Aluminum alloy auxiliary frame shaping equipment and shaping method thereof

Abstract

The invention belongs to the technical field of stamping shaping equipment, and particularly relates to aluminum alloy auxiliary frame shaping equipment and a shaping method thereof.The aluminum alloy auxiliary frame shaping equipment comprises a U-shaped frame, a containing open groove is formed in the bottom end of the U-shaped frame, a bottom plate and a hollow plate are fixedly connected to the inner wall of the U-shaped frame, and a shaping mold mechanism is connected to the upper surface of the hollow plate; a lifting mechanism is fixedly embedded in the top end of the U-shaped frame, and the bottom end of the lifting mechanism is connected with the top end of the shaping die mechanism. The shaping equipment integrates the functions of mold extrusion protruding deformation shaping, air expansion extrusion sinking deformation shaping and heating for improving the elasticity modulus of the aluminum alloy cross beam material, the aluminum alloy material is heated and softened, the shaping process is accelerated, structural damage caused by hard extrusion is avoided, the shaping convenience and efficiency of the aluminum alloy cross beam are improved, and the production cost is reduced. The labor intensity of workers is reduced, the reshaping reliability of the aluminum alloy cross beam is enhanced, and then the use effect of the aluminum alloy auxiliary frame is practically guaranteed.

Description

Technical Field

[0001] The invention belongs to the technical field of stamping and shaping equipment, and in particular relates to an aluminum alloy subframe shaping equipment and a shaping method thereof. Background Art

[0002] As a key component of the automobile chassis, the aluminum alloy subframe is made of aluminum alloy. It shoulders the important mission of supporting the suspension, steering and other systems. It can not only significantly reduce the weight of the vehicle body, but also effectively enhance the vehicle's handling performance and driving quality with its excellent strength and corrosion resistance. At present, there are two main types of aluminum alloy subframes: U-shaped semi-frame and full-frame. On the basis of ensuring the safety and reliability of the vehicle, car companies use U-shaped semi-frame aluminum alloy subframes for low-end models for cost considerations. Based on the price positioning of mid-to-high-end models, full-frame aluminum alloy subframes are often used to highlight product differences. In actual production, in order to achieve the commonality of parts and reduce production costs, aluminum is often welded on the U-shaped semi-frame aluminum alloy subframe. Alloy beams are used to produce full-frame aluminum alloy subframes. However, the aluminum alloy beams are prone to deformation after forming. On the one hand, due to the influence of processing stress, such as the cutting force and heat generated by the friction between the tool and the material during cutting and drilling, local temperature unevenness will be caused, and residual stress will be formed after cooling, which will cause deformation. On the other hand, during the transportation of the aluminum alloy beams, deformation defects will also occur after being bumped or squeezed by external forces. Therefore, the deformed aluminum alloy beams must be shaped before being welded to the U-shaped plate-frame aluminum alloy subframe to ensure the use effect and reliability of the full-frame aluminum alloy subframe. For example, the patent with authorization announcement number CN209156769U discloses an aluminum alloy subframe shaping equipment.

[0003] At present, in the process of repairing the deformation of the aluminum alloy cross beam in the aluminum alloy subframe, the staff needs to use tools to operate, and the staff needs to measure and squeeze the repair in a small range at the same time to prevent the situation of inadequate or excessive repair. This makes the repair process of the aluminum alloy cross beam in the aluminum alloy subframe extremely cumbersome, which not only affects the convenience and efficiency of the repair, but also greatly increases the labor intensity of the staff; In addition, due to the soft texture and relatively low elastic modulus of aluminum alloy itself, during the extrusion shaping and repair process, if the extrusion process parameters are not set properly, such as excessive extrusion pressure and excessive extrusion rate, stress concentration will occur at the deformation site. This stress concentration can easily cause damage to the internal structure of the material, leading to tiny cracks, and at the same time causing rigidity damage and strength reduction defects. These defects seriously affect the reliability of the aluminum alloy beam and ultimately have an adverse effect on the use of the aluminum alloy subframe.

[0004] Therefore, we propose an aluminum alloy subframe shaping device and a shaping method thereof to solve the above problems. Summary of the invention

[0005] The object of the present invention is to provide an aluminum alloy subframe shaping device and a shaping method thereof in view of the above problems.

[0006] To achieve the above object, the present invention adopts the following technical scheme: an aluminum alloy subframe shaping device, comprising a U-shaped frame, a placement slot is opened at the bottom end of the U-shaped frame, a bottom plate and a hollow plate are fixedly connected to the inner wall of the U-shaped frame, and a shaping mold mechanism is connected to the upper surface of the hollow plate; A lifting mechanism is fixedly embedded at the top of the U-shaped frame, and the bottom end of the lifting mechanism is connected to the top of the shaping mold mechanism; The upper surface of the bottom plate is fixedly connected with a hollow heat insulation cover, the top of the hollow heat insulation cover is fixedly connected with the lower surface of the hollow plate, and the inner wall of the hollow heat insulation cover is fixedly connected with an air inflation auxiliary shaping mechanism; The inner wall of the hollow plate is fixedly connected with a heating component.

