Electric vehicle frame welding seam strength detection device

Abstract

The invention relates to an electric vehicle frame welding seam strength detection device in the field of welding seam detection devices, and the electric vehicle frame welding seam strength detection device comprises a fixing unit used for fixing a frame, a placement platform, and a pressurization test part and a detection part which are respectively installed on different mechanical arms, the detection part comprises a telescopic cylinder, and the movable end of the telescopic cylinder is connected with a C-shaped frame; a movable beam used for closing the opening side of the C-shaped frame is hinged to one end of the top of the C-shaped frame, a butt joint is connected to one end of the movable beam, the other end of the movable beam is connected with a rotating shaft used for being hinged to the C-shaped frame, and a butt joint base used for being in butt joint with the butt joint is installed on the C-shaped frame. The C-shaped frame and the movable beam are each rotationally connected with a detection shaft used for collecting welding seam information, the number of the detection shafts on the C-shaped frame is one pair, the detection shafts are driven by a first motor in the detection shafts to rotate, and real-time monitoring on the welding seam state is achieved through the detection part easily adapting to different welding seam conditions. And the detection requirements of different forms of welding seams in an auxiliary frame structure can be easily met.

Description

Technical Field

[0001] The present invention relates to an electric vehicle frame weld detection device, and in particular to an electric vehicle frame weld strength detection device applied in the field of weld detection devices. Background Art

[0002] The background technology of existing electric vehicle frame weld strength detection devices mainly relates to the field of frame weld detection technology. Traditional detection methods mostly rely on manual inspection and simple mechanical testing, which have problems such as low detection efficiency and insufficient accuracy. With the development of technology, electric vehicle frame weld strength detection devices have gradually adopted more advanced sensor technology and data processing methods. For example, the use of pressure sensors to detect the connection strength and sealing performance of key parts of the frame can comprehensively evaluate the strength of the weld. In addition, some devices also combine the characteristics of automation and intelligence, and achieve accurate positioning and efficient detection of welds through precise mechanical structures and control systems.

[0003] Chinese patent CN118090451B discloses a device for detecting the weld strength of an electric vehicle frame. In this device, the detection mechanism includes a first pressure sensor and a second pressure sensor. The first pressure sensor in the detection mechanism detects the connection strength between the front fork tube and the frame body in the frame, and the second pressure sensor in the detection mechanism detects the sealing performance of the front fork tube, that is, detects whether there are cracks or perforations on the front fork tube. The strength of the frame weld is comprehensively tested to ensure the safety and reliability of the electric vehicle frame.

[0004] Chinese patent CN113670726A discloses a bicycle frame weld strength detection device. The bicycle frame weld strength detection device, through the mutual cooperation of parts such as the support, top plate, bracket, motor, second rotating shaft, counterweight block, pointer and slide bar, can make the counterweight block move by the second rotating shaft when the motor is running, press the frame, and then detect the strength of its weld. At the same time, when the counterweight block moves downward, it will drive the pointer to move, so that the staff can understand the strength of the weld by the position of the scale line indicated by the pointer, which solves the problem that the existing equipment uses electronic instruments for detection and is expensive.

[0005] Existing frame weld inspections are mostly performed by scanning the weld area with sensors. If real-time monitoring of the weld is required during the frame test, conventional inspection devices have a limited range of real-time weld data collection and can only collect local weld image data, failing to provide comprehensive real-time monitoring. Existing frame weld strength inspection devices are not easy to collect comprehensive and real-time weld data during frame testing. Summary of the Invention

[0006] In response to the above-mentioned existing technologies, the technical problem to be solved by the present invention is that the existing detection device has a limited range of real-time weld acquisition and can only acquire local weld image data, and cannot monitor the entire weld in real time. The existing frame weld strength detection device is not easy to acquire weld data in a comprehensive and real-time manner when testing the frame.

