Bumper with sheet metal assembly and sheet metal assembly welding process

Abstract

The invention relates to the field of bumpers, in particular to a bumper with a metal plate assembly and a metal plate assembly welding process, the bumper comprises a bumper assembly and the metal plate assembly embedded in the inner side of the bumper assembly, the bumper assembly and the metal plate assembly are used for being assembled with a pickup truck body after being assembled, and the metal plate assembly comprises a vertical middle sheet metal part. First vertical sheet metal parts are fixedly welded to the two ends of the vertical middle sheet metal part correspondingly, support sheet metal assemblies are welded to the sides, away from the vertical middle sheet metal part, of the first vertical sheet metal parts, and second vertical sheet metal parts are welded to the sides, away from the first vertical sheet metal parts, of the support sheet metal assemblies. The other side of the second vertical sheet metal part is welded to the end sheet metal part, and the bearing capacity and the supporting capacity of the bumper are remarkably enhanced while the appearance of the bumper is kept attractive. Due to the design of the metal plate assembly, the bumper can better bear external impact and weight, and stability and safety of the whole structure are improved.

Description

Technical Field

[0001] The present invention relates to the field of bumpers, and specifically to a bumper with a sheet metal assembly and a welding process for the sheet metal assembly. Background Art

[0002] Therefore, a plastic bumper with a sheet metal assembly is innovatively invented. Like a conventional bumper, the bumper can have a variety of appearance colors through painting, and different decorative parts are designed on the bumper, so that the bumper assembly has a better appearance and aesthetic feeling. In addition, for the load-bearing function that a conventional plastic bumper does not have, a sheet metal assembly is designed to support the bumper. The sheet metal assembly plays a key transitional role. It is fixedly connected to the vehicle body through the sheet metal assembly, and then supports and bears the load on the bumper assembly.

[0003] Therefore, we propose a plastic bumper with a sheet metal assembly to replace the metal iron bumper assembly and a welding process for the sheet metal assembly to solve the above problems. Summary of the Invention

[0004] To solve the above technical problems, the present invention provides a bumper with a sheet metal assembly and a welding process for the sheet metal assembly.

[0005] A bumper with a sheet metal assembly provided by the present invention includes a bumper assembly and a sheet metal assembly embedded and installed inside the bumper assembly. After the bumper assembly and the sheet metal assembly are assembled, they are used to be assembled with a pickup truck body. The sheet metal assembly includes a vertical intermediate sheet metal part. Both ends of the vertical intermediate sheet metal part are welded and fixed with a first vertical sheet metal part. A bracket sheet metal assembly is welded to the side of the first vertical sheet metal part away from the vertical intermediate sheet metal part. A second vertical sheet metal part is welded to the side of the bracket sheet metal assembly away from the first vertical sheet metal part. An end sheet metal part is welded to the other side of the second vertical sheet metal part. Horizontal bending parts are provided at the tops of the end sheet metal part, the second vertical sheet metal part, the bracket sheet metal assembly, the first vertical sheet metal part, and the vertical intermediate sheet metal part. The horizontal bending parts are jointly welded and fixed with a first horizontal sheet metal part. The bottoms of the first vertical sheet metal part, the bracket sheet metal assembly, and the second vertical sheet metal part are welded and fixed through a second horizontal sheet metal part.

[0006] Preferably, the fillet radius of the sheet metal assembly is 15 mm or more, which reduces the internal stress of sheet metal stamping and stretching and avoids wrinkling and cracking after sheet metal stamping. At the same time, a stamping simulation analysis is carried out on the sheet metal parts in the early stage to identify the areas at risk of sheet metal surface stamping, increase the fillet or cut off the redundant wrinkling positions. The thickness of the part where the bracket sheet metal assembly is positioned and fixedly connected to the vehicle body is 4 mm to ensure the connection strength and connection effect between the welded bracket sheet metal assembly and the vehicle body. The thickness of the first vertical sheet metal part and the second vertical sheet metal part is 2 mm to ensure the connection strength and support strength. The sheet metal assembly is provided with flanges and reinforcing ribs to increase the strength of the sheet metal part, avoid springback deformation of sheet metal stamping, and ensure the strength and dimensional accuracy of the sheet metal welding assembly.

