A method and equipment for welding the axle ends of a mid-rear axle

Abstract

This invention discloses a method and equipment for welding the axle ends of a mid-to-rear axle, relating to the field of welding technology for mid-to-rear axle ends. The welding equipment includes a first worktable and two second worktables symmetrically distributed on the left and right sides of the first worktable. An axle housing clamping assembly is provided on the top of the first worktable. Two first cylinders are symmetrically fixedly connected to the top of the first worktable, and the output ends of the two first cylinders are symmetrically fixedly connected to the cathodes of two pulse current generators. An electromagnetic heater is installed on the top of the first worktable. By using an ultrasonic welding machine and pulse current generators, safe welding can be achieved during the welding process without light or flame, under low pressure, medium-low temperature, and low voltage, while simultaneously welding materials of a certain thickness without requiring excessively high equipment capabilities, thus avoiding any threat to personnel and equipment in the assembly workshop.

Description

Technical Field

[0001] This invention relates to the field of welding technology for the axle ends of mid- and rear axles, specifically to a welding method and equipment for the axle ends of mid- and rear axles. Background Technology

[0002] The axle housing is an important component in the automotive transmission system. Currently, axle housings are mostly processed in separate parts and formed after welding. That is, the middle section of the axle housing is formed by stamping and welding of steel plates, while the two ends of the axle housing are formed by casting steel. The above two parts are only processed independently after forming. After their respective parts are processed, they are combined and welded to finally form the axle housing.

[0003] The axle housing axle head is a high-precision mating part in the drive axle assembly. Its machined surface directly mates with the oil seal seat ring, wheel hub bearing inner ring, ABS sensor, and axle head nut. These components are all important parts that directly affect the vehicle's wheel transmission efficiency and safety. In the current process, after the axle head is welded, it still needs to undergo shot blasting, painting, workshop buffer transfer, and cleaning before it can be put on the axle assembly line for wheel end assembly. However, when the axle head is welded to the axle housing and then shot blasting, painting, workshop buffer transfer, and cleaning are performed, the difficulty will increase significantly and the axle housing may be damaged during the processing.

[0004] However, if the axle head is shot-blasted, coated, transported in the workshop, and cleaned before being welded to the axle housing, the axle head welding would need to be done in the assembly workshop since the axle housing would be moved and assembled there. However, the industry commonly uses MIG welding, friction welding, and laser welding for axle head welding. These welding processes are highly polluting, have a high risk factor, and require a large area, making them unsuitable for assembly workshops with high personnel density and continuous operation. Therefore, we propose a method and equipment for welding the axle head of the mid- and rear axle. Summary of the Invention

[0005] The purpose of this invention is to provide a method and equipment for welding the axle heads of the middle and rear axles, so as to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a method for welding the axle head of a mid-rear axle, comprising the following steps:

[0007] S1: After coaxially positioning the shaft head and the axle housing, push the shaft head along its axis towards the axle housing until the connection end faces of the two are initially pressed together.

[0008] S2: Spray low-temperature and thermally conductive organic flux that forms cavitation bubbles onto the weld joint of the shaft head and the bridge housing, and then start the ultrasonic welding machine so that the high-frequency vibration mechanism of the ultrasonic welding machine drives the shaft head and the bridge housing to generate high-frequency micron-level radial low-amplitude oscillations at the weld joint.

[0009] S3: The area near the welding end face of the shaft head and bridge housing is heated by an electromagnetic heater until the set temperature is reached;

[0010] S4: A pulsed current is applied between the shaft head welding surface and the bridge housing using a pulsed current generator to cooperate with the ultrasonic welding machine for welding the shaft head and the bridge housing.

