A kind of manual shaping device and method for grain hopper car thin plate U-shaped beam

Abstract

A kind of thin plate U-shaped beam hand shaping device for grain hopper car belongs to railway freight manufacturing technical field, including detachably connected shaping insert and handle, the one end of shaping insert is outwardly convex and forms the circular arc working surface with the radius equal to the radius of U-shaped beam shaping finished product, adjusting space is left between the upper end of shaping insert and the arc top of circular arc working surface, and the lower end and circular arc working surface form clamping groove.A kind of thin plate U-shaped beam hand shaping method for grain hopper car includes preparing U-shaped beam semi-finished product, placing U-shaped beam semi-finished product into auxiliary tooling, inserting the clamping groove of device into U-shaped groove shaping block, rotating handle clockwise, positioning welding is carried out on 2-3 cut points of U-shaped groove shaping block and U-shaped groove vertical plane arc during rotation, removing device, full-welding angle joint weld is welded.The device in the application has simple structure, is easy to make, low in cost, high in universality and light in weight;At the same time, shaping process is easy to control, and shaping quality is good.

Description

Technical Field

[0001] This invention belongs to the field of railway freight manufacturing technology, and relates to a molding device and method for thin-plate U-shaped beams, particularly to a manual molding device and method for thin-plate U-shaped beams used in grain hopper cars. Background Technology

[0002] Currently, in the railway freight car manufacturing industry, there are more and more hopper cars used to load goods such as coal, ore, slag and grain; while grain hopper cars, which are mainly used to load food such as corn and flour, have extremely high quality requirements for the sealing performance of the hopper cars and the materials used in the car body.

[0003] Among grain hopper car models, those with bodies primarily made of carbon steel, stainless steel (T4003), and aluminum alloy are the most common. In the side walls, end walls, roof, or underframe structure of these models, many U-shaped beams require shaping at one or both ends, such as side crossbars, end posts, uprights, upper edges, end beams, longitudinal beams, and support beams. Most U-shaped beams are machined from medium-thick plates (≤5mm thick). These components are generally similar in shape and all require shaping using some kind of shaping tooling or mold. The differences lie in the materials used (carbon steel, stainless steel (T4003), aluminum alloy) and the thickness of the plates used (1.5–12mm). Common shaping methods include:

[0004] 1. Special mold hydraulic press for bending and shaping: Suitable for sheet metal parts with a thickness of 7-12mm, made of carbon steel, stainless steel or aluminum alloy, that require bending, such as the inner reinforcement seat of the side pillar in the ore funnel car series.

[0005] 2. General-purpose bending tooling: Suitable for medium-thickness plate parts with a plate thickness of 3-6mm, made of carbon steel, stainless steel or aluminum alloy, that require bending; such as the upper edge, end beam, and side crossbar in coal hopper car series models;

[0006] 3. Simple tooling combined with a shaping device for manual shaping: suitable for thin plates with a thickness of 1.5-3mm, made of carbon steel, stainless steel and aluminum alloy and other thin plates that need to be shaped; such as end posts, columns, longitudinal beams and support beams in the grain hopper car series.

[0007] 4. Manual flame baking: This method is only suitable for very small batches (≤5 pieces) of medium-thick plates with a thickness >3mm.

[0008] However, existing simmering methods have the following drawbacks:

[0009] 1. The production cost of bending and shaping using a special mold hydraulic press is relatively high, and its versatility is poor. Furthermore, the bending and shaping of U-shaped beams is prone to quality defects such as oil stains.

[0010] 2. General-purpose bending tooling: Bending requires two bending inserts for each type of U-beam component, and the bending surface is prone to quality defects such as misalignment and surface scratches.

[0011] 3. Manual flame molding is required for carbon steel parts that require flame heating for molding, but stainless steel and aluminum alloy parts are not allowed to be molded manually using flame molding.

[0012] In order to create a manual shaping device that does not require much external force, has low manufacturing cost, controllable shaping surface quality, strong versatility, and is easy to promote and apply, this invention proposes a manual shaping device and method for thin plate U-shaped beams of grain hopper carts. Summary of the Invention

[0013] In view of the shortcomings of the prior art described above, the purpose of this invention is to provide a manual shaping device and method for thin-plate U-shaped beams of grain hopper carts, which solves the technical problems of high cost and uncontrollable shaping surface quality of aluminum alloy grain hopper cart thin-plate U-shaped beam shaping devices in the prior art.