[0007] Preferably, the bracket sheet metal assembly itself and its fixation with the mating part are fixed by CO₂ gas shielded welding to ensure the overall strength and durability of the sheet metal assembly fixedly connected to the vehicle body. The joints between the vertical intermediate sheet metal part, the first vertical sheet metal part, the bracket sheet metal assembly, the second vertical sheet metal part, the end sheet metal part, the first horizontal sheet metal part and the second horizontal sheet metal part are welded by spot welding, which is fast and efficient.

[0008] Preferably, the bumper assembly is provided with a receiving space for receiving the sheet metal assembly. The horizontal bending part of the end sheet metal part is connected to the bumper assembly by a first bolt, and the bottom of the end sheet metal part is connected to the bumper assembly by a second bolt. The bumper assembly is provided with positioning posts, and the end sheet metal part is provided with positioning holes. This effectively ensures the compliance of the gap between the bumper assembly and the vehicle body.

[0009] Preferably, the bracket sheet metal assembly includes an upper outer bracket, a lower bracket welded to the bottom of the upper outer bracket, and an upper inner bracket welded and fixed to the inner side of the upper outer bracket. The upper outer bracket is connected to the first horizontal sheet metal part, and the lower bracket is connected to the second horizontal sheet metal part. The welding positions of CO₂ gas shielded welding are arranged at the front and rear ends and the profile contact positions in the middle area of the upper outer bracket, and the welding build-up is guaranteed to be R4 or more. Through the above design, the welding of the bracket sheet metal assembly is ensured to be firm, and the overall strength of the bracket sheet metal assembly is guaranteed. The upper outer bracket is provided with a bolt guiding installation space. The end of the guiding installation space is provided with a fillet, and the arc size of the fillet is R10 mm. The guiding distance of the guiding installation space is greater than 15 mm. The fillet plus the guiding installation space ensure the convenience and stability of the installation of the bracket sheet metal assembly. The upper outer bracket is connected to the first horizontal sheet metal part by a fifth bolt, which is convenient for disassembly.

[0010] Preferably, the upper outer bracket is provided with a plurality of bolt holes, and third bolts are provided in both the bolt holes and the bolt guiding installation space. The upper outer bracket is connected to the vehicle body through the third bolts. The positioning clearance between two of the bolt holes and the corresponding holes on the vehicle body is 0.2 mm, and the positioning clearance between the guiding installation space 20 and the corresponding holes on the vehicle body is 0.5 mm. Through this positioning design scheme, the matching dimensions between the bumper assembly and the vehicle body are ensured.

[0011] Preferably, a connecting ear is welded to the bottom of the second horizontal sheet metal part, and the connecting ear is fixedly connected to the bumper assembly through a fourth bolt to enhance the connection strength between the sheet metal assembly and the bumper assembly.

[0012] Preferably, a large pedal is provided on the bumper assembly. The large pedal is provided with a plurality of first square protrusions, and the size of the first square protrusions is 76 mm × 24 mm, which increases the friction of stepping and the stability of bearing weight. A reinforcing rib is provided on the back of the first square protrusion to increase the strength of the large pedal. Two small pedals are also provided on the bumper assembly. The front of the small pedal is provided with a second square protrusion, and the size of the second square protrusion is 60 mm × 15 mm. A reinforcing rib is provided on the back of the small pedal to increase the strength of the small pedal. The effective depth of the left and right small pedals is 110 mm, which ensures effective support for the front part of the sole when a person gets on and off the cargo box. The height from the left and right small pedals to the upper part is more than 80 mm, which ensures that there is enough height space above the person's feet to enter the left and right stepping areas, facilitating people to get on and off the pickup truck cargo box. The appearance of the large and small pedals is defined as a texture, and the texture surface is a rough surface, which helps to prevent slipping and can also avoid dirt after being stepped on by people. Foam blocks are added to the cooperation with the counter parts of the large and small pedals, and the foam blocks are arranged at equal intervals. The foam blocks play a role in preventing abnormal sounds during stepping and buffering the bearing force.

