Intelligent manufacturing device for roof panel of motor train unit and using method of intelligent manufacturing device

Abstract

The invention discloses an intelligent manufacturing device for a motor train unit roof panel and a using method of the intelligent manufacturing device, and belongs to the field of motor train unit roof panel manufacturing devices. The intelligent manufacturing device comprises a servo motor array control system connected with an upper computer, a plurality of sets of profile positioning mechanisms and an intelligent control lifting matrix mechanism. The profile positioning mechanism comprises a door-shaped support, two sections of T-shaped bolt adjustable guide rails and two vertical industrial pressing pliers. Modularization and maintainability optimization design of the device structure are considered, the product repair rate is reduced, meanwhile, the labor cost can be reduced, the risk that an operator is injured due to collision or workpieces and production equipment are collided and scratched when frequently carrying and adjusting profiles is avoided, and the production efficiency is improved. And obvious effects are achieved in the aspects of saving energy, reducing consumption, prolonging the service life of equipment, reducing the production cost and the like.

Description

Technical Field

[0001] The present invention belongs to the field of EMU roof panel manufacturing devices, and in particular relates to an intelligent manufacturing device for EMU roof panels and a use method thereof. Background Art

[0002] like Figures 1 to 5 As shown, the roof panel A of the EMU is a large-scale welded material with a circular arc surface. It is usually formed by welding two transition circular arc panels A2 and two side circular arc panels A3 in a left-right symmetrical manner on both sides of the middle panel A1. The middle panel A1 is relatively straight, but the curvature of the transition circular arc panel A2 and the two side circular arc panels A3 increases in sequence, so the assembly process of the roof panel A usually requires a more complicated assembly process. Figure 3 As shown, the outer end of the side arc plate A3 has a profiled side A3-1 extending outward; Figure 4 As shown, the upper and lower arc surfaces of the middle plate A1 and the transition arc plate A2 respectively form the first weld seam K1 of the outer end surface and the first weld seam T1 of the inner end surface in the form of a plug-in terminal structure; Figure 5 As shown, the upper and lower arc surfaces of the transition arc plate A2 and the side arc plate A3 respectively form the outer end surface second weld K2 and the inner end surface second weld T2 in the form of a plug-in terminal structure with a larger curvature.

[0003] The known technology for the assembly process of the roof panel A usually uses nylon blocks or plug-in plate type tooling to adjust the weld assembly height and arc splicing angle between the intermediate plate A1, the arc plate A2 and the side arc plate A3, wherein the nylon pad and arc plug-in plate structure tooling are only applicable to the arc and width of the roof panel of a single type of section. However, for the body structure with different cross-sections, the arc, width, weld position, and chute rib position of the roof panels of their respective models are all different. In order to adapt to different cross-sectional characteristics and welding deformation trends, different nylon pads or arc plug-ins need to be made for replacement. Therefore, a large amount of tooling costs and replacement cycles are required to meet the production of different projects. For example, the serial cross-production of train projects of different models requires the design of new nylon block supports or plug-in plate type tooling for daily tooling replacement in order to achieve adaptive matching. This method seriously wastes production time, affects the production line rhythm and reduces production efficiency.

[0004] On the other hand, nylon block supports or plug-in type tooling generally have the problems of low positioning accuracy, easy wear, and the tooling needs to be classified and numbered to avoid confusion when changing models, which leads to the locking of the outbound and inbound processes, and it is difficult to change and adjust after trial production, and can only be reproduced in batches. These factors make their versatility very poor, resulting in the need to repeatedly debug the model and position of the nylon block support or plug-in type tooling during the production process of the roof panel products, causing problems with unstable product quality.

[0005] In addition, when assembling the roof panel profiles, after lifting various types of profiles to the tooling, it is necessary to rely on manual repeated mapping and adjustment of the profile position, and repeatedly adjust the size of the nylon block support or the plug-in plate position and shape to ensure that the weld joint and the welding gap meet the welding requirements. This manual mapping and repeated adjustment of the profile position assembly process is not only time-consuming and labor-intensive, and inefficient, but also has the potential safety hazards of damaging the workpiece or causing bumps and falls to the operator; moreover, for the normal assembly welding of the convex arc surface of the roof panel A and the reverse assembly welding of the concave arc surface, two process equipment, a normal assembly welding station fixture and a reverse assembly welding fixture, need to be manufactured respectively, which increases the design of the fixture to a considerable extent. The design and manufacturing costs increase, and the occupation of workshop space is increased; at the same time, in the production process of the roof panel, it often happens that due to different batches of profiles and changes in suppliers and manufacturers, it is found during the welding process that the prefabricated welding anti-deformation values ​​corresponding to the initial batch of nylon blocks or plug-in tooling cannot achieve the target anti-deformation process effect for the size of the roof panel weldment, resulting in large fluctuations in the values ​​of the prefabricated welding anti-deformation parameters of the roof panel weldment, which in turn causes large fluctuations in the parameters such as the final forming curvature or size of the EMU roof panel after welding and cooling, and a high rework rate. Sometimes, the tooling even needs to be re-manufactured or even newly manufactured, so it cannot well meet the production needs of enterprises to reduce costs and increase efficiency. Summary of the invention

