Manufacturing method of welded components and welded components

Abstract

This invention discloses a method for manufacturing welded components and the welded components themselves. The method includes: assembling and cutting each splicing segment separately to obtain a unit assembly blanking plate for each splicing segment; performing pre-welding processing on the splicing ends of each unit assembly blanking plate; welding the splicing ends of all unit assembly blanking plates to obtain a component assembly blanking plate; dividing the component assembly blanking plate into at least two welded components, thereby enabling at least two separate short welds to be connected into a single long weld. Pre-welding processing, weld welding, and weld flaw detection can all be continuously automated, significantly improving production efficiency. Furthermore, the assembly production reduces the occurrence of arc initiation and termination, thus avoiding end welding defects. In addition, the assembly production also significantly reduces the aspect ratio of the welded component assembly blanking plate, increases rigidity, and reduces welding deformation.

Description

Technical Field

[0001] This invention belongs to the field of welded component manufacturing technology, and particularly relates to a method for manufacturing welded components and welded components. Background Technology

[0002] In recent years, construction machinery and equipment have been developing towards longer and lighter designs. For example... Figure 1 and Figure 2 As shown, to minimize the weight of structural components, some components are designed as ultra-long bent parts welded together from multiple sections of high-strength steel plates of unequal thickness (section 1, section 2, section 3, section 4, and section 5). Because the stress is greater at both ends and less in the middle, the ends are typically thicker plates, and the middle is thinner. The traditional manufacturing method for this type of structural component involves separately cutting and bending each section of plate, and then welding them together. The specific steps are as follows:

[0003] 1) Segments 1, 2, 3, 4 and 5 are CNC cut and blanked (including holes);

[0004] 2) Mill the butt weld bevels for sections 1, 2, 3, 4 and 5 respectively;

[0005] 3) Segments 2, 3, and 4 are each CNC bent;

[0006] 4) Segments 1, 2, 3, 4 and 5 are spliced ​​together to form the shape, and require fetal membranes for positioning.

[0007] 5) Use MAG welding (Metal Active Gas Arc Welding) to perform butt welding at the splice position, with a welding bevel of 60°, and use a backing plate for double-sided welding;

[0008] 6) Inspection: including dimensional inspection and weld flaw detection.

[0009] The traditional manufacturing methods described above have the following problems:

[0010] 1) Each splice weld is relatively short, making it difficult to achieve efficient beveling, welding, and flaw detection for individual parts;

[0011] 2) The two ends of the splice weld are the welding start and end areas, making it difficult to control the welding quality and easily causing defects such as arc craters and lack of fusion;

[0012] 3) High-strength steel plates have high strength and high elastic modulus, resulting in a large springback when bent and poor bending accuracy. This can easily lead to problems such as misalignment, misalignment in thickness or width, and uneven gaps when splicing different sections.

[0013] 4) Cutting before welding: Narrow and long strip parts are prone to shrinkage, bending, warping and other deformations after welding. The relative position and size error of each hole is large, and subsequent processes often require trimming.

[0014] 5) Construction machinery is usually produced in small batches with many varieties. The length, bending position, bending angle and bending radius of each variety of parts are different. Different molds are required for welding, which makes production organization difficult.

[0015] 6) Uneven splicing gaps require backing plates for welding assistance, and only traditional MAG welding can be used, with a large amount of filler wire. Summary of the Invention

[0016] In view of the above-mentioned defects or deficiencies, the present invention provides a method for manufacturing welded components and welded components, aiming to solve at least one of the above-mentioned technical problems.

[0017] To achieve the above objectives, the first aspect of the present invention provides a method for manufacturing welded components, wherein the method includes:

[0018] Each splicing segment is combined and cut separately to obtain a unit combination cutting plate for each splicing segment, wherein the unit combination cutting plate has at least two identical splicing segments arranged along the width direction;

[0019] Each unit assembly blank plate is pre-welded by processing the splicing ends.

[0020] Weld the splicing ends of all unit assembly blanking plates separately to obtain the component assembly blanking plate;

[0021] The component assembly blanking plate is divided into at least two welded components.

[0022] In one embodiment of the present invention, dividing the component assembly blanking plate into at least two weldable components includes:

[0023] On the component assembly blanking plate, a first cutting operation is performed on the long side of each welded component extending along the length direction, wherein the first cutting operation is performed from the middle position of the long side towards both ends;

[0024] Perform a second trimming operation on the remaining short side of each welded component to divide it into at least two welded components.

[0025] In one embodiment of the present invention, performing a first trimming operation on the long side of each welded component along its length direction on the component assembly blanking plate includes:

[0026] The outer contour of the component assembly blanking plate is cut to obtain the component assembly contour plate. The component assembly contour plate has at least two welded components arranged along the width direction. Any two adjacent welded components are arranged with their long sides collinear on the component assembly contour plate. The outer contour of the component assembly contour plate includes the contours of the two outermost long sides of the at least two welded components.

[0027] Perform the first trimming operation on all long sides that are collinearly arranged on the component assembly outline plate.

