Novel welding method and equipment for axle heads of middle and rear axles

Abstract

The invention discloses a novel welding method and equipment for axle heads of middle and rear axles, and relates to the technical field of welding of axle heads of middle and rear axles. The welding equipment for axle heads of middle and rear axles comprises a first workbench and two second workbenches which are symmetrically distributed on the left side and the right side of the first workbench left and right, and an axle housing clamping assembly is arranged at the top of the first workbench; two first air cylinders are fixedly connected to the top of the first workbench in a bilateral symmetry mode, the output ends of the two first air cylinders are symmetrically and fixedly connected with the cathode ends of two pulse current generators, and an electromagnetic heater is installed at the top of the first workbench. By means of the ultrasonic welding machine and the pulse current generator, light-free, flame-free, low-pressure, medium-low-temperature and low-voltage safe welding can be achieved in the welding process, meanwhile, welding materials with a certain thickness can be welded, too high equipment capacity requirements are not needed, and therefore threats caused by welding to personnel and equipment in an assembly workshop are avoided.

Description

Technical Field

[0001] The invention relates to the technical field of center and rear axle head welding, and in particular to a new center and rear axle head welding method and equipment. Background Art

[0002] The bridge housing is an important component in the automobile transmission system. At present, most bridge housings are processed separately and formed after welding. That is, the middle section of the bridge housing is formed by stamping and welding of steel plates, and the shaft heads at both ends are formed by cast steel. The above two parts are only processed independently after forming, and after the processing of their respective parts is completed, they are combined and welded to finally form the bridge housing.

[0003] The axle head of the axle housing is a high-precision mating part in the drive axle assembly. Its machined surface directly cooperates with the oil seal seat ring, wheel hub bearing inner ring, ABS sensor, and axle head nut components. The above components are important parts that directly affect the vehicle wheel transmission efficiency and safety. According to the existing process, after the axle head is welded, it is necessary to perform shot blasting, painting, workshop caching and transfer, cleaning and other processes before it can be put on the bridge assembly line for wheel end assembly. However, when the axle head is welded to the axle housing and then subjected to shot blasting, painting, workshop caching and transfer, cleaning and other processes, the difficulty will be significantly increased and the axle housing may be damaged during the processing.

[0004] However, if the axle head is shot blasted, painted, transferred in the workshop buffer, cleaned and other processes before being welded to the bridge housing, the axle head welding needs to be carried out in the assembly workshop because the bridge housing will be assembled and moved in the assembly workshop. However, the axle head welding in the industry mostly adopts double-protection welding, friction welding and laser welding. This welding process has serious pollution, high risk factor and large footprint. It is not suitable for assembly workshop assembly line operation and high personnel density. For this reason, we propose a new welding method and equipment for the center and rear axle head. Summary of the invention

[0005] The purpose of the present invention is to provide a new welding method and equipment for the center and rear axle heads to solve the problems raised in the above-mentioned background technology.

[0006] To achieve the above object, the present invention provides the following technical solution: a new welding method for a middle and rear axle head, comprising the following steps:

[0007] S1: After the shaft head and the axle housing are coaxially positioned, push the shaft head along its axis line toward the axle housing until the connecting end surfaces of the two are initially pressed against each other;

[0008] S2: Spray the low-temperature and heat-conductive organic solder flux that forms cavitation bubbles onto the welding point between the shaft head and the bridge housing, and then start the ultrasonic welder so that the high-frequency vibration mechanism of the ultrasonic welder (drives the shaft head and the bridge housing to generate high-frequency micron-level radial low-amplitude oscillations at the welding point between the shaft head and the bridge housing;

[0009] S3: heating the position near the welding end surface of the shaft head and the bridge housing by an electromagnetic heater until the set temperature is reached;

[0010] S4: A pulse current is applied between the welding surface of the shaft head and the bridge housing through a pulse current generator to cooperate with an ultrasonic welder to weld the shaft head and the bridge housing.

[0011] Preferably, when the connecting end faces of the shaft head and the bridge housing are initially pressed together, the pressure between the connecting end faces is less than the pressure value required for cold pressure welding, and under the action of this pressure, the fitting distance between the shaft head and the bridge housing can reach an average micrometer level.

[0012] Preferably, the steps of forming cavitation bubbles by the organic solder are as follows: heating the solder to a liquid state by an ultrasonic heating frame, and generating cavitation nuclei by oscillating the solder at an ultrasonic medium frequency; sucking the organic solder generating the cavitation nuclei into a solder nozzle connected to the ultrasonic heating frame; performing high-frequency oscillation on the organic solder at the end of the solder nozzle to form cavitation bubbles; and then spraying the organic solder generating the cavitation bubbles by the solder nozzle through a solder spray mechanism toward the connecting end face of the shaft head and the bridge housing. The advantage of such an arrangement is that the solder generating the cavitation bubbles will destroy the stability of the cavitation bubbles after being sprayed from the solder spray mechanism and colliding with the surface of the component. The cavitation bubbles rupture and close quickly, producing local microscopic impacts, bursting and peeling off the nearby oxide layer and roughness wave peaks. In this way, the high-frequency vibration mechanism of the ultrasonic welder drives the shaft head and the bridge housing to produce high-frequency micron-level radial low-amplitude oscillations at the welding point of the shaft head and the bridge housing, which can effectively remove the oxide layer and roughness at the connecting end faces of the shaft head and the bridge housing, greatly increasing the actual contact area between the welding end faces of the bridge housing and the shaft head. In this way, under the same driving force, the distance between the connecting end faces of the shaft head and the bridge housing can reach the nanometer level so that the attraction of the metal bonds between atoms begins to play a role, preparing for the welding work in conjunction with the pulse current generator.