[0006] In order to solve the existing manufacturing process of EMU roof panels based on nylon block support or plug-in plate tooling, the wide and large arc-shaped profile weldments need to manufacture two workstations, a reverse-mounted welding fixture and a normal-mounted welding fixture, respectively during the welding assembly process, which doubles the equipment investment and increases the site occupation. In addition, the tooling needs to be recalibrated when switching between different models of production, further aggravating the complexity of process adjustment; and the manual operation mode that relies on visual judgment is difficult to ensure the consistency of welding gaps; the traditional tooling positioning method that uses nylon block support or plug-in plates to adjust the arc-shaped surface weldment profiles generally has the problems of inconvenient adjustment and poor versatility, and its insufficient precision can easily cause weld misalignment and excessive assembly. The process is time-consuming, labor-intensive and inefficient; and as a result, when the welding deformations of different batches of profiles are different, the values ​​of the parameters of the prefabricated welding anti-deformation of the roof panel weldment fluctuate greatly, and it is necessary to manually measure and adjust the tooling size repeatedly. It is impossible to flexibly and perfectly adjust the preset values ​​of the anti-deformation by manual inspection alone, which ultimately leads to large fluctuations in the parameters such as the final forming curvature or size of the EMU roof panel after welding and cooling, and a high rework rate; in addition, there is also a risk of collision and injury when operators frequently carry and adjust profiles, which seriously affects the production efficiency and product qualification rate. The present invention provides an intelligent manufacturing device for EMU roof panels and a method for using the same.

[0007] The technical solution adopted by the present invention to solve the technical problem is as follows:

[0008] The intelligent manufacturing device for the roof panel of a multiple unit of the present invention comprises a servo motor array control system connected to a host computer, and is characterized in that: the device comprises a plurality of groups of profile positioning mechanisms and an intelligent control lifting matrix mechanism, the profile positioning mechanism comprises a door-type support, two sections of T-bolt adjustable guide rails and two vertical industrial clamps; the two sections of T-bolt adjustable guide rails are arranged horizontally on both sides of the upper end surface of the door-type support in a mirror image, and the bottom of the clamp support, the lateral stopper and the profile side positioning mechanism are respectively fixed to the T-bolt adjustable guide rail in a detachable manner by T-head bolts; one vertical industrial clamp is fixed to the top of the profile side positioning mechanism, and the other vertical industrial clamp is fixed to the top of the clamp support; the two vertical industrial clamps are arranged in a mirror image posture in the horizontal direction; the lateral stopper is located between the profile side positioning mechanism and the clamp support and is arranged adjacent to the clamp support;

[0009] The intelligent control lifting matrix mechanism is an array composed of multiple lifting roller group devices; the lifting roller group devices span across the middle section in the horizontal direction in an eccentric vertical posture; the bottom of the upgrading roller group device is welded and fixedly connected with the upper end surface of each door-shaped support it spans.

[0010] The method for using the intelligent manufacturing device for the roof panel of a train set comprises the following steps:

[0011] Step 1: Input the 3D virtual model of the EMU roof panel profile structure into the 3D modeling software of the host computer, and use the known algorithm of the 3D software to automatically identify the 3D equation parameters corresponding to each arc surface of the profile workpiece;

[0012] Step 2: Performing three-dimensional virtual modeling of the intelligent manufacturing device for the EMU roof panel in three-dimensional software;

[0013] Step 3: In the 3D software, adjust each virtual servo motor and its corresponding virtual roller array on the virtual intelligent control lifting matrix mechanism on the 3D virtual model corresponding to the intelligent manufacturing device of the roof panel, so that each virtual roller is raised along the vertical direction in the 3D software, until the arc surface formed by the vertices of the virtual roller array in the model is completely consistent with the shape of the reverse outer contour surface of the roof panel, thereby forming a concave upward contour surface;

[0014] Step 4: Using the known functions of the three-dimensional software, respectively obtain the height variation parameter value of each virtual servo motor on the virtual intelligent control lifting matrix mechanism from the uniform initial shortest length to the arc surface of the reversed state of the roof panel;

[0015] Step 5: Input the height variation parameter values ​​of the arc surface of each virtual servo motor corresponding to each virtual roller in the reversed state of the locomotive roof obtained in step 4 into the servo motor array control system in the real world controlled by the host computer, and the servo motor array control system in the real world correspondingly raises the height value of the linear servo motor corresponding to the intelligent control lifting matrix mechanism in the real world one by one, and make the arc surface formed by the vertices of each roller array in the real world completely consistent with the shape of the outer contour surface of the reversed roof, so as to form a concave upward contour surface formed by the vertices of each roller array in the real world;

[0016] Step 6: In the real world, all the EMU roof panel profiles are placed in the reverse state; then the middle panel is first placed on the concave upward contour surface formed by each roller array in the real world. At this time, the middle panel will slide down along the curved surface of the roller array and move to the center position of the concave surface formed by each roller array under the action of its own gravity; thereafter, two transition arc panels are assembled on both sides of the middle panel respectively; the transition arc panels will also slide towards the middle panel along the concave surface formed by the roller array under the action of their own gravity. and approaching, so that the operator can complete the weld splicing of the transition arc plate and the middle plate very smoothly and easily; finally, according to the same method of assembling the transition arc plate and the middle plate, two side arc plates in the reverse installation state are placed on the outside of each transition arc plate, and the side arc plates and the transition arc plates are welded together by the principle that the side arc plates rely on their own weight to slide and approach the outside of the concave transition arc plates formed by the roller array; thus, the preliminary splicing process of the EMU roof panel profile with the concave surface facing upward is completed;

