Multi-stage welding method and system for truck girder

Abstract

The invention provides a multistage welding method and system for a truck girder, and relates to the technical field of mechanical welding. The method comprises the following steps: preprocessing; assembling and clamping; mechanically welding; detecting the welding quality for the first time; manual welding; and secondary welding quality detection. By the adoption of the method, mechanical welding and manual welding can be combined, intelligent welding path planning and reasonable welding sequence setting can be achieved, and therefore the welding efficiency and the finished product quality are improved.

Description

Technical Field

[0001] The present application relates to the technical field of mechanical welding, and in particular to a multi-stage welding method and system for a truck beam. Background Art

[0002] Truck beams are key load-bearing components in the vehicle structure, and their welding quality directly affects the safety performance and service life of the entire vehicle.

[0003] Among traditional welding methods, mechanical welding is usually used. Although mechanical welding has the advantages of high efficiency and continuity, it often has welding dead angles when dealing with complex structures or narrow spaces, making it difficult to ensure the integrity and quality of the weld. Although manual welding is more flexible and can handle complex welds, it is limited by the welder's technical level and experience, and often has welding errors, affecting the strength and appearance of the weld.

[0004] At the same time, truck beams are usually made of 16Mn steel, which has a greater tendency to harden than low-carbon steel, so it is more prone to cold cracking during welding. Truck beams have complex structures and various weld forms, which require high welding quality and precision. At the same time, in the truck manufacturing process, the beam is a key component that bears the weight of the vehicle body and transmits force. The accuracy of its mounting holes directly affects the assembly accuracy, driving stability and safety of the vehicle. Traditional manual inspection methods are not only inefficient, but also easily affected by human factors, making it difficult to ensure the accuracy and consistency of the inspection results.

[0005] In addition, the existing welding methods lack systematic consideration in setting the welding sequence and lack intelligent welding path planning, which leads to uneven heat distribution during the welding process, easily causing welding deformation and residual stress, further affecting the welding quality and finished product performance. Summary of the invention

[0006] The main purpose of this application is to provide a multi-stage welding method and system for truck beams, combining mechanical welding and manual welding, and being able to realize intelligent welding path planning and reasonable welding sequence setting, thereby improving welding efficiency and finished product quality, and enhancing practical application value.

[0007] In order to solve the aforementioned technical problems, the present application provides a multi-stage welding method for a truck beam, comprising the following steps:

[0008] Pretreatment: grinding, drilling and shot blasting the target workpiece of the beam;

[0009] Assembly clamping: Place the pre-processed target workpiece in the preset position through the driving device;

[0010] Mechanical welding: Use mechanical welding equipment to perform preliminary welding on the assembled target workpiece to form a basic welding structure;

[0011] The first welding quality inspection: inspect the weld of the target workpiece after mechanical welding to determine whether the size and strength of the weld meet the standards;

[0012] Manual welding: Manual welding is performed on the blind spots of mechanical welding and the parts that do not meet the preset standards after the first welding quality detection;

[0013] Second welding quality inspection: The entire beam after welding will be inspected to ensure that the weld quality is within the required range.

[0014] Optionally, in some embodiments of the present invention, the above-mentioned step of using mechanical welding equipment to perform preliminary welding on the assembled target workpiece to form a basic welding structure includes: cleaning and grinding the groove before welding, and preheating the target workpiece.

[0015] Optionally, in some embodiments of the present invention, the above-mentioned step of using mechanical welding equipment to perform preliminary welding on the assembled target workpieces to form a basic welding structure includes: using a spray device to evenly spray flux on the area to be welded.

[0016] Optionally, in some embodiments of the present invention, the above step of using mechanical welding equipment to perform preliminary welding on the assembled target workpiece to form a basic welding structure includes: using the welding equipment to perform mechanical welding according to a welding path planning preset by a controller.

[0017] Optionally, in some embodiments of the present invention, the welding temperature and stress changes are monitored in real time during the mechanical welding process.

[0018] Optionally, in some embodiments of the present invention, the above-mentioned step of inspecting the welds of the target workpieces after mechanical welding to determine whether the size and strength of the welds meet the requirements includes: using a measuring tool to measure the assembly accuracy of each target workpiece of the beam, wherein the assembly accuracy includes detecting parallelism, perpendicularity and coaxiality.

