A total assembly welding support device and support method capable of preset deflection and tensioning

Abstract

The present invention discloses an assembly welding support device capable of preset deflection and tensioning, which belongs to the field of rail transit vehicle body welding. The present invention is provided with a gantry fixedly connected to a base plate and arranged along the width direction of the vehicle body; diagonal bracing beams are formed on both sides of the top end of the gantry and extend obliquely upward toward the lower surface of the vehicle body chassis side beam; a lifting mechanism with prefabricated deflection is installed in the support hole opened in the top end of the diagonal bracing beam, which contacts the chassis side beam through the lifting mechanism and provides an upward force thereto; and also includes a tensioner for providing a downward force, the tensioner is fixedly connected to the position of the base plate corresponding to the lifting mechanism, and the tensioner is connected to the pulling hole opened in the chassis side beam or the side wall through a pulling structure. The present invention effectively solves the problem of inaccurate manual adjustment of deflection in the prior art, has a simple structure, is easy to use, and effectively ensures the accuracy and consistency of deflection prefabrication.

Description

Technical Field

[0001] The present invention relates to the technical field of rail transit vehicle body welding, and in particular to an overall assembly welding support device and a support method capable of preset deflection and tensioning. Background Art

[0002] During the assembly process of rail transit vehicles, the deflection of the underframe steel structure is manually adjusted by the operator. When spot-checking the prefabrication of the deflection, it is often found that the prefabrication of the deflection is unqualified, mainly due to inconsistent deflections on both sides of the same section or unreasonable deflection distribution. After analysis, the reasons for this phenomenon are firstly the lack of quality awareness of the operators, secondly, the deflection adjustment of the overall assembly is done manually, which is relatively prone to errors, and finally, the prefabrication of the deflection is not effectively supervised. Even if there are problems in the prefabrication of the deflection, there is no subsequent accountability.

[0003] Therefore, based on the above problems, there is an urgent need to develop an overall assembly welding support device and support method that can preset deflection and tighten. Summary of the Invention

[0004] The purpose of the present invention is to overcome the defects of the prior art and provide a support device and a support method for an assembly welding system with preset deflection and tensioning, which can solve the problem of inaccurate manual adjustment of deflection.

[0005] In order to achieve the above object, the present invention provides the following technical solutions:

[0006] The present invention discloses a total assembly welding support device capable of preset deflection and tensioning, comprising:

[0007] The gantry is fixedly connected to the base plate and arranged along the width direction of the vehicle body;

[0008] Both sides of the top of the gantry are formed with diagonal bracing beams extending obliquely upward toward the lower surface of the vehicle body chassis side beam, and the support holes opened at the top of the diagonal bracing beams are equipped with lifting mechanisms with prefabricated deflection, which contact the chassis side beams through the lifting mechanisms and provide upward force to them;

[0009] A tensioner is used to provide a downward force. The base plate is fixedly connected to the tensioner at a position corresponding to the lifting mechanism. The tensioner is connected to a pulling hole provided on the side beam or side wall of the chassis through a pulling structure.

[0010] Furthermore, the lifting mechanism includes a first jack and a second jack arranged in the support hole, the second jack is arranged below the first jack, and the second jack is used to level two adjacent first jacks.

[0011] Furthermore, an automatic leveling sensor is installed on the side of the first jack base for leveling two adjacent first jacks.

[0012] Furthermore, a distance measuring sensor is installed on the top of the first jack base for measuring the deflection of the chassis.

[0013] Furthermore, the gantry includes two vertical beams arranged at intervals, a first horizontal beam connected to the bottom ends of the two vertical beams, and a second horizontal beam connected to the top ends of the two vertical beams. The diagonal bracing beam is formed at the connection position between the second horizontal beam and the vertical beams, and the gantry is fixedly connected to the base plate through the first horizontal beam.

[0014] Furthermore, the tensioner is a winch, the base plate is located on one side of the vertical beam and is fixedly connected to the winch, and the winch is connected to the pulling hole of the base frame or the side wall through the pulling structure.

[0015] Furthermore, the pulling structure is a drawstring or a drawstring.

