A manufacturing process and apparatus suitable for small piece sub-assembly

Abstract

The present application relates to a kind of manufacturing process and equipment suitable for small piece sub-welding assembly, belong to small piece sub-welding assembly processing technical field, according to curvature radius division plane area, transition area, corner area, and respectively layout diamond grid, gradually change diamond grid and radial sector grid reinforcement rib, targeted to improve the bending stiffness of each area, avoid local collapse or warping, then through rotatable adapter block, elastic compensation mechanism realizes the quick change of different products, solve the problem that traditional rigidity fixture is poor in adaptability, precision loss is big, then using laser scanner to detect deformation, combined with hydraulic compensation device, dynamically exert reverse prestress, solve the defects of traditional compensation device slow response, high energy consumption, realize real-time accurate correction of deformation, finally multi-axis linkage welding gun group is equipped with independent pressure sensor and temperature closed-loop control, ensure that welding pressure and temperature are stable, solve the problem of thermal deformation and virtual welding in traditional welding, improve overall precision.

Description

Technical Field

[0001] This invention belongs to the field of small component welding assembly processing technology, specifically relating to a manufacturing process and equipment suitable for small component welding assemblies. Background Technology

[0002] In the field of manufacturing thin-plate small parts for welding assembly, due to their thinness and complex structure, the parts generally suffer from self-weight deformation and stress concentration during the stamping and welding process. Traditional processes usually adopt a uniform reinforcing rib design, such as arranging regular grid ribs on a whole sheet of material. However, the stress characteristics of the planar area and the curved area are significantly different. The uniform design leads to redundant stiffness in the planar area and insufficient reinforcement in the corner area. After welding, local collapse or warping is likely to occur, which can lead to assembly failure in severe cases. In addition, most existing welding fixtures are rigid fixed structures, which cannot adapt to the deformation compensation requirements of different areas, further aggravating the loss of precision.

[0003] To address the aforementioned issues, some improvement solutions attempt to suppress deformation through local thickening or the addition of supporting structures. However, such methods significantly increase material costs and welding complexity. Other technologies propose using hydraulic or pneumatic compensation devices, but these systems have slow response speeds and high energy consumption, making it difficult to achieve real-time and precise control. Especially for parts with complex curvatures, existing processes lack targeted treatment for transition areas, leading to disordered stress transmission paths and the easy generation of microcracks at the interface. How to achieve full-domain stiffness matching and deformation control for thin-plate parts without sacrificing the advantages of lightweight design remains a core challenge in the manufacturing process of high-precision sub-welded assemblies. To address this, a manufacturing process and equipment suitable for small sub-welded assemblies have been developed. Summary of the Invention

[0004] To address the aforementioned problems in the prior art, this invention provides a manufacturing process and equipment suitable for small component welding assemblies, thus solving the problems of the prior art.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] A manufacturing process suitable for small-part sub-welding assemblies includes the following steps:

[0007] S1: First, determine the easily deformable areas of the thin plate parts. Based on the radius of curvature of the parts, delineate the areas with a radius of curvature > 500 mm as the planar area, the areas with a radius of curvature < 500 mm and ≤ 500 mm as the transition area, and the areas with a radius of curvature ≤ 50 mm as the corner area. Arrange orthogonal 60° staggered diamond grid reinforcing ribs on the planar area to form a mesh structure with balanced bidirectional bending stiffness. Arrange gradually changing diamond grid reinforcing ribs with an included angle linearly changing from 60° to 30° along the direction from the planar area to the corner area on the transition area. Arrange radial fan-shaped grid reinforcing ribs on the corner area. The radial ribs are distributed along the principal stress trace.

[0008] S2: An adjustable combination fixture is set up at the assembly station. The adjustable combination fixture is used to enable different products to share the same basic module.

[0009] S3: A laser scanner is used to detect the deformation of the part in real time. When the flatness deviation exceeds the threshold, the hydraulic compensation device is activated to apply reverse prestress to the deformed area. The magnitude of the reverse prestress is dynamically adjusted according to the deformation.

[0010] S4: A multi-axis linkage welding torch group is arranged at the welding station. Each welding torch is equipped with an independent pressure sensor and a temperature closed-loop control system. High-precision welding of multiple connection points is achieved through synchronous control.

[0011] As a further embodiment of the present invention, the width of the diamond-shaped mesh reinforcing ribs on the planar area in S1 is twice the thickness of the sheet metal part, the height is three times the thickness of the sheet metal part, and the included angle between adjacent ribs is 60°, so as to balance the in-plane stiffness and reduce the weight.