[0019] Optionally, in some embodiments of the present invention, the above-mentioned step of performing quality inspection on the entire beam after welding to ensure that the quality of the weld is within the required range includes: size and assembly accuracy inspection: inspecting the assembly accuracy of the target workpiece, wherein the assembly accuracy includes parallelism, verticality and coaxiality;

[0020] Nondestructive testing: X-ray or ultrasonic testing of welds to detect defects inside the welds, and magnetic particle testing or penetration testing of key areas to detect surface or near-surface defects.

[0021] Optionally, in some embodiments of the present invention, the above-mentioned step of performing quality inspection on the entire beam after welding to ensure that the quality of the weld is within the required range includes: using Hawken welding stress relief equipment to perform stress relief treatment on the target workpiece after welding.

[0022] Optionally, in some embodiments of the present invention, the above-mentioned step of inspecting the weld of the target workpiece after mechanical welding to determine whether the size and strength of the weld meet the standard further includes: measuring the coaxiality of the mounting hole group of the beam located on the same axis by a measuring device.

[0023] Optionally, in some embodiments of the present invention, the above-mentioned measuring device includes a laser displacement sensor assembly and a prism arranged at the front end of the laser displacement sensor;

[0024] The step of measuring the coaxiality of the mounting hole groups of the beam located on the same axis by a measuring device comprises the following steps:

[0025] Adjust the laser displacement sensor assembly to emit and make the calibration laser penetrate through several mounting holes to be measured and pass through the center positions of the first and last mounting holes, with the calibration laser as the reference axis;

[0026] Insert the prism into the inner side of the mounting hole through which any axis passes, and make the rotation axis of the prism coaxial with the calibration axis;

[0027] For any mounting hole to be measured, a prism is extended into the mounting hole to be measured, and the rotation axis of the prism is made to coincide with the reference axis; the laser displacement sensor assembly is controlled to emit a measuring laser, and the prism is controlled to rotate along the rotation axis to obtain measurement data formed by the measuring laser at the receiving end of the laser displacement sensor assembly;

[0028] Repeat the aforementioned steps of measuring any of the mounting holes to be tested for the remaining mounting holes to be tested, so as to obtain measurement data of each mounting hole to be tested;

[0029] Based on the measurement data of each mounting hole to be measured, the coaxiality errors of several mounting holes to be measured are obtained.

[0030] After adopting the above technical solution, the present invention has the following advantages compared with the background technology:

[0031] The embodiment of the present application proposes a multi-stage welding method for a truck beam. The present invention uses mechanical welding to weld the truck beam as a whole, and then strengthens the defects and dead corners caused by the mechanical welding through manual spot welding, which can ensure that the truck beam is not easily deformed during the welding process. At the same time, by arranging welding quality detection between mechanical welding and manual welding, defects in mechanical welding can be roughly detected and remedied through manual welding, thereby improving the welding quality of the final product and further improving the welding efficiency of the truck beam. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 A flow chart of a multi-stage welding method for a truck beam provided by an embodiment of the present invention;

[0033] Figure 2 A flow chart of a multi-stage welding system for a truck beam provided by an embodiment of the present invention;

[0034] Figure 3 A top view of a long side mounting bracket provided by an embodiment of the present invention;

[0035] Figure 4 A front view of a long side mounting bracket provided by an embodiment of the present invention;

[0036] Figure 5 A top view of a broadside mounting bracket provided in an embodiment of the present invention.

[0037] Icons: 1. Pretreatment module; 2. Assembly clamping module; 3. Mechanical welding module; 4. First welding quality inspection module; 5. Manual welding equipment; 6. Second welding quality inspection module; 101. Side panel; 102. Crossbeam; 103. Laser displacement sensor;

[0038] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0039] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0040] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back, etc.) are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0041] In the present invention, unless otherwise clearly specified and limited, the terms "connection", "fixation", etc. should be understood in a broad sense. For example, "fixation" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0042] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the meaning of "and / or" appearing in the full text includes three parallel schemes. Taking "A and / or B" as an example, it includes scheme A, or scheme B, or a scheme that satisfies both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in the field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0043] The present invention is further described in detail below in conjunction with the accompanying drawings so that those skilled in the art can implement the invention with reference to the description.

[0044] In order to achieve the above objectives,

[0045] Reference Figure 1 The first embodiment of the present application provides a multi-stage welding method for a truck beam, comprising the following steps:

[0046] S1. Pretreatment: grinding and shot blasting the target workpiece of the beam;

[0047] Specifically, this embodiment can take out each target workpiece to be welded to the beam separately, and can use a sandblasting machine and a cleaning machine to clean the surface of the target workpiece of the beam and remove oil, rust and oxidation pretreatment to ensure welding quality.