[0013] A welding process for a sheet metal assembly includes the following steps:

[0014] S1: Welding of the upper inner bracket and the upper outer bracket First, the upper inner bracket is welded and fixed inside the upper outer bracket;

[0015] S2: Welding of the connecting ear and the second horizontal sheet metal part The connecting ear is welded and fixed to the bottom of the second horizontal sheet metal part, and the welding points are located at the four corners of the connecting ear;

[0016] S3: Welding of the lower bracket with the upper outer bracket and the second horizontal sheet metal part

[0017] S4: Welding of the first vertical sheet metal part with the first horizontal sheet metal part and the vertical intermediate sheet metal part

[0018] S5: Welding the whole welded in S1 - S3 with the first vertical sheet metal part

[0019] S6: Welding of the second vertical sheet metal part with the first horizontal sheet metal part, the upper outer bracket and the second horizontal sheet metal part

[0020] S7: The end sheet metal part is welded to the second vertical sheet metal part and the first horizontal sheet metal part.

[0021] Compared with the related art, the present invention has the following beneficial effects:

[0022] Enhanced load-bearing and support capabilities:

[0023] By introducing a sheet metal assembly (including a vertical intermediate sheet metal part, a first vertical sheet metal part, a bracket sheet metal assembly, a second vertical sheet metal part, an end sheet metal part, etc.), while maintaining the aesthetic appearance, the bumper significantly enhances its load-bearing and support capabilities. The design of the sheet metal assembly enables the bumper to better withstand external impacts and weights, improving the overall structural stability and safety.

[0024] Optimized connection structure:

[0025] The sheet metal assembly and the bumper assembly are connected by fasteners such as bolts, which not only ensures the firmness of the connection but also facilitates disassembly and maintenance. At the same time, the design of positioning posts on the bumper assembly and positioning holes on the sheet metal assembly ensures the precise assembly between the bumper assembly and the vehicle body, effectively avoiding assembly errors.

[0026] Improved durability and strength:

[0027] The sheet metal assembly is fixed by processes such as welding to ensure the tight connection and overall strength between components. In addition, by optimizing the shape and size of the sheet metal parts (such as increasing the fillet radius, setting reinforcing ribs, etc.), the durability and anti-deformation ability of the sheet metal assembly are further improved.

[0028] Convenient installation and disassembly:

[0029] The design of bolt guiding installation spaces and chamfered corners on the bracket sheet metal assembly makes the installation process more convenient and stable. At the same time, connecting the bumper assembly and the sheet metal assembly by fasteners such as bolts also facilitates disassembly and replacement when needed.

[0030] Diverse appearance and functions:

[0031] This bumper not only has the aesthetic appearance of a conventional bumper but also can achieve multiple color options through processes such as painting. In addition, different decorative parts are designed on the bumper, further enhancing the overall aesthetics and personalization. At the same time, through the supporting role of the sheet metal assembly, this bumper also has a load-bearing function, meeting the needs of more usage scenarios.

[0032] Efficient welding process:

[0033] The provided welding process steps are detailed and efficient, ensuring precise welding between components of the sheet metal assembly and the stability of the overall structure. This welding process not only improves production efficiency but also reduces production costs. Brief Description of the Drawings

[0034] Figure 1 Exploded view of the overall structure of the present invention;

[0035] Figure 2 Schematic diagram of the overall structure of the present invention installed on the vehicle body;

[0036] Figure 3 Assembly schematic diagram of the bumper assembly and the sheet metal assembly of the present invention;

[0037] Figure 4 Schematic diagram of the structure of the sheet metal assembly of the present invention

[0038] Figure 5 Schematic diagram of the structure of the bracket sheet metal assembly of the present invention;

[0039] Figure 6 One of the schematic diagrams of the structure of the bracket sheet metal assembly of the present invention;

[0040] Figure 7 One of the schematic diagrams of the structure of the bracket sheet metal assembly of the present invention;

[0041] Figure 8 Schematic diagram of the back structure of the small pedal of the present invention;

[0042] Figure 9 Top view of the bumper assembly of the present invention;

[0043] Figure 10 is Figure 9 Cross-sectional schematic diagram at D-D in

[0044] Figure 11 Front view of the bumper assembly of the present invention;

[0045] Figure 12 is Figure 11 Cross-sectional schematic diagram at E-E in

[0046] Figure 13 Schematic diagram of the structure of the bracket sheet metal assembly of the present invention;

