustable and reusable, it serves as a reference and covers various other applications for such cylindrical components, providing effective guidance for the coal mining machinery industry and other industries, and generating significant social benefits. Attached Figure Description

[0013] Figure 1 A schematic diagram showing the welding state of the tooling frame plate with the fixing nuts and screws; Figure 2A schematic diagram of the tooling frame plate from one perspective; Figure 3 This is another structural diagram of the tooling frame plate from a different perspective; Figure 4 for Figure 1 An enlarged schematic diagram of part A in the middle; Figure 5 for Figure 3 Enlarged schematic diagram of part B in the middle; Figure 6 A schematic diagram showing the positioning status of the tooling frame plate and the motor base cylinder; In the diagram: tooling frame plate 1, fixing nut 2, screw 3, pad 4, marker line e, motor base cylinder C, axis x, axis y, positioning auxiliary line f. Detailed Implementation

[0014] To make the technical solution of the present invention easier to understand, the technical solution of the present invention will now be clearly and completely described in conjunction with the accompanying drawings and specific embodiments.

[0015] Please also refer to Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 and Figure 6 The adjustable positioning measurement and inspection process for riveting and welding includes the following steps: Step 1: Design the tooling frame plate 1, fixing nuts 2, screws 3, and pads 4; flatten the cut tooling frame plate 1, level it, and strictly inspect the workpiece according to the drawing requirements. Mark the welding points of the fixing nuts with the mark line e. Place the outer surface of the fixing nuts 2 onto the surface of the tooling frame plate 1, align it with the mark line e, and then perform spot welding. Weld the four fixing nuts 2 securely in this way. After welding, perform aging treatment to remove welding stress to ensure the accuracy, reliability, and stability of the tooling as a positioning, measurement, and testing tool. Step two: After aging treatment, measure and mark the scale according to the drawing requirements, and then inspect according to the drawing after completion; Step three: Using the screw-in engagement of fixing nut 2 and screw 3, the tooling frame plate 1 and the motor base cylinder C are radially positioned. The two supporting side plates spliced ​​with the base cylinder are positioned, measured, and inspected according to the scale marked on the tooling frame plate 1. Because the four screws 3 of this tooling can be adjusted in length according to the scale, this tooling can also be used for positioning and measuring asymmetrical cylindrical components. Adopting the concept of using a large-sized inner hole of the tooling to cover a small-sized base cylinder can save on tooling investment and reduce costs for the company.

[0016] Step 4: Fit the tooling frame 1 onto the machine base cylinder from the rear end of the machine base. At this time, the bottom of the tooling frame 1 is flush with the support base of the frequency converter integrated machine, and the center height of the machine base and the tooling frame 1 are the same. Step 5: Screw in the four screws 3 according to the scale marked on the tooling frame 1. Based on the inner diameter of the tooling frame 1 and the outer diameter of the machine base cylinder, we can obtain (inner diameter of tooling frame - outer diameter of the inverter integrated machine base cylinder) / 2 = A. The four screws 3 on the tooling frame should be screwed in to a depth of A mm. Use these four screws 3 to clamp and position the tooling frame 1 and the machine base cylinder. At this point, use a measuring tool to measure the distance from the rear end face of the machine base cylinder to the tooling to ensure accurate axial positioning of the tooling. The inner diameter of the tooling frame 1 is φ774±1mm, and the distance from the center of the inner diameter to the bottom center of the tooling frame is 475mm. YJVFT The outer diameter of the base cylinder of the -355M1-4(400 / 3300) frequency converter is φ674mm. (774-674) / 2=50. The four screws 3 of the tooling should be screwed in 50mm respectively. Use these four screws 3 to clamp and position the tooling to the base cylinder. At this time, use a right-angle ruler, tape measure, or caliper to measure the distance from the rear end face of the base cylinder to the tooling.

