Welding apparatus, welding method and end wall

Abstract

This invention relates to the field of welding technology, providing an assembly welding device, a welding method, and an end wall for end wall assembly. The end wall assembly welding device includes a first welding fixture and a second welding fixture. The first welding fixture includes a first support frame and a first clamping mechanism capable of pressing the end wall against the first support frame. The first support frame has a first support area that supports a first surface of the end wall, and the first support area is adapted to the first surface of the end wall. The second welding fixture includes a second support frame and a second clamping mechanism capable of pressing the end wall against the second support frame. The second support frame has a second support area that supports a second surface of the end wall, and the second support area is adapted to the second surface of the end wall. This arrangement, with corresponding welding fixtures configured on opposite sides of the end wall, improves the compatibility of the end wall assembly welding device with the first and second surfaces of the end wall. Combined with the first and second clamping mechanisms, welding deformation can be effectively limited, ensuring flatness.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and provides an assembly welding device, assembly welding method and end wall for an end wall. Background Technology

[0002] The end walls of rail vehicles are an important component of the vehicle structure, mainly located at the front and rear ends of the car body, forming an enclosed space with the car body and underframe, and undertaking multiple functions and roles. The end walls have a first surface and a second surface that are arranged opposite to each other. The first surface of the end wall is used to connect with the side walls and the roof, while the second surface of the end wall needs to connect with the outer windshield. In actual production, the flatness requirements of the second surface of the end wall are relatively high.

[0003] The end walls of some high-speed trains and other rail vehicles include end corner posts, end wall plates, and end top curved beams. When assembling and welding the end corner posts, end wall plates, and end top curved beams to form the end walls, the end corner posts, end wall plates, and end top curved beams are placed on the assembly welding fixture and manually welded using MIG welding (Metal Inert Gas Arc Welding). This method is inefficient and the welds are segmented welds.

[0004] To improve assembly and welding efficiency, some technologies use automatic welding equipment. Automatic welding involves continuous welds and generates a lot of heat, resulting in significant welding deformation that cannot meet the flatness requirements of the second side of the end wall.

[0005] Therefore, how to solve the problem of the inability to guarantee the flatness of the second surface of the end wall when using automatic welding process to process the end wall in related technologies has become an important technical problem to be solved by those skilled in the art. Summary of the Invention

[0006] This invention provides an assembly welding device, assembly welding method, and end wall for end walls, which solves the defect in the related art where the flatness of the second surface of the end wall cannot be guaranteed when using automatic welding process to process the end wall, reduces the amount of welding deformation, and improves the welding quality of the end wall.

[0007] This invention provides a welding apparatus for an end wall, suitable for supporting an end wall, wherein the end wall has a first surface and a second surface disposed opposite to each other, and the welding apparatus for the end wall includes:

[0008] The first welding fixture includes a first support frame and a first clamping mechanism. The first support frame has a first support area, which is adapted to support the first surface of the end wall. The first support area is adapted to match the first surface of the end wall. The first clamping mechanism is adapted to clamp the end wall onto the first support frame.

[0009] The second welding fixture includes a second support frame and a second clamping mechanism. The second support frame has a second support area, which is adapted to support the second surface of the end wall. The second support area is adapted to match the second surface of the end wall. The second clamping mechanism is adapted to clamp the end wall onto the second support frame.

[0010] According to the present invention, an assembly welding device for an end wall includes an end corner post, an end top curved beam, and an end wall plate. The end corner post and the end top curved beam are provided with connecting stiffeners on one side of the first surface of the end wall plate for connecting the side wall and the top plate. The connecting stiffeners extend along the axial direction of the end corner post and the end top curved beam and are arranged at an angle to the end wall plate.

[0011] The first support area is provided with a clearance joint, which is adapted to avoid the connecting stiffener.

[0012] According to the present invention, an assembly welding device for an end wall is provided, wherein the end wall plate includes a middle wall plate and a pair of side wall plates, the middle wall plate is located between the pair of side wall plates, and the first surface of the adjacent edges of the pair of side wall plates is formed with a stepped structure;

[0013] The first support area is also provided with a clearance groove, which is adapted to avoid the stepped structure.

[0014] According to the present invention, a welding device for an end wall is provided, wherein a plurality of first clamping mechanisms are provided, and the plurality of first clamping mechanisms are distributed at intervals along the circumference of the first support area;

[0015] Multiple second clamping mechanisms are provided, and the multiple second clamping mechanisms are distributed at intervals along the circumference of the second support area.

[0016] According to the present invention, a welding device for an end wall is provided, wherein both the first clamping mechanism and the second clamping mechanism are adapted to clamp the edge position of the end wall;

[0017] Along the support direction of the first support area on the end wall, the projection area of ​​each of the first clamping mechanisms is located outside the projection area of ​​the splice seam on the second side of the end wall.

[0018] Along the support direction of the second support area on the end wall, the projection area of ​​each of the second clamping mechanisms is located outside the projection area of ​​the splice seam on the first surface of the end wall.

[0019] According to the present invention, a welding apparatus for an end wall is provided, wherein both the first clamping mechanism and the second clamping mechanism include:

[0020] A fixing base, suitable for fixing to the first support frame or the second support frame;

[0021] A crimping member is rotatably connected to the fixed base. The rotation axis of the crimping member relative to the fixed base is parallel to the first support area or the second support area. The first end of the crimping member is adapted to be pressed against the end wall.

[0022] A first connecting rod is slidably disposed on the fixed base along its own axis. The axis of the first connecting rod is perpendicular to the first support area or the second support area. The first end of the first connecting rod is rotatably connected to the second end of the crimping member. The rotation axis of the first connecting rod relative to the crimping member is parallel to the rotation axis of the crimping member relative to the fixed base.