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

[0012] Preferably, the step of forming cavitation bubbles with the organic flux is as follows: the flux is heated to a liquid state by an ultrasonic heating frame, and cavitation nuclei are generated by ultrasonic mid-frequency oscillation of the flux; the organic flux with cavitation nuclei is drawn into a flux nozzle connected to the ultrasonic heating frame; the organic flux is subjected to high-frequency oscillation at the end of the flux nozzle to form cavitation bubbles; subsequently, the organic flux with cavitation bubbles is sprayed by the flux nozzle through a flux spraying mechanism to the connection end face of the shaft head and the bridge housing. The advantage of this arrangement is that the flux that forms cavitation bubbles will destroy the stability of the cavitation bubbles after being sprayed out from the flux spraying mechanism and colliding with the surface of the parts. The rapid rupture and closure of cavitation bubbles generates localized microscopic impacts, which burst and peel off the nearby oxide layer and roughness peaks. This, combined with the high-frequency vibration mechanism of the ultrasonic welding machine, drives the shaft head and bridge housing to generate high-frequency, micron-level radial low-amplitude oscillations at the welding point. This effectively removes the oxide layer and roughness at the connection end face of the shaft head and bridge housing, greatly increasing the actual contact area between the welding end face of the bridge housing and the shaft head. This allows the distance between the connection end face of the shaft head and the bridge housing to reach the nanometer level under the same driving force, enabling the interatomic metallic bond attraction to take effect, thus preparing for the welding work in conjunction with the pulse current generator.

[0013] A welding device for the above-described scheme includes a first worktable and two second worktables symmetrically distributed on the left and right sides of the first worktable. A bridge housing clamping assembly is provided on the top of the first worktable. Two first cylinders are symmetrically fixedly connected to the top of the first worktable. Two pulse current generator cathodes are symmetrically fixedly connected to the output ends of the two first cylinders. An electromagnetic heater is installed on the top of the first worktable. Two forward and backward moving assemblies are symmetrically connected to the tops of the two second worktables. 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 welding machines and two pulse current generator anodes are symmetrically provided on the two shaft head clamping assemblies. Two organic flux spraying assemblies are symmetrically provided on the two shaft head clamping assemblies. An auxiliary positioning assembly is also provided on the top of the first worktable to assist in positioning and clamping the bridge housing onto the bridge housing clamping assembly.

[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 moving grooves are symmetrically opened in the two retaining rings. Enclosing rings are slidably connected in the two moving grooves. Multiple driving teeth are fixedly connected at equal angles along the concave arc surface of the enclosing rings. Two through cavities are symmetrically opened at the bottom of the two retaining rings. The tops of the two through cavities are respectively connected to the bottom walls of the two moving grooves. Two first motors are symmetrically fixedly connected to the top of the two first support frames. First gears are fixedly connected to the output ends of the two first motors. The tops of the two first gears respectively penetrate the two through cavities and mesh with the driving teeth on the two enclosing rings.

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

[0016] Preferably, the organic flux spraying assembly includes two ultrasonic heating frames symmetrically fixedly connected to the tops of two second workbenches. The organic flux is heated into a liquid state within the ultrasonic heating frames. Each ultrasonic heating frame is connected to a flux spray pipe, on which a liquid pump is installed. The other end of the flux spray pipe is connected to a flux spraying mechanism. Two flux spraying mechanisms are symmetrically slidably connected to the inner sidewalls of two clamping blind tubes. The organic flux spraying assembly also includes two pairs of first hydraulic cylinders symmetrically fixedly connected to the tops of the two second workbenches. The output ends of the two pairs of first hydraulic cylinders penetrate the sidewalls of the clamping blind tubes and are respectively connected to the two flux spraying mechanisms.

[0017] Preferably, the ultrasonic welding machine includes two movable rings symmetrically slidably connected to the outer circumference of the clamping blind tube via left and right moving components. Two rotating rings are symmetrically rotatably connected to the near ends of the two movable rings. Two high-frequency vibration mechanisms, which are vibration welding rings, are symmetrically fixedly connected to the inner walls of the two rotating rings. Two ring gears are symmetrically fixedly sleeved on the outer circumference of the far ends of the two rotating rings. Annular receiving grooves are symmetrically formed on the inner walls of the two movable rings. Two rectangular cavities are symmetrically formed at the top of the two movable rings, with the bottom ends of the two rectangular cavities respectively connected to the two receiving grooves. Two second motors are symmetrically fixedly connected to the top of the two movable rings. Two second gears are symmetrically fixedly connected to the output ends of the two second motors, passing through the rectangular cavities and meshing with the two ring gears respectively. The anodes of two pulse current generators are symmetrically fixedly inserted into the outer walls of the two rotating rings, with the output ends of the anodes of the two pulse current generators passing through the outer walls of the rotating rings and extending 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 fixing blocks are symmetrically fixedly connected to the output ends of the two pairs of second hydraulic cylinders. Two pairs of third motors are symmetrically fixedly connected to the top of the two pairs of fixing blocks. Two pairs of first rotating shafts are symmetrically fixedly connected to the output ends of the two pairs of third motors. Two pairs of arc-shaped receiving plates are symmetrically fixedly connected to the two pairs of first rotating shafts. Each pair of two receiving plates can be combined to form a semi-circular arc plate. Multiple 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 this arrangement is that it can avoid collisions between the bridge housing and the two retaining rings and the cathode of the pulse current generator when adjusting the position of the bridge housing on the bridge housing clamping assembly. This ensures the safety of the bridge housing clamping assembly, the two retaining rings, the cathode of the pulse current generator, the bridge housing, and nearby personnel, further improving the safety and reliability of the welding equipment.