[0028] In one embodiment of the present invention, performing a first trimming operation on all long sides collinearly arranged on the component assembly outline plate includes:

[0029] Select one of the long sides that are collinearly arranged on the component assembly outline plate and center it to perform the first cutting operation to obtain two component segmentation plates;

[0030] If there are still at least two welded components in the component partition plate, continue to perform the first cutting operation on the long side set in the center of the component partition plate until only one welded component remains.

[0031] In one embodiment of the present invention, before performing the first trimming operation on the long side of each welded component along its length direction on the component assembly blanking plate, the following is further included:

[0032] The component assembly blanking plate is cut with holes, and the cutting operation starts from the center of the component assembly blanking plate and proceeds outwards in sequence.

[0033] In one embodiment of the present invention, the pre-welding processing of the splicing ends of each unit assembly blanking plate includes:

[0034] The thicker end of the two splicing ends to be welded is chamfered to make the thickness of the two splicing ends the same at the weld joint.

[0035] When the thickness of the thin-plate end of the two welded ends is greater than the preset bevel opening thickness, a bevel with a preset bevel angle is opened on the chamfering side of the two welded ends.

[0036] In one embodiment of the present invention, the length of the chamfering process is set to 4 to 5 times the difference in thickness between the two splicing ends.

[0037] In one embodiment of the present invention, the pre-set bevel thickness is 8mm.

[0038] In one embodiment of the present invention, the preset bevel angle is 30° to 45°.

[0039] In one embodiment of the present invention, the splicing ends of all unit assembly blanking plates are welded together to obtain the component assembly blanking plate comprising:

[0040] Plasma composite welding or laser composite welding is used to perform single-sided welding of the welding gap between the two splicing ends from the chamfering side to obtain a component assembly blank plate with double-sided formed welds.

[0041] In one embodiment of the present invention, the method further includes the following steps before dividing the component assembly blanking plate into at least two weldable components:

[0042] The welds on the component assembly blanking plate are subjected to flaw detection.

[0043] In one embodiment of the present invention, each splicing segment is assembled and cut to obtain a unit assembly cutting plate for each splicing segment, comprising:

[0044] Based on the width dimensions of the raw materials, the splicing segment with the largest blanking width requirement in the welded components is designed to obtain the first layout size. The width of the first layout size can accommodate at least two corresponding splicing segments to be arranged along the width direction.

[0045] The remaining splicing segments in the welded components are arranged according to the number of splicing segments in the first layout size, so as to obtain the second layout size of the remaining splicing segments respectively;

[0046] Cut the material according to the first and second layout dimensions to obtain the unit combination cutting board for each splicing segment.

[0047] In one embodiment of the present invention, after dividing the component assembly blanking plate into at least two weldable components, the method further includes:

[0048] The welded components are bent using a four-roll plate bending machine that includes an upper roll mechanism, a lower roll mechanism, a left roll mechanism, and a right roll mechanism. The vertical and / or horizontal positions of the left roll mechanism and / or the right roll mechanism are adjustable.

[0049] To achieve the above objectives, a second aspect of the present invention provides a welded component, wherein the welded component is manufactured using the welded component manufacturing method described above.

[0050] Through the above technical solution, the method for manufacturing welded components provided by the present invention has the following beneficial effects:

[0051] When using the above-described method for manufacturing welded components, because at least two units are combined for cutting each splice segment, and the combined cutting unit plates are first welded together before the welded component is divided, it is possible to connect what would otherwise be at least two separate short welds into a single long weld. Pre-welding processing (e.g., beveling), weld welding, and weld inspection can all be continuously automated, significantly improving production efficiency. Simultaneously, combined production reduces the occurrence of arc initiation and termination, thus avoiding end welding defects. Furthermore, combined production can significantly reduce the aspect ratio of the welded component assembly cutting plates, increase rigidity, and reduce welding deformation.

[0052] Other features and advantages of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0053] The accompanying drawings are provided to further illustrate embodiments of the present invention and form part of the specification. They are used together with the following detailed description to explain the embodiments of the present invention, but do not constitute a limitation thereof. Those skilled in the art can obtain other drawings based on the structures shown in these drawings without any inventive effort. In the drawings:

[0054] Figure 1 This is a structural schematic diagram of a structural component from one perspective in the background art;

[0055] Figure 2 This is a structural schematic diagram of a structural component from another perspective in the background technology;

[0056] Figure 3 This is a flowchart of a method for manufacturing welded components according to an embodiment of the present invention;

[0057] Figure 4 This is a schematic diagram of the structure of the first unit combined feeding plate according to an embodiment of the present invention;

[0058] Figure 5 This is a schematic diagram of the structure of the component assembly blanking plate according to an embodiment of the present invention;

[0059] Figure 6 This is a schematic diagram of a structure with chamfered edges processed at two splicing ends according to an embodiment of the present invention;

[0060] Figure 7 This is a schematic diagram of a structure in which two splicing ends are processed with chamfers and bevels according to an embodiment of the present invention;