[0017] Step 7: Push the EMU roof panel profile that has been preliminarily spliced ​​and has the concave surface facing upward, so that the profile profile profile side of one of the side arc panels is against the side wall of the side stop, and the profile side profile groove block is used to match and clamp the corresponding profile profile profile side of the other side arc panel; then rotate the corresponding screw rods on each group of profile positioning mechanisms one by one, and use the screw principle of the screw rod and the nut thread connection to make the screw rod push the profile side profile groove block support rail to move in the direction of the side stop, until the middle plate, two transition arc plates and two side arc plates that constitute the EMU roof panel are more closely spliced ​​with each other; respectively use the universal joint pressure head to press and fix the arc surface of the EMU roof panel with the concave surface on top, and spot weld and fix each weld, so as to complete the intelligent clamping and positioning process of the EMU roof panel in reverse installation posture;

[0018] Step 8: Input the model corresponding to the reverse installation posture of the roof panel of the EMU into the known welding software, and use the programmable welding manipulator to complete the sequential welding of the two first welds T1 of the inner end surface and the two second welds T2 of the inner end surface respectively according to the preset path and the welding path given by the welding program;

[0019] Step 9: Re-adjust the virtual roof panel 3D model in the 3D software to a normal state with the convex surface facing upward; using the data entered in advance by the process engineer in the 3D software, using the known prefabrication welding anti-deformation process method, prefabricate the welding anti-deformation symmetrically to both sides along the highest vertex of the convex surface of the virtual roof panel standard 3D model;

[0020] Step 10: In the 3D software, adjust each virtual servo motor and its corresponding virtual roller array on the virtual intelligent control lifting matrix mechanism on the 3D virtual model corresponding to the intelligent manufacturing device of the roof panel, so that each virtual roller is raised along the vertical direction in the 3D software, until the arc surface formed by the vertices of the virtual roller array in the model is completely consistent with the shape of the contour surface of the roof panel under the prefabricated welding anti-deformation value described in step 9, thereby forming a contour surface with the convex surface of the virtual roller array upward;

[0021] Step 11: using the known functions of the three-dimensional software, respectively obtain the height variation parameter value of each virtual servo motor on the virtual intelligent control lifting matrix mechanism from the uniform initial shortest length to the arc surface of the roof panel in the normal installation state with the prefabricated welding anti-deformation value;

[0022] Step 12: After the concave weld is cooled, the roof panel of the EMU with the concave weld completed is turned over as a whole by using a hoisting crane and a turning sling, so that it becomes a normal posture with the concave surface facing downward and the convex surface facing upward. Referring to the process of steps 4 to 5, the height value of each roller is reset, so that the height and position of the actual roller are consistent with the virtual model simulated in the three-dimensional software, and then the roof panel is hoisted by the crane and dropped into the intelligent manufacturing device for the roof panel of the EMU;

[0023] Step 13: Use the corresponding screw rod on each set of profile positioning mechanism to push the profile side profile groove block support rail to move in the direction of the lateral stop until the other side arc plate away from the profile side profile groove block is against the side wall of the lateral stop, and use the universal joint pressure head to press and fix the upward arc surface of the roof panel of the EMU, thereby completing the clamping process of the EMU roof panel in the normal installation posture;

[0024] Step 14: Use the universal joint pressure head to press and fix the arc surface of the convex surface of the roof panel of the EMU, so as to complete the intelligent clamping and positioning process of the roof panel of the EMU in the upright posture; thereafter, the programmable welding robot completes the sequential welding of the two first welds K1 of the inner end faces and the outer end faces and the two second welds K2 of the outer end faces according to the welding path given by the program, so as to successfully complete the intelligent manufacturing process of the roof panel of the EMU.

[0025] The beneficial effects of the present invention are as follows: the intelligent manufacturing device for the roof panel of the EMU can realize the dual-position clamping and positioning of the roof panel of the EMU in reverse and forward installation respectively, and can significantly save the workshop space through the two reverse assembly of the lateral stopper and the profile side groove block. Its intelligent control lifting matrix mechanism adopts multiple groups of linear servo motor linkage control to realize intelligent lifting coordinated control and improve welding efficiency. By measuring and mapping the roof panel after cooling during the welding trial production of any batch of profiles and comparing it with the theoretical dimensions on the drawings, the actual prefabrication anti-deformation value can be obtained. This value can be input into the upper computer 3D software, and parameter mapping can be constructed through 3D software simulation and actual roller array. The preset amount of the welding anti-deformation value can be dynamically readjusted to achieve precise preset adjustment of the roller height. This can completely eliminate the use of traditional nylon blocks and plug-ins in the old process, greatly reduce equipment investment costs and save workshop space, significantly reduce the misalignment rate of double-sided welding, and greatly improve the qualification rate of one-time formed welds, realize continuous operation of double-sided welds on the same tooling platform, reduce 40% of the process switching time compared to the traditional sequential welding process, and increase the overall production efficiency by more than 60%.