[0016] The present invention discloses a method for supporting a welding assembly with preset deflection and tension, comprising the above-mentioned device for supporting a welding assembly with preset deflection and tension, and the supporting method comprises the following steps:

[0017] The vehicle body underframe is located above the gantry, and the diagonal support beam of the gantry is located below the side beam of the underframe;

[0018] Prefabrication deflection: The second jack and the first jack are placed in the support holes in sequence. The stroke of the first jack is used to prefabricate the deflection value of the chassis and lock it. The first jack is leveled by the stroke of the second jack so that the first jack on the gantry remains on the same plane before prefabrication deflection.

[0019] Deflection value comparison: Use the distance measuring sensor to measure the deflection value of the vehicle body frame side beam above the first jack and compare it with the preset stroke of the first jack to see if the error exceeds the threshold;

[0020] Pulling the chassis: According to the prefabricated deflection value, during the prefabricated deflection process, if the deflection value measured by the distance sensor exceeds the preset deflection value of the first jack, the tensioner is used to pull the chassis side beam through the pulling structure. After pulling to meet the preset deflection value, the pulling force is kept unchanged. At the same time, the distance sensors under the chassis side beams on both sides of the bolster are used to measure the deflection value. The lower sides of the side beams on both sides of the bolster are in contact with the upper plane of the support column extended by the first jack. This is the reference point for deflection measurement. All first jacks are in contact with the lower plane of the side beams to play a supporting role.

[0021] In the above technical solution, the present invention provides a support device and support method for assembly welding with preset deflection and tension, which has the following advantages compared with the prior art:

[0022] First, the existing main crossbeam supporting the chassis is changed to the chassis side beam, which can more effectively support the prefabrication of the chassis deflection.

[0023] Secondly, the existing manual adjustment of deflection is changed to automatic pre-setting of deflection through the support mechanism, which more effectively ensures the accuracy and consistency of deflection prefabrication;

[0024] In addition, the existing manual tensioning is changed to automatic tensioning through a tensioner, which further effectively ensures the appropriateness and consistency of the tensioning force. Moreover, the support mechanism and the tensioner are connected to the external control system to change the existing manual detection and recording of the deflection value to automatic detection and recording, which can effectively ensure the reliability and authenticity of the data. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments described in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0026] Figure 1 This is a schematic diagram of the overall structure of a total assembly welding support device capable of preset deflection and tensioning disclosed in the present invention;

[0027] Figure 2 This is a schematic diagram of the structure of a fully assembled welding support device capable of preset deflection and tensioning disclosed by the present invention in use;

[0028] Figure 3 This is a partial enlarged view of a total assembly welding support device capable of preset deflection and tensioning disclosed in the present invention;

[0029] Figure 4 This is a partially enlarged view from another perspective of the overall assembly welding support device disclosed in the present invention that can preset deflection and be tightened.

[0030] Description of reference numerals:

[0031] 1. Base plate; 2. Gantry; 21. Diagonal bracing beam; 22. Support hole; 23. Vertical beam; 24. First horizontal beam; 3. Lifting mechanism; 31. First jack; 32. Second jack; 4. Tensioner; 5. Pulling structure; 6. Automatic leveling sensor; 7. Distance sensor. DETAILED DESCRIPTION

[0032] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0033] See also Figure 1-4 As shown;

[0034] A total assembly welding support device capable of preset deflection and tensioning is invented, comprising:

[0035] The gantry 2 is fixedly connected to the base plate 1 and arranged along the width direction of the vehicle body. Specifically, the bottom end of the gantry 2 is fixedly connected to the T-slot of the base plate 1 by a T-bolt. The top of the gantry 2 is formed with a diagonal bracing beam 21 on both sides. The diagonal bracing beam 21 extends obliquely upward toward the lower surface of the vehicle body chassis side beam. The top of the diagonal bracing beam 21 has a supporting surface, and the supporting surface is provided with a supporting hole 22. The supporting hole 22 is equipped with a lifting mechanism 3 with a prefabricated deflection, which contacts the chassis side beam through the lifting mechanism 3 and provides an upward force thereto. It also includes

[0036] The tensioner 4 is fixedly connected to the position of the base plate 1 corresponding to the lifting mechanism 3. The tensioner 4 is used to provide a downward force. The tensioner 4 is connected to the pulling hole opened in the side beam or side wall of the chassis through the pulling structure 5, thereby pulling the chassis or side wall.

