Fuel tank processing method, fuel tank and vehicle

Abstract

The present invention relates to the technical field of fuel tank processing, and in particular, to a fuel tank processing method, a fuel tank, and a vehicle. The processing method comprises: based on a rectangular material plate, notches are respectively processed at both ends of the first side of the material plate. After the notch cutting is completed, the material plate is bent so that the first side and the second side of the material plate have an overlapping area to form a cylindrical shell. Based on the shell molding, the overlapping area is welded by resistance welding. Based on the completion of welding on the overlapping area, the end cover is positioned at the end of the corresponding shell so that the end cover and the shell have a fitting area. Based on the completion of positioning the end cover, the fitting area is welded by resistance welding. Based on the completion of welding on the fitting area, filler welding is performed along the edge line of the notch to form a welding portion, and the end cover welding is completed. Based on the completion of welding of both end covers to the shell, the fuel tank processing is completed. In this way, the problem of the end cover of the fuel tank being not firmly welded to the shell is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of fuel tank processing, and in particular to a fuel tank processing method, a fuel tank and a vehicle. Background Art

[0002] During the fuel tank manufacturing process, sheet metal is typically first bent lengthwise. The bent sheet metal has an overlapping area at its ends that needs to be welded together to form a cylindrical shell. This overlapping area is distributed along the axial direction of the shell. Once the shell is formed, end caps are attached to each open end of the shell. The connection between the end caps and the shell is completed by circumferential welding. This welding step in the manufacturing process is a key step in forming the fuel tank structure and ensuring its sealing. The welding of the axial connection area of ​​the shell ensures the integrity of the cylindrical shell, while the circumferential welding of the end caps to the shell completes the sealing of the fuel tank structure.

[0003] During the circumferential welding process between the end cap and the outer shell, conventional technology often uses resistance welding. When the weld bead formed by welding the end cap passes through the overlapped area, the overlapped area is thicker than other circumferential areas due to the overlapped ends of the plates. This affects the weld quality at this location along the outer shell's circumference. Specifically, the welding temperature has difficulty penetrating the two layers of plate, resulting in a weak weld, which can easily create gaps and ultimately lead to oil leakage. Summary of the Invention

[0004] In order to solve the problem of weak welding between an end cover and an outer shell of a fuel tank, the present invention provides a fuel tank processing method, a fuel tank and a vehicle.

[0005] In a first aspect, the present invention provides a method for processing a fuel tank, the method comprising:

[0006] Based on a rectangular sheet, notches are respectively processed at two adjacent right angles of the sheet, so that the two notches are located at two ends of a first side of the sheet;

[0007] After the notch is cut, the sheet is bent so that the first side and the second side of the sheet have an overlapping area, forming a cylindrical shell; wherein the first side and the second side are arranged in parallel; and in a direction perpendicular to the first side, the size of the notch is larger than the size of the overlapping area;

[0008] Based on the shell molding, the overlapping area of ​​the first side and the second side is welded by resistance welding, so that the contact surface of the first side and the second side forms a straight weld;

[0009] After completing welding on the overlapping area, the end cap is positioned at the corresponding end of the housing so that the end cap and the housing have a fitting area; wherein, in the axial direction of the housing, the size of the fitting area is smaller than the size of the notch;

[0010] After the end cap is positioned, the end cap and the housing are welded by resistance welding to form an annular weld between the contact surfaces of the end cap and the housing;

[0011] Welding is completed based on the fitting area, and filler welding is performed along the edge line of the notch to form a welded portion, and the end cover welding is completed;

[0012] After both end covers are welded to the outer shell, the fuel tank is processed.

[0013] In some embodiments, the rectangular sheet is processed with notches at two adjacent right angles of the sheet, so that the two notches are located at two ends of the first side of the sheet, including:

[0014] Based on a rectangular material sheet, notches are cut at two adjacent right angles of the material sheet so that the two notches are located at both ends of the first side of the material sheet; wherein the two edge lines of the notch are located at the first cutting line and the second cutting line, respectively, and the first cutting line and the second cutting line intersect.

