All-terrain vehicle front vehicle body machining method and clamp

Abstract

The invention discloses an all-terrain vehicle front vehicle body machining method which comprises the following steps that firstly, all butt welding parts are prepared; secondly, the bottom framework assembly and the rear framework assembly are installed and welded synchronously through a special welding clamp; 3, through bottom framework appearance positioning, assembling and welding of a bottom framework assembly and a bottom framework part shell are completed; fourthly, assembling and welding of the bottom framework assembly and the rear framework assembly are completed; and fifthly, butt welding of the remaining shells and fragmentary parts is completed. Through the innovative split machining strategy, the high-precision tool design and the welding deformation cooperative control technology, the core problems that the structure is complex, the precision requirement is high, deformation is difficult to control and the like in the machining process of the front vehicle body of the all-terrain vehicle are successfully solved. The production efficiency is remarkably improved and the comprehensive cost is reduced while the product quality is guaranteed, an efficient and reliable solution is provided for the field of all-terrain vehicle manufacturing, and the method has wide industrial application value.

Description

Technical Field

[0001] The invention belongs to the technical field of mechanical processing, and particularly relates to a method and a fixture for processing the front body of an all-terrain vehicle. Background Art

[0002] All-Terrain Vehicle (ATV) is a multi-purpose vehicle designed for complex terrain. It can flexibly travel in environments such as beaches, mud, mountains, and snow. The front body of an ATV is an important component. The front body of an ATV has a complex structure, numerous parts, multiple matching sizes, high positioning accuracy, and high dimensional accuracy requirements. It is very difficult to process. The main reasons are as follows:

[0003] 1. The front body assembly has numerous parts, multiple matching dimensions, high positioning accuracy, and high product dimensional accuracy requirements, which poses a great challenge to tooling design;

[0004] 2. The side beams in the front chassis frame are slender, making it difficult to calibrate parts and control welding deformation.

[0005] 3. The solution adopts the method of not processing after welding, which makes it difficult to control the positioning of key dimensions;

[0006] 4. The weld seams of the tube sheet assembly in the bottom frame are dense;

[0007] 5. The front body structure is large in size, making it difficult to control the cost of tooling and fixtures. Summary of the Invention

[0008] In order to solve the above problems, the present invention aims to provide a method and fixture for processing the front body of an all-terrain vehicle.

[0009] In order to achieve the above object, the present invention adopts the following technical solution: a method for processing the front body of an all-terrain vehicle, comprising the following steps:

[0010] Step 1: Prepare all butt welding parts;

[0011] Step 2: Use a special welding fixture to simultaneously complete the welding of the bottom frame assembly and the rear frame assembly;

[0012] Step 3: Complete the welding of the bottom frame assembly and the bottom frame shell through positioning of the bottom frame shape;

[0013] Step 4: Complete the welding of the bottom frame assembly and the rear frame assembly;

[0014] Step 5: Complete the welding of the remaining shell and miscellaneous parts.

[0015] Furthermore, the fragmented parts attached to the frame are combined with the frame in order and then attached to the board.

[0016] Furthermore, the bottom frame assembly includes four parts: tail beam, side beam, tube sheet and miscellaneous parts. The welding steps of the bottom frame assembly are as follows: first, place the two side beams on the assembly welding fixture, and then sequentially place the tail beam and tube sheet at both ends of the side beam for assembly welding;

[0017] The butt welding of the tube sheet assembly, tail beam and side beam can be carried out simultaneously.

[0018] Furthermore, the rear frame includes a tail frame, a bracket arranged at the lower end of the tail frame, a left top frame and a right top frame respectively arranged on both sides of the upper end of the tail frame, and the front ends of the left top frame and the right top frame are respectively connected to the left front frame and the right front frame;

[0019] The six plane structures of the rear frame are first assembled independently on four sets of special tooling, and then the rear frame is assembled on the rear frame assembly tooling.

[0020] Furthermore, the step four is specifically that the bottom frame assembly and the rear frame are welded together to complete the positioning based on the shape, the rear frame support legs are aligned with the theoretical position of the bottom frame assembly, and then the top end is controlled to be flush; the step 5 is specifically that the remaining shell parts are butt-welded along the frame shape, and at the same time, the butt welding of the miscellaneous parts is completed through the butt welding template and marking method, and the front body processing is completed.