[0019] Preferably, the auxiliary positioning assembly further includes two third hydraulic cylinders symmetrically fixedly connected to the top of the first worktable, and two top rollers 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 worktable, and two pairs of connecting blocks symmetrically fixedly connected to the output ends of the two fourth motors. Two pairs of round rods are symmetrically rotatably connected to the top ends of the two pairs of connecting blocks. The advantage of this arrangement is that it can avoid the sliding friction 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, which would cause damage. This makes the bridge housing position adjustment work more convenient and safe, and improves the reliability and convenience of the welding equipment.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] This invention utilizes flux that forms cavitation bubbles. Upon impact with the component surface, the stability of the cavitation bubbles is disrupted, causing them to rapidly rupture and close. This generates localized microscopic impacts, shattering and peeling off nearby oxide layers and roughness peaks. Combined with the high-frequency vibration mechanism of an ultrasonic welding machine, high-frequency, micron-level radial low-amplitude oscillations are generated at the weld joint between the shaft head and the bridge housing. This effectively removes the oxide layer and roughness at the connection end faces of the shaft head and bridge housing, significantly increasing the actual contact area between the welded end faces. This allows the distance between the connection end faces of the shaft head and bridge housing to reach the nanometer level under the same driving force, enabling the interatomic metallic bond attraction to take effect. This interatomic metallic bond attraction allows the pulse current generator to apply force to the shaft head and bridge housing. Electrons from the pulsed current loop are transmitted to the connection end face of the shaft head and the bridge housing. When the pulsed current is disconnected, the electrons are absorbed and stored by the flux sprayed on the connection end face during the return flow. This results in a large number of electrons being concentrated at the connection end face. The large accumulation of electrons leads to a decrease in the interaction force between metal bonds and an increase in the diffusion between atoms. This greatly improves the welding efficiency. The welding work is completed by the cooperation of the ultrasonic welding machine and the pulsed current generator. During the welding process, safe welding with no light, no flame, low pressure, medium and low temperature, and low voltage can be achieved. At the same time, welding of a certain thickness of welding material can be performed without excessive equipment capacity requirements, thereby avoiding the threat of welding to personnel and equipment in the assembly workshop. Attached Figure Description

[0022] Figure 1 This is a flowchart of a method for welding the rear axle head of a mid-to-rear axle according to the present invention;

[0023] Figure 2 This is a schematic diagram of the structure of a mid-rear axle head welding device according to the present invention;

[0024] Figure 3 This is a partial structural diagram of a mid-rear axle head welding device according to the present invention;

[0025] Figure 4 This is a schematic diagram of a second partial structure of a mid-rear axle head welding device according to the present invention;

[0026] Figure 5 This is a schematic diagram of a third partial structure of a mid-rear axle head welding device according to the present invention;

[0027] Figure 6 This is a schematic diagram of the fourth partial structure of a mid-rear axle head welding device according to the present invention;

[0028] Figure 7 for Figure 3 A schematic diagram of the fifth partial structure of a welding equipment for the rear axle head of a central axle;

[0029] Figure 8A side view for assisting in positioning components.