[0026] The intelligent manufacturing device of the present invention realizes the matching and positioning of the special-shaped side of the roof panel profile of the EMU through the synergistic effect of the screw mechanism of the profile side positioning mechanism and the vertical guide mechanism, combined with the replaceable nylon profiled groove block. The T-bolt adjustable guide rail, the vertical industrial pressure clamp and the nylon profiled groove block all adopt a quick-release connection structure, which supports the replacement and debugging of core components within 10 minutes, greatly improving the versatility of the whole device and meeting the rapid matching of the roof panel structures of various train models.

[0027] On the other hand, the process method of the present invention effectively improves the management process required for switching production of different vehicle models, reduces the difficulty of implementing the overall process, improves the consistency of the welding process, significantly saves the labor cost required for flipping workpieces, transferring workstations and re-surveying and calibrating the process, and shortens the single clamping and positioning time from 30 minutes in traditional manual operation to 8 minutes.

[0028] In addition, the present invention also takes into account the modularization and maintainability optimization design of the device structure. While reducing the product rework rate, it can also reduce labor costs and avoid the risk of operators being injured or workpieces and production equipment being bumped and scratched when frequently carrying and adjusting profiles. It also has significant effects in energy saving and consumption reduction, extending equipment service life and reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a three-dimensional diagram of the roof panel of an existing EMU and its exploded diagram;

[0030] Figure 2 It is the main view and partial explosion diagram of the existing EMU roof panel;

[0031] Figure 3 yes Figure 2 A partial enlarged view of part I;

[0032] Figure 4 yes Figure 2 A partial enlarged view of part II;

[0033] Figure 5 yes Figure 2 A partial enlarged view of part III;

[0034] Figure 6 It is a three-dimensional diagram of the intelligent manufacturing device for the roof panel of a train set according to the present invention;

[0035] Figure 7 It is a preliminary exploded assembly schematic diagram of the intelligent manufacturing device for the roof panel of a train set of the present invention;

[0036] Figure 8 is a three-dimensional diagram of the profile positioning mechanism of the present invention;

[0037] Fig. 9 It is an exploded assembly schematic diagram of the profile positioning mechanism of the present invention;

[0038] Fig.10 It is a schematic diagram of a partial cross-section of the three-dimensional structure of the profile side positioning mechanism of the present invention;

[0039] Fig.11 is a structural schematic diagram of the profile positioning mechanism of the present invention in another three-dimensional viewing angle;

[0040] Fig.12 is a three-dimensional diagram of the lifting roller assembly device of the present invention;

[0041] Fig.13 yes Fig.12 A partial enlarged view of part IV;

[0042] Fig.14 Yes Yes Fig.13Schematic diagram of the exploded assembly;

[0043] Fig.15 It is a front view of the intelligent manufacturing device for the roof panel of a train set of the present invention;

[0044] Fig.16 It is a three-dimensional application schematic diagram of the intelligent manufacturing device for the roof panel of a motor vehicle unit of the present invention in the reverse installation posture of the roof panel workpiece;

[0045] Fig.17 yes Fig.16 The main view;

[0046] Fig.18 yes Fig.17 A partial enlarged view of the middle V part;

[0047] Fig.19 It is a schematic diagram of the main application of the intelligent manufacturing device for the roof panel of a train set according to the present invention in the upright posture of the roof panel workpiece;

[0048] Fig. 20 yes Fig.19 A partial enlarged view of part VI. DETAILED DESCRIPTION

[0049] The present invention is further described in detail below with reference to the accompanying drawings.

[0050] like Figures 6 to 15 As shown, the intelligent manufacturing device for the roof panel of the EMU of the present invention includes a servo motor array control system connected to the host computer, and is characterized in that: the device includes multiple groups of profile positioning mechanisms B and intelligent control lifting matrix mechanisms C, the profile positioning mechanism B includes a door-type support 1, two sections of T-bolt adjustable guide rails 2, and two vertical industrial clamps 7; the two sections of T-bolt adjustable guide rails 2 are arranged horizontally on both sides of the upper end surface of the door-type support 1 in a mirror image, and the clamp support 3, the lateral stopper 6 and the bottom of the profile side positioning mechanism G are respectively fixed to the T-bolt adjustable guide rail 2 in a detachable manner through T-head bolts; one vertical industrial clamp 7 is fixed to the top of the profile side positioning mechanism G, and the other vertical industrial clamp 7 is fixed to the top of the clamp support 3; the two vertical industrial clamps 7 are arranged in a mirror image posture in the horizontal direction; the lateral stopper 6 is located between the profile side positioning mechanism G and the clamp support 3 and is arranged adjacent to the clamp support 3;

[0051] The intelligent control lifting matrix mechanism C is an array composed of multiple lifting roller group devices 8; the lifting roller group device 8 spans across the middle section in the horizontal direction in an eccentric vertical posture; the bottom of the upgrading roller group device is welded and fixedly connected to the upper end surface of each door-type support 1 it spans.

[0052] The profile side positioning mechanism G includes a vertical guide rail mechanism 4 and a profile side transverse positioning mechanism 5; the vertical guide rail mechanism 4 includes a nut vertical slide groove 4-2 and a transverse open rectangular frame 4-1 composed of two vertical plates and upper and lower end plates; the nut vertical slide groove 4-2 is fixedly connected to the inside of the transverse open rectangular frame 4-1; the profile side transverse positioning mechanism 5 includes a profile side profile groove block 5-1, a screw rod 5-2 and a nut 5-3; the nut 5-3 is slidably connected to the nut vertical slide groove 4-2, the screw rod 5-2 passes through the transverse open rectangular frame 4-1, and the middle section of the screw rod 5-2 and the nut 5-3 together constitute a screw mechanism; the rear end of the profile side profile groove block 5-1 is rotatably connected to the front end head of the screw rod 5-2.