[0021] Furthermore, parts processing needs to be carried out according to the process dimensions. After the components are welded together, each weld needs to be deburred.

[0022] Furthermore, during the assembly welding process of the components, each weld is welded in the designed order. If a weld is blocked on the welding fixture and cannot be welded, it is necessary to repair the weld in the designed welding order after the components are lifted out of the welding fixture.

[0023] Furthermore, during the butt welding process, process tie bars are used to maintain the external dimensions of the welded components, and butt welding templates are used to complete positioning when butt welding small parts.

[0024] A fixture for processing the front body of an all-terrain vehicle. The bottom frame assembly butt welding tooling includes a base plate and several support frames arranged on the base plate. The arrangement of the support frames is adapted to the shape of the bottom frame assembly. The tooling adopts multi-point positioning clamping, and the control project dimensions are all independently positioned by the tooling; the rear frame assembly tooling includes several solid columns, and the number and shape of the columns match the rear frame.

[0025] Furthermore, four sets of specially made tooling include left front frame assembly butt welding tooling), tail frame assembly butt welding tooling, bracket assembly butt welding tooling, and left top frame, right front frame, and right top frame assembly butt welding tooling. Among them, the left front frame assembly butt welding tooling, tail frame assembly butt welding tooling, and left top frame, right front frame, and right top frame assembly butt welding tooling are all equipped with a number of limit blocks and clamps, which are arranged according to the part structure. The bracket assembly butt welding tooling is a rectangular opening frame.

[0026] Compared with the prior art, the present invention has the following advantages:

[0027] 1. High precision and quality stability. Through the independent positioning design of special fixtures, such as the bottom frame assembly fixture and the rear frame split fixture, key dimensions are directly controlled, avoiding indirect positioning errors and ensuring that the product dimensional accuracy meets the design requirements; Deburring treatment: Deburring the welds after assembly welding to improve the product surface quality and avoid safety hazards during subsequent assembly or use.

[0028] 2. Effectively control welding deformation by adopting multi-point positioning and sequential welding: For easily deformed parts such as slender side beams, multi-point calibration clamping and preset welding sequence are adopted to significantly reduce the risk of welding deformation.

[0029] 3. Production efficiency has been significantly improved. The front body is split into modular components such as the bottom frame, rear frame, and outer shell. Each small component can be produced simultaneously, significantly shortening the production cycle. The bottom frame tail beam and side beam assembly tooling are integrated into a design to reduce the number of tooling and lower manufacturing costs. The four tooling structures after the rear frame is split are simple, facilitating quick clamping and reuse.

[0030] 4. Enhanced process adaptability and simplified complex structures: The front body is split into flat or simple spatial structural components, such as the rear frame, left front frame, tail frame, etc., to reduce the difficulty of tooling design and adapt to the needs of small and medium-sized batch production; flexible adjustment capability: Through detachable butt welding templates and modular tooling, it can adapt to the rapid adjustment of different vehicle models or design changes. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the technical solutions in the specific embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0032] Figure 1 This is a schematic diagram of the front vehicle body composition of the present invention;

[0033] Figure 2 Schematic diagram of the midsole skeleton assembly structure of the present invention;

[0034] Figure 3 Schematic diagram of the tube plate structure of the midsole skeleton assembly of the present invention;

[0035] Figure 4 This is a schematic diagram of the tooling structure of the midsole skeleton assembly of the present invention;

[0036] Figure 5 This is a schematic diagram of the front vehicle body and rear frame of the present invention;

[0037] Figure 6 Schematic diagram of the left front frame being welded by the left front frame assembly welding tool in the present invention;

[0038] Figure 7 This is a schematic diagram of the tail frame being welded by the tail frame assembly welding tool in the present invention;

[0039] Figure 8 Schematic diagram of the bracket assembly welded by the butt welding tool of the bracket assembly in the present invention;

[0040] Figure 9 This is a schematic diagram of the welding fixture for the left top frame, right front frame, and right top frame components in the present invention;

[0041] Figure 10 This is a schematic diagram of the welding of the rear frame assembly tooling in the present invention;

[0042] Figure 11 This is a schematic diagram of the assembly welding of the midsole skeleton shell of the present invention;

[0043] Figure 12 This is a schematic diagram of the welding of the midsole frame assembly and the rear frame of the present invention;

[0044] Figure 13 This is a schematic diagram of the structure of the front vehicle body assembly after welding in the present invention;