[0015] In some embodiments, the first cutting line is parallel to the first side; and the first cutting line is perpendicular to the second cutting line.

[0016] In some embodiments, one end of the first cutting line coincides with one end of the second cutting line.

[0017] In some embodiments, one end of the first cutting line is located on the second cutting line.

[0018] In some embodiments, the welding is completed based on the fitting area, filler welding is performed along the edge line of the notch to form a welded portion, and the end cover welding is completed, including:

[0019] Based on the completion of welding in the fitting area, filler welding is performed along the first cutting line and the second cutting line of the notch to form a first welding rod along the first cutting line and a second welding rod along the second cutting line, and the end cover welding is completed.

[0020] In some embodiments, completing welding based on the overlapping area and positioning the end cap at the corresponding end of the shell so that the end cap and the shell have a fitting area includes:

[0021] Based on the completion of welding in the overlapping area, the two end covers are positioned in sequence at the ends of the corresponding shell at intervals of a preset time, so that the end covers and the shell have a fitting area; wherein the preset time is the time for welding a single end cover.

[0022] In a second aspect, the present invention provides a fuel tank, which is applied to a fuel tank processing method according to any one of the above embodiments, and includes:

[0023] The outer shell is a cylindrical structure; the outer periphery of the outer shell has two welding parts; the two welding parts are distributed at both ends of the outer shell; the welding parts include a first welding rod and a second welding rod; the outer shell is formed by bending a rectangular sheet; the first side and the second side of the sheet have an overlapping area; the two ends of the first side have rectangular notches at right angles; the first welding rod and the second welding rod correspond to the edge lines of the notches respectively; the contact area between the first side and the second side has a linear weld; the two welding parts are located at both ends of the linear weld; the first welding rod extends along the axial direction of the outer shell;

[0024] Two end covers, the two end covers correspond to the two ends of the shell one by one; the end covers include sealing covers and support ears; the sealing covers cover the ends of the shell; the support ears are annular; the support ears are fixedly connected to the sealing covers; the support ears and the shell have a fitting area; the contact area between the support ears and the shell has an annular weld; the width of the annular weld is less than the length of the first welding rod.

[0025] In some embodiments, the first welding rod and the second welding rod are perpendicular; one end of the first welding rod is located on the second welding rod; or one end of the first welding rod coincides with one end of the second welding rod.

[0026] In a third aspect, the present invention provides a vehicle, comprising a fuel tank according to any one of the above embodiments.

[0027] To solve the problem of weak welding between the end cover and the shell of the fuel tank, the present invention has the following advantages:

[0028] By processing notches at two adjacent right-angled positions of the material sheet, the material sheet is bent to form a cylindrical shell, so that the size of the overlapping area of ​​the first side and the second side is smaller than the size of the notch, and the size of the fitting area of ​​the end cover and the shell in the axial direction of the shell is smaller than the size of the notch, thereby ensuring that the thickness of the shell near the fitting area along the circumference is close to uniform, so that the annular weld formed by resistance welding of the end cover and the shell is evenly distributed when passing through the overlapping area of ​​the shell, avoiding the situation of loose welding; and then by performing filler welding along the edge line of the notch to form a welding part, the notch can be sealed, thereby preventing oil leakage from the gap, and finally solving the problem of loose welding and oil leakage of the end cover, and ensuring the sealing of the fuel tank. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 A schematic flow chart of a method for manufacturing a fuel tank according to an embodiment is shown;

[0030] Figure 2 A schematic structural diagram of a fuel tank according to an embodiment is shown;

[0031] Figure 3 Shown Figure 2 A top view of the fuel tank in FIG.

[0032] Figure 4 Shown Figure 2 A side view of the fuel tank in FIG.

[0033] Figure 5 Shown Figure 4 A partial enlarged schematic diagram of the fuel tank in direction A;

[0034] Figure 6 Shown Figure 4 A partially enlarged schematic diagram of another embodiment of the fuel tank in direction A.