[0007] To solve the above problems, the present invention provides an electric vehicle frame weld strength testing device, comprising a fixing unit for fixing the frame, a placement platform, and a pressurized testing unit and a testing unit respectively mounted on different robotic arms. The testing unit comprises a telescopic cylinder, the movable end of which is connected to a C-shaped frame, one end of the top of the C-shaped frame is hinged to a movable beam for closing its open side, one end of the movable beam is connected to a docking joint, and the other end is connected to a rotating shaft for hinged connection with the C-shaped frame, and the C-shaped frame is equipped with a docking seat for docking with the docking joint. The C-frame and the movable beam are both rotatably connected to detection shafts for collecting weld information. The detection shafts on the C-frame are provided as a pair and are driven to rotate by a first motor therein. The detection shafts on the movable beam are driven to rotate by a second motor therein after the docking head and the docking seat are docked. An electric telescopic rod is fixedly connected to the outer wall of the C-shaped frame, the movable end of the electric telescopic rod is connected to a rack, and a gear ring engaged with the rack is fixedly connected to the rotating shaft; one end of the detection shaft is a flat end and is equipped with an image acquisition unit and a laser sensor, and the other end opposite to the flat end is paved with a buffer layer.

[0008] The above-mentioned electric vehicle frame weld strength detection device can easily adapt to the real-time detection of welds of different shapes on the frame when performing a pressure test on the frame.

[0009] As a further supplement to the present application, the fixing unit includes a lifter, a movable end of the lifter is fixedly connected to a pressurized cylinder, and a telescopic end of the pressurized cylinder is fixedly connected to a splint.

[0010] As a further supplement to the present application, both the C-frame and the movable beam are provided with a receiving groove that matches the detection shaft. When the detection shaft is not detecting the weld, the detection shaft is driven to rotate so that the buffer layer is exposed to the outside of the receiving groove.

[0011] As a further supplement to the present application, the rotation range of the movable beam is 0-90°, and an electric latch for locking with the C-frame is installed in the movable beam.

[0012] As a further supplement to the present application, the pressure testing unit includes a hydraulic device installed on the robotic arm, a pressure block is installed on the movable end of the hydraulic device, and a silicone pad is laid on the surface of the pressure block.

[0013] As a further supplement to the present application, an auxiliary detection system is also included, the auxiliary detection system includes a processor, and the processor is connected to a control module, a data acquisition module, a data processing module and a data storage module; The control module is used to receive instructions and control the operation of designated associated devices. The control module is provided with a local detection mode for testing a single structural component and a range detection mode for unified pressure testing of multiple structural components. The data acquisition module is used to collect data from the image acquisition unit and the laser sensor, and pre-process the collected data; The data processing module processes and analyzes the data collected by the data acquisition module to obtain relevant parameters for weld strength evaluation; The data storage module is used to store all data collected and generated during the detection process.

[0014] As a further supplement to the present application, when the range detection mode is working: multiple fixing units continuously pressurize multiple structural members within a specified area of ​​the frame. During the pressurization process, the detection unit performs multi-point random detection on the welds of the pressurized structural members.

[0015] As a further supplement to the present application, when the local detection mode is working: when the pressure testing unit selects a single structural member for local pressurization, a pair of detection units collects real-time data changes of the welding seams at both ends of the structural member in real time.

[0016] In summary, this solution enables automated, high-precision testing of electric vehicle frame weld strength. By using a fixed unit to stably clamp the frame, and a pressure test unit to apply pressure to the frame to simulate the stress conditions experienced in actual use, the weld state is monitored in real time using a test unit that is easily adaptable to different weld conditions. This easily adapts to the needs of testing welds of varying configurations within the auxiliary frame structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a three-dimensional schematic diagram of the first embodiment of the present application; Figure 2 This is a front view of the first embodiment of the present application during a pressure test on the frame; Figure 3 This is a side sectional view of the first embodiment of the present application; Figure 4 for Figure 3 Schematic diagram of the structure at A in the middle; Figure 5 This is a cross-sectional view of the detection portion during a pressure test on a vehicle frame according to the first embodiment of the present application; Figure 6 for Figure 5 Schematic diagram of the structure at B in the middle; Figure 7This is a partial three-dimensional diagram of the detection unit of the first embodiment of the present application; Figure 8 This is a system block diagram of the second implementation method of this application.

[0018] Description of the numbers in the figure: 1. Fixing unit; 2. Placement platform; 3. Pressurization test unit; 4. Inspection unit; 41. Telescopic cylinder; 42. C-frame; 421. Docking seat; 43. Movable beam; 431. Docking joint; 432. Rotating shaft; 44. Electric telescopic rod; 441. Rack; 5. Inspection axis. DETAILED DESCRIPTION

[0019] The following describes two implementation methods of the present application in detail with reference to the accompanying drawings.