[0045] In the figure, 1-bottom frame assembly; 2-rear frame assembly; 3-miscellaneous parts; 4-outer shell; 101-tail beam; 102-side beam; 103-tube plate; 104-miscellaneous parts; 201-left front frame; 202-left top frame; 203-right top frame; 204-right front frame; 205-tail frame; 206-bracket; A-bottom frame assembly tooling; B1-left front frame assembly butt welding tooling; B2-tail frame assembly butt welding tooling, B3-bracket assembly butt welding tooling; B4-left top frame, right front frame, right top frame assembly butt welding tooling; B-rear frame assembly tooling. DETAILED DESCRIPTION

[0046] The present invention is further described below with reference to the accompanying drawings and specific embodiments. However, it should not be understood that the scope of the subject matter described in the present invention is limited to the following embodiments. Without departing from the above technical ideas of the present invention, various modifications, substitutions and changes made according to common technical knowledge and customary means in the field are included in the scope of the present invention.

[0047] A method for processing the front body of an all-terrain vehicle comprises the following steps:

[0048] Step 1: Prepare all butt welding parts;

[0049] Step 2: Use a dedicated welding fixture to simultaneously complete the welding of the bottom frame component 1 and the rear frame component 2;

[0050] Step 3: Through the outer shape positioning of the bottom frame 1, the bottom frame assembly 1 and the bottom frame partial shell 4 are welded together;

[0051] Step 4: Complete the welding of the bottom frame assembly 1 and the rear frame assembly 2;

[0052] Step 5: Complete the butt welding of the remaining shell 4 and miscellaneous parts.

[0053] Parts and components must be processed in place according to the process dimensions; after the assembly welding of each component is completed, each weld must be deburred; during the assembly welding process, each weld must be welded in the designed order. If the weld is blocked on the welding fixture and cannot be welded, it must be repaired in the designed welding order after being lifted off the welding fixture; during the butt welding process, process reinforcement will be used to maintain the external dimensions of the welded components; when butt welding fragments, a butt welding template will be used to complete the positioning.

[0054] 2. Processing

[0055] The front body is divided into four parts: bottom frame 1, rear frame 2, shell 4 and fragments 3. Figure 1 Processing is performed as shown.

[0056] First, the bottom frame 1 and the rear frame 2 are welded separately. After the welding of the bottom frame 1 and the rear frame 2 is completed, the two parts are spliced and welded into an overall frame. At this time, the fragmented parts, the parts attached to the frame are combined with the frame in order, and the rear group attached to the plate is then split out of the outer shell and welded to the frame in order. The remaining fragments are combined to complete the overall processing of the front body.

[0057] 1. Processing plan

[0058] After conducting a process analysis on the front car body, a process plan was adopted in which the main dimensions were guaranteed by designing and manufacturing tooling, and no processing was performed after welding.

[0059] 2. Bottom frame butt welding

[0060] The bottom frame assembly 1 is further decomposed into four parts: tail beam 101, side beam 102, tube sheet 103 and fragmentary parts 104. Figure 2 It was decided to first weld the tail beam 101, side beam 102, and tube sheet 103 into small components before proceeding with the overall assembly of the bottom frame. The butt welding of the tail beam 101, side beam 102, and overall assembly was completed on the overall assembly butt welding tool A.

[0061] (1) Tube sheet assembly

[0062] Tube sheet 103 components such as Figure 3 As shown, the structure is relatively simple, but it requires relatively dense pipe joints to be welded on it. A butt welding template is produced to complete the butt welding. However, to ensure that the tube sheet 103 is flat and does not warp after welding, the welding parameters are controlled during the production of the tube sheet 103 assembly to ensure that the tube sheet assembly is flat and meets the design requirements after welding.

[0063] (2) Bottom frame tail beam 101, side beam 102, and overall assembly

[0064] The front body bottom frame 1 has a large structure size, and the corresponding fixture will be relatively large. In order to reduce the cost of the fixture, the bottom frame 1 tail beam 101, side beam 102 and the overall assembly of the butt welding fixture are integrated into one. Figure 4 shown.

[0065] The bottom frame tail beam 101 and side beams 102 are welded together first. Once the tube sheet 103, tail beam 101, and side beams 102 are welded together, the overall assembly is butt-welded. During the butt-welding process, the tube sheet 103, tail beam 101, and side beams 102 can be welded together simultaneously, effectively shortening the production cycle.