[0053] The nut vertical slide 4-2 includes four vertically arranged nut guide rails, which are grouped in pairs and are respectively welded on the left and right inner walls of the transversely open rectangular frame 4-1 in a vertical posture and mirror-symmetrical to each other.

[0054] A profile side conforming groove 5-1-1 is provided at the front end of the profile side conforming groove block 5-1, and the cross-sectional contour line of the profile side conforming groove 5-1-1 is completely the same as the projection contour line of the profile special-shaped side A3-1.

[0055] The rear end of the profile side conforming groove block 5-1 is rotatably connected to the front end of the screw rod 5-2 through a bearing 5-1-2; the minimum initial spacing between the profile side conforming groove 5-1-1 and the lateral stop 6 is greater than the standard width of the finished roof panel A of the EMU.

[0056] The upgraded roller group device includes a lifting roller group device 8 including a supporting slide rail 8-1, at least three translation sliders 8-2 and at least three lifting roller mechanisms D; the translation sliders 8-2 are horizontally slidably connected to the supporting slide rail 8-1; the lifting roller mechanism D includes a lifting mechanism D-1 and a roller mechanism D-2, and the roller mechanism D-2 is composed of a horizontal shaft seat D-2-1 and a roller D-2-2 rotatably connected thereto; the horizontal shaft seat D-2-1 is fixedly connected to the top of the lifting mechanism D-1.

[0057] The outer diameter of the roller D-2-2 is made of nylon; the profile side groove block 5-1 is a replaceable nylon block; the bottom of the vertical pressure rod of the vertical industrial pressure clamp 7 is provided with a universal joint pressure head 7-1 made of nylon.

[0058] The lifting mechanism D-1 is a vertically arranged linear servo motor, and each linear servo motor in the intelligent lifting matrix mechanism C is controlled by a servo motor array control system connected to the host computer.

[0059] like Figures 16 to 20 As shown, the method for using the intelligent manufacturing device for the roof panel of a train set includes the following steps:

[0060] Step 1: Input the 3D virtual model of the EMU roof panel A profile structure into the 3D modeling software of the host computer, and use the known algorithm of the 3D software to automatically identify the 3D equation parameters corresponding to each part of the profile workpiece arc surface;

[0061] Step 2: Performing three-dimensional virtual modeling of the intelligent manufacturing device for the EMU roof panel in three-dimensional software;

[0062] Step 3: In the 3D software, adjust each virtual servo motor and its corresponding virtual roller array on the virtual intelligent control lifting matrix mechanism on the 3D virtual model corresponding to the intelligent manufacturing device of the roof panel, so that each virtual roller is raised along the vertical direction in the 3D software, until the arc surface formed by the vertices of the virtual roller array in the model is completely consistent with the shape of the reverse outer contour surface of the roof panel, thereby forming a concave upward contour surface;

[0063] Step 4: Using the known functions of the three-dimensional software, respectively obtain the height variation parameter value of each virtual servo motor on the virtual intelligent control lifting matrix mechanism from the uniform initial shortest length to the arc surface of the reversed state of the roof panel;

[0064] Step 5: Input the height variation parameter values ​​of the arc surface of each virtual roller corresponding to the virtual servo motor in the reversed state of the locomotive roof obtained in step 4 into the servo motor array control system in the real world controlled by the host computer, and the servo motor array control system in the real world correspondingly raises the height value of the linear servo motor corresponding to the intelligent control lifting matrix mechanism C in the real world one by one, and make the arc surface formed by the vertices of each roller D-2-2 array in the real world completely consistent with the shape of the outer contour surface of the reversed roof, so as to form a concave upward contour surface formed by the vertices of each roller D-2-2 array in the real world;

[0065] Step 6: In the real world, all the EMU roof panel A profiles are placed in the reversed state; then the middle panel A1 is first placed on the upward concave contour surface formed by the roller arrays D-2-2 arrays in the real world. At this time, the middle panel A1 will slide down along the curved surface of the roller array and move to the center position of the concave surface formed by the roller arrays D-2-2 arrays under the action of its own gravity; thereafter, two transition arc panels A2 are assembled on both sides of the middle panel A1; the transition arc panel A2 will also slide along the concave surface formed by the roller D-2-2 array towards the middle panel A1 under the action of its own gravity. The transition arc plate A2 and the middle plate A1 are moved and brought together, so that the operator can complete the weld splicing of the transition arc plate A2 and the middle plate A1 very smoothly and easily; finally, according to the same method of assembling the transition arc plate A2 and the middle plate A1, two side arc plates A3 in a reversed state are placed on the outer side of each transition arc plate A2, and the side arc plates A3 and the transition arc plates A2 are welded together by the principle that the side arc plates A3 rely on their own weight to slide and move together along the outer side of the concave transition arc plate A2 formed by the roller D-2-2 array; thus, the preliminary splicing process of the EMU roof plate A profile with the concave surface facing upward is completed;