[0035] Reference numerals: 10 housing; 20 end cover; 21 sealing cover; 22 lug; 30 welding portion; 31 first welding rod; 32 second welding rod; 40 material plate; 50 first side edge; 60 second side edge; 70 overlapping area; 80 fitting area. DETAILED DESCRIPTION

[0036] The present disclosure will now be discussed with reference to several exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the present disclosure, rather than to imply any limitation on the scope of the present disclosure.

[0037] As used herein, the term "including" and its variations are to be interpreted as open-ended terms meaning "including, but not limited to." The term "based on" is to be interpreted as "based, at least in part, on." The terms "one embodiment" and "an embodiment" are to be interpreted as "at least one embodiment." The term "another embodiment" is to be interpreted as "at least one other embodiment." Terms such as "upper," "lower," "left," "right," "front," "back," "top," "bottom," "inner," "outer," "vertical," "horizontal," "transverse," and "longitudinal" indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings. These terms are primarily intended to better describe the present application and its embodiments and are not intended to limit the devices, elements, or components indicated to having a specific orientation, or to being constructed and operated in a specific orientation. Furthermore, some of the above terms may be used to indicate other meanings besides orientation or positional relationships. For example, the term "on" may, in certain circumstances, be used to indicate a dependency or connection relationship. Those skilled in the art will understand the specific meanings of these terms in this application based on the specific circumstances. Furthermore, the terms "installed," "disposed," "provided with," "connected," and "connected" are to be interpreted broadly. For example, it can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection, an indirect connection through an intermediate medium, or an internal connection between two devices, elements, or components. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to the specific circumstances. In addition, the terms "first", "second", etc. are mainly used to distinguish different devices, elements, or components (the specific types and structures may be the same or different), and are not used to indicate or imply the relative importance or quantity of the indicated devices, elements, or components. Unless otherwise specified, "plurality" means two or more.

[0038] During the fuel tank manufacturing process, after the sheet material 40 is bent to form the cylindrical outer shell 10, the overlapping area 70 of the first side 50 and the second side 60 is resistance welded to form a linear weld, thus achieving axial connection of the outer shell 10. Subsequently, when the end caps 20 are installed at both ends of the outer shell 10, the contact area 80 of the end caps 20 and the outer shell 10 is welded to form an annular weld by resistance welding. Because the annular weld passes through the axial connection of the outer shell 10, where the thickness varies due to the overlap of the first side 50 and the second side 60, the resistance welding quality at this location is reduced, resulting in a weak weld, which is prone to gaps and oil leakage.

[0039] Embodiment 1: In order to solve the above problems, this embodiment discloses a method for processing a fuel tank.

[0040] In this embodiment, if Figure 1As shown, the fuel tank processing method includes the following steps:

[0041] In step S10, based on the rectangular sheet 40, notches are respectively processed at two adjacent right angles of the sheet 40, so that the two notches are located at both ends of the first side 50 of the sheet 40. The processing method of the notches is punching, cutting, etc.

[0042] Step S20: Based on the completion of the notch cutting, the sheet 40 is bent so that the first side 50 and the second side 60 of the sheet 40 have an overlapping area 70, thereby forming a cylindrical shell 10. Figure 4 、 Figure 5 As shown, the first side 50 and the second side 60 are arranged in parallel. In the vertical direction of the first side 50, the size of the notch is larger than the size of the overlapping area 70. This ensures that the notch at least avoids the overlapping area 70, so that the thickness of the housing 10 near the notch is nearly evenly distributed along the circumference.

[0043] In step S30, after the housing 10 has been formed, the overlapping region 70 of the first side 50 and the second side 60 is welded using resistance welding, forming a straight weld seam at the contact surface between the first side 50 and the second side 60. This secures the first side 50 and the second side 60 together, ensuring that the shape of the housing 10 is fixed for subsequent welding of the end cap 20.