[0013] A welding device for the above scheme comprises a first workbench and two second workbench which are symmetrically distributed on the left and right sides of the first workbench, a bridge housing clamping assembly is provided on the top of the first workbench, two first cylinders are symmetrically fixedly connected to the top of the first workbench, the output ends of the two first cylinders are symmetrically fixedly connected to two cathode ends of pulse current generators, an electromagnetic heater is installed on the top of the first workbench, two forward and backward moving assemblies are symmetrically connected to the tops of the two second workbenches, two presses are symmetrically connected to the two forward and backward moving assemblies, two shaft head clamping assemblies are symmetrically fixedly connected to the output ends of the two presses, two ultrasonic welders and two anode ends of pulse current generators are symmetrically provided on the two shaft head clamping assemblies, two organic soft solder spray assemblies are symmetrically provided on the two shaft head clamping assemblies, and an auxiliary positioning assembly for assisting in positioning and clamping the bridge housing on the bridge housing clamping assembly is also provided on the top of the first workbench.

[0014] Preferably, the electromagnetic heater includes two first support frames symmetrically fixedly connected to the top of the first workbench, two retaining rings are symmetrically fixedly connected to the top of the two first support frames, two arc-shaped movable grooves are symmetrically opened in the two retaining rings, and wrapping rings are slidably connected in the two movable grooves, and the concave arc surfaces of the wrapping rings are fixedly connected with a plurality of driving teeth at equal angles along the arc surfaces, two through cavities are symmetrically opened at the bottom of the two retaining rings, and the tops of the two through cavities are respectively connected to the bottom walls of the two movable grooves, and two first motors are symmetrically fixedly connected to the tops of the two first support frames, and the output ends of the two first motors are fixedly connected with first gears, and the tops of the two first gears respectively pass through the two through cavities and respectively mesh with the driving teeth on the two wrapping rings.

[0015] Preferably, the shaft head clamping assembly comprises a clamping blind tube fixedly connected to the output end of the press, and a plurality of clamping claws are connected to the inner side wall of the clamping blind tube in a ring shape with equal angles through a first driving mechanism.

[0016] Preferably, the organic solder flux spray assembly includes two ultrasonic heating frames symmetrically and fixedly connected to the tops of the two second workbenches, the organic solder flux is heated into a liquid state in the ultrasonic heating frames, the ultrasonic heating frames are connected to a solder flux nozzle, a liquid pump is installed on the solder flux nozzle, the other end of the solder flux nozzle is connected to a solder flux spray mechanism, the two solder flux spray mechanisms are symmetrically and slidingly connected to the inner side walls of the two clamping blind tubes, the organic solder flux spray assembly also includes two pairs of first hydraulic cylinders symmetrically and fixedly connected to the tops of the two second workbenches, the output ends of the two pairs of the first hydraulic cylinders pass through the side walls of the clamping blind tubes and are respectively connected to the two solder flux spray mechanisms.

[0017] Preferably, the ultrasonic welding machine includes a moving ring symmetrically and slidingly connected to the outer circumference of the two clamping blind tubes through a left and right moving assembly, the two moving rings are symmetrically and rotatably connected to the ends that are close to each other, and two high-frequency vibration mechanisms are symmetrically and fixedly connected to the inner side walls of the two rotating rings, and the high-frequency vibration mechanism is a vibration welding ring, and two annular gears are symmetrically and fixedly sleeved on the outer circumference of the ends that are far away from each other, and annular receiving grooves are symmetrically provided on the inner side walls of the two moving rings, and two rectangular cavities are symmetrically provided on the tops of the two moving rings, and the bottom ends of the two rectangular cavities are respectively connected to the two receiving grooves, and two second motors are symmetrically and fixedly connected to the tops of the two moving rings, and the output ends of the two second motors are symmetrically and fixedly connected by two second gears, and the two second gears pass through the rectangular cavity and are respectively meshed with the two annular gears, and the anode ends of the two pulse current generators are symmetrically and fixedly inserted on the outer side walls of the two rotating rings, and the output ends of the anode ends of the two pulse current generators pass through the outer side walls of the rotating rings and extend into their inner holes.