[0023] A driving member is disposed on the fixed base, and the driving member is adapted to drive the first connecting rod to slide relative to the fixed base.

[0024] According to the welding apparatus for an end wall provided by the present invention, the first clamping mechanism and the second clamping mechanism further include:

[0025] The second connecting rod connects the crimping member to the fixed base in a rotatable manner. The two ends of the second connecting rod are rotatably connected to the crimping member and the fixed base, respectively.

[0026] According to the welding apparatus for an end wall provided by the present invention, the first welding fixture further includes:

[0027] A first positioning mechanism is disposed on the first support frame, and the first positioning mechanism is adapted to position the end wall;

[0028] The second welding fixture also includes:

[0029] A second positioning mechanism is disposed on the second support frame, and the second positioning mechanism is adapted to position the end wall.

[0030] The first positioning mechanism and the end wall operate at the same position as the second positioning mechanism and the end wall.

[0031] The present invention also provides a method for assembling and welding an end wall, based on the above-mentioned end wall assembly and welding apparatus, the method for assembling and welding the end wall includes:

[0032] Initial fixation involves spot welding the end corner posts, end top curved beams, and end wall panels to form a preliminary end wall component. The end corner posts and end top curved beams both form butt joints with the second surface of the end wall panels, and the end corner posts and end top curved beams both form lap joints with the first surface of the end wall panels.

[0033] Weld the first side of the end wall prototype, place the end wall prototype on the second welding fixture, and weld the lap joint of the first side of the end wall prototype to form an end wall intermediate part.

[0034] The second side of the end wall intermediate component is welded. The end wall intermediate component is placed in the first welding fixture, and the butt joint of the second side of the end wall intermediate component is welded to form the finished end wall component.

[0035] According to a welding method for an end wall provided by the present invention, the end wall plate includes a middle wall plate and a pair of side wall plates, wherein the middle wall plate is located between the pair of side wall plates;

[0036] The welding of the first side of the prototype end wall component and the welding of the second side of the intermediate end wall component both include:

[0037] Welding is performed on the joint formed between the side wall panel and the middle wall panel;

[0038] Weld the joint formed between the end wall panel and the end top curved beam;

[0039] The joint formed by the end wall panel and the end corner post is welded.

[0040] The present invention also provides an end wall, which is welded by the end wall assembly welding device described above, or by the end wall assembly welding method described above.

[0041] The present invention provides an end wall assembly welding device for supporting an end wall during welding, wherein the end wall has a first surface and a second surface disposed opposite to each other. The end wall assembly welding device includes a first welding fixture and a second welding fixture. The first welding fixture includes a first support frame and a first clamping mechanism. The first support frame has a first support area for supporting the first surface of the end wall, and the first support area is adapted to fit the first surface of the end wall. When the end wall is placed on the first welding fixture, the first surface of the end wall can contact and fit with the first support area of ​​the first welding fixture. The second surface of the end wall is away from the first support area of ​​the first support frame, thereby allowing welding operations to be performed on the second surface of the end wall. The first clamping mechanism is used to clamp the end wall onto the first support frame, limiting welding deformation when welding the joint of the second surface of the end wall. Correspondingly, the second welding fixture includes a second support frame and a second clamping mechanism. The second support frame has a second support area for supporting the second surface of the end wall, and the second support area is adapted to fit the second surface of the end wall. When the end wall is placed on the second welding fixture, its second surface can contact and fit with the second support area of ​​the fixture. The first surface of the end wall faces away from the second support area of ​​the second support frame, allowing welding to be performed on its first surface. The second clamping mechanism presses the end wall firmly against the second support frame, limiting welding deformation during welding of the joint on the first surface. This configuration, where the second surface of the end wall differs from the first, allows for separate welding fixtures for welding the second and first surfaces, improving the compatibility between the welding assembly and the second and first surfaces of the end wall. Combined with the first and second clamping mechanisms, welding deformation is effectively limited, welding quality is improved, and the flatness of the second surface is enhanced. This solves the problem of unreliable flatness of the second surface when using automated welding processes in related technologies.

[0042] In addition, since the splice seam on the second side of the end wall is a butt joint and the splice seam on the first side of the end wall is an lap joint, when assembling and welding the end wall, the end wall that has been initially spot-welded and fixed can be placed on the second welding fixture to weld the lap joint on the first side of the end wall, and then the end wall can be placed on the first welding fixture to weld the butt joint on the second side of the end wall. This is also beneficial to control the amount of welding deformation and can further improve the welding quality and the flatness of the second side of the end wall. Attached Figure Description

[0043] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0044] Figure 1 This is a schematic diagram of the second side structure of the end wall provided by the present invention (the thick solid line in the figure is the splice seam to be welded).

[0045] Figure 2 This is a schematic diagram of the first side structure of the end wall provided by the present invention (the thick solid line in the figure is the splice seam to be welded).

[0046] Figure 3 yes Figure 2 Enlarged view of point I in the middle.

[0047] Figure 4 This is a schematic diagram of the structure of the first welding fixture provided by the present invention.

[0048] Figure 5 This is a schematic diagram of the structure of a second welding fixture provided by the present invention.

[0049] Figure 6 This is a schematic diagram of another second welding fixture provided by the present invention.

[0050] Figure 7 This is a schematic diagram of the structure of the first pressing mechanism and the second pressing mechanism provided by the present invention.

[0051] Figure 8 This is a flowchart of the welding method for end walls provided by the present invention.