[0030] In the diagram: 1. First worktable; 2. Second worktable; 3. Bridge housing clamping assembly; 4. First cylinder; 51. Cathode of pulse current generator; 52. Anode of pulse current generator; 6. Electromagnetic heater; 61. First support frame; 62. Snap ring; 63. Wrapping ring; 64. Drive gear; 65. First motor; 66. First gear; 7. Forward and backward moving assembly; 8. Press; 9. Shaft head clamping assembly; 91. Clamping blind tube; 92. Clamping jaw; 10. Ultrasonic welding machine; 101. Moving ring; 102. Rotating ring; 03. High-frequency vibration mechanism; 104. Second motor; 105. Second gear; 11. Organic flux spraying assembly; 1101. Ultrasonic heating frame; 1102. Flux spraying mechanism; 1103. First hydraulic cylinder; 12. Auxiliary positioning assembly; 1201. Second hydraulic cylinder; 1202. Fixing block; 1203. Third motor; 1204. First rotating shaft; 1205. Receiving plate; 1206. Unpowered roller; 1207. Third hydraulic cylinder; 1208. Top roller; 1209. Fourth motor; 1210. Round rod. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] Please see Figure 1 The method for welding the rear axle head shown in the figure includes the following steps:

[0033] S1: After coaxially positioning the shaft head and the axle housing, push the shaft head along its axis towards the axle housing until the connection end faces of the two are initially pressed together.

[0034] S2: Low-temperature and thermally conductive organic flux that forms cavitation bubbles is sprayed onto the weld joint of the shaft head and the bridge housing. Then, the ultrasonic welding machine 10 is started so that the high-frequency vibration mechanism 103 of the ultrasonic welding machine 10 drives the shaft head and the bridge housing to generate high-frequency micron-level radial low-amplitude oscillations at the weld joint.

[0035] S3: The area near the welding end face of the shaft head and bridge housing is heated by electromagnetic heater 6 until the set temperature is reached;

[0036] S4: Apply pulsed current between the shaft head welding surface and the bridge housing using a pulsed current generator to cooperate with the ultrasonic welding machine 10 to weld the shaft head and the bridge housing.

[0037] When the connecting end faces of the shaft head and the axle housing are initially pressed together, the pressure between the two connecting end faces is less than the pressure value required for cold pressure welding, and under this pressure, the contact distance between the shaft head and the axle housing can reach the average micrometer level.

[0038] The steps for forming cavitation bubbles with organic flux are as follows: the flux is heated to a liquid state by an ultrasonic heating frame 1101, and cavitation nuclei are generated by ultrasonic mid-frequency oscillation of the flux; the organic flux with cavitation nuclei is drawn into a flux nozzle connected to the ultrasonic heating frame 1101; the organic flux is oscillated at high frequency at the end of the flux nozzle to form cavitation bubbles; and then the organic flux with cavitation bubbles is sprayed by the flux nozzle through the flux spraying mechanism 1102 to the connection end face of the shaft head and the bridge housing.

[0039] Specifically, the flux forming cavitation bubbles is sprayed from the flux spraying mechanism 1102 and, upon impacting the surface of the component, disrupts the stability of the cavitation bubbles. The cavitation bubbles rapidly rupture and close, generating localized microscopic impacts that burst and peel off the nearby oxide layer and roughness peaks. This, combined with the high-frequency vibration mechanism 103 of the ultrasonic welding machine 10, drives the shaft head and bridge housing to generate high-frequency, micron-level radial low-amplitude oscillations at the welding point, effectively removing the oxide layer and roughness at the connection end face of the shaft head and bridge housing. This significantly increases the actual contact area between the welding end face of the bridge housing and the shaft head, allowing the distance between the connection end face of the shaft head and bridge housing to reach the nanometer level under the same driving force, enabling the interatomic metallic bond attraction to take effect and preparing for the welding work in conjunction with the pulse current generator.

[0040] Please see Figures 2-8 A welding device for the above-mentioned scheme includes a first workbench 1 and two second workbench 2 symmetrically distributed on the left and right sides of the first workbench 1. The top of the first workbench 1 is provided with a bridge housing clamping assembly 3. Two first cylinders 4 are symmetrically fixedly connected to the top of the first workbench 1. The output ends of the two first cylinders 4 are symmetrically fixedly connected with two pulse current generator cathodes 51. An electromagnetic heater 6 is installed on the top of the first workbench 1. The tops of the two second workbench 2 are symmetrically connected with two front-back moving assemblies 7. Two presses 8 are symmetrically connected to the two front-back moving assemblies 7. Two shaft head clamping assemblies 9 are symmetrically fixedly connected to the output ends of the two presses 8. Two ultrasonic welding machines 10 and two pulse current generator anodes 52 are symmetrically provided on the two shaft head clamping assemblies 9. Two organic flux spraying assemblies 11 are symmetrically provided on the two shaft head clamping assemblies 9. The top of the first workbench 1 is also provided with an auxiliary positioning assembly 12 for assisting in positioning and clamping the bridge housing on the bridge housing clamping assembly 3.