[0061] Figure 8 This is a schematic diagram of a structure for cutting holes in a component assembly blanking plate according to an embodiment of the present invention;

[0062] Figure 9 This is a schematic diagram of the structure for performing step S410 according to an embodiment of the present invention;

[0063] Figure 10 This is a schematic diagram of the structure for performing step S420 according to an embodiment of the present invention;

[0064] Figure 11 This is a schematic diagram of the structure preceding step S430 according to an embodiment of the present invention;

[0065] Figure 12 This is a schematic diagram of the structure following the execution of step S430 according to an embodiment of the present invention;

[0066] Figure 13 This is a schematic diagram of the structure for performing step S440 according to an embodiment of the present invention;

[0067] Figure 14 This is a schematic diagram of a welded component undergoing a positive bending operation according to an embodiment of the present invention;

[0068] Figure 15 This is a schematic diagram of a welded component undergoing a reverse bending operation according to an embodiment of the present invention.

[0069] Explanation of reference numerals in the attached figures:

[0070] 10. Splicing segment 10a. First splicing segment.

[0071] 11. Chamfer

[0072] 20-unit combined blanking plate 20a First unit combined blanking plate

[0073] 20b Second unit combined cutting plate; 20c Third unit combined cutting plate

[0074] 20d Fourth Unit Combined Cutting Plate; 20e Fifth Unit Combined Cutting Plate

[0075] 30 Component assembly blanking plate; 40 Component assembly outline plate

[0076] 50 Welded components 51 Long side

[0077] 52 Short side 53 Process hole

[0078] 61 Upper roller mechanism 62 Lower roller mechanism

[0079] 63 Left roller mechanism 64 Right roller mechanism Detailed Implementation

[0080] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0081] The manufacturing method of the welded component and the welded component of the present invention are described below with reference to the accompanying drawings.

[0082] like Figures 3 to 5 as well as Figure 13 As shown, the present invention provides a method for manufacturing welded components, wherein the method for manufacturing welded components includes:

[0083] Step S100: Each splicing segment 10 is combined and cut to obtain a unit combination cutting plate 20 for each splicing segment 10, wherein the unit combination cutting plate 20 has at least two identical splicing segments 10 arranged along the width direction.

[0084] Understandably, the present invention will be used in the context of... Figure 1 and Figure 2 Taking the structural component shown as an example of a welded component 50 to be produced, the segments 1-5 of the structural component are respectively designated as five splicing segments 10 in the welded component 50. The five splicing segments 10 are designated as the first splicing segment 10a, the second splicing segment, the third splicing segment, the fourth splicing segment, and the fifth splicing segment from left to right. In the prior art, each splicing segment 10 is cut to the size of one splicing segment 10. However, in this invention, each splicing segment 10 is combined during the cutting process. That is, the unit combination cutting plate 20 obtained by cutting can have at least two identical splicing segments 10 arranged along the width direction, including the first splicing segment 10. The unit assembly blanking plate 20 of type a can be designated as the first unit assembly blanking plate 20a, the unit assembly blanking plate 20 with the second splicing segment can be designated as the second unit assembly blanking plate 20b, the unit assembly blanking plate 20 with the third splicing segment can be designated as the third unit assembly blanking plate 20c, the unit assembly blanking plate 20 with the fourth splicing segment can be designated as the fourth unit assembly blanking plate 20d, and the unit assembly blanking plate 20 with the fifth splicing segment can be designated as the fifth unit assembly blanking plate 20e. The arrangement along the width direction is to enable the unit assembly blanking plates 20 with different splicing segments 10 to be welded along the length direction.

[0085] Step S200: Perform pre-welding processing on the splicing ends of each unit assembly blanking plate 20.

[0086] Specifically, if the thicknesses of two adjacent splicing segments 10 are different, in order to achieve splicing, the splicing end of the thicker one can be chamfered 11 before welding so that the end face thickness is equal to that of the thinner one, thus achieving a thickness transition. In addition, bevels can be processed on the two adjacent splicing ends to ensure that the welding is in place.

[0087] In step S300, the splicing ends of all unit assembly blanking plates 20 are welded together to obtain component assembly blanking plates 30.

[0088] Specifically, the splicing end of the first unit assembly blanking plate 20a can be welded to the left-facing splicing end of the second unit assembly blanking plate 20b, the right-facing splicing end of the second unit assembly blanking plate 20b can be welded to the left-facing splicing end of the third unit assembly blanking plate 20c, the right-facing splicing end of the third unit assembly blanking plate 20c can be welded to the left-facing splicing end of the fourth unit assembly blanking plate 20d, and the right-facing splicing end of the fourth unit assembly blanking plate 20d can be welded to the splicing end of the fifth unit assembly blanking plate 20e. The order of the above welding is not limited, as long as the final component assembly blanking plate 30 is obtained.

[0089] Step S400: Divide the component assembly blanking plate 30 into at least two weldable components 50.