[0007] The top end of the fixing block is provided with a threaded hole, and the hole wall of the threaded hole is connected with a connecting bolt, and the bottom end of the connecting bolt is threadedly connected with the upper surface of the hollow plate, and the upper surface of the hollow plate is provided with a plurality of threaded blind holes matching the connecting bolts, and the interior of the lower shaping mold is provided with two arc-shaped air guide channels, and the air outlet ends of the two arc-shaped air guide channels are located on both sides of the aluminum alloy crossbeam cavity of the lower shaping mold, the inner wall of the aluminum alloy crossbeam cavity of the lower shaping mold is provided with a countersunk hole, and the hole wall of the countersunk hole is provided with a top material assembly, the upper surface of the lower shaping mold is connected with an upper shaping mold, the cavity of the upper shaping mold and the cavity of the lower shaping mold together constitute an aluminum alloy crossbeam shaping cavity, and the upper surface of the upper shaping mold is fixedly connected with a connecting tube.

[0008] In the above-mentioned aluminum alloy subframe shaping equipment, the lifting mechanism includes a first electric hydraulic rod fixedly embedded in the top of the U-shaped frame, the movable end of the first electric hydraulic rod is fixedly connected to a connecting rod matching the connecting tube, the outer walls of the connecting rod and the connecting tube are jointly provided with a through hole, and the hole wall of the through hole is movably connected with a fixing bolt, the outer wall of the fixing bolt is threadedly connected with a nut, and the rod wall of the connecting rod is fixedly sleeved with a pressure ring.

[0009] In the above-mentioned aluminum alloy subframe shaping equipment, the inflation-assisted shaping mechanism includes a second electric hydraulic rod fixedly connected to the bottom end of the hollow heat insulation cover, the movable end of the second electric hydraulic rod is fixedly connected to a support block, the outer wall of the support block is fixedly sleeved with a heat-resistant rubber cover that is sealingly and slidingly connected to the inner wall of the hollow heat insulation cover, the upper surface of the heat-resistant rubber cover is fixedly connected to a heat insulation board, the upper surface of the heat insulation board is fixedly connected to a U-shaped limit block, the outer wall of the hollow heat insulation cover is provided with a through hole, and the hole wall of the through hole is sealed and fixedly connected to an air pump, the air inlet end of the air pump is fixedly connected to an air inlet check valve, the air outlet end of the air pump is fixedly connected to a heat-resistant hose, the outer wall of the hollow heat insulation cover is fixedly connected to a PLC controller, the inner wall of the bottom end of the U-shaped frame is fixedly connected to an alarm, and the outer wall of the hollow heat insulation cover is fixedly embedded with a helium replenishing valve, a temperature sensor and an air pressure sensor.

[0010] In the above-mentioned aluminum alloy subframe shaping equipment, the heating component includes a three-way reversing solenoid valve fixedly embedded in the inner wall of the hollow plate, the air inlet end of the three-way reversing solenoid valve passes through the lower surface of the hollow plate and is fixedly connected to the air outlet end of the heat-resistant hose, the top air outlet end of the three-way reversing solenoid valve passes through the upper surface of the hollow plate and is fixedly connected to the countersunk hole of the lower shaping mold, the lateral air outlet end of the three-way reversing solenoid valve is fixedly connected to a heat-resistant metal pipe, the air outlet end of the heat-resistant metal pipe passes through the upper surface of the hollow plate and is fixedly connected to the lower shaping mold. One of the arc-shaped air guide channels in the shaping mold is sealed and connected, the outer wall of the heat-resistant metal tube is fixedly sleeved with an electromagnetic heating coil, the lower surface of the hollow plate is provided with two fixed through holes matching the electromagnetic heating coil, the top of the hollow plate is fixedly connected with an air guide pipe, the top air inlet end of the air guide pipe is sealed and connected with another arc-shaped air guide channel in the lower shaping mold, the air outlet end of the air guide pipe is fixedly connected with an exhaust one-way valve, the bottom end of the exhaust one-way valve passes through the lower surface of the hollow plate, and is located inside the hollow heat insulation cover.

[0011] In the above-mentioned aluminum alloy subframe shaping equipment, the ejection assembly includes a ejection block movably embedded in the lower shaping mold, the bottom end of the ejection block is movably connected to the top end of the countersunk hole in a sealing manner, the bottom end of the ejection block is fixedly connected to a guide rod, the rod wall of the guide rod is movably sleeved with a limiting ring, the outer wall of the limiting ring is fixedly connected to the hole wall of the countersunk hole, and the bottom end of the guide rod is fixedly connected to a limiting convex ring.

[0012] In the above-mentioned aluminum alloy subframe shaping equipment, the outer walls on both sides of the upper shaping mold and the lower shaping mold are respectively fixedly connected with the first limit sleeve and the second limit sleeve, and the inner walls of the first limit sleeve and the second limit sleeve on the same side are jointly movably sleeved with a guide column, and the bottom end of the guide column is fixedly connected to the upper surface of the hollow plate.