[0018] Preferably, the auxiliary positioning assembly includes two pairs of second hydraulic cylinders symmetrically fixedly connected to the top of the first workbench, two pairs of fixed blocks symmetrically fixedly connected to the output ends of the two pairs of the second hydraulic cylinders, two pairs of third motors symmetrically fixedly connected to the tops of the two pairs of the fixed blocks, two pairs of first rotating shafts symmetrically fixedly connected to the output ends of the two pairs of the third motors, two pairs of circular arc-shaped receiving plates symmetrically fixedly connected to the two pairs of the first rotating shafts, each pair of two receiving plates can be combined into a semicircular arc-shaped plate, and a plurality of unpowered rollers are equidistantly connected to the concave arc surface of the receiving plate along the arc direction of the arc surface. The advantage of such a setting is that it can avoid the collision between the bridge housing and the two retaining rings and the cathode end of the pulse current generator when the bridge housing position is adjusted on the bridge housing clamping assembly, thereby ensuring the safety of the bridge housing clamping assembly, the two retaining rings, the cathode end of the pulse current generator, the bridge housing and nearby personnel, and further improving the safety and reliability of the welding equipment.

[0019] Preferably, the auxiliary positioning assembly also includes two third hydraulic cylinders symmetrically fixedly connected to the top of the first workbench, and two top rollers are symmetrically fixedly connected to the output ends of the two third hydraulic cylinders. The auxiliary positioning assembly also includes two pairs of fourth motors symmetrically fixedly connected to the top of the first workbench, and two pairs of connecting blocks are symmetrically fixedly connected to the output ends of the two fourth motors. The top ends of the two pairs of connecting blocks are symmetrically rotatably connected to two pairs of round rods. The advantage of such an arrangement is that it can avoid sliding friction and damage between the bridge housing and the unpowered roller when adjusting the axial position of the bridge housing on the unpowered roller at the receiving plate, making the bridge housing position adjustment work more convenient and safe, and improving the reliability and convenience of the welding equipment.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] The present invention destroys the stability of cavitation bubbles after the flux forming cavitation bubbles collides with the surface of the parts, and the cavitation bubbles quickly break and close, generating local microscopic impacts, bursting and peeling off the nearby oxide layer and roughness wave peaks, and then cooperates with the high-frequency vibration mechanism of the ultrasonic welder to drive the shaft head and the bridge housing to generate high-frequency micron-level radial low-amplitude oscillations at the welding point of the shaft head and the bridge housing, which can effectively remove the oxide layer and roughness at the connecting end face of the shaft head and the bridge housing, so that the actual contact area between the welding end face of the bridge housing and the shaft head is greatly increased. In this way, under the same driving force, the distance between the connecting end face of the shaft head and the bridge housing can reach the nanometer level so that the metal bond attraction between atoms begins to play a role, and the metal bond attraction between atoms can make the pulse current generator applied to the shaft head and the bridge housing The electrons brought by the pulse current loop are transmitted to the connecting end face of the shaft head and the bridge housing, and then when the pulse current is disconnected, the electrons will be absorbed and stored by the flux sprayed on the connecting end face when they flow back, so that a large number of motors are enriched at the connecting end face, and the large amount of electrons gathers and the force between metal bonds decreases, and the diffusion effect between atoms increases, which can greatly improve the welding efficiency. The welding work is completed by the cooperation of ultrasonic welding machine and pulse current generator. During the welding process, lightless, flameless, low pressure, medium and low temperature, and low voltage safe welding can be achieved. At the same time, a certain thickness of welding materials can be welded without excessive equipment capacity requirements, thereby avoiding welding. The threat to personnel and equipment in the assembly workshop. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 A method flow chart of a new welding method for a middle and rear axle shaft head in the present invention;

[0023] Figure 2 It is a structural schematic diagram of a middle and rear axle shaft head welding device in the present invention;

[0024] Figure 3 It is a schematic diagram of a first partial structure of a middle and rear axle shaft head welding device in the present invention;

[0025] Figure 4 It is a second partial structural schematic diagram of a middle and rear axle shaft head welding device in the present invention;

[0026] Figure 5 It is a third partial structural schematic diagram of a middle and rear axle shaft head welding device in the present invention;

[0027] Figure 6 It is a schematic diagram of a fourth partial structure of a middle and rear axle shaft head welding device in the present invention;

[0028] Figure 7 for Figure 3 A fifth partial structural schematic diagram of a middle and rear axle shaft end welding device;

[0029] Figure 8A side view of the auxiliary positioning component.

[0030] In the figure: 1, first workbench; 2, second workbench; 3, bridge housing clamping assembly; 4, first cylinder; 51, cathode end of pulse current generator; 52, anode end of pulse current generator; 6, electromagnetic heater; 61, first support frame; 62, clamping ring; 63, wrapping ring; 64, driving gear; 65, first motor; 66, first gear; 7, forward and backward moving assembly; 8, press machine; 9, shaft head clamping assembly; 91, clamping blind pipe; 92, clamping claw; 10, ultrasonic welder; 101, moving ring; 102, rotating ring; 1 03. High-frequency vibration mechanism; 104. Second motor; 105. Second gear; 11. Organic solder spray assembly; 1101. Ultrasonic heating frame; 1102. Solder spray mechanism; 1103. First hydraulic cylinder; 12. Auxiliary positioning assembly; 1201. Second hydraulic cylinder; 1202. Fixed block; 1203. Third motor; 1204. First rotating shaft; 1205. Receiver plate; 1206. Unpowered roller; 1207. Third hydraulic cylinder; 1208. Top roller; 1209. Fourth motor; 1210. Round rod. DETAILED DESCRIPTION

[0031] 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.