[0044] In step S40, welding is completed based on the overlapping area 70, and the end cap 20 is positioned at the end of the corresponding shell 10 so that the end cap 20 and the shell 10 have a fitting area 80. Figure 4 、 Figure 5 As shown, in the axial direction of the housing 10 , the size of the fitting area 80 is smaller than the size of the notch.

[0045] In step S50, after the end cap 20 has been positioned, the end cap 20 and the outer shell 10 are welded together using resistance welding at the contact area 80, forming a circular weld between the contact surfaces of the end cap 20 and the outer shell 10. Thus, the end cap 20 and the outer shell 10 are welded together to form a closed structure of the fuel tank.

[0046] In step S60, welding is completed based on the fitting area 80, and filler welding is performed along the edge of the notch to form the welded portion 30, and the end cap 20 is welded. This prevents fuel leakage from the notch in the fuel tank and ensures good sealing of the fuel tank.

[0047] In step S70, the fuel tank is completed after both end caps 20 are welded to the outer shell 10. By cutting notches at both ends of the first side 50 of the sheet 40 and bending it to form the outer shell 10, the overlapping region 70 is smaller than the notch. At the same time, the axial dimension of the contact region 80 between the end caps 20 and the outer shell 10 is smaller than the notch. This ensures that the notch avoids the intersection of the overlapping region 70 and the contact region 80, resulting in a uniform circumferential thickness of the annular weld across the outer shell 10 and ensuring a secure resistance weld. Filler welding is performed along the edge of the notch to form the weld 30, which seals the notch and thus ensures the fuel tank's tightness, resolving issues such as weak welds and oil leaks.

[0048] Furthermore, step S10 includes: based on the rectangular sheet 40, cutting notches at two adjacent right angles in the sheet 40, such that the two notches are located at opposite ends of the first side 50 of the sheet 40; wherein the two edge lines of the notches are located at a first cutting line and a second cutting line, respectively, and the first cutting line and the second cutting line intersect. Using cutting to process the notches is convenient and fast, and can reduce processing costs. The intersection of the first cutting line and the second cutting line provides the basis for forming the notches into a specific shape, facilitating the subsequent avoidance of the annular weld.

[0049] Furthermore, the first cutting line is parallel to the first side edge 50; the first cutting line is perpendicular to the second cutting line. Figure 5 As shown, the edge of the first welding rod 31 is the first cutting line, and the edge of the second welding rod 32 is the second cutting line. The first cutting line is parallel to the first side 50, which facilitates the determination of the position of the notch on the sheet 40 and ensures more precise processing. The first cutting line and the second cutting line are perpendicular. This simple arrangement can simplify the processing process and improve processing efficiency.

[0050] Furthermore, one end of the first cutting line coincides with one end of the second cutting line. Figure 5 As shown, one end of the first cutting line overlaps with one end of the second cutting line to form an L-shaped notch. This shape can effectively avoid the annular weld passing through the overlapping area 70, ensure that the thickness of the annular weld is uniform in the circumferential direction, and improve the welding quality.

[0051] Furthermore, one end of the first cutting line is located on the second cutting line. Figure 6 As shown, one end of the first cutting line is located on the second cutting line, forming a T-shaped notch. This shape avoids the annular weld while reducing the area of ​​the notch that requires filler welding, thereby saving filler material and enhancing the sealing of the weld portion 30.

[0052] Furthermore, step S60 includes completing welding based on the contact area 80 and performing filler welding along the first and second cutting lines of the notch, thereby forming a first welding rod 31 along the first cutting line and a second welding rod 32 along the second cutting line, thereby completing the welding of the end cap 20. Filler welding along the first and second cutting lines of the notch provides a targeted seal at the notch. The formed first and second welding rods 31, 32 effectively fill the notch space, ensuring the fuel tank's tightness.