[0052] Figure label:

[0053] 1. First welding fixture; 2. First support frame; 3. First clamping mechanism; 4. Second welding fixture; 5. Second support frame; 6. Second clamping mechanism; 7. End wall; 8. End corner post; 9. End top curved beam; 10. Connecting stiffener plate; 11. Clearance joint; 12. Middle wall panel; 13. Side wall panel; 14. Clearance groove; 15. Fixing seat; 16. Pressing component; 17. First connecting rod; 18. Driving component; 19. Second connecting rod; 20. First positioning block; 21. Second positioning block; 22. Protective pad; 23. Weight reduction hole. Detailed Implementation

[0054] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0055] The following is combined with Figures 1 to 7 The present invention describes an assembly welding apparatus for an end wall, which is used to support an end wall during welding. The end wall has a first surface and a second surface disposed opposite to each other. The first surface of the end wall is used to connect a side wall and a top plate, and the second surface of the end wall is used to connect an outer windshield.

[0056] like Figures 1 to 7 As shown, the end wall assembly welding device provided in this embodiment of the invention includes a first welding fixture 1 and a second welding fixture 4.

[0057] Specifically, the first welding fixture 1 is used to weld the splice seam on the second side of the end wall 7. When the end wall 7 is placed on the first welding fixture 1, the second side of the end wall 7 faces upward. The second welding fixture 4 is used to weld the splice seam on the first side of the end wall 7. When the end wall 7 is placed on the second welding fixture 4, the first side of the end wall 7 faces upward.

[0058] The first welding fixture 1 includes a first support frame 2 and a first clamping mechanism 3. The first support frame 2 has a first support area, which is used to support the first surface of the end wall 7. The first support area is adapted to the first surface of the end wall 7.

[0059] When the end wall 7 is placed on the first welding fixture 1, its first surface can contact and fit with the first support area of ​​the first welding fixture 1. The second surface of the end wall 7 is away from the first support area of ​​the first support frame 2, thereby allowing welding operations to be performed on the second surface of the end wall 7. The first clamping mechanism 3 is used to clamp the end wall 7 onto the first support frame 2, and can limit welding deformation when welding the joint of the second surface of the end wall 7.

[0060] Accordingly, the second welding fixture 4 includes a second support frame 5 and a second clamping mechanism 6. The second support frame 5 has a second support area for supporting the second surface of the end wall 7. The second support area is adapted to the first surface of the end wall.

[0061] When the end wall 7 is placed on the second welding fixture 4, its second surface can contact and fit with the second support area of ​​the second welding fixture 4. The first surface of the end wall 7 is away from the second support area of ​​the second support frame 5, thus allowing welding operations to be performed on the first surface of the end wall 7. The second clamping mechanism 6 is used to clamp the end wall 7 onto the second support frame 5, thereby limiting welding deformation when welding the joint on the first surface of the end wall 7.

[0062] With this configuration, the second surface structure of the end wall 7 differs from the first surface structure. The welding processes for the second surface and the first surface of the end wall 7 are respectively equipped with corresponding welding fixtures, which improves the compatibility between the welding device and the second surface of the end wall 7, as well as the compatibility between the welding device and the first surface of the end wall 7. Combined with the first clamping mechanism 3 and the second clamping mechanism 6, welding deformation can be effectively limited, welding quality can be improved, and the flatness of the second surface of the end wall 7 can be improved. This solves the problem that the flatness of the second surface of the end wall 7 cannot be guaranteed when using automatic welding processes to process the end wall 7 in related technologies.

[0063] In addition, since the splice seam on the second side of the end wall 7 is a butt joint and the splice seam on the first side of the end wall 7 is an lap joint, when assembling and welding the end wall 7, the end wall 7 that has been initially spot-welded and fixed can be placed on the second welding fixture 4 to weld the lap joint on the first side of the end wall 7, and then the end wall 7 can be placed on the first welding fixture 1 to weld the butt joint on the second side of the end wall 7. This is also beneficial to control the amount of welding deformation and can further improve the welding quality and the flatness of the second side of the end wall 7.

[0064] The end wall 7 includes end corner posts 8, end top curved beams 9, and end wall panels. A pair of end corner posts 8 are provided, arranged side by side, and respectively connected to the two ends of the end top curved beams 9. The end corner posts 8 and end top curved beams 9 are located at the edges of the end wall panels. The edges of the second surface and the first surface of the end wall panels need to be welded and fixed to the end corner posts 8 and end top curved beams 9.

[0065] The first surface of the end wall 7 needs to be connected to the side wall and the top slab. A connecting stiffener 10 is provided on one side of the first surface of the end wall panel corresponding to the end corner column 8 and the end top curved beam 9. The connecting stiffener 10 extends along the axial direction of the end corner column 8 and the end top curved beam 9, and the connecting stiffener 10 is set at an angle to the end wall panel. Specifically, the connecting stiffener 10 is perpendicular to the end wall panel.

[0066] In this embodiment, a clearance joint 11 is provided in the first support area to avoid the connecting stiffener 10. When the end wall 7 is placed on the first welding fixture 1, the connecting stiffener 10 on the first side of the end wall 7 is located in the clearance joint 11 to ensure that the first side of the end wall can contact the first support area, thus ensuring the stability of the end wall 7. By utilizing the interaction between the first support area and the end wall 7, as well as the interaction between the first clamping mechanism 3 and the end wall 7, welding deformation can be sufficiently limited.

[0067] In a specific embodiment, the width of the clearance seam 11 is 30-40 mm. In this embodiment, the width of the clearance seam 11 is set to 35 mm.

[0068] A doorway structure is formed on the end wall 7. Specifically, the end wall panel includes a middle wall panel 12 and a pair of side wall panels 13, with the middle wall panel 12 located between the pair of side wall panels 13. One of the pair of side wall panels 13 is called the left wall panel, and the other is called the right wall panel.

[0069] Along the height of the end wall 7, the length of the middle wall panel 12 is smaller than the length of the side wall panel 13. The first face of the adjacent edges of a pair of side wall panels 13 forms a stepped structure to create a doorpost structure.