[0013] A shaping method for an aluminum alloy subframe shaping device, the shaping method comprising the following steps: Step S1: Preparation stage: the PLC controller controls the second electric hydraulic rod moving end to retract, and at the same time opens the helium replenishing valve to fill helium into the hollow heat insulation cover, and firmly connects the connecting tube and the connecting rod with fixing bolts and nuts; Step S2: mold separation and beam placement: the PLC controller controls the first electric hydraulic rod moving end to contract, driving the upper shaping mold to separate from the lower shaping mold, and placing the aluminum alloy beam to be shaped in the mold cavity of the lower shaping mold; Step S3: mold closing and extrusion: the PLC controller controls the moving end of the first electric hydraulic rod to extend, pushes the upper shaping mold and the lower shaping mold to close the mold, and performs preliminary extrusion and shaping repair on the protruding deformation of the aluminum alloy beam; Step S4: Heating and temperature raising auxiliary shaping: after mold closing, the PLC controller starts the heating component and the vacuum pump, and uses helium circulation heating to increase the temperature of the aluminum alloy beam. When the temperature reaches the Celsius threshold, the electromagnetic heating coil and the vacuum pump are controlled to be powered off and paused, and the alarm is triggered; Step S5: Inflating extrusion and depression shaping: after the PLC controller controls the vacuum pump and the electromagnetic heating coil to be powered off, the second electric hydraulic rod is started, and the expansion force of compressed helium is used to shape and repair the depression deformation of the aluminum alloy beam. When the air pressure reaches the preset warning threshold, the second electric hydraulic rod is controlled to suspend work and maintain the air pressure for 2 minutes; Step S6: Helium recovery and mold separation: After 2 minutes, the PLC controller controls the second electric hydraulic rod to retract and recover helium, and when the air pressure in the hollow heat insulation cover returns to the initial value, controls the moving end of the first electric hydraulic rod to retract, so that the upper shaping mold is separated from the lower shaping mold; Step S7: Removing the crossbeam: The PLC controller controls the vacuum pump and the three-way reversing solenoid valve to be energized for 5 seconds, extracting a small amount of helium to separate the aluminum alloy crossbeam from the lower shaping mold cavity, taking out the shaped aluminum alloy crossbeam, and then naturally cooling it for welding to form a full-frame aluminum alloy subframe.

[0014] Compared with the existing technology, the advantages of an aluminum alloy subframe shaping device and shaping method are: By setting up the lower shaping mold, upper shaping mold and lifting mechanism, when the aluminum alloy beam of the full-frame aluminum alloy subframe needs to be shaped due to deformation before welding, the lifting mechanism is first connected to the shaping mold mechanism, and then the PLC controller controls the moving end of the first electric hydraulic rod to contract, and drives the upper shaping mold to separate from the lower shaping mold through the connecting rod and the connecting cylinder, so as to place the aluminum alloy beam in the mold cavity of the lower shaping mold, and then the PLC controller extends the moving end of the first electric hydraulic rod to push the upper shaping mold and the lower shaping mold to close the mold, and use the aluminum alloy beam mold cavity composed of the two to perform preliminary extrusion shaping and repair on the protruding deformation of the beam. The mold has precise matching and can effectively correct the protruding deformation, laying a solid foundation for subsequent processes.

[0015] Through the set vacuum pump and heating component, when the shaping mold mechanism is closed, the PLC controller starts the heating component and the vacuum pump synchronously. The vacuum pump circulates and heats the helium in the hollow heat insulation cover, and carries the heat to the aluminum alloy beam, raising the temperature of the aluminum alloy beam to 460 degrees Celsius. The temperature sensor monitors the helium temperature in real time and feeds back the electrical signal to the PLC controller. When the temperature reaches the preset threshold of 460 degrees Celsius, the PLC controller controls the electromagnetic heating coil and the vacuum pump to cut off the power and pause, and triggers the alarm to remind the staff. At this time, the aluminum alloy material softens, the yield strength decreases and the elastic modulus increases, which makes it easier to plastically deform under the action of external force, greatly improving the shaping efficiency, ensuring the precise achievement of the expected shape and dimensional accuracy, effectively avoiding small cracks caused by hard deformation, and making the internal structure of the aluminum alloy more uniform, ensuring the reliable performance of the beam after shaping.

[0016] Through the air expansion auxiliary shaping mechanism and the ejection component, after the PLC controller controls the vacuum pump and the electromagnetic heating coil to be powered off, the PLC controller can control the air expansion auxiliary shaping mechanism to work, increase the helium pressure at the aluminum alloy beam, and use the expansion force of compressed helium to repair the concave deformation of the aluminum alloy beam. Due to the restriction of the inner wall of the aluminum alloy beam cavity composed of the upper shaping mold and the lower shaping mold, the concave deformation of the aluminum alloy beam is automatically and quickly repaired under the action of the expansion force of compressed helium. At this time, the temperature of the aluminum alloy beam is still high, the hardness of the aluminum alloy material is low, and the shaping It is more convenient and will not cause damage defects. After the aluminum alloy beam is shaped, the upper shaping mold is separated from the lower shaping mold, and then the three-way reversing solenoid valve and the vacuum pump are energized for 5 seconds. During this 5 seconds, the vacuum pump draws a small amount of helium in the hollow heat insulation cover into the countersink, and then a small amount of helium will lift the lifting component. The lifting component separates the shaped aluminum alloy beam from the lower shaping mold and is easy to take out. This mechanism enables the shaping equipment to have the function of air expansion, extrusion, depression, deformation and shaping, which improves the convenience and efficiency of aluminum alloy beam shaping and reduces the labor intensity of staff. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1It is a structural schematic diagram of an aluminum alloy subframe shaping device and a shaping method thereof provided by the present invention; Figure 2 yes Figure 1 A schematic diagram of the structure with a partial cross-section in the middle; Figure 3 yes Figure 1 Structural diagram of the middle shaping die mechanism; Figure 4 yes Figure 1 A schematic diagram of the structure of the middle connecting rod part; Figure 5 yes Figure 2 Schematic diagram of the structure of the heat-resistant rubber cover; Figure 6 yes Figure 2 Schematic diagram of the structure of the middle top material assembly.