[0041] See 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 opened in the two retaining rings 62. Enclosing rings 63 are slidably connected in the two moving grooves. Multiple driving teeth 64 are fixedly connected at equal angles along the concave arc surface of the enclosing rings 63. Two through cavities are symmetrically opened at the bottom of the two retaining rings 62. The tops of the two through cavities are respectively connected to the bottom walls of the two moving grooves. Two first motors 65 are symmetrically fixedly connected to the top of the two first support frames 61. First gears 66 are fixedly connected to the output ends of the two first motors 65. The tops of the two first gears 66 pass through the two through cavities and mesh with the driving teeth 64 on the two enclosing rings 63 respectively.

[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 moving groove through the drive gear 64. This allows the wrapping ring 63 to rotate into the moving groove when the bridge housing is placed into or removed from the retaining ring 62, making the insertion or removal of the bridge housing convenient. When the bridge housing is placed into the retaining ring 62 and needs to be heated, the wrapping ring 63 is rotated above the retaining ring 62 to surround and wrap the bridge housing to ensure the heating effect.

[0043] See Figure 5 The shaft head clamping assembly 9 includes a clamping blind tube 91 fixedly connected to the output end of the press 8. Several clamping claws 92 are connected in a ring at equal angles on the inner wall of the clamping blind tube 91 by a first driving mechanism.

[0044] See Figure 4 and Figure 5 The organic flux spraying assembly 11 includes two ultrasonic heating frames 1101 symmetrically fixedly connected to the top of the two second workbenches 2. The organic flux is heated into a liquid state inside the ultrasonic heating frames 1101. The ultrasonic heating frames 1101 are connected to flux spray pipes, and a liquid pump is installed on the flux spray pipes. The other end of the flux spray pipes is connected to flux spraying mechanisms 1102. The two flux spraying mechanisms 1102 are symmetrically slidably connected to the inner sidewalls of the two clamping blind tubes 91. The organic flux spraying assembly 11 also includes two pairs of first hydraulic cylinders 1103 symmetrically fixedly connected to the top of the two second workbenches 2. The output ends of the two pairs of first hydraulic cylinders 1103 pass through the sidewalls of the clamping blind tubes 91 and are respectively connected to the two flux spraying mechanisms 1102.

[0045] See Figure 6The ultrasonic welding machine 10 includes two movable rings 101 symmetrically slidably connected to the outer circumferential surfaces of two clamping blind tubes 91 via left and right moving components 13. Two rotating rings 102 are symmetrically rotatably connected to the near ends of the two movable rings 101. Two high-frequency vibration mechanisms 103, which are vibration welding rings, are symmetrically fixedly connected to the inner walls of the two rotating rings 102. Two annular gears are symmetrically fixedly sleeved on the outer circumferential surfaces of the far ends of the two rotating rings 102. Annular receiving grooves are symmetrically formed on the inner walls of the two movable rings 101. Two rectangular cavities are symmetrically opened at the top, and the bottom ends of the two rectangular cavities are respectively connected to two receiving slots. 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 to two second gears 105. The two second gears 105 pass through the rectangular cavities and mesh with two ring gears respectively. The anodes 52 of two pulse current generators are symmetrically fixedly inserted into the outer walls of the two rotating rings 102. The output ends of the anodes 52 of the two pulse current generators pass through the outer walls of the rotating rings 102 and extend into their inner holes.

[0046] See Figure 8 The auxiliary positioning component 12 includes two pairs of second hydraulic cylinders 1201 symmetrically fixedly connected to the top of the first worktable 1. Two pairs of fixing 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 top of the two pairs of fixing 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 to form a semi-circular arc plate. Multiple unpowered rollers 1206 are equidistantly connected to the concave arc surface of the receiving plate 1205 along the arc direction of the arc surface.