[0032] See also Figure 1 A new welding method for the middle and rear axle head shown in the figure includes the following steps:

[0033] S1: After the shaft head and the axle housing are coaxially positioned, push the shaft head along its axis line toward the axle housing until the connecting end surfaces of the two are initially pressed against each other;

[0034] S2: spraying low-temperature and heat-conductive organic solder that forms cavitation bubbles onto the welding point between the shaft head and the bridge housing, and then starting the ultrasonic welder 10, so that the high-frequency vibration mechanism 103 of the ultrasonic welder 10 drives the shaft head and the bridge housing to generate high-frequency micron-level radial low-amplitude oscillation at the welding point between the shaft head and the bridge housing;

[0035] S3: heating the position near the welding end surface of the shaft head and the bridge housing by the electromagnetic heater 6 until reaching the set temperature;

[0036] S4: A pulse current is applied between the shaft head welding surface and the bridge housing by a pulse current generator to cooperate with the ultrasonic welder 10 to weld the shaft head and the bridge housing.

[0037] Among them, when the connecting end faces of the shaft head and the bridge housing are initially pressed together, the pressure between the connecting end faces is less than the pressure value required for cold pressure welding, and under the action of this pressure, the fitting distance between the shaft head and the bridge housing can reach an average micron level.

[0038] Among them, the steps for the organic soft solder to form cavitation bubbles are: heating the solder to a liquid state through an ultrasonic heating frame 1101, and generating cavitation nuclei by oscillating the solder through ultrasonic medium frequency; sucking the organic soft solder that generates the cavitation nuclei into a solder nozzle connected to the ultrasonic heating frame 1101; oscillating the organic soft solder at a high frequency at the end of the solder nozzle to form cavitation bubbles; and then the organic soft solder that forms the cavitation bubbles is sprayed toward the connecting end face of the shaft head and the bridge housing by the solder nozzle through the solder spraying mechanism 1102.

[0039] Specifically, after the flux that forms cavitation bubbles is sprayed out from the flux spraying mechanism 1102 and collides with the surface of the component, the stability of the cavitation bubbles will be destroyed. The cavitation bubbles will quickly rupture and close, generating local microscopic impacts, causing the nearby oxide layer and roughness wave peaks to burst and peel off. In this way, the high-frequency vibration mechanism 103 of the ultrasonic welder 10 drives the shaft head and the bridge housing to generate high-frequency micron-level radial low-amplitude oscillations at the welding point of the shaft head and the bridge housing, which can effectively remove the oxide layer and roughness at the connecting end faces of the shaft head and the bridge housing, thereby greatly increasing the actual contact area between the welding end faces of the bridge housing and the shaft head. In this way, under the same driving force, the distance between the connecting end faces of the shaft head and the bridge housing can reach the nanometer level so that the attraction of the metal bonds between atoms begins to play a role, thus preparing for the welding work in cooperation with the pulse current generator.

[0040] See also Figure 2-Figure 8 A welding device for the above scheme comprises a first workbench 1 and two second workbench 2 symmetrically distributed on the left and right sides of the first workbench 1, a bridge housing clamping assembly 3 is provided on the top of the first workbench 1, two first cylinders 4 are symmetrically fixedly connected to the top of the first workbench 1, and two cathode ends 51 of pulse current generators are symmetrically fixedly connected to the output ends of the two first cylinders 4, an electromagnetic heater 6 is installed on the top of the first workbench 1, two forward and backward moving assemblies 7 are symmetrically connected to the tops of the two second workbench 2, two presses 8 are symmetrically connected to the two forward and backward moving assemblies 7, two shaft head clamping assemblies 9 are symmetrically fixedly connected to the output ends of the two presses 8, two ultrasonic welders 10 and two anode ends 52 of pulse current generators are symmetrically provided on the two shaft head clamping assemblies 9, two organic soft solder spraying assemblies 11 are symmetrically provided on the two shaft head clamping assemblies 9, and an auxiliary positioning assembly 12 for assisting in positioning and clamping the bridge housing on the bridge housing clamping assembly 3 is also provided on the top of the first workbench 1.

[0041] See also Figure 7The electromagnetic heater 6 includes two first support frames 61 symmetrically fixedly connected to the top of the first workbench 1, two retaining rings 62 are symmetrically fixedly connected to the top of the two first support frames 61, two arc-shaped moving grooves are symmetrically provided in the two retaining rings 62, and wrapping rings 63 are slidably connected in the two moving grooves. The concave arc surface of the wrapping ring 63 is fixedly connected with a plurality of driving teeth 64 at equal angles along the arc surface, and two through cavities are symmetrically provided at the bottom of the two retaining rings 62, and the tops of the two through cavities are respectively connected to the bottom walls of the two moving grooves, and two first motors 65 are symmetrically fixedly connected to the top of the two first support frames 61, and the output ends of the two first motors 65 are fixedly connected to the first gears 66, and the tops of the two first gears 66 respectively pass through the two through cavities and respectively mesh with the driving teeth 64 on the two wrapping rings 63.