[0018] In the figure: 1 U-shaped frame, 2 bottom plate, 3 hollow plate, 4 shaping mold mechanism, 41 lower shaping mold, 42 fixing block, 43 connecting bolt, 44 arc-shaped air guide channel, 45 countersunk hole, 46 upper shaping mold, 47 connecting cylinder, 5 lifting mechanism, 51 first electric hydraulic rod, 52 connecting rod, 53 fixing bolt, 54 nut, 55 pressure ring, 6 inflation auxiliary shaping mechanism, 61 second electric hydraulic rod, 62 support block, 63 heat-resistant rubber cover, 64 heat insulation board, 65 U-shaped limit block, 66 drawer Air pump, 67 air intake check valve, 68 heat-resistant hose, 69 PLC controller, 610 alarm, 611 helium replenishing valve, 612 temperature sensor, 613 pressure sensor, 7 heating component, 71 three-way reversing solenoid valve, 72 heat-resistant metal tube, 73 electromagnetic heating coil, 74 air guide pipe, 75 exhaust check valve, 8 ejector component, 81 ejector block, 82 guide rod, 83 limit ring, 84 limit convex ring, 9 guide column, 10 hollow heat insulation cover, 11 first limit sleeve, 12 second limit sleeve. DETAILED DESCRIPTION

[0019] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] like Figure 1-Figure 6As shown, an aluminum alloy subframe shaping device includes a U-shaped frame 1, a placement slot is opened at the bottom end of the U-shaped frame 1, a bottom plate 2 and a hollow plate 3 are fixedly connected to the inner wall of the U-shaped frame 1, a shaping mold mechanism 4 is connected to the upper surface of the hollow plate 3, and the shaping mold mechanism 4 includes a lower shaping mold 41 fixedly connected to the upper surface of the hollow plate 3, and two fixing blocks 42 are fixedly connected to the outer walls on both sides of the bottom end of the lower shaping mold 41, and a threaded hole is opened on the upper surface of the fixing block 42, and the hole wall of the threaded hole The hollow plate 3 is connected with a connecting bolt 43, the bottom end of the connecting bolt 43 is threadedly connected to the upper surface of the hollow plate 3, and the upper surface of the hollow plate 3 is provided with a plurality of threaded blind holes matched with the connecting bolt 43. The lower shaping mold 41 is provided with two arc-shaped air guide channels 44 inside, and the air outlet ends of the two arc-shaped air guide channels 44 are located on both sides of the aluminum alloy beam cavity of the lower shaping mold 41. The inner wall of the aluminum alloy beam cavity of the lower shaping mold 41 is provided with a countersink 45, and the hole wall of the countersink 45 is provided with a top material assembly 8. The upper surface of the lower shaping mold 41 is connected to the upper shaping mold 46, and the mold cavity of the upper shaping mold 46 and the mold cavity of the lower shaping mold 41 together form an aluminum alloy crossbeam shaping mold cavity. The upper surface of the upper shaping mold 46 is fixedly connected to a connecting tube 47, and the outer walls of both sides of the upper shaping mold 46 and the lower shaping mold 41 are respectively fixedly connected to the first limiting sleeve 11 and the second limiting sleeve 12, and the inner walls of the first limiting sleeve 11 and the second limiting sleeve 12 on the same side are jointly movably sleeved with a guide column 9, and the bottom end of the guide column 9 Fixedly connected to the upper surface of the hollow plate 3, the guide column 9 cooperates with the first limit sleeve 11 and the second limit sleeve 12 to ensure the accurate mold closing of the upper shaping mold 46 and the lower shaping mold 41, ensure the sealing of the mold cavity after mold closing, and lay the foundation for inflation shaping. The upper shaping mold 46 and the lower shaping mold 41 are closed, and the aluminum alloy beam mold cavity composed of the two is used to perform preliminary extrusion and shaping repair on the protruding deformation of the beam. The mold is accurately matched and can effectively correct the protruding deformation, laying a solid foundation for subsequent processes.

[0021] The ejection assembly 8 includes an ejection block 81 movably embedded in the lower shaping mold 41, the bottom end of the ejection block 81 is sealingly and movably connected to the top end of the countersunk hole 45, the bottom end of the ejection block 81 is fixedly connected to a guide rod 82, the rod wall of the guide rod 82 is movably sleeved with a limiting ring 83, the outer wall of the limiting ring 83 is fixedly connected to the hole wall of the countersunk hole 45, and the bottom end of the guide rod 82 is fixedly connected to a limiting convex ring 84. This mechanism can facilitate the separation of the aluminum alloy beam from the lower shaping mold 41 after shaping, and then facilitate the removal of the aluminum alloy beam after shaping.