[0066] Step 7: Push the EMU roof panel A profile that has been preliminarily spliced ​​and has the concave surface facing upward, so that the profile profile side A3-1 of one of the side arc panels A3 is pressed against the side wall of the lateral stop 6, and the profile side profile groove block 5-1 is used to match and clamp the corresponding profile profile side A3-1 on the other side arc panel A3; then rotate the corresponding screw rod 5-2 on each group of profile positioning mechanism B one by one, and use the screw principle of the screw rod 5-2 and the nut 5-3 threaded connection to make the screw rod 5-2 Push the profile side groove block 5-1 to support the slide rail 8-1 to move in the direction of the lateral stopper 6 until the welds of the middle plate A1, the two transition arc plates A2 and the two side arc plates A3 constituting the roof plate A of the EMU are more closely fitted to each other; respectively use the universal joint press head 7-1 to press and fix the arc surface of the roof plate A of the EMU with the concave surface on top, and spot weld and fix each weld, so as to complete the intelligent clamping and positioning process of the reverse installation posture of the roof plate A of the EMU;

[0067] Step 8: Input the model corresponding to the reverse installation posture of the roof panel A of the EMU into the known welding software, and use the programmable welding manipulator to complete the sequential welding of the two first welds T1 of the inner end surface and the two second welds T2 of the inner end surface respectively according to the preset path and the welding path given by the welding program;

[0068] Step 9: Re-adjust the virtual roof panel 3D model in the 3D software to a normal state with the convex surface facing upward; using the data entered in advance by the process engineer in the 3D software, using the known prefabrication welding anti-deformation process method, prefabricate the welding anti-deformation symmetrically to both sides along the highest vertex of the convex surface of the virtual roof panel standard 3D model;

[0069] Step 10: In the 3D software, adjust each virtual servo motor and its corresponding virtual roller array on the virtual intelligent control lifting matrix mechanism on the 3D virtual model corresponding to the intelligent manufacturing device of the roof panel, so that each virtual roller is raised along the vertical direction in the 3D software, until the arc surface formed by the vertices of the virtual roller array in the model is completely consistent with the shape of the contour surface of the roof panel under the prefabricated welding anti-deformation value described in step 9, thereby forming a contour surface with the convex surface of the virtual roller array upward;

[0070] Step 11: using the known functions of the three-dimensional software, respectively obtain the height variation parameter value of each virtual servo motor on the virtual intelligent control lifting matrix mechanism from the uniform initial shortest length to the arc surface of the roof panel in the normal installation state with the prefabricated welding anti-deformation value;

[0071] Step 12: After the concave weld is cooled, the roof panel A of the EMU with the concave weld completed is turned over as a whole by using a hoisting crane and a turning sling, so that it becomes a normal posture with the concave surface facing downward and the convex surface facing upward. Referring to the process of steps 4 to 5, the height value of each roller is reset, so that the height and position of the actual roller are consistent with the virtual model simulated in the three-dimensional software, and then the roof panel A is hoisted and dropped into the intelligent manufacturing device for the roof panel of the EMU by using a crane;

[0072] Step 13: Use the corresponding screw rod 5-2 on each set of profile positioning mechanism B again to push the profile side groove block 5-1 to support the slide rail 8-1 to move in the direction of the lateral stop 6, until the other side arc plate A3 away from the profile side groove block 5-1 is against the side wall of the lateral stop 6, and use the universal joint press head 7-1 to press and fix the upward arc surface of the roof plate A of the EMU, thereby completing the clamping process of the EMU roof plate A in the normal installation posture;

[0073] Step 14: Use the universal joint pressure head 7-1 to press and fix the arc surface of the convex surface of the roof panel A of the EMU, so as to complete the intelligent clamping and positioning process of the roof panel A of the EMU in the upright posture; thereafter, the programmable welding robot completes the sequential welding of the two first welds K1 of the inner end faces and the outer end faces and the two second welds K2 of the outer end faces according to the welding path given by the program, so as to successfully complete the intelligent manufacturing process of the roof panel A of the EMU.

Claims

1. An intelligent manufacturing device for a roof panel of a train set, comprising a servo motor array control system connected to a host computer, characterized in that: The device comprises a plurality of profile positioning mechanisms (B) and an intelligent control lifting matrix mechanism (C), wherein the profile positioning mechanism (B) comprises a door-type support (1), two sections of T-bolt adjustable guide rails (2), and two vertical industrial clamps (7); the two sections of T-bolt adjustable guide rails (2) are arranged horizontally on both sides of the upper end surface of the door-type support (1) in a mirror image, and the bottom of the clamp support (3), the lateral stopper (6) and the profile side positioning mechanism (G) are respectively fixed on the T-bolt adjustable guide rails (2) in a detachable manner by T-head bolts; one vertical industrial clamp (7) is fixed on the top of the profile side positioning mechanism (G), and the other vertical industrial clamp (7) is fixed on the top of the clamp support (3); the two vertical industrial clamps (7) are arranged in a mirror image posture in the horizontal direction; the lateral stopper (6) is located between the profile side positioning mechanism (G) and the clamp support (3) and is arranged adjacent to the clamp support (3); The intelligent control lifting matrix mechanism (C) is an array composed of a plurality of lifting roller assembly devices (8); the lifting roller assembly devices (8) span across the middle section in a horizontal direction in an eccentric vertical posture; the bottom of the lifting roller assembly devices are respectively welded and fixedly connected to the upper end surface of each door-shaped support (1) that they span.