[0048] Among them, by using a sandblasting machine: it is used to sandblast the surface of the truck beam to remove oil, rust and oxides. By using a cleaning machine: it uses a high-pressure water gun or chemical cleaning agent to deeply clean the truck beam to ensure that the surface is clean and free of impurities.

[0049] S2, assembly clamping: placing the pre-processed target workpiece at a preset position through a driving device;

[0050] Specifically, in this embodiment, the pre-treated truck beam is precisely assembled according to the design requirements and fixed with a suitable clamping device to ensure stability and accuracy during the welding process.

[0051] The drive equipment can use electric or pneumatic clamping to fix the truck beam to prevent movement or deformation during welding. At the same time, a high-precision assembly platform can be used to ensure the precise assembly of the truck beam components.

[0052] S3. Mechanical welding: Use mechanical welding equipment to perform preliminary welding on the assembled target workpiece to form a basic welding structure.

[0053] Specifically, the mechanical welding equipment of this embodiment can use a mechanical welding robot and a double-head spot welder. The mechanical welding robot has high-precision and automated welding functions and can perform precise welding according to the program set in the preprocessor.

[0054] Optionally, the mechanical welding robot of this embodiment can be connected to the mains for power supply.

[0055] Optionally, the processor of this embodiment may adopt an AT89S51 chip. AT89S51 is a low-power, high-performance CMOS 8-bit processor, which integrates a general-purpose 8-bit central processing unit and an ISP Flash storage unit in the chip, and can process the received information in a timely and effective manner. It should be noted that the processor can be an integrated circuit chip with signal processing capabilities. The processor can be a general-purpose processor, including a central processing unit, a network processor; it can also be a digital signal processor, an application-specific integrated circuit, a field programmable gate array or other programmable logic device, a discrete gate or transistor logic device, a discrete hardware component. It is not limited to the AT89S51 chip in this embodiment.

[0056] Optionally, in this embodiment, before the mechanical welding equipment performs preliminary welding on the assembled target workpiece, a spray device can be used to evenly spray flux on the area to be welded. The flux can remove oxides on the surface of the target workpiece, improve welding quality, and help prevent pores and cracks from being generated during welding.

[0057] Furthermore, before mechanical welding, the present embodiment can preheat the welded part by means of a heating device, which helps to improve welding quality and reduce welding deformation and cracks. The heating device can use a laser heating device, which uses a high energy density laser beam to quickly heat the weld, with high heating accuracy and a small heat affected zone, and is suitable for welding work with high precision and high quality requirements. The laser heating method can also be combined with robot technology to realize automation and intelligence of the welding process.

[0058] Optionally, in the process of mechanical welding, this embodiment can ensure welding quality and production safety by setting up real-time monitoring of welding temperature and stress changes.

[0059] Specifically, the real-time monitoring of welding temperature in this embodiment can be achieved by using an infrared thermal imager, which adopts a non-contact temperature measurement method and measures the temperature by capturing the infrared radiation of the welding area. It is suitable for high-temperature environments and will not interfere with the welding process, thus ensuring the safety and accuracy of the measurement. At the same time, it can respond quickly, monitor temperature changes in real time, generate thermal imaging images, and display the detailed temperature distribution of the welding area.

[0060] Real-time monitoring of stress changes can use fiber Bragg grating (FBG) sensors, which are based on fiber coupled mode theory and use the periodic refractive index changes of FBG to measure temperature and strain. Temperature and strain can be monitored simultaneously with high accuracy and long-term stability. It is suitable for real-time monitoring in complex welding processes, especially for scenarios where temperature and strain changes need to be distinguished.

[0061] It can be understood that the data of the welding temperature and stress changes monitored in real time in this embodiment are transmitted to the processor, and the changes of the welding temperature and stress can be displayed in real time by connecting to a display screen. At the same time, the monitoring data can be automatically recorded to facilitate subsequent analysis and quality control. By setting the alarm threshold, an automatic alarm is triggered when the temperature and stress exceed the set range.

[0062] Optionally, in this embodiment, the key mounting holes on the beam can be preliminarily positioned during welding to prepare for subsequent coaxiality calibration.

[0063] S4. First welding quality inspection: Perform quality inspection on the target workpiece after mechanical welding to check whether the size and strength of the weld meet the requirements and ensure that the welding quality meets the preset standards.