[0020] The first implementation method: Figure 1 - Figure 7 It shows a device for testing the weld strength of an electric vehicle frame, comprising a fixing unit 1 for fixing the frame, a placement platform 2, and a pressurized testing part 3 and a detection part 4 respectively installed on different robotic arms. The fixing unit 1 comprises a lifter, the movable end of the lifter is fixedly connected to a pressurized cylinder, and the telescopic end of the pressurized cylinder is fixedly connected to a splint.

[0021] The detection unit 4 includes a telescopic cylinder 41, the movable end of which is connected to a C-shaped frame 42. A movable beam 43 for closing the open side of the C-shaped frame 42 is hinged at one end of the top of the C-shaped frame 42. The movable beam 43 can be rotated to close the open side of the C-shaped frame 42, so that the movable beam 43 and the C-shaped frame 42 form a rectangular ring structure. One end of the movable beam 43 is connected to a docking head 431, and the other end is connected to a rotating shaft 432 for hinged connection with the C-shaped frame 42. A docking seat 421 for docking with the docking head 431 is installed on the C-shaped frame 42. After the docking head 431 and the docking seat 421 are docked, power can be supplied to the equipment in the movable beam 43, and data can be transmitted to the detection axis 5 in the movable beam 43. The C-frame 42 and the movable beam 43 are both rotatably connected to a detection shaft 5 for collecting weld information. The detection shaft 5 on the C-frame 42 is provided as a pair and is driven to rotate by a first motor therein. The power output end of the first motor and one end of the detection shaft 5 in the C-frame 42 are respectively connected to two bevel gears that mesh with each other. After the docking joint 431 is docked with the docking seat 421, the detection shaft 5 on the movable beam 43 can be driven to rotate by the second motor therein. The detection shaft 5 in the movable beam 43 is connected to the power output end of the second motor through a transmission structure. The rotation range of the movable beam 43 is 0-90 degrees. An electric latch for locking with the C-shaped frame 42 is installed in the movable beam 43. The electric latch is activated after the docking joint 431 is docked with the docking seat 421. Clamps are provided on both sides of the docking seat 421. Sockets are provided on the top of the clamps. Slots matching the clamps are provided on both sides of the docking joint 431. After the docking joint 431 is docked with the docking seat 421, the telescopic end of the electric latch in the movable beam 43 extends out and is inserted into the socket of the clamp, thereby locking the movable beam 43 with the C-shaped frame 42.

[0022] An electric telescopic rod 44 is fixedly connected to the outer wall of the C-shaped frame 42, and a rack 441 is connected to the movable end of the electric telescopic rod 44. A gear ring meshing with the rack 441 is fixedly connected to the rotating shaft 432. One end of the detection shaft 5 is a flat end and is equipped with an image acquisition unit and a laser sensor. The image acquisition unit is used to capture weld images in real time. The laser sensor includes a laser scanning sensor and a laser ranging sensor. The laser detection unit can assist in scanning the weld and can also monitor the bending changes of the steel structure during the frame test. When the deformation of the steel structure in its monitoring area exceeds a set value (that is, the distance between the steel structure and the laser sensor changes to exceed the set value), an alarm can be triggered in time. The other end opposite to the flat end is paved with a cushion layer. When the detection unit 4 assists in moving the frame, the cushion layer contacts the frame and provides cushioning protection for the detection shaft 5, ensuring that the detection unit 4 assists in moving the detection shaft 5 and is not easily damaged. Both the C-frame 42 and the movable beam 43 are provided with a receiving groove matching the detection shaft 5. The rotation range of the detection shaft 5 is 0-180°. When the detection shaft 5 is not detecting the weld, the buffer layer is exposed to the outside of the receiving groove by driving the detection shaft 5 to rotate.