[0022] A lifting mechanism 5 is fixedly embedded in the top of the U-shaped frame 1, and the bottom end of the lifting mechanism 5 is connected to the top of the shaping mold mechanism 4. The lifting mechanism 5 includes a first electric hydraulic rod 51 fixedly embedded in the top of the U-shaped frame 1, and the movable end of the first electric hydraulic rod 51 is fixedly connected to a connecting rod 52 that cooperates with the connecting tube 47. The connecting rod 52 and the outer wall of the connecting tube 47 are jointly provided with a through hole, and the hole wall of the through hole is movably connected with a fixing bolt 53, the outer wall of the fixing bolt 53 is threadedly connected with a nut 54, and the rod wall of the connecting rod 52 is fixedly sleeved with a pressure ring 55.

[0023] The upper surface of the bottom plate 2 is fixedly connected with a hollow heat insulation cover 10, the top of the hollow heat insulation cover 10 is fixedly connected to the lower surface of the hollow plate 3, the inner wall of the hollow heat insulation cover 10 is fixedly connected with an inflation auxiliary shaping mechanism 6, the inflation auxiliary shaping mechanism 6 includes a second electric hydraulic rod 61 fixedly connected to the bottom end of the hollow heat insulation cover 10, the movable end of the second electric hydraulic rod 61 is fixedly connected with a support block 62, the outer wall of the support block 62 is fixedly sleeved with a heat-resistant rubber cover 63 that is sealingly and slidably connected to the inner wall of the hollow heat insulation cover 10, the upper surface of the heat-resistant rubber cover 63 is fixedly connected with a heat insulation board 64, the upper surface of the heat insulation board 64 is fixedly connected with a U-shaped limit block 65, and the outer wall of the hollow heat insulation cover 10 is provided with a through hole The outer wall of the hollow heat insulation cover 10 is fixedly connected with a PLC controller 69, and the inner wall of the bottom end of the U-shaped frame 1 is fixedly connected with an alarm device 610. The outer wall of the hollow heat insulation cover 10 is fixedly embedded with a helium replenishing valve 611, a temperature sensor 612 and an air pressure sensor 613. This mechanism can improve the shaping effect and reliability. This inflation shaping process does not require measurement and shaping at the same time, which saves time and effort, avoids stress concentration and causes structural damage to the aluminum alloy beam material, eliminates micro cracks, and prevents rigidity damage and strength reduction.

[0024] The inner wall of the hollow plate 3 is fixedly connected with a heating component 7, and the heating component 7 includes a three-way reversing solenoid valve 71 fixedly embedded in the inner wall of the hollow plate 3, the air inlet end of the three-way reversing solenoid valve 71 passes through the lower surface of the hollow plate 3, and is fixedly connected to the air outlet end of the heat-resistant hose 68, the top air outlet end of the three-way reversing solenoid valve 71 passes through the upper surface of the hollow plate 3, and is fixedly connected to the countersunk hole 45 of the lower shaping mold 41, the lateral air outlet end of the three-way reversing solenoid valve 71 is fixedly connected with a heat-resistant metal pipe 72, the air outlet end of the heat-resistant metal pipe 72 passes through the upper surface of the hollow plate 3, and is sealed and connected to one of the arc-shaped air guide channels 44 in the lower shaping mold 41, the outer wall of the heat-resistant metal pipe 72 is fixedly sleeved with an electromagnetic heating coil 73, and the lower surface of the hollow plate 3 is opened. There are two fixed through holes matched with the electromagnetic heating coil 73. The top of the hollow plate 3 is fixedly connected with an air guide pipe 74. The top air inlet end of the air guide pipe 74 is sealed and connected with another arc-shaped air guide channel 44 in the lower shaping mold 41. The air outlet end of the air guide pipe 74 is fixedly connected with an exhaust check valve 75. The bottom end of the exhaust check valve 75 passes through the lower surface of the hollow plate 3 and is located inside the hollow heat insulation cover 10. The heating component 7 can soften the aluminum alloy material, reduce the yield strength and increase the elastic modulus, and it is easier to plastically deform under the action of external force, which greatly improves the shaping efficiency, ensures that the expected shape and dimensional accuracy are accurately achieved, effectively avoids small cracks caused by hard deformation, and makes the internal structure of the aluminum alloy more uniform, ensuring the reliable performance of the beam after shaping.

[0025] The first electric hydraulic rod 51, the second electric hydraulic rod 61, the alarm 610, the helium replenishing valve 611, the three-way reversing solenoid valve 71 and the electromagnetic heating coil 73 are all electrically connected to the output end of the PLC controller 69 through wires, the temperature sensor 612 and the air pressure sensor 613 are all electrically connected to the input end of the PLC controller 69 through wires, and the input end of the PLC controller 69 can also be externally connected to a control panel for easy control of the equipment. The above-mentioned electrical connections and power-on devices are all existing technologies and will not be repeated here.