[0037] In this structure, the diagonal bracing beam 21 at the top of the gantry 2 is tilted, and the lower plane of the chassis side beam contacts the upper plane of the supporting column from which the first jack on the diagonal bracing beam 21 extends. The diagonal bracing beam 21 exists as a rooting device for the jack, and can be supported on the lower surface of the chassis side beam through the first jack 31, solving the problem of inaccurate deflection prefabrication caused by the current support on the lower plane of the main crossbeam 100-200mm away from the side beam. At the same time, with the detour welding equipment, the detour welding equipment can be completely avoided during welding (see Figure 2 ), the circuitous welding lower electrode can move in the vehicle width direction to avoid the support device and avoid interference. The tensioner 4 is connected with the chassis side beam through the pulling structure 5, which can not only pull the chassis side beam downward, but also connect with the side wall to pull the side wall downward to ensure that the side wall is tightened in place, thereby solving the problem of manual tightening not being in place or over-tightening.

[0038] See also Figure 3 As shown, the lifting mechanism 3 includes a first jack 31 and a second jack 32 disposed in the support hole 22;

[0039] The second jack 32 is arranged below the first jack 31, and the two adjacent first jacks 31 are leveled by the second jack 32. When in use, the two first jacks 31 on the same gantry 2 are leveled by the second jack 32. When multiple supporting devices are used in combination, the two adjacent first jacks 31 on two adjacent groups of supporting devices can also be kept on the same plane. Specifically, there are 2 in the length direction and 1 in the width direction, a total of 3.

[0040] Specifically, the first jack 31 and the second jack 32 are both hydraulic jacks, which are connected to an external control system. The control system effectively detects and records the prefabricated deflection data of the chassis, making it traceable. At the same time, the control system can control the stroke of the first jack 31 and the second jack 32, completely prefabricating the deflection and avoiding the problem of inaccurate manual adjustment of the deflection.

[0041] The support hole 22 has a diameter of 60 mm and a depth of 80 mm. The first jack 31 has a diameter of 60 mm, a height of 80 mm, and a stroke of 40 mm. The second jack 32 has a diameter of 60 mm, a height of 40 mm, and a stroke of 20 mm.

[0042] See also Figure 4 As shown, preferably, an automatic leveling sensor 6 is installed on the side of the base of the first jack 31 to level the two first jacks 31 on the same cross-section in the width direction of the vehicle body and the two adjacent first jacks 31 in the length direction of the vehicle body. Specifically, there are two sensors in the length direction and one in the width direction, for a total of three. At the four corners, there are two sensors in the length direction and one in the width direction, for a total of two. Preferably, a distance sensor 7 is installed on the top of the base of the first jack 31 to measure the deflection of the chassis.

[0043] See also Figure 1 As shown, preferably, the gantry 2 includes two vertical beams 23 arranged at intervals, a first horizontal beam 24 connected to the bottom ends of the two vertical beams 23, and a second horizontal beam connected to the top ends of the two vertical beams 23. A diagonal bracing beam 21 is formed at the connection position between the second horizontal beam and the vertical beam 23, and the gantry 2 is fixedly connected to the base plate 1 through the first horizontal beam 24.

[0044] See also Figure 2 As shown, preferably, the tensioner 4 is a winch in the prior art, the base plate 1 is located on one side of the vertical beam 23 and is fixedly connected to the winch, and the winch is connected to the pulling hole of the base frame or the side wall through the pulling structure 5, and the pulling structure 5 is a pull belt or pull rope or other rope in the prior art.