[0064] This embodiment uses a displacement sensor or a telescopic rod measuring tool to accurately measure the width, height, and excess height of the weld, and transmits the measured values ​​to the processor for judgment, marks the weld positions that do not meet the preset standards, and performs secondary welding through subsequent manual welding.

[0065] At the same time, in the truck manufacturing process, the beam is a key component that bears the weight of the vehicle body and transmits force. The accuracy of its mounting holes directly affects the assembly accuracy, driving stability and safety of the vehicle. The traditional manual inspection method is not only inefficient, but also easily affected by human factors, making it difficult to ensure the accuracy and consistency of the inspection results.

[0066] Specifically, before detecting the width, height, and excess height of the weld in this embodiment, the coaxiality of multiple coaxial mounting hole groups for connecting other key components, such as the front and rear axle mounting hole groups, the suspension system mounting hole groups, and the steering system mounting hole groups, can be measured by using the reflection of the laser displacement sensor 103 to facilitate subsequent riveting or punching.

[0067] The specific measurement method is:

[0068] First start the calibration laser, adjust the intensity and direction of the calibration laser, and after it passes through several mounting holes that need to be coaxially inspected, adjust it to the center position of the two mounting holes at the head and tail ends that the calibration laser can pass through, which is the farthest end from each other, and use it as the reference axis.

[0069] According to the hole diameter and hole depth of the installation hole to be tested, a wedge-shaped prism with a suitable diameter and a slope angle of 45° is selected, and its mirror surface is directed toward the emission direction of the detection laser.

[0070] The detection laser emitted by the laser displacement sensor 103 is controlled to hit the wedge-shaped prism and reflect it. At the same time, the wedge-shaped prism is rotated so that the detection laser reflected by the wedge-shaped prism can be received by the laser displacement sensor 103. The depth of the wedge-shaped prism inserted into the mounting hole is adjusted until the detection laser reflected by the wedge-shaped prism cannot be detected. Thus, the distance between the point corresponding to the angle of the mounting hole to be measured and the reference axis can be calculated by the distance moved by the wedge-shaped prism relative to the original position. At the same time, the detection laser reflected by the wedge-shaped prism can be rotated by rotating the wedge-shaped prism, and matched with the calculation result of the aforementioned depth adjustment, it is fitted into a cross-sectional circle of a quasi-circular structure through a preset existing program, and the coaxiality is determined by calculating the deviation between the geometric center of the cross-sectional circle and the reference line.

[0071] Furthermore, cross-sectional circle fitting can be performed on both sides of any mounting hole, so as to more accurately determine the coaxial offset thereof.

[0072] At the same time, the coaxiality error of a group of mounting holes should be controlled below 2 mm. When it is detected that the coaxiality error exceeds a certain range, it can be adjusted manually using relevant equipment to keep the coaxiality error of the corresponding mounting holes below 2 mm.

[0073] The device for measuring the coaxiality of the mounting hole using the reflection of the laser displacement sensor 103 is:

[0074] A detection laser emitting device, a detection laser receiving device, a calibration laser emitting device, a calibration laser receiving device, a wedge-shaped prism, a detection mechanical arm, a calibration mechanical arm, and an adjustment mechanical arm. The detection mechanical arm is used to adjust the positions of the detection laser emitting device and the detection laser receiving device. The calibration mechanical arm is used to adjust the positions of the calibration laser emitting device and the calibration laser receiving device. The wedge-shaped prism is installed on the adjustment mechanical arm.

[0075] This embodiment realizes the measurement of the inner surface cross section of the small hole through reflection measurement of a 45° wedge prism combined with mirror imaging, thereby overcoming the interference problem caused by the large size of the traditional high-speed laser displacement sensor 103 .

[0076] At the same time, 45° wedge prisms of different sizes can be selected to adjust the measurement range, which has a wide range of application value.

[0077] The system is highly integrated and automated. The sensors used can directly collect measurement data for processing by computers, which increases the scale of original data and thus improves the accuracy of measurement data. The motion control part uses motion control cards as the core target workpiece of the control part, which improves the accuracy of the motor motion link, facilitates deployment and application, and facilitates subsequent maintenance and analysis by detection personnel. At the same time, the computer can be used to mark the parts that do not meet the preset standards.

[0078] Before measuring the coaxiality of the mounting hole, the verticality of the hole inside the mounting hole can be detected by a laser sensor, so that the target workpiece of the beam can penetrate or be inserted into the mounting hole.