[0090] When using the above-described method for manufacturing welded components, since at least two components are combined for cutting each splice segment 10, and the combined cutting unit plates 20 are welded together before the welded component 50 is divided, at least two separate short welds can be connected into a single long weld. Pre-welding processing (e.g., beveling), weld welding, and weld inspection can all be continuously automated, significantly improving production efficiency. Simultaneously, combined production reduces the occurrence of arc initiation and termination, thus avoiding end welding defects. Furthermore, combined production can significantly reduce the aspect ratio of the welded component assembly cutting plate 30, increase rigidity, and reduce welding deformation.

[0091] It should be noted that the welded component 50 includes, but is not limited to, the manufacture of multiple welded components due to different thicknesses of each segment. However, the manufacturing method of the welded component provided by the present invention is particularly applicable to the manufacture of multiple welded components 50 with different thicknesses.

[0092] In one embodiment of the present invention, step S400, dividing the component assembly blanking plate 30 into at least two weldable components 50, includes:

[0093] Step S405: Perform a first cutting operation on the long side 51 of each welded component 50 extending along the length direction on the component assembly blanking plate 30, wherein the first cutting operation is performed from the middle position of the long side 51 towards both ends.

[0094] Specifically, each welded component 50 has a long side 51 extending along its length. The long side 51 of each welded component 50, arranged on the component assembly blanking plate 30, can be cut first. When cutting each long side 51, cutting can begin from the middle and proceed towards both ends. Firstly, since the middle is a thin plate and the ends are thick plates, the first cut position has greater constraint and less deformation, while the later cut position has less constraint and greater deformation. Therefore, cutting the easily deformable thin plate position first, with the thick plates at both ends constraining it, results in less deformation, followed by cutting the less deformable thick plate positions at both ends. Secondly, cutting from the middle to both ends allows the cutting heat to be dispersed from the middle to both ends, resulting in less heat accumulation and less deformation compared to cutting sequentially from left to right. It should be noted that the starting point of the cut is not necessarily the exact center of the entire long side 51; the middle position is defined relative to the ends and can be any point on the long side 51 of the middle splicing segment 10.

[0095] In step S440, a second trimming operation is performed on the remaining short side 52 of each welded component 50 to divide it into at least two welded components 50.

[0096] More specifically, such as Figure 13 As shown, after all the long sides 51 of each welded component 50 have been cut, if there are any remaining short sides 52, a second cutting operation can be performed on the remaining short sides 52 to obtain at least two welded components 50. It should be noted that when setting up the layout for the first cutting operation on the long sides 51 of the welded component 50, if the end of the welded component 50 is a smooth arc transition, the long side 51 of the layout can extend to the end, and some of the short sides 52 of the welded component 50 can be cut in the first cutting operation.

[0097] In one embodiment of the present invention, step S405, performing a first trimming operation on the long side 51 of each welded component 50 along the length direction on the component assembly blanking plate 30, includes:

[0098] Step S410: Cut the outer contour of the component assembly blanking plate 30 to obtain the component assembly contour plate 40. The component assembly contour plate 40 has at least two welded components 50 arranged along the width direction. Any two adjacent welded components 50 are arranged collinearly on the component assembly contour plate 40 with their long sides 51. The outer contour of the component assembly contour plate 40 includes the contours of the two outermost long sides 51 of the at least two welded components 50.

[0099] Step S415: Perform the first trimming operation on all long sides 51 that are collinearly arranged on the component assembly outline plate 40.

[0100] Specifically, arranging any two adjacent welded components 50 on the component assembly outline plate 40 with their long sides 51 collinear can reduce the number of cuts required for the long sides 51, thereby improving production efficiency. It should be noted that each welded component 50 has two long sides 51, one above the other, and the shape of these two long sides 51 can be either entirely horizontal straight lines or partially horizontal straight lines. If they are entirely horizontal straight lines, the long sides 51 of any two adjacent welded components 50 can be completely collinear when arranged on the component assembly outline plate 40; if they are partially horizontal straight lines, such as… Figure 1 and Figure 2 When any two adjacent welded components 50 are arranged on the component assembly outline plate 40, they can only be arranged in horizontal straight lines. The remaining long sides 51 cannot be arranged in a collinear manner. Therefore, when performing the first cutting operation, the first cutting operation can be performed on the long side 51 of one of the welded components 50. Since it is collinear with the long side 51 of the other welded component 50, the cutting of part of the long side 51 of the other welded component 50 can also be completed. The remaining long side 51 of the other welded component 50 can be completed together with the short side 52 in the second cutting operation.

[0101] Furthermore, the component assembly blanking plate 30 is formed by splicing at least two unit assembly blanking plates 20 along the length direction. Each unit assembly blanking plate 20 can be a square plate during blanking. After splicing to form the component assembly blanking plate 30, at least two welded components 50 can be divided and arranged on the component assembly blanking plate 30. Since any two adjacent welded components 50 can be arranged collinearly on the component assembly outline plate 40 with their long sides 51 during arrangement, all welded components 50 on the component assembly blanking plate 30 can be arranged together. Therefore, the outermost contour of all the welded components 50 after arrangement can be cut to obtain the component assembly outline plate 40. Specifically, it can be done as follows: Figure 9 As shown, Figure 9 The thick solid line in the middle represents the outer contour of the cut, which not only completes the cutting of the long side 51 of the two outermost welded components 50, but also realizes the cutting and positioning of all welded components 50.