[0045] In the above technical solution, the present invention provides a total assembly welding support device capable of preset deflection and tensioning. First, the position of the existing supporting chassis main crossbeam is changed to the chassis side beam, which more effectively supports the effect of prefabrication of the chassis deflection. Secondly, the existing manual adjustment of the deflection is changed to automatic preset deflection through the support mechanism, which more effectively ensures the accuracy and consistency of the deflection prefabrication. In addition, the existing manual tensioning through the tensioner 4 is changed to automatic tensioning, which further effectively ensures the appropriateness and consistency of the tensioning force. Moreover, the support mechanism and the tensioner 4 are connected to an external control system to change the existing manual detection and recording of the deflection value to automatic detection and recording, which can effectively ensure the reliability and authenticity of the data.

[0046] A method for supporting the assembly welding of a component capable of preset deflection and tensioning is invented, which utilizes the above-mentioned supporting device for support;

[0047] The supporting method comprises the following steps: the vehicle body underframe is positioned above the gantry 2, and the diagonal bracing beam 21 of the gantry 2 is positioned below the underframe side beam;

[0048] Prefabrication deflection: The second jack 32 and the first jack 31 are placed in the support hole 22 in sequence. The stroke of the first jack 31 is used to prefabricate the deflection value of the chassis and lock it. The first jack 31 is leveled by the stroke of the second jack 32 so that the first jack 31 on the gantry 2 must be in the same plane before prefabrication deflection.

[0049] Deflection value comparison: Use the distance measuring sensor 7 to measure the deflection value of the vehicle body underframe side beam above the first jack 31 and compare it with the preset stroke of the first jack 31 to see if the error exceeds the threshold;

[0050] Specifically, the gap between the upper plane of the first jack 31 and the side beam of the chassis is measured by the deflection distance measuring sensor 7. After all the positions that need to be measured are measured, they can be stored in the external control system. At the same time, this value needs to be compared with the preset stroke of the first jack 31. When the error exceeds a threshold (the specific threshold is 1mm), the external control system will issue an alarm.

[0051] Pulling the chassis: Based on the prefabricated deflection value, the actual deflection measured by the distance sensor 7 and the preset deflection of the first jack 31, after the comparison exceeds the threshold, the tensioner 4 is used to pull the chassis side beam through the pulling structure 5. After the deflection reaches the preset deflection value, the pulling force is kept unchanged.

[0052] The deflection is measured by the distance measuring sensor 7 below the underframe side beams on both sides of the bolster. The side beams on both sides of the bolster are also supported below. The upper plane of the first jack contacts the lower plane of the side beam, playing a supporting role. The winch also pulls here.

[0053] Specifically, by setting a gantry 2 under the chassis side beams on both sides of the bolster, and measuring the deflection through the distance sensor 7 on the gantry 2, the accuracy of the deflection measurement is further improved. During the pulling process, after the first jack 31 reaches the preset deflection value and is locked, the tensioner 4 is used to pull. During the pulling process, the change in the deflection value of the lower plane of the chassis side beam is continuously detected. If it is unqualified, it needs to be adjusted. First, the deflection is preset, then tightened, and then tested and confirmed.

[0054] Secondly, a gantry 2 is set under the bolster, and this gantry 2 participates in the pulling work. Here, the distance sensor 7 of the gantry 2 is the 0 reference point. It is necessary to pull the chassis side beam and the jack to make them close together. A center positioning pin is set in the center of the gantry 2. The center positioning pin can provide a positioning reference in the length and width directions for the chassis (i.e., the length and width positioning references). A positioning hole in the height direction is set below the air spring mounting surface on both sides of the center pin to provide a reference horizontal plane (i.e., the height positioning reference and support the chassis bolster), thereby achieving the purpose of positioning and supporting the bolster;

[0055] In a specific embodiment, nine gantries 2 are provided below the chassis side beams to participate in the support, including one at the center of the vehicle body, two at the centers of the two bolsters, and two at both ends. The remaining positions are distributed between the bolsters and the center of the vehicle body. Each gantry 2 has a jack and a sensor on it. The sensors are adjusted by the jacks. First, it is ensured that all sensors (rooted on the top first jack 31) are on the same plane. Then, the first jack 31 is extended to different lengths to simulate the deflection of the chassis. Then, the tensioner 4 is used to tighten the lower plane of the chassis side beam to the upper plane of the first jack 31, and the chassis deflection is formed.