[0023] When the weld strength detection device of this solution is working, the frame is clamped and fixed by the fixing unit 1; Before testing, the two detection parts 4 are moved to the welding positions at both ends of the component, and the tilt angle of the detection parts 4 is adjusted to make them close to the weld seam. Then, the electric telescopic rod 44 is controlled to move the rack 441 and drive the movable beam 43 to rotate until the docking joint 431 docks with the docking seat 421. At this time, the multiple detection shafts 5 are controlled to rotate so that their planar ends face the weld seam. The image acquisition unit and laser sensor at the planar ends are used to monitor the weld seam status. After the position of the detection unit 4 is adjusted, the pressure test unit 3 is started to perform a pressure impact test on the designated component position of the frame; During the test, the detection unit 4 collects weld data in real time, and the collection range of the detection unit 4 covers the weld, making it easy to obtain comprehensive weld change data; During the detection process, it is sometimes necessary to adjust the placement state or position of the frame. The detection shaft 5 can be rotated so that its flat end is retracted into the receiving groove and the buffer layer is exposed to the outside; when the movable beam 43 is locked by the electric latch; the detection part 4 is a closed annular structure. At this time, the frame can be lifted by the detection part 4 to assist in changing the placement state of the frame or assist in changing the placement position of the frame.

[0024] The detection part 4 is a closed ring structure during detection, and the steel structure of the weld to be detected passes through the detection part 4. After the detection part 4 moves to the weld position, the tilt angle and the rotation angle of the detection axis 5 can be adjusted to make the detection end of the detection part 4 fully cover the weld of the steel structure, especially for the inclined weld. This solution can ensure that real-time data of most weld areas can be collected when the steel structure is pressurized. Figure 4 As shown; This solution enables automated, high-precision testing of the weld strength of electric vehicle frames. The frame is stably clamped by a fixing unit 1, and pressure is applied to the frame using a pressure testing unit 3 to simulate the stress conditions experienced during actual use. Simultaneously, a detection unit 4, adaptable to varying weld conditions, monitors the weld state in real time, easily adapting to the needs of testing welds of varying configurations within the auxiliary frame structure.

[0025] Second implementation method: Figure 8 As shown, it also includes an auxiliary detection system, which includes a processor, and the processor is connected to a control module, a data processing module and a data storage module; The control module is used to receive instructions and control the operation of designated associated devices. The control module is provided with a local detection mode for testing a single structural component and a range detection mode for unified pressure testing of multiple structural components. The data acquisition module is used to collect data from the image acquisition unit and the laser sensor, and pre-process the collected data. A data collector is provided in the C-frame 42, which collects the data transmitted by each detection axis 5 and uploads it to the data acquisition module. The pre-processing includes data filtering, noise reduction and format standardization. The data processing module is used to process and analyze the data collected by the data acquisition module to obtain relevant parameters for weld strength assessment. The relevant parameters include: weld geometric feature data and defect feature data. The weld geometric feature data includes weld width and depth; the defect feature data includes identification of defect types such as pores, cracks, and slag inclusions, the location of each defect, and the size of each defect. Those skilled in the art use existing pattern recognition, image analysis, and other technologies to process the data uploaded by the data acquisition module to obtain the relevant parameters for weld strength assessment. This solution will not be further described. The data storage module is used to store all data during the detection process, including image data, laser detection data and data calculated by the data processing module, to facilitate subsequent data query and analysis.

[0026] When the range detection mode is working: multiple fixing units 1 continuously pressurize multiple structural parts within a specified area of ​​the vehicle frame (i.e., the fixing units 1 clamp the vehicle frame by clamping multiple structural parts, and the pressurizing cylinder increases the clamping pressure during clamping, so that multiple structural parts are continuously pressurized at the same time). During the pressurization process, the detection unit 4 performs multi-point random inspections on the welds of the pressurized structural parts. That is, at every set interval, the detection unit 4 inspects the weld of another pressurized structural part, thereby realizing random sampling of multiple welds when multiple structural parts are pressurized; When the local detection mode is working: when the pressure test part 3 selects a single structural part for local pressurization, a pair of detection parts 4 collects real-time data changes of the welding seams at both ends of the structural part in real time.

[0027] This implementation achieves fully automated testing and data analysis of electric vehicle frame weld strength. The introduction of an auxiliary detection system not only enhances the intelligence level of testing but also ensures the accuracy and traceability of test data. In range detection mode, continuous, large-scale pressure testing can be performed on designated areas of the frame, effectively simulating the complex stress conditions experienced in actual use. In local detection mode, precise pressure can be applied to individual structural components, collecting real-time data on weld changes under local pressure.