[0053] Furthermore, step S40 includes completing welding based on the overlapping region 70 and sequentially positioning the two end caps 20 at the corresponding ends of the housing 10 at predetermined intervals, such that the end caps 20 and the housing 10 have a contact region 80. The predetermined interval is the duration of welding a single end cap 20. Sequentially positioning the end caps 20 at predetermined intervals eliminates the need for multiple sets of welding equipment, saving equipment costs. Furthermore, the step-by-step process reduces complexity and facilitates quality control.

[0054] Embodiment 2: This embodiment discloses a fuel tank, which is applied to a fuel tank processing method of any one of the above-mentioned embodiments. Figure 2 、 Figure 3 、 Figure 4 、 Figure 5As shown, the fuel tank includes an outer shell 10 and two end caps 20. The outer shell 10 is a cylindrical structure. Two welding portions 30 are formed on the outer periphery of the outer shell 10. The two welding portions 30 are located at either end of the outer shell 10. The welding portions 30 include a first welding rod 31 and a second welding rod 32. The outer shell 10 is formed by bending a rectangular sheet 40. The first side 50 and the second side 60 of the sheet 40 have an overlapping area 70. Rectangular notches are formed at right angles to each other at both ends of the first side 50. The rectangular notches are used to avoid the overlapping area 70 in the contact area 80, ensuring a uniform thickness distribution of the outer shell 10 in the contact area 80 and improving the securement of the end caps 20 welded to the outer shell 10. The first welding rod 31 and the second welding rod 32 correspond to the edge lines of the notches, respectively. The contact area between the first side 50 and the second side 60 has a straight weld seam. The two welding portions 30 are located at either end of the straight weld seam. The first welding rod 31 extends axially along the outer shell 10. Two end covers 20, the two end covers 20 correspond to the two ends of the outer shell 10 one by one. The end cover 20 includes a sealing cover 21 and a lug 22. The sealing cover 21 covers the end of the outer shell 10. The lug 22 is annular. The lug 22 is fixedly connected to the sealing cover 21. The lug 22 and the outer shell 10 have a fitting area 80. The contact area between the lug 22 and the outer shell 10 has an annular weld. The width of the annular weld is less than the length of the first welding rod 31. The outer shell 10 is formed by bending a rectangular sheet 40, and the overlapping area 70 of the first side 50 and the second side 60 is connected by a straight weld, which ensures the integrity of the outer shell 10. The setting of the rectangular notch provides a positional basis for the formation of the welding portion 30. The first welding rod 31 and the second welding rod 32 correspond to the edge line of the notch, which can effectively seal the notch. The sealing cover 21 of the end cover 20 covers the end of the shell 10. The lug 22 is connected to the fitting area 80 of the shell 10 by an annular weld. Combined with the sealing effect of the weld 30, the overall welding strength and sealing of the fuel tank are ensured.

[0055] Further, if Figure 5 、 Figure 6 As shown, the first welding rod 31 and the second welding rod 32 are perpendicular; one end of the first welding rod 31 rests on the second welding rod 32; or one end of the first welding rod 31 overlaps one end of the second welding rod 32. This perpendicularity facilitates processing and ensures the structural stability of the weld 30. Positioning one end of the first welding rod 31 on or overlapping one end of the second welding rod 32 effectively fills the gap and enhances the fuel tank's sealing. Positioning one end of the first welding rod 31 on the second welding rod 32 reduces filler welding costs.

[0056] Embodiment 3: This embodiment discloses a vehicle comprising a fuel tank according to any one of Embodiment 2. A vehicle equipped with such a fuel tank can reduce malfunctions caused by fuel tank leakage due to uniform welding and good sealing, thereby ensuring normal vehicle operation and improving vehicle reliability.

[0057] Those skilled in the art will understand that the above-mentioned embodiments are specific examples for implementing the present disclosure, and in actual applications, various changes may be made thereto in form and details without departing from the scope of the present disclosure.