[0026] The operating principle of the present invention is now described as follows: when the aluminum alloy crossbeam of the full-frame aluminum alloy subframe needs to be reshaped due to deformation before welding, the PLC controller 69 first controls the second electric hydraulic rod 61 to retract the moving end, and at the same time opens the helium replenishing valve 611, so that helium is filled into the hollow heat insulation cover 10 through the gas guide pipe, and the connecting cylinder 47 is firmly connected to the connecting rod 52 by the fixing bolt 53 and the nut 54. Then, the PLC controller 69 controls the moving end of the first electric hydraulic rod 51 to retract, and drives the upper shaping mold 46 to separate from the lower shaping mold 41 through the connecting rod 52 and the connecting cylinder 47, so as to place the aluminum alloy crossbeam in the mold cavity of the lower shaping mold 41. Then, the PLC controller 69 controls the moving end of the first electric hydraulic rod 51 to extend, and pushes the upper shaping mold 46 and the lower shaping mold 41 to close the mold, and uses the aluminum alloy crossbeam mold cavity formed by the two to perform preliminary extrusion shaping and repair on the protruding deformation of the crossbeam. The mold is precisely matched and can effectively correct the protruding deformation, laying a solid foundation for subsequent processes. After the shaping mold mechanism 4 is closed, the PLC controller 69 starts the heating component 7 and the vacuum pump 66 synchronously. When the heating component 7 is working, the electromagnetic heating coil 73 is energized to generate heat, thereby raising the temperature of the heat-resistant metal tube 72. At the same time, the vacuum pump 66 extracts helium from the hollow heat-insulating cover 10 through the air intake check valve 67, and enters the heat-resistant metal tube 72 through the heat-resistant hose 68 and the three-way reversing electromagnetic valve 71 to increase the temperature. The heated helium enters the aluminum alloy crossbeam through the arc-shaped air guide channel 44, and then enters the air guide pipe 74 through another arc-shaped air guide channel 44, and finally returns to the hollow heat-insulating cover 10 through the exhaust check valve 75, thereby realizing cyclic heating by utilizing the excellent thermal conductivity of helium. , quickly increase the temperature of the aluminum alloy beam, the temperature sensor 612 monitors the helium temperature in real time and feeds back the electrical signal to the PLC controller 69, when the temperature reaches the preset threshold of 460 degrees Celsius, the PLC controller 69 controls the electromagnetic heating coil 73 and the vacuum pump 66 to cut off the power and pause, and triggers the alarm 610 to remind the staff. At this time, the aluminum alloy material softens, the yield strength decreases and the elastic modulus increases, and it is easier to plastically deform under the action of external force, which greatly improves the shaping efficiency, ensures that the expected shape and dimensional accuracy are accurately achieved, effectively avoids small cracks caused by hard deformation, and makes the internal structure of the aluminum alloy more uniform, ensuring the reliable performance of the beam after shaping; After the PLC controller 69 controls the vacuum pump 66 and the electromagnetic heating coil 73 to be powered off, the second electric hydraulic rod 61 is immediately controlled to work. The second electric hydraulic rod 61 pushes the support block 62, the heat-resistant rubber cover 63 and the heat insulation board 64 to move upward. As the heat-resistant rubber cover 63 rises, the air pressure inside the aluminum alloy beam gradually increases. When the second electric hydraulic rod 61 is started, the PLC controller 69 presets the initial air pressure in the hollow heat insulation cover 10 through the air pressure sensor 613. The helium in the hollow heat insulation cover 10 flows into the aluminum alloy beam through the air inlet check valve 67, the vacuum pump 66, the heat-resistant hose 68, the three-way reversing solenoid valve 71, the heat-resistant metal pipe 72 and the arc-shaped air guide channel 44. The expansion force of the compressed helium is used to repair the concave deformation of the aluminum alloy beam. The aluminum alloy beam cavity inner wall is restricted, and the concave deformation of the aluminum alloy beam is automatically and quickly repaired under the expansion force of compressed helium. At this time, the temperature of the aluminum alloy beam is still high, and the hardness of the aluminum alloy material is low, so the shaping is more convenient and no damage defects will occur. The air pressure sensor 613 monitors the air pressure change in real time and feeds it back to the PLC controller 69. When the air pressure reaches the preset warning air pressure threshold, the PLC controller 69 controls the second electric hydraulic rod 61 to suspend work and maintain the air pressure for 2 minutes according to the air pressure electrical signal fed back by the air pressure sensor 613, so as to ensure that the aluminum alloy beam is fully inflated and shaped under high temperature and high pressure, and the shaping effect and reliability are guaranteed. This inflation shaping process does not require simultaneous measurement and shaping, which saves time and effort, avoids stress concentration leading to structural damage of the aluminum alloy beam material, eliminates micro cracks, and prevents rigidity damage and strength reduction. After 2 minutes, the PLC controller 69 controls the second electric hydraulic rod 61 to retract, and the hollow heat insulation cover 10 recovers helium through the arc-shaped air guide channel 44, the air guide pipe 74 and the exhaust check valve 75 to reduce waste. When the air pressure sensor 613 detects that the air pressure in the hollow heat insulation cover 10 has returned to the initial air pressure value, the PLC controller 69 controls the first electric hydraulic rod 51 to retract according to the initial air pressure electrical signal fed back by the air pressure sensor 613, so that the upper shaping mold 46 is separated from the lower shaping mold 41, so as to facilitate the removal of the shaped aluminum alloy beam. At the same time, the PLC controller 69 controls the vacuum pump 66 and The three-way reversing solenoid valve 71 is energized for 5 seconds. After being energized, the three-way reversing solenoid valve 71 changes the air guide direction, and the vacuum pump 66 extracts a small amount of helium in the hollow heat insulation cover 10 into the countersunk hole 45. Then a small amount of helium lifts up the limiting convex ring 84, and pushes the top block 81 through the limiting convex ring 84 and the guide rod 82, so that the aluminum alloy cross beam is separated from the mold cavity of the lower shaping mold 41, which is convenient for taking out. After the aluminum alloy cross beam is naturally cooled in the outside, the problem of metal performance degradation of the aluminum alloy cross beam caused by rapid cooling is avoided. The shaped aluminum alloy cross beam is welded to the U-shaped plate frame type aluminum alloy subframe to form a full frame type aluminum alloy subframe; The shaping equipment integrates the functions of mold extrusion convex deformation shaping, gas expansion extrusion concave deformation shaping and heating to improve the elastic modulus of aluminum alloy beam materials. It heats and softens the aluminum alloy material, accelerates the shaping process, avoids structural damage caused by hard extrusion, improves the convenience and efficiency of aluminum alloy beam shaping, reduces the labor intensity of staff, enhances the reliability of aluminum alloy beam shaping, and thus effectively guarantees the effect of the use of aluminum alloy subframe.