[0070] In a further embodiment, the first support area is also provided with a clearance groove 14, which is used to avoid the aforementioned stepped structure. For the end wall 7 with a stepped structure on the first side of the side wall panel 13, the clearance groove 14 can ensure that the position on the end wall panel outside the stepped structure can contact the first support area, thus ensuring the stability of the end wall 7.

[0071] The depth of the recess of the clearance groove 14 relative to the first support area is consistent with the protrusion size of the step structure relative to the rest of the side wall plate 13. When the end wall 7 is placed on the first welding fixture 1, the bottom of the clearance groove 14 can also support the step structure. When welding the second side of the end wall 7 corresponding to the position around the step structure, welding deformation can be reduced.

[0072] In a specific embodiment, the width of the aforementioned clearance groove 14 can be 135 mm.

[0073] In this invention, multiple first clamping mechanisms 3 are provided, and these multiple first clamping mechanisms 3 are distributed circumferentially along the first support area. By using multiple spaced-apart first clamping mechanisms 3 to clamp and fix the end wall 7 to the first support area of ​​the first support frame 2, multiple positions of the end wall 7 can be clamped and fixed simultaneously, resulting in a sufficient fixing effect on the end wall 7. During the welding process of the second surface of the end wall 7, the stability of the end wall 7 is high.

[0074] Specifically, 22 first clamping mechanisms 3 are provided on the first support frame 2. Two first clamping mechanisms 3 are provided on the first support frame 2 corresponding to each arc-shaped part of the end-top curved beam 9 to control the welding deformation of the arc-shaped parts. Two to three first clamping mechanisms 3 are provided on the first support frame 2 corresponding to the remaining positions of the edge of the end wall 7. The distribution positions of the first clamping mechanisms 3 are as follows: Figure 4 As shown.

[0075] Similarly, multiple second clamping mechanisms 6 are provided, and these multiple second clamping mechanisms 6 are distributed at intervals along the circumference of the second support area. By using multiple spaced-apart second clamping mechanisms 6 to clamp and fix the end wall 7 to the second support area of ​​the second support frame 5, multiple positions of the end wall 7 can be clamped and fixed simultaneously, resulting in a sufficient fixing effect on the end wall 7. During the welding process on the first surface of the end wall 7, the stability of the end wall 7 is high.

[0076] Specifically, 22 second clamping mechanisms 6 are provided on the second support frame 5. Two second clamping mechanisms 6 are provided on the second support frame 5 corresponding to each arc-shaped part of the end-top curved beam 9 to control the welding deformation of the arc-shaped parts. Two to three second clamping mechanisms 6 are provided on the second support frame 5 corresponding to the remaining positions of the edge of the end wall 7. The distribution of the second clamping mechanisms 6 is as follows: Figure 5 and Figure 6 As shown.

[0077] To avoid interference between the first clamping mechanism 3 and the second clamping mechanism 6 and the automatic welding process of the automatic welding equipment, in this embodiment of the invention, both the first clamping mechanism 3 and the second clamping mechanism 6 are clamped to the edge of the end wall 7. Along the support direction of the first support region on the end wall 7, the projection area of ​​each first clamping mechanism 3 is located outside the projection area of ​​the splice seam on the second side of the end wall 7; along the support direction of the second support region on the end wall 7, the projection area of ​​each second clamping mechanism 6 is located outside the projection area of ​​the splice seam on the first side of the end wall 7.

[0078] Understandably, the same first clamping mechanism 3 will not cross the splice seam on the second side of the end wall 7, and any structure of the same first clamping mechanism 3 is located on the same side of the splice seam at the location of the first clamping mechanism 3. The same second clamping mechanism 6 will not cross the splice seam on the first side of the end wall 7, and any position of the same second clamping mechanism 6 is located on the same side of the splice seam at the location of the second clamping mechanism 6.

[0079] Specifically, each of the first clamping mechanisms 3 can be positioned on the first support frame 2 outside the first support area, and the first clamping mechanism 3 can be clamped against the corner post 8, the top curved beam 9, the adjacent edges of the pair of side wall plates 13, the edge of the middle wall plate 12 away from the top curved beam 9, and the edge of the side wall plate 13 away from the top curved beam 9 of the end wall 7. Similarly, each of the second clamping mechanisms 6 can be positioned on the second support frame 5 outside the second support area, and the second clamping mechanism 6 can be clamped against the corner post 8, the top curved beam 9, the adjacent edges of the pair of side wall plates 13, the edge of the middle wall plate 12 away from the top curved beam 9, and the edge of the side wall plate 13 away from the top curved beam 9 of the end wall 7.

[0080] Simultaneously, it is necessary to control the distance between the pressing position of the first pressing mechanism 3 on the second side of the end wall 7 and the splice joint of the second side of the end wall 7, generally controlling this distance to around 20 mm. Similarly, it is necessary to control the distance between the pressing position of the second pressing mechanism 6 on the first side of the end wall 7 and the splice joint of the first side of the end wall 7, generally controlling this distance to around 20 mm.

[0081] In this embodiment of the invention, the first pressing mechanism 3 and the second pressing mechanism 6 are arranged in similar positions and have the same structure.

[0082] Both the first pressing mechanism 3 and the second pressing mechanism 6 include a fixed base 15, a pressing member 16, a first connecting rod 17, and a driving member 18.

[0083] The following explanation uses the structure of the first pressing mechanism 3 as an example.

[0084] The fixing seat 15 is used to fix the first support frame 2 as a support component of the first pressing mechanism 3 for fixed installation.

[0085] The crimping member 16 is rotatably connected to the fixed base 15, and the axis of rotation of the crimping member 16 relative to the fixed base 15 is parallel to the first support area. When the crimping member 16 rotates relative to the fixed base 15, the distance between the first end of the crimping member 16 and the first support area will change.