[0079] There are two types of beam mounting holes: one is the verticality detection of flat mounting holes, and the other is the verticality detection of curved mounting holes.

[0080] The plane mounting hole directly passes through the high-precision laser sensor, which projects the laser beam vertically to the center of the mounting hole. The verticality of the hole is calculated by measuring the reflection position of the laser beam on the hole wall and combining it with the distance between the sensor and the hole.

[0081] The curved mounting hole can be measured by using the hole circumference normal vector on the surrounding surface of the mounting hole to be tested:

[0082] According to the surface data, the theoretical position and direction of the mounting hole are determined. The actual position and direction of the mounting hole are measured by a laser sensor, and compared with the theoretical value to evaluate the verticality of the hole. This method is suitable for complex surfaces and mounting hole detection with high precision requirements.

[0083] Among them, in the process of measuring the verticality of the mounting hole located on the curved surface, the accurate acquisition of the normal vector of the surface around the hole is the key to accurately measuring the verticality of the assembly hole. Since the normal vector direction of the mounting hole changes with the change of the curved surface shape of the target workpiece, when the laser displacement sensor 103 is used to measure the verticality of the mounting hole, the surface normal vector deviation has a significant impact on the measurement of the hole verticality;

[0084] A commonly used method for measuring the normal vector at any point on the target workpiece surface is the triangular patch method, which uses several laser displacement sensors 103 to project lasers to the surface area to be measured, and a small triangular plane composed of several laser points on the surface approximates the deformed plane to obtain the normal vector at the surface to be measured.

[0085] However, the measurement accuracy of this method is affected by the curvature of the surface to be measured and the area of ​​the small triangular plane. When the curvature of the surface to be measured is constant, the larger the area of ​​the small triangular plane, the lower the measurement accuracy and precision of the surface normal vector, which in turn leads to misjudgment of the quality of aviation products.

[0086] Reference Figure 3-Figure 5 In this embodiment, two laser displacement sensor 103 mounting brackets of different sizes are provided to be applicable to different curved surface conditions; the laser displacement sensor 103 mounting bracket includes a wide side mounting bracket and a long side mounting bracket;

[0087] Among them, the wide side mounting bracket and the long side mounting bracket are both equilateral triangle structures, and both can be adjusted to install three laser sensors. Among them, the three side panels 101 of the wide side mounting bracket are surrounded into a triangle, and a beam 102 is installed at the connection position of any two side panels 101. The side of any beam 102 away from the side panel 101 is connected to the central axis of the bracket, and the long sides of the laser displacement sensor 103 are installed on the side of the clockwise moving direction of the beam 102.

[0088] The long side mounting bracket includes three side panels 101, which are L-shaped. The horizontal parts of the side panels 101 are connected in sequence to form a triangular frame, and the vertical parts of the side panels 101 are convenient for the staff to control the bracket and the laser displacement sensor 103 on the bracket. The long sides of the laser displacement sensor 103 are detachably mounted on the inner side wall of the side by bolts.

[0089] The selection method for using the wide side mounting bracket and the long side mounting bracket is as follows:

[0090] According to the diameter of the mounting hole, with a certain point on the central axis of the mounting hole as the center, determine the size of the curved surface around the mounting hole, the curved surface is used to obtain the normal vector of the curved surface around the mounting hole, wherein the diameter of the mounting hole is smaller than the size of the curved surface around the mounting hole, and the size of the curved surface around the mounting hole is smaller than twice the diameter of the mounting hole;

[0091] The vertical distances from the laser line projected by the laser displacement sensor 103 to the long side and the short side of the outer contour of the laser displacement sensor 103 are measured, recorded as L and H respectively, and L / H is calculated.

[0092] The relative position relationship between the long side of the outer contour of the laser displacement sensor 103 and the bracket structure of the laser displacement sensor 103 is preliminarily determined according to the L / H value: when L / H≥0.9, the long side of the outer contour of the laser displacement sensor 103 is parallel to the length direction of the bracket crossbeam 102, and the plane formed by the laser line and the central axis of the bracket is perpendicular to the wide side of the outer contour of the laser displacement sensor 103; when L / H≤1.1, the long side of the outer contour of the laser displacement sensor 103 is parallel to the length direction of the bracket side plate 101, and the plane formed by the laser line and the central axis of the bracket is perpendicular to the long side of the outer contour of the laser displacement sensor 103; when 0.9≤L / H≤1.1, the wide side mounting bracket and the long side mounting bracket are used to measure the range to be measured respectively, and the smaller value of the triangle area is used as the small triangle plane area, thereby improving the measurement accuracy.