[0017] Step six: Then, according to the dimensions in the drawing, refer to the scale marked on the tooling to position and measure the support side plates on both sides of the frequency converter. After adjustment and calibration, proceed with riveting and welding. After completion, the operator and product inspector can use this tooling frame to inspect the workpiece. Once the dimensions of the workpiece meet the requirements of the drawing, the tooling frame can be removed to carry out subsequent production work.

[0018] The fixing nut 2 is M12, the screw 3 is 4 M12*110 internal hex screws, and the pad 4 is a cube structure with 4 pads designed.

[0019] In this embodiment, please also refer to Figure 3 , Figure 4 , Figure 5 and Figure 6 Mount the fixture frame plate 1 and the motor base cylinder C movable part together. Position the motor base cylinder C movable part and the fixture frame plate 1 radially concentrically using the screws 3 in the horizontal and vertical directions of the fixture frame plate 1. (774-674) / 2=50. The four screws 3 on the fixture frame plate 1 should be screwed in 50mm each. Use these four screws 3 to mount and position the fixture frame plate 1 and the motor base cylinder C. At this point, use a right-angle ruler, caliper, or measuring tool to measure the distance from the rear end face of the base cylinder to the fixture.

[0020] The stiffener is placed on the surface of the cylinder C of the motor base. The size is adjusted along the x-axis and the positioning auxiliary line f according to the scale of the tooling frame plate 1 to meet the requirements. This ensures both the perpendicularity of the stiffener in the y-axis direction and the precise dimensional requirements of the stiffener on the surface of the cylinder part in the x-axis direction. After the riveting is completed, the riveting dimensions of the stiffening plates on the surface of the C-shaped live part of the motor base cylinder can be inspected in the same way.

[0021] Because new products such as frequency converters have only been on the market for a short time and their structures differ from traditional motors, the manufacturing process and tooling have also evolved accordingly. The key challenge in implementing this project lies in ensuring the accuracy of the scale lines on the tooling. Therefore, the tooling frame 1 should be made flat, all cutting dimensions inspected, and after welding, it should undergo aging treatment to release stress before proper marking and inspection.

[0022] To ensure the welding strength between the tooling frame plate and the fixing nut 2, the outer side of the fixing nut 2 is attached to the tooling frame plate 1. When using an Allen wrench to tighten the screw 3, the operating space is somewhat restricted, which is not conducive to operation. In subsequent improvement work, a 10*10*5 shim block 4 was added at the position where the fixing nut 2 is welded to the tooling frame plate 1. After welding, the fixing nut 2 is welded, which solves the problem of the tooling frame plate and the fixing nut 2 being too close together, which restricts the operating space and causes the screw 3 to rub against the tooling frame plate when being tightened.

[0023] Beneficial Effects: This invention, through a combination of design and practical production site considerations, makes a small innovation in the riveting and welding process, revolutionizing the original production process and solving the problem of inaccurate positioning and measurement of dimensions required by drawings when riveting and welding such parts in the workshop. This achieves precise and controllable control of the parts during riveting and welding to meet the dimensional requirements of the drawings. It improves the product qualification rate, avoids rework and repairs caused by ineffective positioning and measurement, reduces production costs and avoids unnecessary waste of company assets, reduces the labor intensity of operators, improves production efficiency, and enables the company to achieve and perfect refined and standardized production.

[0024] This invention features a simple and practical structure that is reusable; it is adjustable and has a wide coverage, meeting the needs of positioning and measuring workpieces during the riveting and welding of machine casing cylinders within a certain outer diameter range; it innovatively incorporates self-made scale lines, which further ensures accurate clamping and positioning measurement of workpieces during production operations.

[0025] Before the implementation of this invention, precise and effective positioning and measurement were impossible when riveting and welding such cylindrical components in the actual production process of the workshop, often resulting in uneven subsequent processing. The inability to process these components led to rework and repairs, wasting materials, labor, and time, and causing direct or indirect waste to the company's property. After the implementation of this invention, product quality can be effectively guaranteed, thereby minimizing material waste and property losses to the company caused by rework and repairs, as well as defective products. It also effectively improves operator productivity. Because this invention is adjustable and reusable, it serves as a reference and covers various other applications for such cylindrical components, providing effective guidance for the coal mining machinery industry and other industries, and generating significant social benefits.