[0047] Figure 14 is Figure 13 Cross-sectional schematic diagram at A-A in

[0048] Figure 15 is Figure 13 Cross-sectional schematic diagram at B-B in

[0049] Figure 16 isFigure 13 Schematic cross-section view at C-C

[0050] In the figure: 1. Bumper assembly; 2. Sheet metal assembly; 3. Vertical intermediate sheet metal part; 4. First vertical sheet metal part; 5. Bracket sheet metal assembly; 6. Second vertical sheet metal part; 7. End sheet metal part; 8. Horizontal bending part; 9. First horizontal sheet metal part; 10. Second horizontal sheet metal part; 11. Reinforcing rib; 12. Installation space; 13. First bolt; 14. Second bolt; 15. Positioning post; 16. Positioning hole; 17. Upper outer bracket; 18. Lower bracket; 19. Upper inner bracket; 20. Bolt guiding installation space; 21. Fifth bolt; 22. Bolt hole; 23. Third bolt; 24. Connecting ear; 25. Fourth bolt; 26. Large pedal; 27. First square bump; 28. Small pedal; 29. Second square bump; 30. Reinforcing rib. Specific embodiments

[0051] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0052] Please refer to Figure 1-16 , a bumper with a sheet metal assembly, comprising a bumper assembly 1 and a sheet metal assembly 2 embedded and installed inside the bumper assembly 1. After the bumper assembly 1 and the sheet metal assembly 2 are assembled, they are used for assembling with the pickup body. The sheet metal assembly 2 is composed of a vertical intermediate sheet metal part 3. At both ends of the vertical intermediate sheet metal part 3, first vertical sheet metal parts 4 are welded. On the side of these first vertical sheet metal parts 4 away from the vertical intermediate sheet metal part 3, a bracket sheet metal assembly 5 is welded. Extending from the bracket sheet metal assembly 5 are second vertical sheet metal parts 6, which are then connected to the end sheet metal part 7. At the tops of the end sheet metal part 7, second vertical sheet metal parts 6, bracket sheet metal assembly 5, first vertical sheet metal parts 4, and vertical intermediate sheet metal part 3, horizontal bending parts 8 are provided, and a first horizontal sheet metal part 9 is welded and fixed together through these horizontal bending parts 8. In addition, the bottoms of the first vertical sheet metal parts 4, bracket sheet metal assembly 5, and second vertical sheet metal parts 6 are welded and fixed through a second horizontal sheet metal part 10.

[0053] Preferably, when designing the sheet metal assembly 2, the fillet radius is considered to be not less than R15mm to reduce the internal stress generated during the sheet metal stamping process and avoid wrinkling or cracking. The selection of the material thickness is also optimized. For example, the thickness of the part where the bracket sheet metal assembly 5 is positioned and fixed to the body is 4mm, ensuring the connection strength; while the material thickness of the first vertical sheet metal parts 4 and the second vertical sheet metal parts 6 is 2mm. Flanges and reinforcing ribs 11 are also provided on the sheet metal assembly 2 to enhance the overall structural strength, prevent deformation, and ensure dimensional accuracy.

[0054] To improve durability, the bracket sheet metal assembly 5 is fixed to itself and to the mating parts by carbon dioxide gas shielded welding, while spot welding technology is used at the joints between the vertical intermediate sheet metal part 3, the first vertical sheet metal part 4, the bracket sheet metal assembly 5, the second vertical sheet metal part 6, the end sheet metal part 7, the first horizontal sheet metal part 9 and the second horizontal sheet metal part 10. This combination not only ensures the firmness of the overall structure but also improves production efficiency.

[0055] Furthermore, a receiving space 12 for accommodating the sheet metal assembly 2 is provided inside the bumper assembly 1, enabling the end sheet metal part 7 to be firmly connected to the bumper assembly 1 at the horizontal bending part 8 position and the bottom through the first bolt 13 and the second bolt 14 respectively. The positioning posts 15 on the bumper assembly 1 match the positioning holes 16 on the end sheet metal part 7, ensuring accurate positioning.