[0102] In one embodiment of the present invention, step S415, performing a first trimming operation on all long sides 51 collinearly arranged on the component assembly outline plate 40, includes:

[0103] Step S420: Select a centered long side 51 from all the collinear long sides 51 on the component assembly outline plate 40 and perform the first cutting operation to obtain two component segmentation plates.

[0104] Step S430: If there are still at least two welded components 50 in the component partition plate, continue to perform the first cutting operation on the long side 51 set in the center of the component partition plate until only one welded component 50 remains to be arranged.

[0105] Specifically, if there are at least three collinear long sides 51, the middle long side 51 can be cut first, followed by the other long sides 51. This allows for heat dissipation from the middle outwards, resulting in less heat accumulation and deformation. In the embodiment provided by this invention, five welded components 50 are arranged on the component assembly outline plate 40. Four of the five welded components 50 have collinear long sides 51. One of the two centrally located long sides 51 can be selected to perform the first cutting operation, resulting in two component segmentation plates. Specifically, as shown... Figure 10 As shown in the diagram, the solid black line completes the current processing of the long side 51. However, one of the component dividing plates has two welded components 50 arranged in a layout, leaving only one collinear long side 51 for cutting, as detailed below. Figure 12 The long side 51 shown in the diagram has three welded components 50 arranged in a separate component plate, with two collinear long sides 51 left for cutting, as detailed below. Figure 11 and Figure 12 The long side 51 shown for processing can be cut by selecting either one of the two collinear long sides 51 since there is no centering setting. This process continues until all collinear long sides 51 are cut.

[0106] In one embodiment of the present invention, before performing the first trimming operation on the long side 51 of each welded component 50 along the length direction on the component assembly blanking plate 30, the following is also included:

[0107] The component assembly blanking plate 30 is cut with holes, wherein the cutting operation starts from the center of the component assembly blanking plate 30 and proceeds outwards in sequence.

[0108] Understandably, if process holes 53 are required on the welded components 50, the cutting operation for the process holes 53 can be set after the component assembly blanking plate 30 is assembled and before the individual welded components 50 are divided, so that the cutting operation on all the welded components 50 on the component assembly blanking plate 30 can be completed in one go. At the same time, each splicing segment 10 of the welded components 50 needs to have a process hole 53. If there are five welded components 50 arranged on the component assembly outline plate 40, the process holes 53 on the component assembly blanking plate 30 can form a shape radiating outwards from the center. The cutting operation proceeds sequentially from the center outwards, allowing the generated cutting heat to dissipate outwards in a regular manner, preventing heat accumulation and deformation. Figure 8As shown, the process holes 53 on the component assembly blanking plate 30 can be cut in sequence according to the order 53a, 53b, 53c... to 53j. Of course, the present invention is not limited to this, and other cutting sequences that radiate outward from the center are also possible.

[0109] In one embodiment of the present invention, step S200, which involves pre-welding processing of the splicing ends of each unit assembly blanking plate 20, includes:

[0110] Step S210: Chamfer 11 is performed on the thicker end of the two splicing ends to make the thickness of the two splicing ends the same at the welding point.

[0111] Understandably, in the two splicing ends being welded, one splicing end has a plate thickness greater than the other splicing end, and the splicing end with the larger plate thickness can be defined as a splicing end with a thicker plate. Specifically, the thickness transition can be achieved by chamfering the splicing end with the larger plate thickness 11, thereby making the welded component assembly blank plate 30 smoothly transition at the abrupt change in thickness, increasing the aesthetics and reliability of the product.

[0112] In step S220, if the thickness of the thin-plate splicing end in the two splicing ends to be welded is greater than the preset bevel opening thickness, a bevel with a preset bevel angle is opened on the chamfer 11 processing side of the two splicing ends to be welded.

[0113] Understandably, in a weld, the end with the smaller plate thickness can be defined as the thinner end. A bevel is only required on the chamfered side of both ends when the thinner end is thicker than the pre-set bevel thickness. This ensures that the weld can reach the bottom even with a larger thickness. Specifically... Figure 7 As shown; when the splicing end of a thin plate is less than the preset bevel thickness, no bevel is needed, and the welding equipment can weld to the bottom between the weld gaps, thereby reducing the amount of welding work and the amount of filler wire required. Specifically, as shown... Figure 6 As shown.

[0114] In one embodiment of the present invention, the length of the chamfer 11 is set to 4 to 5 times the difference in thickness between the two splicing ends. Specifically, the length L of the chamfer 11 is 4(t2-t1) to 5(t2-t1), where t1 represents the thickness of the splicing end that is a thin plate and t2 represents the thickness of the splicing end that is a thick plate. By using reasonable dimensions for thickness transition, the stability of the splicing position can be guaranteed.