[0086] The axis of the first link 17 is perpendicular to the first support area. The first link 17 is slidably connected to the fixed base 15, and the sliding direction of the first link 17 relative to the fixed base 15 is perpendicular to the first support area.

[0087] The first end of the crimping member 16 is a free end, used to press against the end wall 7. The second end of the crimping member 16 is rotatably connected to the first end of the first connecting rod 17, and the rotation axis of the first connecting rod 17 relative to the crimping member 16 is parallel to the rotation axis of the crimping member 16 relative to the fixed base 15. The driving member 18 is disposed between the fixed base 15 and the second end of the first connecting rod 17. The driving member 18 can drive the first connecting rod 17 to slide relative to the fixed base 15, thereby driving the crimping member 16 to rotate relative to the fixed base 15, so that the first end of the crimping member 16 moves closer to or further away from the end wall 7.

[0088] The aforementioned drive component 18 may be configured as a hydraulic cylinder, pneumatic cylinder, etc.

[0089] In this embodiment, a hydraulic cylinder is selected as the driving component 18, and the axis of the hydraulic cylinder is perpendicular to the first support area or the second support area. The cylinder barrel of the hydraulic cylinder is fixed to the fixed base 15, and the piston rod of the hydraulic cylinder is connected to the first connecting rod 17. By controlling the extension and retraction of the hydraulic cylinder, the pressing component 16 can be rotated relative to the fixed base 15. Specifically, controlling the hydraulic cylinder to retract can drive the pressing component 16 to rotate in a direction that moves the first end of the pressing component 16 away from the end wall 7, for releasing the end wall 7; controlling the hydraulic cylinder to extend can drive the pressing component 16 to rotate in a direction that moves the first end of the pressing component 16 closer to the end wall 7, for pressing the end wall 7.

[0090] The extension and retraction of the hydraulic cylinder is controlled by the hydraulic system. The pressure holding capacity of the hydraulic system is optimized to ensure that both the first clamping mechanism 3 and the second clamping mechanism 6 can provide a clamping force of 2 tons (ton, symbol t).

[0091] In addition, the driving components 18 of each first clamping mechanism 3 and each second clamping mechanism 6 can be electrically connected to the control system. By controlling the actions of the driving components 18 of each first clamping mechanism 3 and each second clamping mechanism 6 through the control system, the automated control of the first clamping mechanism 3 and the second clamping mechanism 6 can be realized, which promotes the automation of welding, reduces manual operation, and reduces labor intensity.

[0092] In a further embodiment, the first pressing mechanism 3 and the second pressing mechanism 6 further include a second connecting rod 19, which is disposed between the pressing member 16 and the fixed seat 15, and both ends of the second connecting rod 19 are rotatably connected to the pressing member 16 and the fixed seat 15, respectively. That is, the pressing member 16 is rotatably connected to the fixed seat 15 through the second connecting rod 19.

[0093] The second link 19 allows the driving member 18 to increase the rotation angle of the pressing member 16 when driving the pressing member 16 to rotate in the direction that moves the first end of the pressing member 16 away from the end wall 7. This allows the pressing member 16 to rotate until the first end of the pressing member 16 is outside the first support area or the second support area. When the end wall 7 is placed in the first support area or the second support area, or when the end wall 7 is lifted from the first support area or the second support area, interference between the pressing member 16 and the end wall 7 can be effectively avoided, collisions with the end wall 7 can be avoided, and bumps to the end wall 7 can be prevented. This facilitates the hoisting of the end wall 7 and helps to improve efficiency.

[0094] The rotational connection between the aforementioned crimping member 16 and the second connecting rod 19, the rotational connection between the second connecting rod 19 and the fixed base 15, and the rotational connection between the crimping member 16 and the first connecting rod 17 can all be achieved by means of pin hinges, with the axes of each pin being parallel to each other.

[0095] In some embodiments, a protective pad 22 is provided at the first end of the crimping member 16. When the crimping member 16 presses against the end wall 7, the protective pad 22 applies a clamping force to the end wall 7. The end wall 7 is made of aluminum alloy, and an aluminum plate is selected as the protective pad 22. The crimping member 16 contacts the end wall 7 through the protective pad 22, which can avoid direct contact between the end wall 7 and dissimilar metals, thus protecting the end wall 7.

[0096] In a specific embodiment, 5-series aluminum plate is selected as the protective pad 22. 5-series aluminum plate, also known as aluminum-magnesium alloy plate, is an aluminum alloy plate with magnesium as the main alloying element. It has the advantages of low density, good elongation, and good fatigue strength. It can still maintain good performance stability under long-term alternating loads.

[0097] In some embodiments, a weight-reducing hole 23 is provided on at least one of the first support frame 2 and the second support frame 5 to reduce the weight of the first welding fixture 1 or the second welding fixture 4.

[0098] The weight reduction hole 23 should be positioned as far away as possible from the splice joint of the first support frame 2 or the second support frame 5 for the end wall 7, so as to ensure stable support of the splice joint of the end wall 7 by the first support frame 2 or the second support frame 5.

[0099] In this embodiment of the invention, the first welding fixture 1 further includes a first positioning mechanism. The first positioning mechanism is disposed on the first support frame 2 and is used to position the end wall 7.

[0100] The second welding fixture 4 also includes a second positioning mechanism. The second positioning mechanism is disposed on the second support frame 5 and is used to position the end wall 7.

[0101] The first positioning mechanism and the end wall 7 operate at the same position. The second positioning mechanism and the end wall 7 operate at the same position. This can improve the consistency between the positioning effect when welding the second side of the end wall 7 and the positioning effect when welding the first side of the end wall 7, which is conducive to further improving the welding quality.