[0066] The side beam 102 component structure is relatively slender, and the main body is made of rectangular tube material. The material is prone to deformation when it is incoming and is also very easy to deform after the components are welded. In order to ensure accurate positioning during the welding process, the welding tooling adopts multi-point positioning clamping. Through multi-point calibration, its positioning accuracy is ensured, and deformation during welding is effectively reduced.

[0067] Due to the large dimensions of the bottom frame 1, all control dimensions during the butt welding process are independently positioned using fixtures. This avoids indirect errors caused by positioning the component body. It also effectively performs rough inspections on the welded parts, preventing unqualified parts from entering the next process. Furthermore, during the butt welding of the bottom frame 1 assembly, many welds can be completed on the fixture, with welding and cooling performed in a fixed and clamped state, effectively reducing weld deformation.

[0068] 3. Rear frame butt welding

[0069] The rear frame 2 is further divided into six parts: a left front frame 201, a left top frame 202, a right top frame 203, a right front frame 204, a tail frame 205 and a bracket 206. Figure 5 As shown in the figure, after being split into six parts, each part is almost flat, which is convenient for forming and welding. At the same time, after being split into six parts, the six parts can be produced simultaneously, which can effectively shorten the production cycle and increase production capacity.

[0070] The six parts of the split were assembled and butt-welded independently. To ensure the normal butt-welding of the six parts of the rear frame, 4 sets of butt-welding tools were made according to the needs. Figures 6 to 9 As shown, the four sets of tooling include the left front skeleton assembly butt welding tooling B1, the tail skeleton assembly butt welding tooling B2, the bracket assembly butt welding tooling B3, and the left top skeleton, right front skeleton, and right top skeleton assembly butt welding tooling B4. Among them, the left front skeleton assembly butt welding tooling B1, the tail skeleton assembly butt welding tooling B2, and the left top skeleton, right front skeleton, and right top skeleton assembly butt welding tooling B4 are all provided with a number of limit blocks and clamps. The limit blocks and clamps are arranged according to the part structure. The bracket assembly butt welding tooling B3 is a rectangular opening frame. After the six components of the rear skeleton are welded into assemblies using the four sets of tooling, the rear skeleton assembly is carried out. In order to ensure the normal welding of the rear skeleton, the rear skeleton assembly tooling is designed and manufactured. The tooling is as shown Figure 10 shown.

[0071] The butt-welding method for the rear frame 2 is to split its structure into multiple small components and assemble them first, and then assemble them as a whole after the small components are assembled. Not only does this simplify the spatial structure of the small components and facilitate the design of tooling fixtures, but multiple small components can also be produced simultaneously, which can effectively increase production capacity. At the same time, after the parts are welded into components, the number of all butt-welded parts in the overall assembly is greatly reduced, reducing the difficulty of designing the overall assembly fixture.

[0072] 4. Bottom frame shell 4 group welding

[0073] The front body bottom frame shell 4 has the characteristics of large size and heavy, and is covered at the bottom of the front body. For the convenience of operation, after the bottom frame is welded, the shell of the bottom frame part needs to be welded first, as shown in the figure. Figure 11 As shown, the connected parts and components are completed and the welding is completed in this process.

[0074] 5. The bottom frame assembly 1 is welded to the rear frame 2, and the whole is welded to the shell.

[0075] After the bottom frame 1 and the shell parts 4 are welded together, they are then welded together with the rear frame 2. The structure after welding is as follows: Figure 12 The bottom frame assembly 1 and the rear frame 2 are welded together and positioned based on their outer shapes. Align the rear frame legs with the theoretical position of the bottom frame assembly, and then make sure the tops are flush.

[0076] After the bottom frame assembly 1 and the rear frame assembly 2 are welded, the remaining shell 4 parts are welded along the frame shape. At the same time, the remaining parts 3 are welded by welding the template and marking, and the front body processing is completed. Figure 13 shown.

[0077] The above describes in detail the method for machining the front body of an all-terrain vehicle provided by the present invention. Specific examples are used herein to illustrate the structure and operating principles of the present invention. The description of the above embodiments is intended only to facilitate understanding of the method and core concepts of the present invention. It should be noted that those skilled in the art will be able to make various improvements and modifications to the present invention without departing from the principles of the present invention, and such improvements and modifications fall within the scope of protection of the claims of the present invention.