[0042] Specifically, the first motor 65 drives the first gear 66 to rotate, and the first gear 66 drives the wrapping ring 63 to rotate along the movable groove through the driving tooth 64, so that when the bridge housing is placed in the retaining ring 62 or taken out from the retaining ring 62, the wrapping ring 63 can be transferred into the movable groove so that the bridge housing can be placed in or taken out conveniently. When the bridge housing is placed in the retaining ring 62 and needs to be heated, the wrapping ring 63 is rotated to above the retaining ring 62 to wrap the bridge housing around and ensure the heating effect.

[0043] See also Figure 5 The shaft head clamping assembly 9 includes a clamping blind tube 91 fixedly connected to the output end of the press 8, and a plurality of clamping claws 92 are connected to the inner wall of the clamping blind tube 91 in a ring shape with equal angles through a first driving mechanism.

[0044] See also Figure 4 and Figure 5 The organic solder flux spray assembly 11 includes two ultrasonic heating frames 1101 symmetrically fixedly connected to the tops of the two second workbenches 2. The organic solder flux is heated into a liquid state in the ultrasonic heating frames 1101. The ultrasonic heating frames 1101 are connected to a solder flux nozzle, and a liquid pump is installed on the solder flux nozzle. The other end of the solder flux nozzle is connected to a solder flux spray mechanism 1102. The two solder flux spray mechanisms 1102 are symmetrically slidably connected to the inner side walls of the two clamping blind tubes 91. The organic solder flux spray assembly 11 also includes two pairs of first hydraulic cylinders 1103 symmetrically fixedly connected to the tops of the two second workbenches 2. The output ends of the two pairs of first hydraulic cylinders 1103 penetrate the side walls of the clamping blind tube 91 and are respectively connected to the two solder flux spray mechanisms 1102.

[0045] See also Figure 6The ultrasonic welding machine 10 includes a moving ring 101 connected to the outer circumference of two clamping blind tubes 91 by a left and right moving assembly 13, and the two moving rings 101 are symmetrically connected to the outer circumference of the blind tube 91 by sliding. The two moving rings 101 are symmetrically connected to the inner side walls of the two rotating rings 102. Two high-frequency vibration mechanisms 103 are symmetrically fixedly connected. The high-frequency vibration mechanism 103 is a vibration welding ring. Two annular gears are symmetrically fixedly sleeved on the outer circumference of the ends of the two rotating rings 102 that are far away from each other. Annular receiving grooves are symmetrically opened on the inner side walls of the two moving rings 101. Two rectangular cavities are symmetrically opened at the top, and the bottom ends of the two rectangular cavities are respectively connected to the two accommodating grooves. The tops of the two moving rings 101 are symmetrically fixedly connected to two second motors 104, and the output ends of the two second motors 104 are symmetrically fixedly connected by two second gears 105. The two second gears 105 pass through the rectangular cavities and are respectively meshed with the two annular gears. The two pulse current generator anode ends 52 are symmetrically fixedly inserted on the outer walls of the two rotating rings 102, and the output ends of the two pulse current generator anode ends 52 pass through the outer wall of the rotating ring 102 and extend into its inner hole.

[0046] See also Figure 8 The auxiliary positioning assembly 12 includes two pairs of second hydraulic cylinders 1201 symmetrically fixedly connected to the top of the first workbench 1, two pairs of fixed blocks 1202 are symmetrically fixedly connected to the output ends of the two pairs of second hydraulic cylinders 1201, two pairs of third motors 1203 are symmetrically fixedly connected to the tops of the two pairs of fixed blocks 1202, two pairs of first rotating shafts 1204 are symmetrically fixedly connected to the output ends of the two pairs of third motors 1203, two pairs of arc-shaped receiving plates 1205 are symmetrically fixedly connected to the two pairs of first rotating shafts 1204, each pair of two receiving plates 1205 can be combined into a semicircular arc plate, and a plurality of unpowered rollers 1206 are equidistantly connected to the concave arc surface of the receiving plate 1205 for rotation along the arc direction of the arc surface.

[0047] Specifically, two pairs of receiving plates 1205 can be combined into two symmetrical semicircular arc plates to first receive the bridge shell lifted and transported by the lifting equipment, and then the staff cooperates with the unpowered roller 1206 on the receiving plate 1205 to adjust the position of the bridge shell so that the bridge shell is located directly above the welding position, and then the second hydraulic cylinder 1201 is started to drive the receiving plate 1205 to move downward so that the bridge shell moves downward to a position close to the top of the bridge shell clamping assembly 3, and then the two pairs of third motors 1203 are started to drive the two pairs of receiving plates 1205 to rotate in a direction away from each other until the ends of the two pairs of receiving plates 1205 are separated. When the bridge housing is welded, the bridge housing falls vertically on the bridge housing clamping assembly 3 and is clamped and fixed, thereby preventing the bridge housing from colliding with the bridge housing clamping assembly 3, the two clamping rings 62 and the cathode end 51 of the pulse current generator due to the shaking of the bridge housing position when the bridge housing falls directly on the bridge housing clamping assembly 3 and the two clamping rings 62 through the lifting equipment. It can also prevent the bridge housing from colliding with the two clamping rings 62 and the cathode end 51 of the pulse current generator when the bridge housing position is adjusted on the bridge housing clamping assembly 3, thereby ensuring the safety of the bridge housing clamping assembly 3, the two clamping rings 62, the cathode end 51 of the pulse current generator, the bridge housing and nearby personnel, and further improving the safety and reliability of the welding equipment.