[0102] In a specific embodiment, the first positioning mechanism includes two sets of first positioning blocks 20, the distribution directions of the two sets of first positioning blocks 20 are perpendicular, one set of first positioning blocks 20 is used to abut against the bottom edge of one of the side wall panels 13, and the other set of first positioning blocks 20 is used to abut against the side edge of the side wall panel 13.

[0103] Specifically, four first positioning blocks 20 can be provided for abutting against the bottom edge of the side wall panel 13, with two first positioning blocks 20 corresponding to the bottom edge of each side wall panel 13, and the two first positioning blocks 20 are distributed at intervals. Three first positioning blocks 20 can be provided for abutting against the side edge of the side wall panel 13, and the three first positioning blocks 20 are distributed at intervals.

[0104] Similarly, the second positioning mechanism includes two sets of second positioning blocks 21, which are distributed perpendicularly. One set of second positioning blocks 21 is used to abut against the bottom edge of one of the side wall panels 13, and the other set of second positioning blocks 21 is used to abut against the side edge of the side wall panel 13.

[0105] Specifically, four second positioning blocks 21 can be provided for abutting against the bottom edge of the side wall panel 13, with two second positioning blocks 21 corresponding to the bottom edge of each side wall panel 13, and the two second positioning blocks 21 are distributed at intervals. Three second positioning blocks 21 can be provided for abutting against the side edge of the side wall panel 13, and the three second positioning blocks 21 are distributed at intervals.

[0106] One of the pair of sidewall plates 13 is the first sidewall plate and the other is the second sidewall plate, which can make each of the first positioning blocks 20 of the first positioning mechanism and each of the second positioning blocks 21 of the second positioning mechanism interact with the first sidewall plate.

[0107] In summary, the end wall assembly welding device provided in this embodiment of the invention can meet the positioning requirements of the automatic welding process for the end wall 7. While realizing the processing of the end wall 7 using the automatic welding process, it can also effectively control the amount of welding deformation, improve the welding quality of the end wall 7, and ensure the flatness of the second surface of the end wall 7.

[0108] Furthermore, while ensuring welding quality, the end wall assembly welding device provided in this embodiment of the invention can simultaneously perform welding operations on the second and first surfaces of different end walls, which can greatly improve the assembly and welding efficiency of end walls for mass production.

[0109] On the other hand, the present invention also provides a method for assembling an end wall based on the end wall assembly welding apparatus provided in any of the above embodiments. The end wall assembly welding method described below can be referred to in correspondence with the end wall assembly welding apparatus described above.

[0110] like Figure 8 As shown, the end wall assembly welding method provided in this embodiment of the invention includes steps 110 to 130.

[0111] Step 110: Initial fixing. Spot weld the end corner post, end top curved beam and end wall plate to form the prototype of the end wall. The end corner post and end top curved beam form a butt joint with the second side of the end wall plate, and the end corner post and end top curved beam form an lap joint with the first side of the end wall plate.

[0112] Step 120: Weld the first side of the end wall prototype. Place the end wall prototype on the second welding fixture and weld the lap joint of the first side of the end wall prototype to form the end wall intermediate part.

[0113] Step 130: Weld the second side of the end wall intermediate component. Place the end wall intermediate component on the first welding fixture and weld the butt joint of the second side of the end wall intermediate component to form the finished end wall component.

[0114] The end wall assembly welding method provided in this embodiment of the invention requires the use of the end wall assembly welding device provided in any of the above embodiments. The end wall 7 is supported and positioned by the end wall assembly welding device provided in the above embodiments to limit welding deformation.

[0115] In this embodiment, when assembling and welding the end wall 7, it is necessary to first preliminarily fix the various components that make up the end wall 7. Specifically, the various components of the end wall 7 include end corner posts 8, end top curved beams 9, middle wall plates 12, and side wall plates 13. There is a pair of side wall plates 13, and the middle wall plate 12 is located between the pair of side wall plates 13. Both of the pair of side wall plates 13 are connected to the middle wall plate 12 to form the end wall plate. There is a pair of end corner posts 8, which are arranged side by side and respectively connected to the two ends of the end top curved beam 9. The end wall plate is located between the pair of end corner posts 8, and both the end corner posts 8 and the end top curved beam 9 are connected to the end wall plate.

[0116] During the initial fixing, the end corner post 8 is spot welded to the side wall plate 13, the end top curved beam 9 is spot welded to the side wall plate 13, the end top curved beam 9 is spot welded to the middle wall plate 12, and the middle wall plate 12 is spot welded to the side wall plate 13 to achieve initial positioning. This facilitates the hoisting of various components on the second welding fixture 4 and reduces the difficulty of positioning the end wall 7 by the second welding fixture 4.

[0117] The initial fixing process can be carried out at a non-automatic welding station, and the specific positioning welding can be performed manually.

[0118] For the second side of end wall 7, the splice joints formed by the end wall plate and the end corner column 8, as well as the splice joints formed by the end wall plate and the end top curved beam 9, are all butt joints. To ensure welding quality, full welding is performed when welding the second side of end wall 7. That is, welding is performed at any position of the splice joint formed by the end wall plate and the end corner column 8, and at any position of the splice joint formed by the end wall plate and the end top curved beam 9 on the second side of end wall 7.

[0119] For the first side of the end wall 7, the splice joint formed by the end wall plate and the end corner column 8 and the splice joint formed by the end wall plate and the end top curved beam 9 are both lap joints. When welding the first side of the end wall 7, segment welding can be performed at the lap joint position.