[0028] In summary, this solution achieves high efficiency, accuracy and intelligence in the strength detection of electric vehicle frame welds; through the highly adaptable detection unit 4, the detection device can easily and flexibly adapt to the real-time and comprehensive data collection requirements of welds of different shapes.

[0029] In view of current actual needs, the protection scope of the above-mentioned implementation mode adopted in this application is not limited to this. Various changes made within the knowledge scope of technical personnel in this field without departing from the concept of this application still fall within the protection scope of the present invention.

Claims

1. A device for testing the weld strength of an electric vehicle frame, comprising a fixing unit (1) for fixing the frame, a placement platform (2), and a pressurized testing unit (3) and a testing unit (4) respectively mounted on different robotic arms, characterized in that: The detection portion (4) includes a telescopic cylinder (41), a C-shaped frame (42) is connected to the movable end of the telescopic cylinder (41), a movable beam (43) for closing the open side of the C-shaped frame (42) is hingedly connected to one end of the top of the C-shaped frame (42), one end of the movable beam (43) is connected to a docking joint (431), and the other end is connected to a rotating shaft (432) for hinged connection with the C-shaped frame (42), and a docking seat (421) for docking with the docking joint (431) is installed on the C-shaped frame (42); The C-shaped frame (42) and the movable beam (43) are both rotatably connected with detection shafts (5) for collecting weld information. The detection shafts (5) on the C-shaped frame (42) are arranged as a pair and are driven to rotate by a first motor therein. The detection shafts (5) on the movable beam (43) can be driven to rotate by a second motor therein after the docking joint (431) is docked with the docking seat (421). An electric telescopic rod (44) is fixedly connected to the outer wall of the C-shaped frame (42), a rack (441) is connected to the movable end of the electric telescopic rod (44), and a gear ring meshing with the rack (441) is fixedly connected to the rotating shaft (432); one end of the detection shaft (5) is a flat end and is equipped with an image acquisition unit and a laser sensor, and the other end opposite to the flat end is paved with a buffer layer.

2. The electric vehicle frame weld strength detection device according to claim 1, characterized in that: The fixing unit (1) comprises a lifter, a movable end of the lifter is fixedly connected to a pressurizing cylinder, and a telescopic end of the pressurizing cylinder is fixedly connected to a clamping plate.

3. The electric vehicle frame weld strength detection device according to claim 1, characterized in that: The C-shaped frame (42) and the movable beam (43) are both provided with a receiving groove matching the detection shaft (5). When the detection shaft (5) is not detecting the weld, the detection shaft (5) is driven to rotate so that the buffer layer is exposed outside the receiving groove.

4. The electric vehicle frame weld strength detection device according to claim 1, characterized in that: The rotation range of the movable beam (43) is 0-90°, and an electric latch for locking with the C-shaped frame (42) is installed in the movable beam (43).

5. The electric vehicle frame weld strength detection device according to claim 1, characterized in that: The pressurized test part (3) comprises a hydraulic device mounted on a mechanical arm, a pressurized block is mounted on the movable end of the hydraulic device, and a silicone pad is laid on the surface of the pressurized block.

6. The electric vehicle frame weld strength detection device according to claim 1, characterized in that: It also includes an auxiliary detection system, which includes a processor, and the processor is connected to a control module, a data acquisition module, a data processing module and a data storage module; The control module is used to receive instructions and control the operation of the designated associated device. The control module is provided with a local detection mode for testing a single structural component and a range detection mode for unified pressure testing of multiple structural components; The data acquisition module is used to collect data from the image acquisition unit and the laser sensor, and pre-process the collected data; The data processing module processes and analyzes the data collected by the data acquisition module to obtain relevant parameters for weld strength evaluation; The data storage module is used to store all data collected and generated during the detection process.

7. The electric vehicle frame weld strength detection device according to claim 6, characterized in that: When the range detection mode is in operation, the plurality of fixing units (1) continuously pressurize the plurality of structural members within a designated area of ​​the vehicle frame, and during the pressurization process, the detection unit (4) performs multi-point random detection on the welds of the pressurized structural members.

8. The electric vehicle frame weld strength detection device according to claim 6, characterized in that: When the local detection mode is in operation, the pressure test unit (3) selects a single structural component for local pressure application, and a pair of detection units (4) collects real-time data changes of the welding seams at both ends of the structural component in real time.

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