[0047] Specifically, the bridge housing, lifted and transported by the hoisting equipment, can be initially supported by two pairs of receiving plates 1205 forming two symmetrical semi-circular arc plates. Then, workers use the non-powered rollers 1206 on the receiving plates 1205 to adjust the position of the bridge housing so that it is directly above the welding position. Next, the second hydraulic cylinder 1201 is activated to move the receiving plates 1205 downwards, causing the bridge housing to move down to a position close to the top of the bridge housing clamping assembly 3. Then, two pairs of third motors 1203 are activated to rotate the two pairs of receiving plates 1205 in a direction away from each other until the ends of the two pairs of receiving plates 1205 connected separate. When the bridge housing is vertically placed on the bridge housing clamping assembly 3 and clamped and fixed, it can avoid the bridge housing from colliding with the bridge housing clamping assembly 3, the two retaining rings 62, and the cathode end 51 of the pulse current generator due to the swaying position of the bridge housing when it is directly placed on the top of the bridge housing clamping assembly 3 and the two retaining rings 62 by the hoisting equipment. It can also avoid the bridge housing colliding with the two retaining rings 62 and the cathode end 51 of the pulse current generator when adjusting the position of the bridge housing on the bridge housing clamping assembly 3. This ensures the safety of the bridge housing clamping assembly 3, the two retaining rings 62, the cathode end 51 of the pulse current generator, the bridge housing, and the nearby personnel, and further improves the safety and reliability of the welding equipment.

[0048] See Figure 8 The auxiliary positioning component 12 also includes two third hydraulic cylinders 1207 symmetrically fixedly connected to the top of the first worktable 1. Two top rollers 1208 are symmetrically fixedly connected to the output ends of the two third hydraulic cylinders 1207. The auxiliary positioning component 12 also includes two pairs of fourth motors 1209 symmetrically fixedly connected to the top of the first worktable 1. Two pairs of connecting blocks are symmetrically fixedly connected to the output ends of the two fourth motors 1209. 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 bridge housing is adjusted to the front and rear positions on the two pairs of support plates 1205, the third hydraulic cylinder 1207 is activated to drive the two top rollers 1208 upwards, so that the bridge housing is lifted and separated from the support plates 1205. Then, the two pairs of fourth motors 1209 drive the two pairs of round rods 1210 to move towards the bridge housing to adjust the position of the bridge housing and limit its movement. At the same time, with the assistance of the top rollers 1208, the operator manually pushes the bridge housing back and forth along the axis of the shaft head to complete the bridge housing position adjustment. Then, the third hydraulic cylinder 1207 drives the top rollers 1208 downwards until the bridge housing falls on the two pairs of support plates 1205. This avoids the sliding friction between the bridge housing and the unpowered rollers 1206 when adjusting the axial position of the bridge housing on the support plates 1205, which could cause damage. This makes the bridge housing position adjustment more convenient and safe, and improves 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 components 9, and then the bridge shell is hoisted onto the two pairs of receiving plates 1205 by the hoisting equipment. Then, the staff uses the non-powered rollers 1206 on the receiving plates 1205 to adjust the position of the bridge shell so that the front and rear positions of the bridge shell can be easily adjusted.

[0051] Then, the third hydraulic cylinder 1207 is activated to drive the two top rollers 1208 to move upward so that the bridge shell is lifted and separated from the receiving plate 1205. Then, the two pairs of fourth motors 1209 drive the two pairs of round rods 1210 to move towards the bridge shell to adjust the position of the bridge shell and limit the bridge shell. At the same time, with the assistance of the top roller hand 1208, the operator manually pushes the bridge shell back and forth along the axis of the shaft head 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, the second hydraulic cylinder 1201 is activated to move the receiving plate 1205 downward so that the bridge housing moves downward to a position close to the top of the bridge housing clamping assembly 3. Then, the two pairs of third motors 1203 are activated to drive the two pairs of receiving plates 1205 to rotate in a direction away from each other until the end of the two pairs of receiving plates 1205 connected is 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 surface 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 drive teeth 64 until the wrapping ring 63 rotates above the retaining ring 62 to surround and wrap the bridge housing to ensure the heating effect.

[0054] Then, the two shaft head clamping components 9 are moved back and forth by the forward and backward moving component 7 until the two shaft heads and the axis of the axle housing are collinear. Then, the press 8 is started to push the end faces of the two shaft heads to press tightly against the left and right end faces of the axle housing.

[0055] The flux is then heated to a liquid state by the ultrasonic heating frame 1101, and cavitation nuclei are generated by the ultrasonic mid-frequency oscillation of the flux. Then, the flux spraying mechanism 1102 is moved to the welding end face by the first hydraulic cylinder 1103. The organic soft flux that generates cavitation nuclei is then sucked into the flux spraying pipe connected to the ultrasonic heating frame 1101. The organic soft flux is subjected to high-frequency oscillation at the end of the flux spraying pipe to form cavitation bubbles. The organic soft flux that forms cavitation bubbles is then sprayed by the flux spraying pipe through the flux spraying mechanism 1102 to the connection end face of the shaft head and the axle housing.