2. The intelligent manufacturing device for the roof panel of a train set according to claim 1, characterized in that: The profile side positioning mechanism (G) comprises a vertical guide rail mechanism (4) and a profile side transverse positioning mechanism (5); the vertical guide rail mechanism (4) comprises a nut vertical slide groove (4-2) and a transversely open rectangular frame (4-1) composed of two vertical plates and upper and lower end plates; the nut vertical slide groove (4-2) is fixedly connected to the inside of the transversely open rectangular frame (4-1); the profile side transverse positioning mechanism (5) comprises a profile side profile groove block (5-1), a screw rod (5-2) and a nut (5-3); the nut (5-3) is slidably connected to the nut vertical slide groove (4-2), the screw rod (5-2) passes through the transversely open rectangular frame (4-1), and the middle section of the screw rod (5-2) and the nut (5-3) together form a screw mechanism; the rear end of the profile side profile groove block (5-1) is rotatably connected to the front end of the screw rod (5-2).

3. The intelligent manufacturing device for the roof panel of a train set according to claim 2, characterized in that: The nut vertical slide groove (4-2) comprises four vertically arranged nut guide rails, which are grouped in pairs and are respectively welded on the left and right inner side walls of the transversely open rectangular frame (4-1) in a vertical posture and in a mirror-symmetrical manner.

4. The intelligent manufacturing device for the roof panel of a train set according to claim 2, characterized in that: The front end of the profile side conforming groove block (5-1) is provided with a profile side conforming groove clamping groove (5-1-1), and the cross-sectional contour line of the profile side conforming groove clamping groove (5-1-1) is completely identical to the projection contour line of the profile special-shaped side (A3-1).

5. The intelligent manufacturing device for the roof panel of a train set according to claim 4, characterized in that: The rear end of the profile side conforming groove block (5-1) is rotatably connected to the front end of the screw rod (5-2) via a bearing (5-1-2); the minimum initial spacing between the profile side conforming groove clamping groove (5-1-1) and the lateral stopper (6) is greater than the standard width of the finished product of the roof panel (A) of the EMU.

6. The intelligent manufacturing device for the roof panel of a train set according to claim 1, characterized in that: The upgrading roller assembly device comprises a lifting roller assembly device (8) comprising a supporting slide rail (8-1), at least three translational sliders (8-2) and at least three lifting roller mechanisms (D); the translational sliders (8-2) are horizontally slidably connected to the supporting slide rail (8-1); the lifting roller mechanism (D) comprises a lifting mechanism (D-1) and a roller mechanism (D-2); the roller mechanism (D-2) is composed of a horizontal shaft seat (D-2-1) and a roller (D-2-2) rotatably connected thereto; the horizontal shaft seat (D-2-1) is fixedly connected to the top of the lifting mechanism (D-1).

7. The intelligent manufacturing device for the roof panel of a train set according to claim 6, characterized in that: The outer diameter of the roller (D-2-2) is made of nylon; the profile side groove block (5-1) is a replaceable nylon block; and a universal joint pressure head (7-1) made of nylon is provided at the bottom of the vertical pressure rod of the vertical industrial pressure clamp (7).

8. The intelligent manufacturing device for the roof panel of a train set according to claim 7, characterized in that: The lifting mechanism (D-1) is a vertically arranged linear servo motor, and each linear servo motor in the intelligent control lifting matrix mechanism (C) is controlled by a servo motor array control system connected to a host computer.