[0056] In the above technical solution, the present invention provides a method for welding and supporting a total component with preset deflection and tensioning, which utilizes the above-mentioned welding and supporting device for total component with preset deflection and tensioning for support and deflection prefabrication, and has the same beneficial effects as the supporting device, which will not be described in detail here.

[0057] The above description is merely illustrative of certain exemplary embodiments of the present invention. It goes without saying that those skilled in the art will be able to modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and description are illustrative in nature and should not be construed as limiting the scope of protection of the claims.

Claims

1. A fully assembled welding support device with preset deflection and tension, characterized in that: include: A gantry (2) is fixedly connected to the base plate (1) and arranged along the width direction of the vehicle body; Both sides of the top of the gantry (2) are formed with diagonal bracing beams (21) extending obliquely upward toward the lower surface of the vehicle body chassis side beam, and a prefabricated deflection lifting mechanism (3) is installed in the support hole (22) opened at the top of the diagonal bracing beam (21), which contacts the chassis side beam through the lifting mechanism (3) and provides an upward force to the chassis side beam; and A tensioner (4) for providing a downward force, wherein the base plate (1) is fixedly connected with the tensioner (4) at a position corresponding to the lifting mechanism (3), and the tensioner (4) is connected to a pulling hole provided in a side beam or a side wall of the chassis via a pulling structure (5); The lifting mechanism (3) comprises a first jack (31) and a second jack (32) arranged in the support hole (22); the second jack (32) is arranged below the first jack (31); and two adjacent first jacks (31) are leveled by the second jack (32); An automatic leveling sensor (6) is installed on the side of the base of the first jack (31) for leveling two adjacent first jacks (31); A distance measuring sensor (7) is installed on the top of the base of the first jack (31) for measuring the deflection of the chassis.

2. A fully assembled welding support device capable of preset deflection and tensioning according to claim 1, It is characterized by: The gantry (2) comprises two vertical beams (23) arranged at intervals, a first horizontal beam (24) connected to the bottom ends of the two vertical beams (23), and a second horizontal beam connected to the top ends of the two vertical beams (23), wherein the diagonal bracing beam (21) is formed at the connection position between the second horizontal beam and the vertical beam (23), and the gantry (2) is fixedly connected to the base plate (1) via the first horizontal beam (24).

3. A fully assembled welding support device capable of preset deflection and tensioning according to claim 2, It is characterized by: The tensioner (4) is a winch, and the base plate (1) is located on one side of the vertical beam (23) and is fixedly connected to the winch. The winch is connected to the pulling hole of the base frame or the side wall through the pulling structure (5).

4. The assembly welding support device capable of preset deflection and tensioning according to claim 2 is characterized in that ； The pulling structure (5) is a drawstring or a drawstring.

5. A method for welding and supporting a component assembly with preset deflection and tension, characterized in that: The support method comprises the following steps: The vehicle body underframe is located above the gantry (2), and the diagonal support beam (21) of the gantry (2) is located below the underframe side beam; Prefabrication deflection: the second jack (32) and the first jack (31) are sequentially placed in the support hole (22), the stroke of the first jack (31) is used to prefabricate the deflection value of the chassis and lock it, and the first jack (31) is leveled by the stroke of the second jack (32) so that the first jack (31) on the gantry (2) remains on the same plane before prefabrication deflection; Deflection value comparison: using the distance measuring sensor (7) to measure the deflection value of the vehicle body underframe side beam above the first jack (31), and comparing it with the preset stroke of the first jack (31), to determine whether the error exceeds the threshold; Pulling the chassis: According to the prefabricated deflection value, during the prefabricated deflection process, if the deflection value measured by the distance sensor exceeds the preset deflection value of the first jack, the chassis side beam is pulled through the pulling structure (5) in conjunction with the tensioner (4). After the tension is pulled to meet the preset deflection value, the pulling force is kept unchanged. At the same time, the deflection value is measured by the distance sensor (7) below the chassis side beam on both sides of the pillow beam.

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