[0056] Then, the electromagnetic heater 6 is activated to heat the bridge housing and shaft head connection end face to a medium-low temperature through medium-frequency heating. 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 their free movement speed increases. The sliding frequency between Fe+ metal atomic layers increases, thereby ensuring that the welding efficiency is improved.

[0057] Then, the second motor 104 is started to drive the second gear 105 to rotate. The second gear 105 meshes with and drives 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] Simultaneously, the first cylinder 4 is activated, pushing the cathode end 51 of the pulse current generator upward to contact the surface of the bridge housing. This, together with the rotating anode end 52 of the pulse current generator, forms a pulse current between the shaft head and the bridge housing. The electrons generated by the pulse current accumulate at the connection end face of the shaft head and the bridge housing. When the pulse current is disconnected, the electrons are absorbed and stored by the flux sprayed on the connection end face during their return flow. This results in a large number of electrons being concentrated at the connection end face. The large accumulation of electrons leads to a decrease in the interaction force between metal bonds and an increase in the diffusion effect between atoms, which can greatly improve the welding efficiency.

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

[0060] This equipment integrates the axle head welding process and the main reducer assembly process in bridge assembly production into one process, which does not interfere with the normal operation of workers, provides sufficient space to complete the assembly, and shortens the time required for the production of the whole bridge.

[0061] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

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

Claims

1. A method for welding the axle head of a mid-rear axle, characterized in that, Includes the following steps: S1: After coaxially positioning the shaft head and the axle housing, push the shaft head along its axis towards the axle housing until the connection end faces of the two are initially pressed together. S2: Spray low-temperature and conductive organic flux that forms cavitation bubbles onto the weld joint of the shaft head and the bridge housing, and then start the ultrasonic welding machine (10) so that the high-frequency vibration mechanism (103) of the ultrasonic welding machine (10) drives the shaft head and the bridge housing to generate high-frequency micron-level radial low-amplitude oscillations at the weld joint. S3: The area near the welding end face of the shaft head and bridge housing is heated by electromagnetic heater (6) until the set temperature is reached; S4: Apply pulsed current between the shaft head welding surface and the bridge housing using a pulsed current generator to cooperate with the ultrasonic welding machine (10) to weld the shaft head and the bridge housing; The steps for forming cavitation bubbles with the organic flux are as follows: the flux is heated to a liquid state by an ultrasonic heating frame (1101), and cavitation nuclei are generated by ultrasonic mid-frequency oscillation of the flux; the organic flux with cavitation nuclei is drawn into a flux nozzle connected to the ultrasonic heating frame (1101); the organic flux is oscillated at high frequency at the end of the flux nozzle to form cavitation bubbles; and then the organic flux with cavitation bubbles is sprayed by the flux nozzle through the flux spraying mechanism (1102) to the connection end face of the shaft head and the bridge housing.

2. The method for welding the axle head of a mid-rear axle 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 two connecting end faces is less than the pressure value required for cold pressure welding, and under this pressure, the contact distance between the shaft head and the bridge housing can reach the average micrometer level.