[0012] As a further aspect of the present invention, in S1, the density of the gradient rhomboid mesh reinforcing ribs in the transition zone along the direction from the planar zone to the corner zone increases at equal intervals.

[0013] As a further aspect of the present invention, the radius of the radial fan-shaped mesh reinforcing ribs in the corner area of ​​S1 is 3 to 5 times the thickness of the plate.

[0014] A device suitable for welding small parts assemblies includes a main body, an adjustable combination fixture mounted on the main body, a laser scanner, a hydraulic compensation device, and a multi-axis linkage welding torch assembly slidably mounted on the main body. The laser scanner is suspended above the adjustable combination fixture and is used to detect workpiece deformation in real time. The adjustable combination fixture is connected to the hydraulic compensation device.

[0015] As a further embodiment of the present invention, the adjustable combination fixture includes a basic positioning part, a rotating part, a limiting part and an elastic compensation part that are slidably set on the main body of the equipment. The rotating part is rotatably set on one end of the limiting part, and the elastic compensation part is sleeved on the other end of the limiting part. A clamping area is formed between the basic positioning part and the rotating part. By adjusting the rotating part, different products can share the same basic module.

[0016] As a further embodiment of the present invention, the basic positioning part includes a positioning plate and a plurality of positioning rods disposed on the positioning plate. The plurality of positioning rods slide through the positioning plate, and each of the plurality of positioning rods is fitted with a first spring, the two ends of the first spring being connected to the positioning plate and the positioning rods respectively.

[0017] As a further embodiment of the present invention, the end of the positioning rod is provided with a silicone sleeve.

[0018] As a further embodiment of the present invention, the rotating part is an elastic rotating block.

[0019] As a further embodiment of the present invention, the elastic compensation part is a second spring, a fixing block is provided on the main body of the device, the limiting part is a limiting rod, the limiting rod slides through the fixing block, the second spring is sleeved on the limiting rod, and the two ends of the second spring are respectively connected to the fixing block and the limiting rod.

[0020] The beneficial effects of this invention are as follows:

[0021] The system is divided into planar, transition, and corner zones based on the radius of curvature, and reinforced with rhomboid, gradient rhomboid, and radial fan-shaped grids to specifically enhance the bending stiffness of each zone and prevent local collapse or warping. A rotatable adapter block and elastic compensation mechanism enable rapid product changeover, addressing the poor adaptability and significant accuracy loss of traditional rigid fixtures. A laser scanner detects deformation, and a PID closed-loop controlled hydraulic compensation device dynamically applies reverse prestress, overcoming the slow response and high energy consumption of traditional compensation devices, achieving real-time and precise deformation correction. Finally, a multi-axis linkage welding torch assembly is equipped with independent pressure sensors and temperature closed-loop control to ensure stable welding pressure and temperature, resolving thermal deformation and incomplete weld problems in traditional welding and improving overall accuracy. Attached Figure Description

[0022] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0023] Figure 1 This is a flowchart illustrating the manufacturing process of the small component welding assembly of the present invention.

[0024] Figure 2 This is a schematic diagram of the adjustable combination clamp structure of the present invention;

[0025] Figure 3 This is a schematic diagram of the basic positioning part structure of the present invention.

[0026] Explanation of key component symbols:

[0027] In the diagram: 1. Main body of the equipment; 21. Foundation positioning part; 211. Positioning plate; 212. Positioning rod; 213. First spring; 22. Rotating part; 23. Limiting part; 24. Elastic compensation part; 25. Fixing block. Detailed Implementation

[0028] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided.

[0029] Please see Figures 1-3 As shown, this embodiment provides a manufacturing process suitable for small component welding assemblies, including the following steps:

[0030] S1: First, determine the easily deformable areas of the thin plate part. The bending stiffness difference between different curvature areas can be 5-10 times, directly affecting the deformation sensitivity. Therefore, based on the curvature radius of the part, the area with a curvature radius > 500mm is designated as the planar area, the area with a curvature radius < 50mm and ≤ 500mm as the transition area, and the area with a curvature radius ≤ 50mm as the corner area. Orthogonal 60° staggered diamond-shaped mesh reinforcements are arranged on the planar area to form a mesh structure with balanced bidirectional bending stiffness. On the transition area, gradually changing diamond-shaped mesh reinforcements with an included angle linearly changing from 60° to 30° are arranged along the direction from the planar area to the corner area. Radial fan-shaped mesh reinforcements are arranged on the corner area, with the radial reinforcements distributed along the principal stress traces. The curvature radius division is based on: planar area (> 500mm), approximately planar... The structure primarily withstands bidirectional bending. In the transition zone (50-500mm), combined stresses such as bending and tension can easily lead to shear slip bands. In the corner zone (≤50mm), triaxial stress is concentrated, with the maximum principal stress concentrated on the inner side. The planar zone features an orthogonal 60° rhomboid mesh, providing balanced bidirectional bending stiffness. The transition zone uses a gradually changing rhomboid mesh (linearly changing from 60° to 30° angle), while the corner zone uses a radial fan-shaped mesh distributed along the principal stress lines. Traditional uniform stiffener designs result in redundant stiffness in the planar zone and insufficient reinforcement in the corner zone, leading to potential collapse or warping after welding. Here, the rhomboid mesh in the planar zone optimizes bidirectional bending performance and improves stiffness. The gradually changing design in the transition zone smooths the stress transmission path and reduces the risk of shear slip. The radial stiffeners in the corner zone match the principal stress lines, reducing stress concentration and suppressing microcracks.

[0031] S2: An adjustable combination fixture is set up at the assembly station. The adjustable combination fixture is used to enable different products to share the same basic module.

[0032] S3: A laser scanner is used to detect the deformation of the part in real time. When the flatness deviation exceeds the threshold, the hydraulic compensation device is activated to apply reverse prestress to the deformed area. The magnitude of the reverse prestress is dynamically adjusted according to the deformation. The laser scanner, with a line laser scanning head, generates three-dimensional point cloud data. The threshold is set, and compensation is triggered when the flatness deviation exceeds the preset value. The hydraulic actuator is controlled by PID closed loop.

[0033] S4: A multi-axis linkage welding torch assembly is arranged at the welding station. Each welding torch is equipped with an independent pressure sensor and a temperature closed-loop control system. High-precision welding of multiple connection points is achieved through synchronous control. The multi-axis linkage welding torch assembly is a 6-axis multi-degree-of-freedom robotic arm that moves along a linear guide rail.

[0034] Currently, in the field of manufacturing thin-plate small-part welded assemblies, some improvement solutions attempt to suppress deformation by locally thickening or adding support structures. However, such methods significantly increase material costs and welding complexity. Other technologies propose using hydraulic or pneumatic compensation devices, but the system response speed is slow and energy consumption is high, making it difficult to achieve real-time and precise control. Especially for parts with complex curvature, existing processes lack targeted treatment for transition areas, leading to disordered stress transmission paths and easy generation of microcracks at the interface. How to achieve full-domain stiffness matching and deformation control of thin-plate parts without sacrificing the advantages of lightweighting remains a core challenge in the manufacturing process of high-precision welded assemblies.

[0035] To address this issue, this embodiment first divides the area into planar, transition, and corner zones based on the radius of curvature, and then applies diamond-shaped, gradient diamond-shaped, and radial fan-shaped reinforcing ribs to specifically enhance the bending stiffness of each zone, preventing local collapse or warping. Next, a rotatable adapter block and elastic compensation mechanism enable rapid product changeover, resolving the poor adaptability and significant accuracy loss issues of traditional rigid fixtures. Then, a laser scanner detects deformation, and a PID closed-loop controlled hydraulic compensation device dynamically applies reverse prestress, overcoming the slow response and high energy consumption of traditional compensation devices, achieving real-time and precise deformation correction. Finally, a multi-axis linkage welding torch assembly is equipped with independent pressure sensors and temperature closed-loop control to ensure stable welding pressure and temperature, resolving thermal deformation and incomplete welding issues in traditional welding, and improving overall accuracy.

[0036] To better avoid local collapse in the planar area, in one embodiment, the width of the diamond-shaped mesh reinforcing ribs in the planar area of ​​S1 is twice the thickness of the sheet metal part, and the height is three times the thickness of the sheet metal part. This design can balance the in-plane stiffness under the premise of lightweighting, avoid stiffness redundancy or insufficiency, and the included angle between adjacent ribs is 60° to balance the in-plane stiffness and reduce weight. The orthogonal 60° staggered layout optimizes the bidirectional bending performance.