[0027] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. An aluminum alloy subframe shaping device, comprising a U-shaped frame (1), characterized in that: A placement slot is provided at the bottom end of the U-shaped frame (1); a bottom plate (2) and a hollow plate (3) are fixedly connected to the inner wall of the U-shaped frame (1); and a shaping mold mechanism (4) is connected to the upper surface of the hollow plate (3); A lifting mechanism (5) is fixedly embedded at the top of the U-shaped frame (1), and the bottom end of the lifting mechanism (5) is connected to the top of the shaping mold mechanism (4); A hollow heat insulation cover (10) is fixedly connected to the upper surface of the bottom plate (2), a top end of the hollow heat insulation cover (10) is fixedly connected to the lower surface of the hollow plate (3), and an inflation auxiliary shaping mechanism (6) is fixedly connected to the inner wall of the hollow heat insulation cover (10); A heating component (7) is fixedly connected to the inner wall of the hollow plate (3).

2. The aluminum alloy subframe shaping equipment according to claim 1 is characterized in that: The shaping mold mechanism (4) comprises a lower shaping mold (41) fixedly connected to the upper surface of the hollow plate (3); two fixing blocks (42) are fixedly connected to the outer walls on both sides of the bottom end of the lower shaping mold (41); a threaded hole is provided on the upper surface of the fixing block (42); a connecting bolt (43) is connected to the hole wall of the threaded hole; the bottom end of the connecting bolt (43) is threadedly connected to the upper surface of the hollow plate (3); a plurality of threaded blind holes matching the connecting bolts (43) are provided on the upper surface of the hollow plate (3); and two arc holes are provided inside the lower shaping mold (41). The lower shaping mold (41) has an aluminum alloy beam mold cavity and an aluminum alloy beam mold cavity. The aluminum alloy beam mold cavity of the lower shaping mold (41) has two arc-shaped air guide channels (44), and the air outlet ends of the two arc-shaped air guide channels (44) are located on both sides of the aluminum alloy beam mold cavity of the lower shaping mold (41). The inner wall of the aluminum alloy beam mold cavity of the lower shaping mold (41) is provided with a countersunk hole (45), and the hole wall of the countersunk hole (45) is provided with a material ejection assembly (8). The upper surface of the lower shaping mold (41) is connected to an upper shaping mold (46), and the mold cavity of the upper shaping mold (46) and the mold cavity of the lower shaping mold (41) together form an aluminum alloy beam shaping mold cavity. The upper surface of the upper shaping mold (46) is fixedly connected to a connecting tube (47).

3. The aluminum alloy subframe shaping equipment according to claim 2, characterized in that: The lifting mechanism (5) comprises a first electric hydraulic rod (51) fixedly embedded in the top of the U-shaped frame (1); the movable end of the first electric hydraulic rod (51) is fixedly connected to a connecting rod (52) matched with the connecting tube (47); the outer walls of the connecting rod (52) and the connecting tube (47) are jointly provided with a through hole, and the hole wall of the through hole is movably connected to a fixing bolt (53); the outer wall of the fixing bolt (53) is threadedly connected to a nut (54); and the rod wall of the connecting rod (52) is fixedly sleeved with a pressure ring (55).

4. The aluminum alloy subframe shaping equipment according to claim 3 is characterized in that: The inflation-assisted shaping mechanism (6) comprises a second electric hydraulic rod (61) fixedly connected to the bottom end of the hollow heat-insulating cover (10); the movable end of the second electric hydraulic rod (61) is fixedly connected to a support block (62); the outer wall of the support block (62) is fixedly sleeved with a heat-resistant rubber cover (63) sealingly and slidably connected to the inner wall of the hollow heat-insulating cover (10); the upper surface of the heat-resistant rubber cover (63) is fixedly connected to a heat-insulating plate (64); the upper surface of the heat-insulating plate (64) is fixedly connected to a U-shaped limit block (65); the outer wall of the hollow heat-insulating cover (10) A through hole is provided, and a vacuum pump (66) is sealed and fixedly connected to the hole wall of the through hole; an air inlet end of the vacuum pump (66) is fixedly connected to an air inlet check valve (67); an air outlet end of the vacuum pump (66) is fixedly connected to a heat-resistant hose (68); an outer wall of the hollow heat-insulating cover (10) is fixedly connected to a PLC controller (69); an inner wall of the bottom end of the U-shaped frame (1) is fixedly connected to an alarm (610); and a helium replenishing valve (611), a temperature sensor (612), and an air pressure sensor (613) are fixedly embedded in the outer wall of the hollow heat-insulating cover (10).