Claims

1. A method for processing the front body of an all-terrain vehicle, characterized by: The following steps are included: Step 1: Prepare all butt welding parts; Step 2: Using a special welding fixture, the bottom frame assembly (1) and the rear frame assembly (2) are welded together simultaneously; Step 3: By positioning the bottom frame (1) shape, complete the assembly welding of the bottom frame assembly (1) and the bottom frame partial shell (4); Step 4: Complete the welding of the bottom frame assembly (1) and the rear frame assembly (2); Step 5: Complete the butt welding of the remaining shell (4) and the fragmentary parts (3).

2. The method for processing the front body of an all-terrain vehicle according to claim 1, characterized in that: The fragmented parts (3) attached to the frame are combined with the frame in order, and the rear group is attached to the board.

3. The method for processing the front body of an all-terrain vehicle according to claim 1, characterized in that: The bottom frame assembly (1) comprises four parts: a tail beam (101), a side beam (102), a tube sheet (103) and miscellaneous parts (104). The welding steps of the bottom frame assembly (1) are as follows: firstly, the two side beams (102) are placed on the assembly welding device, and then the tail beam (101) and the tube sheet (103) are placed on both ends of the side beam (102) in sequence for assembly welding; The butt welding of the tube sheet (103) assembly, the tail beam (101) and the side beam (102) can be carried out simultaneously.

4. The method for processing the front body of an all-terrain vehicle according to claim 1, characterized in that: The rear frame (2) includes a tail frame (205), a bracket (206) arranged at the lower end of the tail frame (205), a left top frame (202) and a right top frame (203) respectively arranged on both sides of the upper end of the tail frame (205), and the front ends of the left top frame (202) and the right top frame (203) are respectively connected to the left front frame (201) and the right front frame (204); The six plane structures of the rear frame (2) are first independently assembled on four sets of specially made tooling, and then the rear frame is assembled on the rear frame assembly tooling (A).

5. The method for processing the front body of an all-terrain vehicle according to claim 1, characterized in that: The specific step 4 is that the bottom frame assembly (1) and the rear frame (2) are welded together to complete positioning based on the outer shape, the rear frame (2) legs are aligned with the theoretical position of the bottom frame assembly (1), and then the top ends are controlled to be flush; the specific step 5 is that the remaining shell parts are butt-welded along the outer shape of the frame, and at the same time, the miscellaneous parts (3) are butt-welded by the butt-welding template and marking method, and the front body processing is completed.

6. The method for processing the front body of an all-terrain vehicle according to claim 1, characterized in that: Parts must be processed according to the process dimensions. After the components are welded together, each weld must be deburred.

7. The method for processing the front body of an all-terrain vehicle according to claim 1, characterized in that: During the assembly welding process of the components, each weld is welded in the designed order. If a weld is blocked on the welding fixture and cannot be welded, it is necessary to perform repair welding in the designed welding order after the components are lifted out of the welding fixture.

8. The method for processing the front body of an all-terrain vehicle according to claim 1, characterized in that: During the butt welding process, process tie bars are used to maintain the external dimensions of the welded components, and butt welding templates are used to complete positioning when butt welding small parts.

9. A machining fixture for machining the front body of an all-terrain vehicle according to any one of claims 1 to 8, characterized in that: The bottom frame assembly butt welding fixture (A) includes a bottom plate and a plurality of support frames arranged on the bottom plate. The arrangement of the support frames is adapted to the shape of the bottom frame assembly (1). The fixture adopts multi-point positioning clamping, and the control project size adopts independent positioning of the fixture; the rear frame assembly fixture (B) includes a plurality of solid columns. The number and shape of the columns match the rear frame (2).

10. The all-terrain vehicle front body processing fixture according to claim 9, characterized in that: The four sets of specially made tooling include a left front frame assembly butt welding tooling (B1), a tail frame assembly butt welding tooling (B2), a bracket assembly butt welding tooling (B3), and a left top frame, right front frame, and right top frame assembly butt welding tooling (B4). The left front frame assembly butt welding tooling (B1), the tail frame assembly butt welding tooling (B2), and the left top frame, right front frame, and right top frame assembly butt welding tooling (B4) are all provided with a number of limit blocks and clamps, which are arranged according to the part structure. The bracket assembly butt welding tooling (B3) is a rectangular opening frame.

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