[0037] Since the transition zone is subjected to combined bending and tensile stresses, in order to reduce the risk of interface microcracks, in one embodiment, the density of the gradient rhomboid mesh reinforcing ribs in the transition zone in S1 increases at equal intervals along the direction from the planar area to the corner area. The density of the reinforcing ribs is gradually increased from the planar area to the corner area to achieve a stiffness gradient transition, avoid shear slip bands caused by stress abrupt changes, and the equal interval increase in density can smooth the stress transmission path and reduce the risk of interface microcracks.

[0038] Because the corner region has a small radius of curvature, stress concentration is significant. To address this, in one embodiment, the radius of the radial fan-shaped mesh reinforcement in the corner region of S1 is 3-5 times the thickness of the plate. The corner region is designed with radial fan-shaped mesh reinforcement distributed along the principal stress trace, optimizing the stress transmission path. Due to its small radius of curvature, the corner region bears complex tensile, compressive, and shear stresses, with the maximum principal stress typically concentrated on the inner side of the corner. The layout direction of the radial fan-shaped mesh reinforcement is consistent with the principal stress trace, forming a support structure that matches the stress field. The ribs of the radial fan-shaped mesh reinforcement extend along the principal stress direction, gradually dispersing the concentrated stress to the surrounding area, avoiding local stress peaks, reducing abrupt changes in the stress transmission path, lowering the shear strain energy density at the interface, and suppressing microcracks.

[0039] A device suitable for welding small parts assemblies includes a main body 1, an adjustable combination fixture mounted on the main body 1, a laser scanner, a hydraulic compensation device, and a multi-axis linkage welding torch assembly slidably mounted on the main body 1. The laser scanner is suspended above the adjustable combination fixture and is used to detect workpiece deformation in real time. The adjustable combination fixture is connected to the hydraulic compensation device. The adjustable combination fixture includes a basic positioning part 21, a rotating part 22, a limiting part 23, and an elastic compensation part 24 slidably mounted on the main body 1. The rotating part 22 is rotatably mounted on one end of the limiting part 23, and the elastic compensation part 24 is sleeved on the other end of the limiting part 23. A clamping area is formed between the basic positioning part 21 and the rotating part 22. Different products can share a common basic module by adjusting the rotating part 22.

[0040] Following the above embodiments, in one embodiment, the basic positioning part 21 includes a positioning plate 211 and a plurality of positioning rods 212 disposed on the positioning plate 211. The plurality of positioning rods 212 slide through the positioning plate 211, and each of the plurality of positioning rods 212 is fitted with a first spring 213. The two ends of the first spring 213 are respectively connected to the positioning plate 211 and the positioning rod 212. The ends of the positioning rods 212 are provided with silicone sleeves. The rotating part 22 is an elastic rotating block, and the elastic compensation part 24 is a second spring. A fixing block 25 is disposed on the main body 1, and a limiting part 23 is a limiting rod. The limiting rod slides through the fixing block 25, and the second spring is fitted on the limiting rod. The two ends of the second spring are respectively connected to the fixing block 25 and the limiting rod. The basic positioning part 21 is constructed by... The positioning rod 212 and the spring achieve flexible positioning, reducing workpiece scratches. The rotating part 22 adapts to different product contours, and the elastic compensation part 24 absorbs assembly deformation, improving versatility and precision. The second spring, combined with the slide rail damping unit, balances the requirements of rigid fixation and flexible compensation. Thin plates are easily damaged by external forces. The silicone material has both elasticity and wear resistance, protecting the integrity of the workpiece surface. The silicone sleeve reduces the contact hardness between the positioning rod 212 and the workpiece, preventing indentations or scratches on the thin plate surface, which is especially suitable for high-gloss parts. In addition, complex curvature parts need to tolerate a certain deformation during assembly. The elastic material provides buffering and improves clamping stability. Therefore, the elastic rotating block can adapt to small deviations in the workpiece contour, avoiding local stress concentration caused by rigid clamping.

[0041] The working principle and process of this invention:

[0042] First, based on the radius of curvature of the thin plate part, the planar area, transition area, and corner area are divided. The planar area is reinforced with orthogonal 60° staggered rhomboid mesh ribs, and the stiffness is balanced through bidirectional bending design. The transition area adopts a gradually changing rhomboid mesh with a linear change in included angle from 60° to 30°, and the density gradually increases to smooth the stress transmission path. The corner area is equipped with radial fan-shaped mesh distributed along the principal stress trace. The stress concentration factor is reduced through geometric optimization. This design achieves global stiffness matching for the stress characteristics of different areas and suppresses local collapse or warping.