[0048] See also Figure 8 The auxiliary positioning assembly 12 also includes two third hydraulic cylinders 1207 symmetrically fixedly connected to the top of the first workbench 1, and two top rollers 1208 are symmetrically fixedly connected to the output ends of the two third hydraulic cylinders 1207. The auxiliary positioning assembly 12 also includes two pairs of fourth motors 1209 symmetrically fixedly connected to the top of the first workbench 1, and two pairs of connecting blocks are symmetrically fixedly connected to the output ends of the two fourth motors 1209, and two pairs of round rods 1210 are symmetrically rotatably connected to the top ends of the two pairs of connecting blocks.

[0049] Specifically, after the front and rear positions of the bridge shell are adjusted on the two pairs of receiving plates 1205, the third hydraulic cylinder 1207 is started to drive the two top rollers 1208 to move upward so that the bridge shell is lifted up and separated from the receiving plates 1205, and then the two pairs of fourth motors 1209 are used to drive the two pairs of round rods 1210 to move in the direction close to the bridge shell to adjust the position of the bridge shell and limit the bridge shell. At the same time, the staff manually pushes the bridge shell back and forth along the axis of the shaft head with the assistance of the top roller hand 1208 to complete the bridge shell position adjustment work. Then the third hydraulic cylinder 1207 drives the top roller 1208 to move downward until the bridge shell falls on the two pairs of receiving plates 1205. This avoids sliding friction between the bridge shell and the unpowered roller 1206 when adjusting the axial position of the bridge shell on the unpowered roller 1206 at the receiving plate 1205, thereby avoiding damage caused by sliding friction, making the bridge shell position adjustment work more convenient and safe, and improving the reliability and convenience of the welding equipment.

[0050] Working principle: When in use, the two shaft heads are clamped on the two shaft head clamping assemblies 9, and then the bridge housing is hoisted onto the two pairs of receiving plates 1205 by hoisting equipment. Then the staff cooperates with the unpowered roller 1206 on the receiving plate 1205 to adjust the position of the bridge housing, so that the front and rear position of the bridge housing can be easily adjusted.

[0051] Then, the third hydraulic cylinder 1207 is started to drive the two top rollers 1208 to move upward so that the bridge shell is lifted up and separated from the receiving plate 1205. Then, two pairs of fourth motors 1209 are used to drive the two pairs of round rods 1210 to move toward the direction close to the bridge shell to adjust the position of the bridge shell and limit the bridge shell. At the same time, the staff manually pushes the bridge shell back and forth along the axis of the shaft head with the assistance of the top roller hand 1208 to complete the left and right position adjustment of the bridge shell. Then, the third hydraulic cylinder 1207 drives the top roller 1208 to move downward until the bridge shell falls on the two pairs of receiving plates 1205.

[0052] Then start the second hydraulic cylinder 1201 to drive the receiving plate 1205 to move downward so that the bridge housing moves downward to a position close to the top of the bridge housing clamping assembly 3, and then start the two pairs of third motors 1203 to drive the two pairs of receiving plates 1205 to rotate in a direction away from each other until the connected ends of the two pairs of receiving plates 1205 are separated. At this time, the bridge housing falls vertically on the bridge housing clamping assembly 3 and is clamped and fixed. At the same time, the two ends of the bridge housing fall on the concave arc surfaces of the two wrapping rings 63.

[0053] Then, the first motor 65 is started to drive the first gear 66 to rotate. The first gear 66 drives the wrapping ring 63 to rotate along the moving groove through the driving tooth 64 until the wrapping ring 63 rotates above the clamping ring 62 to wrap around the bridge housing to ensure the heating effect.

[0054] Subsequently, the two shaft head clamping assemblies 9 are driven to move forward and backward by the forward and backward moving assembly 7 until the axis lines of the two shaft heads and the bridge housing are collinear, and then the press 8 is started to push the end faces of the two shaft heads tightly against the left and right end faces of the bridge housing.

[0055] The flux is then heated to a liquid state by the ultrasonic heating frame 1101, and ultrasonic medium-frequency oscillation is used to generate cavitation nuclei in the flux. The flux spraying mechanism 1102 is then pushed to the welding end face by the first hydraulic cylinder 1103, and the organic flux that generates the cavitation nuclei is then sucked into the flux nozzle connected to the ultrasonic heating frame 1101, and high-frequency oscillation is performed on the organic flux at the end of the flux nozzle to form cavitation bubbles. The organic flux that forms cavitation bubbles is then sprayed toward the connecting end face of the shaft head and the bridge housing by the flux nozzle through the flux spraying mechanism 1102.

[0056] Then, the electromagnetic heater 6 is started to heat the temperature of the connecting end faces of the bridge housing and the shaft head to medium-low temperature through medium-frequency heating, so that under the conditions of increased temperature inside the metal and small eddy currents generated by the magnetic field, the free electrons in the interatomic metal bonds gain energy and increase their free movement rate, and the sliding frequency between the Fe+ metal atomic layers increases, thereby ensuring that the welding efficiency is improved.