[0026] It should be noted that the embodiments described herein are only some embodiments of the present invention, and not all implementations of the present invention. These embodiments are merely illustrative and are intended only to provide a more intuitive and clear way to understand the content of the present invention, not to limit the technical solutions described herein. All other implementation methods that can be conceived by those skilled in the art without creative effort, as well as other simple substitutions and variations of the technical solutions of the present invention, without departing from the concept of the present invention, are within the scope of protection of the present invention.

Claims

1. An adjustable positioning measurement and inspection process for riveting and welding, characterized in that: The adjustable positioning measurement and inspection process for riveting and welding includes the following steps: Step 1: Design the tooling frame, fixing nuts, and screws. After cutting the tooling frame, flatten the surface and level it. Strictly inspect the workpiece according to the drawing requirements. Mark the welding points of the fixing nuts. Place the outer surface of the fixing nuts on the surface of the tooling frame, align with the marking lines, and then spot weld. Weld the four fixing nuts securely in this way. After welding, perform aging treatment. Step two: After aging treatment, measure and mark the scale according to the drawing requirements, and then inspect according to the drawing after completion; Step 3: Use a combination of fixing nuts and screws to radially position the tooling frame plate and the motor base cylinder. Based on the scale marked on the tooling frame plate, position, measure, and inspect the two support side plates that are spliced ​​with the base cylinder. Step 4: Fit the tooling frame plate onto the machine base cylinder from the rear end of the machine base. At this time, the bottom of the tooling frame plate is flush with the support base of the frequency converter integrated machine, and the center height of the machine base and the tooling frame plate are the same. Step 5: Screw in 4 screws according to the scale marked on the tooling frame plate. According to the inner hole size of the tooling frame plate and the outer diameter size of the machine base cylinder, we can get: (inner hole size of tooling frame plate - outer diameter of machine base cylinder of frequency converter) / 2 = A. The 4 screws of the tooling frame plate should be screwed in A mm respectively. Use these 4 screws to clamp and position the tooling frame plate and the machine base cylinder. At this time, use a measuring tool to measure the distance from the rear end face of the machine base cylinder to the tooling to ensure that the axial dimension of the tooling is accurately positioned. Step six: Then, according to the dimensions in the drawing, refer to the scale marked on the tooling to position and measure the support side plates on both sides of the frequency converter. After adjustment and calibration, proceed with riveting and welding. After completion, the operator and product inspector can use this tooling frame to inspect the workpiece. Once the dimensions of the workpiece meet the requirements of the drawing, the tooling frame can be removed to carry out subsequent production work.

2. The adjustable positioning measurement and inspection process for riveting and welding as described in claim 1, characterized in that: Add a pad at the location where the fixing nut is welded to the tooling frame plate.

3. The adjustable positioning measurement and inspection process for riveting and welding as described in claim 2, characterized in that: The tooling frame plate has an inner hole size of φ774±1mm, and the distance from the center of the inner hole to the bottom center of the tooling frame plate is 475mm. The outer diameter of the base cylinder of the YJVFT-355M1-4(400 / 3300) frequency converter is φ674mm. (774-674) / 2=50. The four screws of the tooling should be screwed in 50mm each. Use these four screws to clamp and position the tooling to the base cylinder. At this time, use a right-angle ruler, tape measure, and caliper to measure the distance from the rear end face of the base cylinder to the tooling.

4. The adjustable positioning measurement and inspection process for riveting and welding as described in claim 3, characterized in that: The fixing nuts are M12, the screws are four M12*110 internal hex screws, and the spacers are cubic structures with four spacers.

Images