[0120] In this embodiment, after the initial fixing step is completed, the formed end wall prototype is placed on the second welding fixture 4, and the second clamping mechanism 6 is used to press the end wall prototype onto the second support frame 5. Then, the first side of the end wall prototype is segmentally welded. After the welding of the first side of the end wall prototype is completed, the end wall intermediate part is obtained. The second clamping mechanism 6 releases the end wall intermediate part, and the formed end wall intermediate part is placed on the first welding fixture 1. The first clamping mechanism 3 is used to press the end wall intermediate part onto the first support frame 2, and then the second side of the end wall intermediate part is fully welded. After the welding of the second side of the end wall intermediate part is completed, the finished end wall part is obtained.

[0121] Thus, the second surface structure of the end wall 7 is different from the first surface structure. The welding processes for the second surface and the first surface of the end wall 7 are respectively equipped with corresponding welding fixtures, which improves the compatibility between the welding device and the second surface of the end wall 7, as well as the compatibility between the welding device and the first surface of the end wall 7. Combined with the first clamping mechanism 3 and the second clamping mechanism 6, welding deformation can be effectively limited, welding quality can be improved, and the flatness of the second surface of the end wall 7 can be improved. This solves the problem that the flatness of the second surface of the end wall 7 cannot be guaranteed when using automatic welding process to process the end wall 7 in related technologies.

[0122] Furthermore, the amount of welding on the first side of end wall 7 is relatively small, resulting in less welding heat and less welding deformation. After completing the welding of the first side of end wall 7, the connection strength between the various components of end wall 7 is significantly improved. When welding the second side of end wall 7, the connection strength between the various components can further reduce the deformation caused by the welding process on the second side, which also helps to control the welding deformation.

[0123] The derivation process of the beneficial effects of the end wall welding method in the embodiments of the present invention is largely similar to the derivation process of the beneficial effects of the end wall welding device described above, so it will not be repeated here.

[0124] In this embodiment of the invention, during the welding of the first side of the end wall prototype and the welding of the second side of the end wall intermediate, the welding sequence at each position is consistent, and the welding is carried out from the inside out and from the top to the bottom.

[0125] Specifically, the joint formed by the side wall panel 13 and the middle wall panel 12 can be welded first; then the joint formed by the end wall panel and the end top curved beam 9 can be welded; and finally the joint formed by the end wall panel and the end corner column 8 can be welded.

[0126] When welding the joint between the side wall panel 13 and the middle wall panel 12, and when welding the joint between the end wall panel and the end corner post 8, welding should be performed along the direction from the top to the bottom of the end wall 7 itself.

[0127] When welding the joint formed by the end wall panel and the end top curved beam 9, welding is performed along the direction from one end of the end top curved beam 9 to the other end.

[0128] In some embodiments, a gantry-type dual-manipulator automatic welding equipment is used for welding. This equipment includes a main body and a moving mechanism. The equipment comprises a main manipulator and a secondary manipulator, both with a certain range of travel. The main body is mounted on the moving mechanism, which drives the main body to move, further increasing the reach of the main and secondary manipulators beyond their permissible travel range.

[0129] The moving mechanism controls the movement distance of the dual-manipulator automatic welding equipment with the main manipulator as a reference, which will affect the positional accuracy of the auxiliary manipulator. When the moving mechanism drives the dual-manipulator automatic welding equipment to move, only the main manipulator is used for welding, and the auxiliary manipulator stops welding.

[0130] For the first structure of end wall 7, the joint formed between side wall plate 13 and middle wall plate 12 is a fillet weld. During welding, the welding torch needs to be tilted. In this case, welding can be performed using only the main robotic arm, which will sequentially weld the joints between the left and middle wall plates 12, and then between the right and middle wall plates 12. The joint between the end wall plate and the end top curved beam 9 is also welded using only the main robotic arm. For the joint between the end wall plate and the end corner column 8, the main robotic arm can weld the joint between one end corner column 8 and the end wall plate, while the auxiliary robotic arm welds the joint between the other end corner column 8 and the end wall plate.

[0131] For the second structure of end wall 7, the joint formed between side wall panel 13 and middle wall panel 12 is a butt joint. During welding, the main robot can be used to weld the joint between one side wall panel 13 and middle wall panel 12, while the auxiliary robot can be used to weld the joint between the other side wall panel 13 and middle wall panel 12. For the joint between end wall panel and end fixed bending beam, only the main robot is used for welding. For the joint between end wall panel and end corner column 8, the main robot can be used to weld the joint between one end corner column 8 and end wall panel, while the auxiliary robot can be used to weld the joint between the other end corner column 8 and end wall panel.

[0132] Through extensive experimental statistics, the welding device for the end wall provided in the above embodiments, combined with the welding method for the end wall, can complete the automatic welding of the first and second sides of the end wall 7. Moreover, the quality of the welded end wall 7 meets the requirement that the flatness of the second side of the end wall 7 is no more than 2 mm / 3 meters. In other words, the flatness deviation of the finished end wall part does not exceed 2 mm within a measurement range of 3 meters.

[0133] In another aspect, embodiments of the present invention also provide an end wall, which is welded using the end wall assembly welding device provided in any of the above embodiments, or welded using the end wall assembly welding method provided in any of the above embodiments.

[0134] The derivation process of the beneficial effects of the end wall in the embodiments of the present invention is largely similar to the derivation process of the beneficial effects of the welding device or welding method for the end wall described above, so it will not be repeated here.