[0115] In one embodiment of the present invention, the preset bevel thickness can be 8mm. Specifically, when the thickness of the splicing end, which is a thin plate, is greater than 8mm, a bevel is formed on the chamfer 11 processing side to facilitate the welding equipment to weld the two splicing ends from the chamfer 11 processing side; when the thickness of the splicing end, which is a thin plate, is less than 8mm, no bevel is required, and the welding equipment welds the reserved splicing gap between the two splicing ends.

[0116] In one embodiment of the present invention, the preset bevel angle can be 30° to 45° to adapt to the welding equipment used in high-efficiency welding processes. Preferably, when the welding equipment is a plasma hybrid welding or laser hybrid welding, the preset bevel angle can be 30°.

[0117] In one embodiment of the present invention, step S300 involves welding the splicing ends of all unit assembly blanking plates 20 to obtain the component assembly blanking plate 30, which includes:

[0118] Plasma composite welding or laser composite welding is used to perform single-sided welding of the welding gap between the two splicing ends from the chamfered 11 processing side to obtain a component assembly blank plate 30 with double-sided forming welds.

[0119] Understandably, regardless of whether a beveling is used, a 0-1mm welding gap will always remain between the two spliced ​​ends. However, by employing efficient welding processes such as plasma hybrid welding or laser hybrid welding, a double-sided weld can be achieved by welding from only one side. Furthermore, since the welding is done before cutting holes and trimming edges, there is no need to consider the assembly forming length and hole positioning during the welding process. This allows for precise control of the splicing gap, which is beneficial for using efficient welding processes such as plasma hybrid welding or laser hybrid welding, which have high requirements for gaps. This enables single-sided welds to achieve double-sided forming, and with a smaller beveling and less filler wire, welding efficiency is increased by more than 50%.

[0120] In one embodiment of the present invention, before step S400, which divides the component assembly blanking plate 30 into at least two weldable components 50, the method further includes:

[0121] The welds on the component assembly blanking plate 30 are subjected to flaw detection.

[0122] Specifically, before the component assembly blanking plate 30 is divided, the weld is inspected. Since the short welds of at least two welded components 50 at the same position can be connected to form a long weld, the welds of at least two welded components 50 at the same position can be inspected at one time during the inspection, which helps to improve the efficiency of the inspection.

[0123] In one embodiment of the present invention, step S100, which involves combining and cutting each splicing segment 10 to obtain a unit assembly cutting plate 20 for each splicing segment 10, includes:

[0124] Step S110: Based on the width dimensions of the raw materials, the splicing segment 10 with the largest cutting width requirement in the welded component 50 is designed for layout to obtain the first layout size. The width of the first layout size is sufficient for at least two corresponding splicing segments 10 to be laid out along the width direction.

[0125] Specifically, we can first determine the splicing segment 10 with the largest cutting width requirement among the welded components 50, and then... Figure 1 and Figure 2 In the structural components, the splicing segment 10 with the largest required cutting width is the first splicing segment 10a. The layout design of the splicing segment 10 with the largest cutting width requirement is then carried out according to the width dimensions of the raw material. The main goal is to maximize the number of splicing segments 10 arranged along the width direction, thereby making full use of the raw material. In the embodiment provided by this invention, the width dimensions of the raw material allow for five first splicing segments 10a to be arranged sequentially along the width direction, and the first layout dimension is W1*L1, specifically as follows... Figure 4 As shown.

[0126] Step S120: The remaining splicing segments 10 in the welded component 50 are arranged according to the number of splicing segments 10 in the first layout size, so as to obtain the second layout size of the remaining splicing segments 10 respectively.

[0127] Understandably, once the number of splicing segments 10 with the largest cutting width requirement is determined, the number of welded components 50 to be processed together and the number of the remaining splicing segments 10 are also determined and kept consistent with it. Since the cutting width requirements of the remaining splicing segments 10 are all less than or equal to those of the splicing segment 10 with the largest cutting width requirement, the width of the raw materials can meet the cutting width requirements of the remaining splicing segments 10.

[0128] Step S130: Cut the material according to the first layout size and the second layout size to obtain the unit combination cutting plate for each splicing segment 10.

[0129] Furthermore, after determining the first and second layout dimensions, the material can be cut directly according to the first and second layout dimensions, or a machining allowance of 2mm to 3mm can be added to the width dimension based on the first and second layout dimensions to perform fine machining on the splicing end during pre-welding processing.

[0130] In one embodiment of the present invention, after dividing the component assembly blanking plate 30 into at least two weldable components 50, step S400 further includes:

[0131] Step S500: The welded component 50 is bent. The bending operation uses a four-roller plate rolling device including an upper roller mechanism 61, a lower roller mechanism 62, a left roller mechanism 63 and a right roller mechanism 64. The vertical and / or horizontal positions of the left roller mechanism 63 and / or the right roller mechanism 64 are adjustable.