[0057] Then start the second motor 104 to drive the second gear 105 to rotate, the second gear 105 engages to drive the ring gear to rotate, the ring gear drives the rotating ring 102 to rotate, the rotating ring 102 drives the high-frequency vibration mechanism 103 and the anode end 52 of the pulse current generator to contact the shaft head and rotate along the outer circumference of the shaft head, so that the high-frequency vibration mechanism 103 can perform ultrasonic vibration welding.

[0058] At the same time, the first cylinder 4 is started to push the cathode end 51 of the pulse current generator to move upward and contact the surface of the bridge housing, thereby forming a pulse current between the shaft head and the bridge housing together with the rotating anode end 52 of the pulse current generator. The electrons formed by the pulse current will be enriched at the connecting end face of the shaft head and the bridge housing. When the pulse current is disconnected, the electrons will be absorbed and stored by the flux sprayed on the connecting end face when they flow back, so that a large number of motors are enriched at the connecting end face, and the large accumulation of electrons causes the force between metal bonds to decrease and the diffusion effect between atoms to increase, which can greatly improve the welding efficiency.

[0059] When the pulse period of the pulse current generator, the contact and separation period of the anode terminal 52 of the pulse current generator, the oscillation frequency of the high-frequency vibration mechanism 103 of the ultrasonic welder 10, and the eddy current frequency of the electromagnetic heater 6 are kept consistent, each oscillation friction welding of the parts can be in a state where the metal atoms are most active and the metal bond attraction is smallest, thereby greatly improving the welding efficiency. At the same time, the diffused metal Fe+ atoms enter the conductive organic solder, forming a liquid-solid bonding state at a low temperature.

[0060] This equipment can integrate the shaft head welding process and the main reducer assembly assembly process in the bridge assembly production into one process, which does not interfere with the normal operation of the workers, provides sufficient space for completing the assembly, and shortens the time required for the production of the entire bridge.

[0061] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0062] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A new welding method for the middle and rear axle shaft head, characterized in that: The following steps are involved: S1: After the shaft head and the axle housing are coaxially positioned, push the shaft head along its axis line toward the axle housing until the connecting end surfaces of the two are initially pressed against each other; S2: spraying a low-temperature and conductive organic solder that forms cavitation bubbles onto the welding point between the shaft head and the bridge housing, and then starting the ultrasonic welder (10) so that the high-frequency vibration mechanism (103) of the ultrasonic welder (10) drives the shaft head and the bridge housing to generate high-frequency micron-level radial low-amplitude oscillations at the welding point between the shaft head and the bridge housing; S3: heating the position near the welding end surface of the shaft head and the bridge housing by means of an electromagnetic heater (6) until a set temperature is reached; S4: applying a pulse current between the shaft head welding surface and the bridge housing through a pulse current generator to cooperate with an ultrasonic welder (10) to weld the shaft head and the bridge housing.

2. A new welding method for a center and rear axle shaft head according to claim 1, characterized in that: When the connecting end faces of the shaft head and the bridge housing are initially pressed together, the pressure between the connecting end faces is less than the pressure value required for cold pressure welding, and under the action of this pressure, the fitting distance between the shaft head and the bridge housing can reach an average micrometer level.

3. A new welding method for a middle and rear axle head according to claim 2, characterized in that: The steps of forming cavitation bubbles by the organic solder are as follows: heating the solder to a liquid state by an ultrasonic heating frame (1101), and generating cavitation nuclei by oscillating the solder at an ultrasonic medium frequency; sucking the organic solder generating the cavitation nuclei into a solder nozzle connected to the ultrasonic heating frame (1101); performing high-frequency oscillation on the organic solder at the end of the solder nozzle to form cavitation bubbles; and then spraying the organic solder generating the cavitation bubbles by the solder nozzle through a solder spraying mechanism (1102).

4. A center and rear axle head welding device for the center and rear axle head new welding method according to any one of claims 1 to 3, comprising a first workbench (1) and two second workbench (2) symmetrically distributed on the left and right sides of the first workbench (1), characterized in that: A bridge housing clamping assembly (3) is provided on the top of the first workbench (1); two first cylinders (4) are symmetrically fixedly connected to the top of the first workbench (1); two cathode terminals (51) of pulse current generators are symmetrically fixedly connected to the output terminals of the two first cylinders (4); an electromagnetic heater (6) is installed on the top of the first workbench (1); two forward and backward moving assemblies (7) are symmetrically connected to the tops of the two second workbenches (2); two presses (8) are symmetrically connected to the two forward and backward moving assemblies (7); two shaft head clamping assemblies (9) are symmetrically fixedly connected to the output terminals of the two presses (8); two ultrasonic welders (10) and two anode terminals (52) of pulse current generators are symmetrically provided on the two shaft head clamping assemblies (9); two organic solder spraying assemblies (11) are symmetrically provided on the two shaft head clamping assemblies (9); and an auxiliary positioning assembly (12) for assisting in positioning and clamping the bridge housing on the bridge housing clamping assembly (3) is also provided on the top of the first workbench (1).