9. The method for using the intelligent manufacturing device for the roof panel of a train set according to any one of claims 1 to 8, characterized in that: The method comprises the following steps: Step 1: Input the three-dimensional virtual model of the EMU roof panel (A) profile structure into the three-dimensional modeling software of the host computer, and use the known algorithm of the three-dimensional software to automatically identify the three-dimensional equation parameters corresponding to each arc surface of the profile workpiece; Step 2: Performing three-dimensional virtual modeling of the intelligent manufacturing device for the EMU roof panel in three-dimensional software; Step 3: In the 3D software, adjust each virtual servo motor and its corresponding virtual roller array on the virtual intelligent control lifting matrix mechanism on the 3D virtual model corresponding to the intelligent manufacturing device of the roof panel, so that each virtual roller is raised along the vertical direction in the 3D software, until the arc surface formed by the vertices of the virtual roller array in the model is completely consistent with the shape of the reverse outer contour surface of the roof panel, thereby forming a concave upward contour surface; Step 4: Using the known functions of the three-dimensional software, respectively obtain the height variation parameter value of each virtual servo motor on the virtual intelligent control lifting matrix mechanism from the uniform initial shortest length to the arc surface of the reversed state of the roof panel; Step 5: Input the height variation parameter values ​​of the arc surface of each virtual servo motor corresponding to each virtual roller in the reversed state of the locomotive roof obtained in step 4 into the servo motor array control system in the real world controlled by the host computer, and the servo motor array control system in the real world correspondingly raises the height value of the linear servo motor corresponding to the intelligent control lifting matrix mechanism (C) in the real world one by one, and make the arc surface formed by the vertices of each roller (D-2-2) array in the real world completely consistent with the shape of the reversed outer contour surface of the roof, thereby forming a concave upward contour surface formed by the vertices of each roller (D-2-2) array in the real world; Step 6: In the real world, all the EMU roof panels (A) are placed in reverse; then the middle panel (A1) is first placed on the upward concave contour surface formed by the roller arrays (D-2-2) in the real world. At this time, the middle panel (A1) will slide down along the curved surface of the roller array under its own weight and move to the center of the concave surface formed by the roller arrays (D-2-2); thereafter, two transition arc panels (A2) are assembled on both sides of the middle panel (A1); the transition arc panel (A2) will also slide along the concave surface formed by the roller array (D-2-2) under its own weight. The transition arc plate (A2) and the middle plate (A1) are brought close together, so that the operator can complete the weld splicing of the transition arc plate (A2) and the middle plate (A1) very smoothly and easily; finally, according to the same method of assembling the transition arc plate (A2) and the middle plate (A1), two side arc plates (A3) in a reversed state are placed on the outer side of each transition arc plate (A2), and the side arc plates (A3) and the transition arc plates (A2) are weld spliced ​​by the principle that the side arc plates (A3) rely on their own weight to slide and approach the outer side of the concave transition arc plate (A2) formed by the roller (D-2-2) array; thereby completing the preliminary splicing process of the EMU roof plate (A) profile with the concave surface facing upward; Step 7: Push the EMU roof panel (A) profile that has been preliminarily spliced ​​and has the concave surface facing upward, so that the profile profile shaped side (A3-1) of one of the side arc panels (A3) is pressed against the side wall of the lateral stopper (6), and the profile side profile groove block (5-1) is used to match and clamp the corresponding profile profile shaped side (A3-1) on the other side arc panel (A3); then rotate the corresponding screw rods (5-2) on each group of profile positioning mechanisms (B) one by one, and use the screw principle of the screw rod (5-2) and the nut (5-3) threadedly connected to make the screw rod (5-2) and the nut (5-3) threadedly connected to each other. 2) pushing the profile side follower groove block (5-1) to support the slide rail (8-1) in the direction of the side stopper (6) until the welds of the middle plate (A1), the two transition arc plates (A2) and the two side arc plates (A3) constituting the roof plate (A) of the EMU are more closely joined; using the universal joint press head (7-1) to press and fix the arc surface of the EMU roof plate (A) with the concave surface on top, and spot welding and fixing each weld, thereby completing the intelligent clamping and positioning process of the EMU roof plate (A) in the reverse installation posture; Step 8: Input the model corresponding to the reverse installation posture of the roof panel (A) of the EMU into the known welding software, and use the programmable welding manipulator to complete the sequential welding of the two first welds T1 of the inner end surface and the two second welds T2 of the inner end surface respectively according to the preset path and the welding path given by the welding program; Step 9: Re-adjust the virtual roof panel 3D model in the 3D software to a normal state with the convex surface facing upward; using the data entered in advance by the process engineer in the 3D software, using the known prefabrication welding anti-deformation process method, prefabricate the welding anti-deformation symmetrically to both sides along the highest vertex of the convex surface of the virtual roof panel standard 3D model; Step 10: In the 3D software, adjust each virtual servo motor and its corresponding virtual roller array on the virtual intelligent control lifting matrix mechanism on the 3D virtual model corresponding to the intelligent manufacturing device of the roof panel, so that each virtual roller is raised along the vertical direction in the 3D software, until the arc surface formed by the vertices of the virtual roller array in the model is completely consistent with the shape of the contour surface of the roof panel under the prefabricated welding anti-deformation value described in step 9, thereby forming a contour surface with the convex surface of the virtual roller array upward; Step 11: using the known functions of the three-dimensional software, respectively obtain the height variation parameter value of each virtual servo motor on the virtual intelligent control lifting matrix mechanism from the uniform initial shortest length to the arc surface of the roof panel in the normal installation state with the prefabricated welding anti-deformation value; Step 12: After the concave weld is cooled, the roof panel (A) of the EMU with concave surface welding is turned over as a whole by using a hoisting crane and a turning sling, so that it becomes a normal posture with the concave surface facing downward and the convex surface facing upward. Referring to the process of steps 4 to 5, the height value of each roller is reset, so that the height and position of the actual roller are consistent with the virtual model simulated in the three-dimensional software, and then the roof panel (A) is hoisted and dropped into the intelligent manufacturing device for the roof panel of the EMU by using a crane; Step 13: Use the corresponding screw rod (5-2) on each set of profile positioning mechanism (B) again to push the profile side profile groove block (5-1) support slide rail (8-1) to move in the direction of the lateral stopper (6) until the other side arc plate (A3) away from the profile side profile groove block (5-1) is against the side wall of the lateral stopper (6), and use the universal joint pressure head (7-1) to press and fix the upward arc surface of the EMU roof plate (A), thereby completing the clamping process of the EMU roof plate (A) in the normal installation posture; Step 14: The arc surface of the convex surface of the roof panel (A) of the EMU is pressed and fixed by using the universal joint pressing head (7-1) to complete the intelligent clamping and positioning process of the roof panel (A) of the EMU in the upright posture; thereafter, the programmable welding manipulator completes the sequential welding of the two first welds K1 of the inner end surface and the outer end surface and the two second welds K2 of the outer end surface according to the welding path given by the program, thereby successfully completing the intelligent manufacturing process of the roof panel (A) of the EMU.

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