[0132] Understandably, when the welded component 50 is a bent part, it can be bent last, i.e., in this application, it is welded first and then bent. Compared to bending first and then welding, welding first and then splicing flat plates makes the splicing easier and does not require the assistance of a mold. Meanwhile, the welded component 50 has at least two bending operations, and the bending radii of these two bending operations are different, including both forward and reverse bends. To solve the problem of the difficulty in bending such parts, a four-roller plate rolling machine can be used. Compared with traditional plate rolling machines, the left and right roller mechanisms 64 can be adjusted arbitrarily up and down and left and right relative to the upper and lower roller mechanisms 62. On the one hand, the left roller mechanism 63 and the right roller mechanism 64 can be adjusted up and down according to different bending directions of the part, and the workpiece can be bent forward or backward without flanging; on the other hand, the left roller mechanism 63 and the right roller mechanism 64 can be adjusted left and right according to different bending radii of the part, adjusting the horizontal distance between them and the upper roller mechanism 61 and the lower roller mechanism 62, thereby satisfying different bending radii. Figure 14 As shown, during positive bending, the left roller mechanism 63 is adjusted to a lower side roller, cooperating with the upper and lower roller mechanisms 62 to complete the bending; as Figure 15 As shown, during reverse bending, the right roller mechanism 64 is adjusted to a side upper roller, cooperating with the upper and lower roller mechanisms 62 to complete the bending. Of course, the invention is not limited to this; the welded component 50 can also be a straight piece, eliminating the need for bending.

[0133] Specifically, this invention employs a technical solution of first combining and welding materials, followed by overall cutting and bending, to achieve high-precision and high-efficiency manufacturing of narrow and long strip-shaped bent parts made of multiple high-strength steel plates of unequal thickness. The specific steps of the manufacturing method for the welded components are as follows:

[0134] 1. Based on the width dimensions of the raw materials, design the layout of the splicing segment with the largest cutting width requirement in the welded components to obtain the first layout size W1*L1;

[0135] 2. Based on the number of splicing segments in the first layout size, design the layout of the remaining splicing segments in the welded components to obtain the second layout size of the remaining splicing segments respectively;

[0136] 3. Cut the material according to the first and second layout dimensions to obtain the unit combination cutting board for each splicing segment;

[0137] 4. Determine the length of the chamfer and whether to perform beveling. The length of the chamfer is set to 4 to 5 times the difference in thickness between the two splicing ends. If the thickness of the thinner splicing end in the two splicing ends to be welded is greater than the preset beveling thickness, then beveling is required.

[0138] 5. All splicing segments should be assembled and placed in sequence, with a welding gap of 0-1mm left at the splicing position;

[0139] 6. Use plasma composite welding or laser composite welding to perform single-sided welding on the welding gap between the two splicing ends from the chamfering side to obtain a component assembly blank plate with double-sided forming welds;

[0140] 7. Cut holes in the component assembly blanking plate;

[0141] 8. Cut the outer contour of the component assembly blanking plate to obtain the component assembly contour plate;

[0142] 9. Select one of the long sides that are collinear on the component assembly outline plate and center it to perform the first cutting operation to obtain two component segmentation plates;

[0143] 10. If there are still at least two welded components in the component partition plate, continue to perform the first cutting operation on the long side set in the center of the component partition plate until only one welded component remains.

[0144] 11. Perform a second trimming operation on the remaining short side of each welded component to divide it into at least two welded components;

[0145] 12. Perform bending operations on the welded components;

[0146] 13. Dimensional inspection.

[0147] Compared with existing technologies, the above-described method for manufacturing welded components has the following advantages:

[0148] 1. After multiple narrow and long strip parts are combined, multiple short welds are connected to form a single long weld. Beveling, weld welding and weld flaw detection can all be achieved in continuous automated production, which greatly improves production efficiency. At the same time, it reduces the start and end of the arc and avoids the occurrence of end welding defects.

[0149] 2. After combining multiple parts, the aspect ratio of the parts is significantly reduced, the rigidity of the parts is increased, and the welding deformation is reduced;

[0150] 3. Welding before cutting avoids the impact of welding deformation on dimensional accuracy, resulting in higher dimensional accuracy for each hole;

[0151] 4. Weld first, then bend. The splicing is done by butt joint of flat plates, which is easy and does not require the assistance of a membrane.

[0152] 5. The splicing gap can be precisely controlled during splicing, which is conducive to adapting to high-efficiency welding processes such as plasma composite welding and laser welding that have high gap requirements. It can achieve single-sided welding and double-sided forming, and the small bevel and small amount of welding wire filler can improve welding efficiency by more than 50%.

[0153] 6. After splicing, the parts are generally thinner in the middle and thicker at both ends. They are cut from the middle to both ends, which results in less deformation compared to cutting thin plates separately before splicing.

[0154] Furthermore, the present invention also provides a welded component, wherein the welded component is manufactured according to the welded component manufacturing method described above. Since the welded component adopts all the technical solutions of the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated further here.