Claims

1. A method for processing a fuel tank, characterized in that: The fuel tank processing method includes: Based on a rectangular sheet, notches are respectively processed at two adjacent right angles of the sheet, so that the two notches are located at two ends of a first side of the sheet; After the notch is cut, the sheet is bent so that the first side and the second side of the sheet have an overlapping area, forming a cylindrical shell; wherein the first side and the second side are arranged in parallel; and in a direction perpendicular to the first side, the size of the notch is larger than the size of the overlapping area; Based on the shell molding, the overlapping area of ​​the first side and the second side is welded by resistance welding, so that the contact surface of the first side and the second side forms a straight weld; After completing welding on the overlapping area, the end cap is positioned at the corresponding end of the housing so that the end cap and the housing have a fitting area; wherein, in the axial direction of the housing, the size of the fitting area is smaller than the size of the notch; After the end cap is positioned, the end cap and the housing are welded by resistance welding to form an annular weld between the contact surfaces of the end cap and the housing; Welding is completed based on the fitting area, and filler welding is performed along the edge line of the notch to form a welded portion, and the end cover welding is completed; After both end covers are welded to the outer shell, the fuel tank is processed.

2. A fuel tank processing method according to claim 1, characterized in that: The rectangular sheet is processed with notches at two adjacent right angles of the sheet, so that the two notches are located at two ends of the first side of the sheet, including: Based on a rectangular material sheet, notches are cut at two adjacent right angles of the material sheet so that the two notches are located at both ends of the first side of the material sheet; wherein the two edge lines of the notch are located at the first cutting line and the second cutting line, respectively, and the first cutting line and the second cutting line intersect.

3. A fuel tank processing method according to claim 2, characterized in that: The first cutting line is parallel to the first side; the first cutting line is perpendicular to the second cutting line.

4. A fuel tank processing method according to claim 3, characterized in that: One end of the first cutting line coincides with one end of the second cutting line.

5. The method for processing a fuel tank according to claim 3, characterized in that: One end of the first cutting line is located on the second cutting line.

6. A fuel tank processing method according to claim 5, characterized in that: The welding is completed based on the fitting area, and filler welding is performed along the edge line of the notch to form a welding portion, and the end cover welding is completed, including: Based on the completion of welding in the fitting area, filler welding is performed along the first cutting line and the second cutting line of the notch to form a first welding rod along the first cutting line and a second welding rod along the second cutting line, and the end cover welding is completed.

7. The method for processing a fuel tank according to claim 1, characterized in that: The method of completing welding based on the overlapping area and positioning the end cap at the corresponding end of the shell so that the end cap and the shell have a fitting area includes: Based on the completion of welding in the overlapping area, the two end covers are positioned in sequence at the ends of the corresponding shell at intervals of a preset time, so that the end covers and the shell have a fitting area; wherein the preset time is the time for welding a single end cover.

8. A fuel tank, applied to the fuel tank processing method according to any one of claims 1 to 7, characterized in that: The fuel tank comprises: The outer shell is a cylindrical structure; the outer periphery of the outer shell has two welding parts; the two welding parts are distributed at both ends of the outer shell; the welding parts include a first welding rod and a second welding rod; the outer shell is formed by bending a rectangular sheet; the first side and the second side of the sheet have an overlapping area; the two ends of the first side have rectangular notches at right angles; the first welding rod and the second welding rod correspond to the edge lines of the notches respectively; the contact area between the first side and the second side has a linear weld; the two welding parts are located at both ends of the linear weld; the first welding rod extends along the axial direction of the outer shell; Two end covers, the two end covers correspond to the two ends of the shell one by one; the end covers include sealing covers and support ears; the sealing covers cover the ends of the shell; the support ears are annular; the support ears are fixedly connected to the sealing covers; the support ears and the shell have a fitting area; the contact area between the support ears and the shell has an annular weld; the width of the annular weld is less than the length of the first welding rod.

9. A fuel tank according to claim 8, characterized in that: The first welding rod is perpendicular to the second welding rod; one end of the first welding rod is located on the second welding rod; or one end of the first welding rod coincides with one end of the second welding rod.

10. A vehicle, characterized in that: The vehicle comprises a fuel tank according to claim 8 or 9.

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