[0135] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for assembling and welding an end wall, characterized in that, The end wall (7) is supported by the welding device of the end wall. The end wall (7) has a first surface and a second surface arranged opposite to each other. The end wall (7) includes an end corner column (8), an end top curved beam (9) and an end wall plate. The end corner column (8) and the end top curved beam (9) form a butt joint with the second surface of the end wall plate. The end corner column (8) and the end top curved beam (9) form an lap joint with the first surface of the end wall plate. The end corner column, the end top curved beam and the end wall plate are fixed by spot welding to form a prototype end wall. The welding method for the end wall includes: Initial fixation involves spot welding the end corner posts, end top curved beams, and end wall panels to form a preliminary end wall component. The end corner posts and end top curved beams both form butt joints with the second surface of the end wall panels, and the end corner posts and end top curved beams both form lap joints with the first surface of the end wall panels. Weld the first side of the end wall prototype, place the end wall prototype on the second welding fixture, and weld the lap joint of the first side of the end wall prototype to form an end wall intermediate part. The second side of the end wall intermediate component is welded, the end wall intermediate component is placed in the first welding fixture, and the butt joint of the second side of the end wall intermediate component is welded to form the finished end wall component. The welding device for the end wall includes: The first welding fixture (1) includes a first support frame (2) and a first clamping mechanism (3). The first support frame (2) has a first support area, which is adapted to support the first surface of the end wall (7). The first support area is adapted to match the first surface of the end wall (7). The first clamping mechanism (3) is adapted to clamp the end wall (7) onto the first support frame (2). The second welding fixture (4) includes a second support frame (5) and a second clamping mechanism (6). The second support frame (5) has a second support area, which is adapted to support the second surface of the end wall (7). The second support area is adapted to match the second surface of the end wall (7). The second clamping mechanism (6) is adapted to clamp the end wall (7) onto the second support frame (5). When assembling the welding end wall (7), the second welding fixture (4) is used to support the second side of the end wall prototype to perform segment welding on the first side of the end wall prototype to form an end wall intermediate part; then the first welding fixture (1) is used to support the first side of the end wall intermediate part to perform full welding on the second side of the end wall intermediate part to form an end wall finished part.

2. The welding method for the end wall according to claim 1, characterized in that, The corner post (8) and the top beam (9) are provided with a connecting stiffener (10) on one side of the first surface of the end wall panel for connecting the side wall and the top panel. The connecting stiffener (10) extends along the axial direction of the corner post (8) and the top beam (9) and is set at an angle to the end wall panel. The first support area is provided with a clearance joint (11), which is adapted to avoid the connecting stiffener (10).

3. The welding method for the end wall according to claim 2, characterized in that, The end wall panel includes a middle wall panel (12) and a pair of side wall panels (13), the middle wall panel (12) being located between the pair of side wall panels (13), and the first surface of the adjacent edges of the pair of side wall panels (13) having a stepped structure; The first support area is also provided with a relief groove (14), which is adapted to avoid the step structure.

4. The welding method for the end wall according to claim 1, characterized in that, Multiple first pressing mechanisms (3) are provided, and the multiple first pressing mechanisms (3) are distributed at intervals along the circumference of the first support area; The second pressing mechanism (6) is provided in multiple ways, and the multiple second pressing mechanisms (6) are distributed at intervals along the circumference of the second support area.

5. The welding method for the end wall according to claim 4, characterized in that, Both the first clamping mechanism (3) and the second clamping mechanism (6) are adapted to clamp the edge position of the end wall (7); Along the support direction of the first support area on the end wall (7), the projection area of ​​each of the first clamping mechanisms (3) is located outside the projection area of ​​the splice seam on the second surface of the end wall (7); Along the support direction of the second support area on the end wall (7), the projection area of ​​each of the second clamping mechanisms (6) is located outside the projection area of ​​the splice seam of the first surface of the end wall (7).

6. The method for assembling and welding end walls according to any one of claims 1-5, characterized in that, Both the first clamping mechanism (3) and the second clamping mechanism (6) include: The fixing seat (15) is adapted to be fixed to the first support frame (2) or the second support frame (5); A crimping member (16) is rotatably connected to the fixed base (15). The rotation axis of the crimping member (16) relative to the fixed base (15) is parallel to the first support area or the second support area. The first end of the crimping member (16) is adapted to be pressed against the end wall (7). The first link (17) is slidably disposed on the fixed base (15) along its own axis. The axis of the first link (17) is perpendicular to the first support area or the second support area. The first end of the first link (17) is rotatably connected to the second end of the crimping member (16). The rotation axis of the first link (17) relative to the crimping member (16) is parallel to the rotation axis of the crimping member (16) relative to the fixed base (15). A driving member (18) is disposed on the fixed base (15), and the driving member (18) is adapted to drive the first connecting rod (17) to slide relative to the fixed base (15).

7. The welding method for end walls according to claim 6, characterized in that, The first clamping mechanism (3) and the second clamping mechanism (6) further include: The second link (19) is used to rotatably connect the crimping member (16) to the fixed base (15). The two ends of the second link (19) are rotatably connected to the crimping member (16) and the fixed base (15) respectively.

8. The method for assembling and welding end walls according to any one of claims 1-5, characterized in that, The first welding fixture (1) also includes: A first positioning mechanism is disposed on the first support frame (2), and the first positioning mechanism is adapted to position the end wall (7); The second welding fixture (4) also includes: A second positioning mechanism is disposed on the second support frame (5), and the second positioning mechanism is adapted to position the end wall (7). The first positioning mechanism and the end wall (7) are positioned at the same location as the second positioning mechanism and the end wall (7).

9. The welding method for end walls according to claim 1, characterized in that, The end wall panel includes a middle wall panel and a pair of side wall panels, wherein the middle wall panel is located between the pair of side wall panels; The welding of the first side of the end wall prototype and the welding of the second side of the end wall intermediate both include: Welding is performed on the joint formed between the side wall panel and the middle wall panel; Weld the joint formed between the end wall panel and the end top curved beam; The joint formed by the end wall panel and the end corner post is welded.

10. An end wall, characterized in that, The end wall is welded into shape using the assembly welding method described in any one of claims 1-9.

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