[0093] In actual use, the two laser displacement sensor 103 brackets are adjusted to the mounting holes at corresponding positions by a mechanical arm for detection.

[0094] At the same time, the parts that do not meet the preset standards can be marked by computer coordination to facilitate subsequent repair or adjustment of the mounting holes that do not meet the standards.

[0095] Furthermore, before the laser profilometer method is used to detect the mounting holes of the present embodiment, they can be flushed with a high-pressure water gun and then pre-treated with absorbent cotton and sanding paper towels to clean the mounting holes and their surrounding areas as much as possible to remove oil, impurities and rust, thereby reducing the error in hole verticality detection.

[0096] S5. Manual welding: Manual welding is performed on the blind spots of mechanical welding and the parts that do not meet the preset standards as detected by the first welding quality inspection.

[0097] This embodiment can weld the dead angle existing in mechanical welding on the basis of mechanical welding, and can also perform secondary welding on the welding parts that fail the first welding quality inspection, thereby enhancing the stability of welding.

[0098] Optionally, in this embodiment, spot welding is performed on the beam after being flattened at intervals of 150-200 mm.

[0099] Optionally, during manual welding and mechanical welding in this embodiment, a suction device can be provided to collect the generated toxic gases to prevent workers from inhaling toxic gases, thereby improving safety. The suction device can use a vacuum pump.

[0100] S6. Second welding quality inspection: Carry out quality inspection on the entire beam after welding to ensure that the weld quality is within the required range.

[0101] Specifically, the second welding quality inspection of this embodiment includes:

[0102] Comprehensive visual inspection: Perform a detailed visual inspection of the entire welding target workpiece, including the weld and heat-affected zone. Check the integrity and smoothness of the weld. Record any visible defects such as cracks, deformation, and pores.

[0103] Dimension and assembly accuracy inspection: Use measuring tools to re-inspect the dimensions of the entire target workpiece to ensure that it meets the design requirements. Check the assembly accuracy of the target workpiece, such as parallelism, verticality, and coaxiality.

[0104] Nondestructive testing: X-ray or ultrasonic testing of welds to find defects inside the welds. Magnetic particle testing or penetration testing of key parts to find surface or near-surface defects.

[0105] Functional testing: According to the use requirements of the target workpiece, necessary functional tests are carried out, such as pressure test, sealing test, and vibration test.

[0106] This allows the performance and reliability of the welding target workpiece to be evaluated under actual usage conditions.

[0107] Optionally, before the second welding quality inspection is performed in this embodiment, Hawking welding stress relief equipment can be used to perform stress relief treatment on the welded truck beam to reduce welding residual stress and improve the fatigue strength and corrosion resistance of the welded joint.

[0108] Among them, the Hawken energy welding stress relief equipment uses a high-power Hawken energy impact tool to impact the surface of a metal object at a frequency of more than 20,000 times per second. Under the high frequency, high efficiency and high focus of Hawken energy, the metal surface produces a large compressive plastic deformation, thereby eliminating welding residual stress.

[0109] Reference Figure 2 , Figure 2 A flow chart of a multi-stage welding system for a truck beam provided by an embodiment of the present invention;

[0110] A multi-stage welding system for a truck beam in this embodiment includes: a pretreatment module 1, an assembly clamping module 2, a mechanical welding module 3, a first welding quality detection module 4, a manual welding device 5 and a second welding quality detection module 6.

[0111] Among them, the pretreatment module 1 is a device used to grind and shot blast the target workpiece surface of the beam, and the welding quality is ensured by cleaning the surface of the target workpiece of the beam and removing oil, rust and oxide.

[0112] Optionally, the pretreatment module 1 of this embodiment can use a sandblasting machine and a cleaning machine. The sandblasting machine is used to sandblast the surface of the truck beam to remove oil, rust and oxides; the cleaning machine uses a high-pressure water gun or chemical cleaning agent to deeply clean the truck beam to ensure that the surface is clean and free of impurities.

[0113] The assembly clamping module 2 is used to accurately assemble the pre-processed truck beam according to the design requirements and fix it with appropriate clamping devices to ensure stability and accuracy during the welding process.

[0114] Optionally, the assembly and clamping module 2 of this embodiment may include a precision assembly table and a clamping device.