3. A welding device for the axle head of a mid-rear axle as described in any one of claims 1-2, comprising a first worktable (1) and two second worktables (2) symmetrically distributed on the left and right sides of the first worktable (1), characterized in that: The first workbench (1) is provided with a bridge housing clamping assembly (3) on the top. Two first cylinders (4) are symmetrically fixedly connected to the top of the first workbench (1). Two pulse current generator cathodes (51) 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 front and back moving assemblies (7) are symmetrically connected to the top of the two second workbench (2). Two presses (8) are symmetrically connected to the two front and back moving assemblies (7). Two shaft head clamping assemblies (9) are symmetrically fixedly connected to the output ends of the two presses (8). Two ultrasonic welding machines (10) and two pulse current generator anodes (52) are symmetrically provided on the two shaft head clamping assemblies (9). Two organic soft flux spraying assemblies (11) are symmetrically provided on the two shaft head clamping assemblies (9). The top of the first workbench (1) is also provided with an auxiliary positioning assembly (12) for assisting in positioning and clamping the bridge housing on the bridge housing clamping assembly (3). The ultrasonic welding machine (10) includes two movable rings (101) symmetrically slidably connected to the outer circumference of two clamping blind tubes (91) via left and right moving components (13). Two rotating rings (102) are symmetrically rotatably connected to the near ends of the two movable rings (101). Two high-frequency vibration mechanisms (103) are symmetrically fixedly connected to the inner walls of the two rotating rings (102). The high-frequency vibration mechanisms (103) are vibration welding rings. Two annular gears are symmetrically fixedly sleeved on the outer circumference of the far ends of the two rotating rings (102). Annular receiving grooves are symmetrically opened on the inner walls of the two movable rings (101). Two rectangular cavities are symmetrically opened on the top of the two moving rings (101). The bottom ends of the two rectangular cavities are respectively connected to two receiving slots. 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 to two second gears (105). The two second gears (105) pass through the rectangular cavities and mesh with two ring gears respectively. The anodes (52) of the two pulse current generators are symmetrically fixedly inserted into the outer walls of the two rotating rings (102). The output ends of the anodes (52) of the two pulse current generators pass through the outer walls of the rotating rings (102) and extend into their inner holes.

4. The welding equipment for the middle and rear axle ends according to claim 3, characterized in that: The 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 opened in the two retaining rings (62). Enclosing rings (63) are slidably connected in the two moving grooves. Multiple driving teeth (64) are fixedly connected at equal angles along the concave arc surface of the enclosing rings (63). Two through cavities are symmetrically opened at the bottom of the two retaining rings (62). The top of the two through cavities are respectively connected to the bottom wall of the two moving grooves. Two first motors (65) are symmetrically fixedly connected to the top of the two first support frames (61). The output end of the two first motors (65) is fixedly connected to the first gears (66). The top of the two first gears (66) respectively penetrates the two through cavities and meshes with the driving teeth (64) on the two enclosing rings (63).

5. The welding equipment for the rear axle head of a mid-to-rear axle according to claim 4, characterized in that: The shaft head clamping assembly (9) includes a clamping blind tube (91) fixedly connected to the output end of the press (8). Several clamping claws (92) are connected in a ring at equal angles on the inner side wall of the clamping blind tube (91) by the first driving mechanism.

6. The welding equipment for the middle and rear axle ends according to claim 5, characterized in that: The organic flux spraying assembly (11) includes two ultrasonic heating frames (1101) symmetrically fixedly connected to the top of two second workbenches (2). The organic flux is heated into a liquid state in the ultrasonic heating frames (1101). The ultrasonic heating frames (1101) are connected to flux spray pipes. A liquid pump is installed on the flux spray pipes. The other end of the flux spray pipes is connected to flux spraying mechanisms (1102). The two flux spraying mechanisms (1102) are symmetrically slidably connected to the inner sidewalls of two clamping blind tubes (91). The organic flux spraying assembly (11) also includes two pairs of first hydraulic cylinders (1103) symmetrically fixedly connected to the top of two second workbenches (2). The output ends of the two pairs of first hydraulic cylinders (1103) penetrate the sidewalls of the clamping blind tubes (91) and are respectively connected to the two flux spraying mechanisms (1102).

7. The welding equipment for the rear axle head of a mid-to-rear axle according to claim 6, characterized in that: The auxiliary positioning component (12) includes two pairs of second hydraulic cylinders (1201) symmetrically fixedly connected to the top of the first workbench (1). Two pairs of fixing 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 top of the two pairs of fixing 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 to form a semi-circular arc plate. Multiple unpowered rollers (1206) are equidistantly connected to the concave arc surface of the receiving plate (1205) along the arc direction of the arc surface.

8. The welding equipment for the middle and rear axle ends according to claim 7, characterized in that: The auxiliary positioning component (12) also includes two third hydraulic cylinders (1207) symmetrically fixedly connected to the top of the first worktable (1). Two top rollers (1208) are symmetrically fixedly connected to the output ends of the two third hydraulic cylinders (1207). The auxiliary positioning component (12) also includes two pairs of fourth motors (1209) symmetrically fixedly connected to the top of the first worktable (1). Two pairs of connecting blocks are symmetrically fixedly connected to the output ends of the two fourth motors (1209). Two pairs of round rods (1210) are symmetrically rotatably connected to the top ends of the two pairs of connecting blocks.

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