[0155] In the description of this invention, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0156] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0157] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0158] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A method for manufacturing welded components, characterized in that, The method for manufacturing the welded components includes: Each splicing segment (10) is combined and cut separately to obtain a unit combination cutting plate (20) for each splicing segment (10), wherein the unit combination cutting plate (20) has at least two identical splicing segments (10) arranged along the width direction; Each unit assembly blank plate (20) is pre-welded at its splicing end; Weld the splicing ends of all unit assembly blanking plates (20) to obtain component assembly blanking plates (30); The component assembly blanking plate (30) is divided into at least two welded components (50); The process of dividing the component assembly blanking plate (30) into at least two welded components (50) includes: On the component assembly blanking plate (30), a first cutting operation is performed on the long side (51) of each welded component (50) extending along the length direction, wherein the first cutting operation is performed from the middle position of the long side (51) towards both ends; A second trimming operation is performed on the remaining short side (52) of each welded component (50) to divide it into at least two welded components (50); The first trimming operation performed on the long side (51) of each welded component (50) extending along the length direction on the component assembly blanking plate (30) includes: The outer contour of the component assembly blanking plate (30) is cut to obtain the component assembly contour plate (40). The component assembly contour plate (40) has at least two welded components (50) arranged along the width direction. Any two adjacent welded components (50) are arranged collinearly on the component assembly contour plate (40) with their long sides (51). The outer contour of the component assembly contour plate (40) includes the contours of the two outermost long sides (51) of the at least two welded components (50). Perform the first trimming operation on all long sides (51) that are collinearly arranged on the component assembly outline plate (40).

2. The method for manufacturing welded components according to claim 1, characterized in that, The first trimming operation on all long sides (51) collinearly arranged on the component assembly outline plate (40) includes: Select one of the long sides (51) that are collinearly arranged on the component assembly outline plate (40) and perform the first cutting operation to obtain two component division plates; If there are still at least two welded components (50) in the component partition plate, continue to perform the first cutting operation on the long side (51) set in the center of the component partition plate until only one welded component (50) remains.

3. The method for manufacturing welded components according to claim 1, characterized in that, Before performing the first trimming operation on the long side (51) extending along the length direction of each welded component (50) on the component assembly blanking plate (30), the following is also included: The component assembly blanking plate (30) is cut with holes, wherein the cutting operation starts from the middle position of the component assembly blanking plate (30) and proceeds outwards to the surrounding periphery.

4. The method for manufacturing welded components according to claim 1, characterized in that, The pre-welding processing of the splicing ends of each unit assembly blanking plate (20) includes: The thick plate end of the two splicing ends to be welded is chamfered (11) so that the thickness of the two splicing ends at the weld is the same; When the thickness of the thin-plate splicing end in the two splicing ends to be welded is greater than the preset bevel opening thickness, a bevel with a preset bevel angle is opened on the chamfer (11) processing side of the two splicing ends to be welded.

5. The method for manufacturing welded components according to claim 4, characterized in that, The length of the chamfer (11) is set to 4 to 5 times the difference in thickness between the two splicing ends; And / or, the preset bevel thickness is 8mm; And / or, the preset bevel angle is 30°~45°; And / or, the welding of the splicing ends of all unit assembly blanking plates (20) to obtain the component assembly blanking plate (30) includes: Plasma composite welding or laser composite welding is used to perform single-sided welding of the welding gap between the two splicing ends from the chamfered (11) processing side to obtain a component assembly blank plate (30) with double-sided forming weld.

6. The method for manufacturing welded components according to any one of claims 1 to 5, characterized in that, The process of dividing the component assembly blanking plate (30) into at least two welded components (50) further includes: The welds on the component assembly blanking plate (30) are subjected to flaw detection. And / or, the step of combining and cutting each splicing segment (10) to obtain a unit combination cutting plate (20) for each splicing segment (10) includes: The layout design of the splicing segment (10) with the largest blanking width requirement in the welded component (50) is carried out according to the width dimension of the raw material to obtain the first layout size, wherein the width of the first layout size can be used for at least two corresponding splicing segments (10) to be laid out along the width direction. The remaining splicing segments (10) in the welded component (50) are designed according to the number of splicing segments (10) in the first layout size, so as to obtain the second layout size of the remaining splicing segments (10); Cutting is performed according to the first and second layout dimensions to obtain the unit combination cutting plate (20) for each splicing segment (10).

7. The method for manufacturing welded components according to any one of claims 1 to 5, characterized in that, The process of dividing the component assembly blanking plate (30) into at least two weldable components (50) further includes: The welded components (50) are bent using a four-roll plate bending machine comprising an upper roller mechanism (61), a lower roller mechanism (62), a left roller mechanism (63), and a right roller mechanism (64), wherein the vertical and / or horizontal positions of the left roller mechanism (63) and / or the right roller mechanism (64) are adjustable.

8. A welded component (50), characterized in that, The welded component (50) is manufactured using the welded component manufacturing method according to any one of claims 1 to 7.

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