[0056] The bracket sheet metal assembly 5 consists of an upper outer bracket 17, a lower bracket 18 and an upper inner bracket 19. Among them, the upper outer bracket 17 is connected to the first horizontal sheet metal part 9, and the lower bracket 18 is connected to the second horizontal sheet metal part 10. Argon arc welding is applied to the front and rear ends and the middle area of the upper outer bracket 17 to ensure welding quality. A bolt guiding installation space 20 is provided on the upper outer bracket 17, with an R10mm rounded corner at its end and a guiding distance exceeding 15mm, which is beneficial for simplifying the installation process and improving stability. The upper outer bracket 17 is connected to the first horizontal sheet metal part 9 through the fifth bolt 21, facilitating disassembly and maintenance.

[0057] Finally, the bumper assembly 1 is equipped with a large pedal 26 and two small pedals 28. The former has multiple first square bumps 27 with dimensions of 76mm×24mm, the latter has second square bumps 29 with dimensions of 60mm×15mm on the front and reinforcing ribs 30 on the back, which not only increases the friction but also improves the load-bearing capacity.

[0058] A welding process for a sheet metal assembly includes the following steps:

[0059] S1: First, weld and fix the upper inner bracket 19 to the inside of the upper outer bracket 17;

[0060] S2: Next, weld the connecting ear 24 to the bottom of the second horizontal sheet metal part 10, ensuring good welding points at all four corners;

[0061] S3: Then, perform the welding between the lower bracket 18, the upper outer bracket 17 and the second horizontal sheet metal part 10;

[0062] S4: Subsequently, complete the welding of the first vertical sheet metal part 4, the first horizontal sheet metal part 9 and the vertical intermediate sheet metal part 3;

[0063] S5: Next, weld the whole welded in steps S1 - S3 to the first vertical sheet metal part 4;

[0064] S6: Weld the second vertical sheet metal part 6 to the first horizontal sheet metal part 9, the upper outer bracket 17 and the second horizontal sheet metal part 10;

[0065] S7: Finally, weld the end sheet metal part 7 to the second vertical sheet metal part 6 and the first horizontal sheet metal part 9 together.

[0066] The above are only embodiments of the present invention, and do not thus limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the content of the specification and drawings of the present invention, or directly or indirectly applied in other related technical fields, shall equally be included in the patent protection scope of the present invention.

Claims

1. A bumper with a sheet metal assembly, characterized in that, It includes a bumper assembly (1) and a sheet metal assembly (2) embedded and installed inside the bumper assembly (1). After the bumper assembly (1) and the sheet metal assembly (2) are assembled, they are used to be assembled with the pickup body. The sheet metal assembly (2) includes a vertical intermediate sheet metal part (3). Both ends of the vertical intermediate sheet metal part (3) are welded and fixed with a first vertical sheet metal part (4). A bracket sheet metal assembly (5) is welded on the side of the first vertical sheet metal part (4) away from the vertical intermediate sheet metal part (3). A second vertical sheet metal part (6) is welded on the side of the bracket sheet metal assembly (5) away from the first vertical sheet metal part (4). The other side of the second vertical sheet metal part (6) is welded to an end sheet metal part (7). Horizontal bending parts (8) are provided at the tops of the end sheet metal part (7), the second vertical sheet metal part (6), the bracket sheet metal assembly (5), the first vertical sheet metal part (4) and the vertical intermediate sheet metal part (3). The horizontal bending parts (8) are jointly welded and fixed with a first horizontal sheet metal part (9). The bottoms of the first vertical sheet metal part (4), the bracket sheet metal assembly (5) and the second vertical sheet metal part (6) are welded and fixed by a second horizontal sheet metal part (10).

2. The bumper with a sheet metal assembly according to claim 1, characterized in that, The fillet radius size of the sheet metal assembly (2) is 15 mm or more. The material thickness of the part where the bracket sheet metal assembly (5) is positioned and fixedly connected to the body is 4 mm. The material thickness of the first vertical sheet metal part (4) and the second vertical sheet metal part (6) is 2 mm. The sheet metal assembly (2) is provided with flanges and reinforcing ribs (11).