5. The center and rear axle head welding equipment according to claim 4 is characterized in that: The electromagnetic heater (6) comprises two first support frames (61) symmetrically fixedly connected to the top of the first workbench (1), two retaining rings (62) are symmetrically fixedly connected to the top of the two first support frames (61), two arc-shaped movable grooves are symmetrically provided in the two retaining rings (62), and a wrapping ring (63) is slidably connected in the two movable grooves, and a plurality of driving teeth (64) are fixedly connected at equal angles along the concave arc surface of the wrapping ring (63), two through cavities are symmetrically provided at the bottom of the two retaining rings (62), and the tops of the two through cavities are respectively connected to the bottom walls of the two movable grooves, and two first motors (65) are symmetrically fixedly connected to the top of the two first support frames (61), and the output ends of the two first motors (65) are fixedly connected to the first gears (66), and the tops of the two first gears (66) respectively pass through the two through cavities and respectively mesh with the driving teeth (64) on the two wrapping rings (63).

6. The center and rear axle head welding equipment according to claim 5 is characterized by: The shaft head clamping assembly (9) comprises a clamping blind tube (91) fixedly connected to the output end of the press machine (8), and a plurality of clamping claws (92) are connected to the inner side wall of the clamping blind tube (91) in an annular manner at equal angles through a first driving mechanism.

7. The center and rear axle head welding equipment according to claim 6 is characterized by: The organic solder flux spray assembly (11) comprises two ultrasonic heating frames (1101) symmetrically fixedly connected to the tops of the two second workbenches (2), the organic solder flux is heated into a liquid state in the ultrasonic heating frames (1101), the ultrasonic heating frames (1101) are connected to a solder flux spray pipe, a liquid pump is installed on the solder flux spray pipe, the other end of the solder flux spray pipe is connected to a solder flux spray mechanism (1102), the two solder flux spray mechanisms (1102) are symmetrically slidably connected to the inner side walls of the two clamping blind tubes (91), and the organic solder flux spray assembly (11) further comprises two pairs of first hydraulic cylinders (1103) symmetrically fixedly connected to the tops of the two second workbenches (2), the output ends of the two pairs of the first hydraulic cylinders (1103) penetrate the side walls of the clamping blind tube (91) and are respectively connected to the two solder flux spray mechanisms (1102).

8. The center and rear axle head welding equipment according to claim 4 is characterized by: The ultrasonic welding machine (10) comprises a moving ring (101) connected to the outer circumference of two clamping blind tubes (91) by symmetrical sliding through a left and right moving assembly (13); two rotating rings (102) are symmetrically rotatably connected at one end of the two moving rings (101) that are close to each other; two high-frequency vibration mechanisms (103) are symmetrically fixedly connected to the inner side walls of the two rotating rings (102); the high-frequency vibration mechanism (103) is a vibration welding ring; two annular gears are symmetrically fixedly sleeved on the outer circumference of one end of the two rotating rings (102) that are far away from each other; annular accommodating grooves are symmetrically provided on the inner side walls of the two moving rings (101); and the two moving rings (101) are provided with a plurality of ring-shaped gears. Two rectangular cavities are symmetrically provided on the top of the two moving rings (101), and the bottom ends of the two rectangular cavities are respectively connected to the two receiving grooves; two second motors (104) are symmetrically fixedly connected to the top of the two moving rings (101); the output ends of the two second motors (104) are symmetrically fixedly connected by two second gears (105); the two second gears (105) pass through the rectangular cavity and are respectively meshed with the two annular gears; the two anode ends (52) of the pulse current generators are symmetrically fixedly inserted on the outer side walls of the two rotating rings (102); the output ends of the two anode ends (52) of the pulse current generators pass through the outer side walls of the rotating rings (102) and extend into the inner hole thereof.

9. The center and rear axle head welding equipment according to claim 8, characterized in that: The auxiliary positioning assembly (12) comprises two pairs of second hydraulic cylinders (1201) symmetrically fixedly connected to the top of the first workbench (1), two pairs of fixed blocks (1202) symmetrically fixedly connected to the output ends of the two pairs of the second hydraulic cylinders (1201), two pairs of third motors (1203) symmetrically fixedly connected to the tops of the two pairs of the fixed blocks (1202), two pairs of first rotating shafts (1204) symmetrically fixedly connected to the output ends of the two pairs of the third motors (1203), two pairs of arc-shaped receiving plates (1205) symmetrically fixedly connected to the two pairs of the first rotating shafts (1204), each pair of two receiving plates (1205) can be combined into a semicircular arc plate, and a plurality of unpowered rollers (1206) are equidistantly connected to the concave arc surface of the receiving plate (1205) for rotation along the arc direction of the arc surface.

10. The center and rear axle head welding equipment according to claim 9, characterized in that: The auxiliary positioning assembly (12) also includes two third hydraulic cylinders (1207) symmetrically fixedly connected to the top of the first workbench (1), and two top rollers (1208) are symmetrically fixedly connected to the output ends of the two third hydraulic cylinders (1207). The auxiliary positioning assembly (12) also includes two pairs of fourth motors (1209) symmetrically fixedly connected to the top of the first workbench (1), and two pairs of connecting blocks are symmetrically fixedly connected to the output ends of the two fourth motors (1209), and the top ends of the two pairs of connecting blocks are symmetrically rotatably connected to two pairs of round rods (1210).

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