[0115] The precision assembly table is a high-precision assembly platform that ensures the precise assembly of the truck beam components. The clamping device uses electric or pneumatic clamping to fix the truck beam to prevent movement or deformation during welding.

[0116] Optionally, a flux application module is further provided between the assembly clamping module 2 and the mechanical welding module 3, and the flux application module sprays flux evenly on the area to be welded to improve welding quality and efficiency.

[0117] Optionally, the flux application module of this embodiment may include a spray device and a flux storage tank.

[0118] Among them, the spray device uses high-pressure spray technology to evenly spray the flux on the area to be welded on the truck beam.

[0119] The flux tank is used to store the flux and ensure a continuous supply to the spray unit.

[0120] Mechanical welding module 3 uses mechanical welding equipment to perform preliminary welding on the assembled truck beam to form a basic welded structure.

[0121] Optionally, the mechanical welding module 3 of this embodiment may include a mechanical welding robot and a double-head spot welding machine.

[0122] Among them, the mechanical welding robot has high-precision and automated welding functions, and can perform precise welding according to preset programs.

[0123] The double-head spot welding machine is specially designed for truck beam welding and has efficient and precise welding capabilities.

[0124] The first welding quality inspection module 4 performs quality inspection on the weld after mechanical welding to determine whether the size and strength of the weld meet the required standards.

[0125] Optionally, the first welding quality inspection module 4 of this embodiment mainly includes a laser rangefinder, a three-coordinate measuring machine, and an angle measuring instrument. These tools should have the characteristics of high precision, high stability, and easy operation.

[0126] The manual welding module performs manual fine welding, modification and reinforcement of welds based on mechanical welding.

[0127] Among them, manual welding mainly uses spot welding, and welding tools can use welding guns and welding rods, etc., for manual welding.

[0128] At the same time, some protective equipment, such as welding masks and gloves, can be set up to ensure the safety of operators.

[0129] Optionally, a Hawken energy stress relief processing module is also provided between the manual welding equipment 5 and the second welding quality inspection module 6 of this embodiment. The Hawken energy stress relief processing module uses the Hawken energy welding stress relief equipment to perform stress relief treatment on the welded truck beam to reduce welding residual stress and improve the fatigue strength and corrosion resistance of the welded joint.

[0130] Among them, the Hawken energy welding stress relief equipment uses a high-power Hawken energy impact tool to impact the surface of a metal object at a frequency of more than 20,000 times per second. Under the high frequency, high efficiency and high focus of Hawken energy, the metal surface produces a large compressive plastic deformation, thereby eliminating welding residual stress.

[0131] The second welding quality inspection module 6 is used to carry out overall quality inspection on the truck beam after Hawken stress relief treatment, including comprehensive appearance inspection, size and assembly accuracy inspection, non-destructive testing and functional testing.

[0132] Among them, comprehensive appearance inspection, size and assembly accuracy inspection include visual inspection and measurement tool inspection, the measurement tools include:

[0133] Such as laser rangefinders, three-coordinate measuring machines and angle measuring machines, etc., are used to measure and inspect the size and assembly accuracy of truck beams.

[0134] Non-destructive testing includes:

[0135] X-ray inspection equipment is used to detect whether there are defects inside the weld, where defects include cracks and pores.

[0136] Ultrasonic testing equipment, used in conjunction with X-ray testing equipment, can further improve the accuracy of detecting internal defects in welds.

[0137] Magnetic particle testing equipment is used to detect whether there are crack defects on the surface of truck beams.

[0138] Penetrant testing equipment is used to detect tiny defects such as pinholes on the surface of truck beams.

[0139] Functional testing includes:

[0140] Pressure testing equipment, which performs pressure tests on truck beams to check their overall strength and stability.

[0141] The multi-stage welding system for truck beams can achieve efficient and high-quality welding of truck beams through the coordinated work of various modules. Each module is equipped with professional equipment and tools to ensure the stability and accuracy of the welding process.

[0142] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. It is obvious to those skilled in the art that the present application is not limited to the details of the above exemplary embodiments, and the present application can be implemented in other specific forms without departing from the spirit or basic features of the present application.