5. The aluminum alloy subframe shaping equipment according to claim 4 is characterized in that: The heating assembly (7) comprises a three-way reversing solenoid valve (71) fixedly embedded in the inner wall of the hollow plate (3); the air inlet end of the three-way reversing solenoid valve (71) passes through the lower surface of the hollow plate (3) and is fixedly connected to the air outlet end of the heat-resistant hose (68); the top air outlet end of the three-way reversing solenoid valve (71) passes through the upper surface of the hollow plate (3) and is fixedly connected to the countersunk hole (45) of the lower shaping mold (41); the lateral air outlet end of the three-way reversing solenoid valve (71) is fixedly connected to a heat-resistant metal tube (72); the air outlet end of the heat-resistant metal tube (72) passes through the upper surface of the hollow plate (3) and is fixedly connected to one of the arcs in the lower shaping mold (41). The hollow plate (3) is provided with an electromagnetic heating coil (73) on its outer wall, and two fixed through holes matching the electromagnetic heating coil (73) are provided on the lower surface of the hollow plate (3). The top end of the hollow plate (3) is fixedly connected with an air guide pipe (74). The top air inlet end of the air guide pipe (74) is sealedly connected with another arc-shaped air guide channel (44) in the lower shaping mold (41). The air outlet end of the air guide pipe (74) is fixedly connected with an exhaust check valve (75). The bottom end of the exhaust check valve (75) passes through the lower surface of the hollow plate (3) and is located inside the hollow heat insulation cover (10).

6. The aluminum alloy subframe shaping equipment according to claim 5, characterized in that: The ejector assembly (8) comprises an ejector block (81) movably embedded in the lower shaping die (41); the bottom end of the ejector block (81) is movably connected to the top end of the countersunk hole (45) in a sealed manner; the bottom end of the ejector block (81) is fixedly connected to a guide rod (82); the rod wall of the guide rod (82) is movably sleeved with a limiting ring (83); the outer wall of the limiting ring (83) is fixedly connected to the hole wall of the countersunk hole (45); and the bottom end of the guide rod (82) is fixedly connected to a limiting convex ring (84).

7. The aluminum alloy subframe shaping equipment according to claim 6, characterized in that: The outer walls of both sides of the upper shaping mold (46) and the lower shaping mold (41) are respectively fixedly connected with a first limiting sleeve (11) and a second limiting sleeve (12); the inner walls of the first limiting sleeve (11) and the second limiting sleeve (12) on the same side are movably sleeved with a guide column (9); the bottom end of the guide column (9) is fixedly connected to the upper surface of the hollow plate (3).

8. A shaping method applied to the aluminum alloy subframe shaping equipment according to claim 7, characterized in that: The method comprises the following steps: Step S1: Preparation stage: the PLC controller (69) controls the second electric hydraulic rod (61) to retract its moving end, and at the same time opens the helium replenishing valve (611) to fill helium into the hollow heat insulation cover (10), and firmly connects the connecting tube (47) and the connecting rod (52) with fixing bolts (53) and nuts (54); Step S2: mold separation and beam placement: the PLC controller (69) controls the first electric hydraulic rod (51) to retract its moving end, driving the upper shaping mold (46) to separate from the lower shaping mold (41), and placing the aluminum alloy beam to be shaped in the mold cavity of the lower shaping mold (41); Step S3: mold closing and extrusion: the PLC controller (69) controls the moving end of the first electric hydraulic rod (51) to extend, pushes the upper shaping mold (46) and the lower shaping mold (41) to close the mold, and performs preliminary extrusion and shaping repair on the protruding deformation of the aluminum alloy beam; Step S4: Heating and temperature raising to assist shaping: After the mold is closed, the PLC controller (69) starts the heating component (7) and the vacuum pump (66), and uses helium circulation heating to raise the temperature of the aluminum alloy beam. When the temperature reaches a threshold value of (460) degrees Celsius, the electromagnetic heating coil (73) and the vacuum pump (66) are controlled to be powered off and paused, and an alarm (610) is triggered; Step S5: Inflating and squeezing the concave shape: the PLC controller (69) controls the vacuum pump (66) and the electromagnetic heating coil (73) to be powered off, and then starts the second electric hydraulic rod (61) to shape and repair the concave deformation of the aluminum alloy beam using the expansion force of compressed helium. When the air pressure reaches a preset warning threshold, the second electric hydraulic rod (61) is controlled to stop working and maintain the air pressure for 2 minutes; Step S6: Helium recovery and mold separation: After 2 minutes, the PLC controller (69) controls the second electric hydraulic rod (61) to retract and recover the helium, and when the air pressure in the hollow heat insulation cover (10) returns to the initial value, controls the moving end of the first electric hydraulic rod (51) to retract, so that the upper shaping mold (46) is separated from the lower shaping mold (41); Step S7: Removing the crossbeam: The PLC controller (69) controls the vacuum pump (66) and the three-way reversing solenoid valve (71) to be energized for 5 seconds, extracting a small amount of helium to separate the aluminum alloy crossbeam from the cavity of the lower shaping mold (41), and removing the shaped aluminum alloy crossbeam. After natural cooling, the crossbeam is then used for welding to form a full-frame aluminum alloy subframe.

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