3. The bumper with a sheet metal assembly according to claim 1, characterized in that, The bracket sheet metal assembly (5) itself and its fixation with the mating part are fixed by carbon dioxide gas shielded welding. The joints between the vertical intermediate sheet metal part (3), the first vertical sheet metal part (4), the bracket sheet metal assembly (5), the second vertical sheet metal part (6), the end sheet metal part (7), the first horizontal sheet metal part (9) and the second horizontal sheet metal part (10) are welded by spot welding.

4. The bumper with a sheet metal assembly according to claim 1, characterized in that, The bumper assembly (1) is provided with a receiving space (12) for receiving the sheet metal assembly (2). The horizontal bending part (8) of the end sheet metal part (7) is connected to the bumper assembly (1) by a first bolt (13). The bottom of the end sheet metal part (7) is connected to the bumper assembly (1) by a second bolt (14). The bumper assembly (1) is provided with positioning posts (15), and the end sheet metal part (7) is provided with positioning holes (16).

5. The bumper with a sheet metal assembly according to claim 1, wherein, The bracket sheet metal assembly (5) includes an upper outer bracket (17), a lower bracket (18) welded to the bottom of the upper outer bracket (17), and an upper inner bracket (19) welded and fixed to the inner side of the upper outer bracket (17). The upper outer bracket (17) is connected to the first horizontal sheet metal part (9), and the lower bracket (18) is connected to the second horizontal sheet metal part (10). The welding positions of the CO2 gas shielded welding are arranged at the front and rear ends and the profile contact positions in the middle area of the upper outer bracket (17), and the welding build-up ensures R4 or more. A bolt guiding installation space (20) is provided on the upper outer bracket (17). The end of the guiding installation space (20) is provided with a chamfered corner, and the size of the chamfered corner arc is R10mm. The guiding distance of the guiding installation space (20) is greater than 15mm. The upper outer bracket (17) is connected to the first horizontal sheet metal part (9) through a fifth bolt (21).

6. The bumper with a sheet metal assembly according to claim 1, wherein, The upper outer bracket (17) is provided with a plurality of bolt holes (22), and third bolts (23) are provided in both the bolt holes (22) and the bolt guiding installation space (20). The upper outer bracket (17) is connected to the vehicle body through the third bolts (23). The positioning clearance between two of the bolt holes (22) and the corresponding holes on the vehicle body is 0.2mm, and the positioning clearance between the guiding installation space (20) and the corresponding holes on the vehicle body is 0.5mm.

7. The bumper with a sheet metal assembly according to claim 1, characterized in that, A connecting ear (24) is welded to the bottom of the second horizontal sheet metal part (10), and the connecting ear (24) is fixedly connected to the bumper assembly (1) through a fourth bolt (25).

8. The bumper with a sheet metal assembly according to claim 1, characterized in that, A large pedal (26) is provided on the bumper assembly (1). A plurality of first square bumps (27) are provided on the large pedal (26), and the size of the first square bumps (27) is 76mm×24mm. Two small pedals (28) are also provided on the bumper assembly (1). A second square bump (29) is provided on the front of the small pedal (28), and the size of the second square bump (29) is 60mm×15mm. A reinforcing rib (30) is provided on the back of the second square bump (29).

9. A welding process for the sheet metal assembly according to any one of claims 1-8, characterized in that, Including the following steps: S1: Welding the upper inner bracket (19) and the upper outer bracket (17) First, the upper inner bracket (19) is welded and fixed to the inner side of the upper outer bracket (17); S2: Welding the connecting ear (24) and the second horizontal sheet metal part (10) The connecting ear (24) is welded and fixed to the bottom of the second horizontal sheet metal part (10), and the welding points are located at the four corners of the connecting ear (24); S3: Welding the lower bracket (18) to the upper outer bracket (17) and the second horizontal sheet metal part (10) S4: Welding the first vertical sheet metal part (4) to the first horizontal sheet metal part (9) and the vertical intermediate sheet metal part (3) Welding S5: Welding the whole welded in S1 - S3 to the first vertical sheet metal part (4) S6: Welding the second vertical sheet metal part (6) to the first horizontal sheet metal part (9), the upper outer bracket (17), and the second horizontal sheet metal part (10) S7: Welding the end sheet metal part (7) to the second vertical sheet metal part (6) and the first horizontal sheet metal part (9).

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