[0043] The adjustable combination fixture flexibly fixes the workpiece through the basic positioning part 21, the rotating part 22 adapts to different contours, and the second spring and limit rod in the elastic compensation part 24 work together to absorb deformation errors. The laser scanner detects the deformation in real time. When the deviation exceeds the threshold, the hydraulic compensation device applies dynamic reverse prestress through PID closed-loop control to accurately offset the deformation. Subsequently, the 6-axis robotic arm of the multi-axis linkage welding gun group moves to the welding station along the linear guide rail. Through independent pressure sensors and temperature closed-loop control, multiple welding points are simultaneously welded to ensure consistent weld strength. Finally, the efficient and high-precision manufacturing of the thin plate welding assembly is achieved.

[0044] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A manufacturing process suitable for small-part sub-welding assemblies, characterized in that, Includes the following steps: S1: First, determine the easily deformable areas of the thin plate parts. Based on the radius of curvature of the parts, delineate the areas with a radius of curvature > 500 mm as the planar area, the areas with a radius of curvature < 500 mm and ≤ 500 mm as the transition area, and the areas with a radius of curvature ≤ 50 mm as the corner area. Arrange orthogonal 60° staggered diamond grid reinforcing ribs on the planar area to form a mesh structure with balanced bidirectional bending stiffness. Arrange gradually changing diamond grid reinforcing ribs with an included angle linearly changing from 60° to 30° along the direction from the planar area to the corner area on the transition area. Arrange radial fan-shaped grid reinforcing ribs on the corner area. The radial ribs are distributed along the principal stress trace. S2: An adjustable combination fixture is set up at the assembly station. The adjustable combination fixture is used to enable different products to share the same basic module. S3: A laser scanner is used to detect the deformation of the part in real time. When the flatness deviation exceeds the threshold, the hydraulic compensation device is activated to apply reverse prestress to the deformed area. The magnitude of the reverse prestress is dynamically adjusted according to the deformation. S4: A multi-axis linkage welding torch group is arranged at the welding station. Each welding torch is equipped with an independent pressure sensor and a temperature closed-loop control system. High-precision welding of multiple connection points is achieved through synchronous control.

2. The manufacturing process for a small-part sub-welding assembly according to claim 1, characterized in that, The width of the diamond-shaped mesh reinforcing ribs in the planar area of ​​S1 is twice the thickness of the sheet metal part, and the height is three times the thickness of the sheet metal part. The included angle between adjacent ribs is 60° to balance the in-plane stiffness and reduce the weight.

3. The manufacturing process for a small-part sub-welding assembly according to claim 1, characterized in that, In S1, the density of the gradually increasing diamond-shaped mesh reinforcing ribs in the transition zone increases at equal intervals along the direction from the planar zone to the corner zone.

4. The manufacturing process for a small-part sub-welding assembly according to claim 1, characterized in that, The radius of the radial fan-shaped mesh reinforcing ribs in the corner area of ​​S1 is 3 to 5 times the thickness of the plate.

5. A device suitable for welding small parts assemblies, characterized in that, The equipment includes a main body, an adjustable combination fixture mounted on the main body, a laser scanner, a hydraulic compensation device, and a multi-axis linkage welding torch assembly slidably mounted on the main body. The laser scanner is suspended above the adjustable combination fixture and is used to detect workpiece deformation in real time. The adjustable combination fixture is connected to the hydraulic compensation device. The adjustable combination fixture includes a basic positioning part, a rotating part, a limiting part slidably mounted on the main body, and an elastic compensation part. The rotating part is rotatably mounted on one end of the limiting part, and the elastic compensation part is sleeved on the other end of the limiting part. The basic positioning part... A clamping area is formed between the rotating part and the base, allowing different products to share the same base module by adjusting the rotating part; the base positioning part includes a positioning plate and several positioning rods set on the positioning plate, the positioning rods slide through the positioning plate, and each positioning rod is fitted with a first spring, the two ends of the first spring being connected to the positioning plate and the positioning rod respectively; the elastic compensation part is a second spring, a fixing block is set on the main body of the equipment, the limiting part is a limiting rod, the limiting rod slides through the fixing block, the second spring is fitted on the limiting rod, and the two ends of the second spring are connected to the fixing block and the limiting rod respectively.

6. The equipment for welding small parts according to claim 5, characterized in that, The end of the positioning rod is provided with a silicone sleeve.

7. The equipment for welding small parts according to claim 5, characterized in that, The rotating part is an elastic rotating block.

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