Claims

1. A multi-stage welding method for a truck beam, characterized in that: The following steps are involved: Pretreatment: grinding, drilling and shot blasting the target workpiece of the beam; Assembly clamping: Place the pre-processed target workpiece at the preset position through the driving device; Mechanical welding: Use mechanical welding equipment to perform preliminary welding on the assembled target workpiece to form a basic welding structure; The first welding quality inspection: inspect the weld of the target workpiece after mechanical welding to determine whether the size and strength of the weld meet the standards; Manual welding: Manual welding is performed on the blind spots of mechanical welding and the parts that do not meet the preset standards after the first welding quality detection; Second welding quality inspection: The entire beam after welding will be inspected to ensure that the weld quality is within the required range.

2. The multi-stage welding method for a truck beam according to claim 1, characterized in that: The method of using mechanical welding equipment to perform preliminary welding on the assembled target workpiece to form a basic welding structure also includes: Use a spray device to evenly spray the flux on the area to be soldered.

3. The multi-stage welding method for a truck beam according to claim 1, characterized in that: The step of using mechanical welding equipment to perform preliminary welding on the assembled target workpiece to form a basic welding structure includes: Use welding equipment to perform mechanical welding according to the welding path planning preset by the controller.

4. The multi-stage welding method for a truck beam according to claim 4, characterized in that: Real-time monitoring of welding temperature and stress changes during mechanical welding.

5. The multi-stage welding method for a truck beam according to claim 1, characterized in that: The step of detecting the weld of the target workpiece after mechanical welding to determine whether the size and strength of the weld meet the requirements includes: The assembly accuracy of each target workpiece of the beam is measured using a measuring tool, wherein the assembly accuracy includes detecting parallelism, perpendicularity and coaxiality.

6. The multi-stage welding method for a truck beam according to claim 1, characterized in that: The beam after welding is inspected as a whole to ensure that the weld quality is within the required range, including: Dimension and assembly accuracy inspection: Check the assembly accuracy of the target workpiece, where the assembly accuracy includes parallelism, verticality and coaxiality; Nondestructive testing: X-ray or ultrasonic testing of welds to detect defects inside the welds, and magnetic particle testing or penetration testing of key areas to detect surface or near-surface defects.

7. The multi-stage welding method for a truck beam according to claim 1, characterized in that: The above-mentioned quality inspection of the entire beam after welding is carried out to ensure that the quality of the weld is within the required range, including: Use Hawken welding stress relief equipment to relieve stress on the target workpiece after welding.

8. The multi-stage welding method for a truck beam according to claim 1, characterized in that: Before inspecting the weld of the target workpiece after mechanical welding to determine whether the size and strength of the weld meet the standards, the method includes: The coaxiality of the mounting hole groups of the beam located on the same axis is measured by a measuring device.

9. The multi-stage welding method for a truck beam according to claim 8, characterized in that: The measuring device comprises a laser displacement sensor assembly and a prism arranged at the front end of the laser displacement sensor; The step of measuring the coaxiality of the mounting hole groups of the beam located on the same axis by a measuring device comprises the following steps: Adjust the laser displacement sensor assembly to emit and make the calibration laser penetrate through several mounting holes to be measured and pass through the center positions of the first and last mounting holes, with the calibration laser as the reference axis; Insert the prism into the inner side of the mounting hole through which any axis passes, and make the rotation axis of the prism coaxial with the calibration axis; For any mounting hole to be measured, a prism is extended into the mounting hole to be measured, and the rotation axis of the prism is made to coincide with the reference axis; the laser displacement sensor assembly is controlled to emit a measuring laser, and the prism is controlled to rotate along the rotation axis to obtain measurement data formed by the measuring laser at the receiving end of the laser displacement sensor assembly; Repeat the aforementioned steps of measuring any of the mounting holes to be tested for the remaining mounting holes to be tested, so as to obtain measurement data of each mounting hole to be tested; Based on the measurement data of each mounting hole to be measured, the coaxiality errors of several mounting holes to be measured are obtained.

10. A system for a multi-stage welding method for a truck beam according to any one of claims 1 to 9, characterized in that: include: Pre-treatment module: used for grinding, drilling and shot blasting the target workpiece of the beam; Assembly clamping module: used to place the pre-processed target workpiece at a preset position through a driving device; Mechanical welding module: used to perform preliminary welding on the assembled target workpieces using mechanical welding equipment to form a basic welding structure; The first welding quality inspection module is used to inspect the weld of the target workpiece after mechanical welding to determine whether the size and strength of the weld meet the standards; Manual welding equipment: used for manual welding of blind spots in mechanical welding and parts that do not meet the preset standards after the first welding quality detection; Second welding quality inspection module: used to inspect the quality of the entire beam after welding to ensure that the weld quality is within the required range.

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