[0014] To achieve the above and other related objectives, the present invention provides a manual shaping device for thin U-shaped beams of grain hopper carts, comprising a detachably connected shaping insert and a handle. The shaping insert includes a main body, with one end of the main body away from the handle protruding outward to form an arc-shaped working surface. The radius of the arc-shaped working surface is equal to the radius of the U-shaped beam shaping product. Horizontal blocks are connected to the upper and lower ends of the main body of the insert. An adjustment space is provided between the suspended end of the upper horizontal block and the arc top of the arc-shaped working surface, and a groove is formed between the lower horizontal block and the arc-shaped working surface.

[0015] In any of the above schemes, it is preferred that the width of the shaped insert is m2, where m2≤a-30mm, and a is the maximum inner spacing of the U-shaped groove.

[0016] In any of the above solutions, the preferred option is that the width of the slot is t1, where t1 = t + 0.5 mm, and t is the thickness of the U-shaped groove molding block.

[0017] In any of the above schemes, the preferred option is that the distance of the adjustment space is m3, m3 = 1.5t, where t is the thickness of the U-shaped groove molded block.

[0018] Preferably, in any of the above embodiments, the U-shaped beam manual shaping device further includes auxiliary tooling, which includes a base plate and an L-shaped plate connected to the base plate, with a fixing groove formed between the L-shaped plate and the base plate.

[0019] A method for manually shaping thin-plate U-shaped beams for grain hopper carts mainly includes the following steps:

[0020] S1. Prepare a semi-finished product of a thin-plate U-shaped beam for a grain funnel cart, wherein the semi-finished product of the U-shaped beam includes a shaped U-shaped beam body and a U-shaped groove molding block;

[0021] S2. Place the U-shaped beam body with the U-shaped groove opening facing downwards into the auxiliary tooling;

[0022] S3. Insert the slot of the U-shaped beam manual bending device into the U-shaped channel bending block, and turn the handle clockwise to make the U-shaped channel bending block bend along the arcs on both sides of the U-shaped channel facade;

[0023] S4. Continue to rotate the handle clockwise to make the U-shaped groove bending block continue to bend along the arc of the U-shaped groove vertical surface, and position weld the tangent point E2 between the U-shaped groove bending block and the arc on both sides of the U-shaped groove vertical surface;

[0024] S5. Continue to rotate the handle clockwise to make the U-shaped groove bending block continue to bend along the arc of the U-shaped groove vertical surface, and position weld the tangent point E3 between the U-shaped groove bending block and the arc on both sides of the U-shaped groove vertical surface;

[0025] S6. Complete the shaping and positioning welding, and remove the manual shaping device for the U-shaped beam;

[0026] S7. After the shaping is completed, the fillet weld between the U-shaped groove shaping block and the arc on both sides of the facade is fully welded.

[0027] In any of the above schemes, it is preferred that, in step S3, during the bending process of the U-shaped groove bending block along the arcs on both sides of the U-shaped groove facade, the tangent point E1 between the U-shaped groove bending block and the arcs on both sides of the U-shaped groove facade is positioned and welded.

[0028] Preferably, in any of the above schemes, E1 or E2 is located 5 to 10 mm from the middle of the U-shaped groove molding block.

[0029] In any of the above solutions, it is preferred that E3 is located at the very end corner where the U-shaped groove block meets the arcs on both sides of the U-shaped groove facade.

[0030] Preferably, in step S6, before removing the manual shaping device for the U-shaped beam, the shaping insert is fine-tuned, specifically as follows:

[0031] If the U-shaped groove is not properly molded and the teeth misalign, continue rotating the handle clockwise to ensure the U-shaped groove molding block fits tightly against the two sides of the U-shaped groove.

[0032] When the U-shaped groove is over-molded and misaligned, rotate the handle counterclockwise to make the U-shaped groove molding block fit tightly against the two sides of the U-shaped groove.

[0033] As described above, the present invention provides a manual shaping device and method for thin-plate U-shaped beams in grain hopper carts, which has the following beneficial effects:

[0034] 1. In this invention, the device is designed for cold bending of thin stainless steel or aluminum alloy U-shaped beams with a thickness of <3mm. It does not require the manufacture of costly bending dies or large and medium-sized bending fixtures. The entire device has a simple structure, is easy to manufacture, has low cost, high versatility, and is lightweight, making it easy to operate manually.

[0035] 2. In this invention, the molding process is easy to control, and no surface oil stains or scratches are generated during the molding process. The molding surface can be adjusted to prevent misalignment between the molding surface and the two sides of the U-shaped groove, thereby effectively ensuring the molding quality. Attached Figure Description

[0036] Figure 1 The image shown is a three-view drawing of the U-shaped manual simmering device of this invention.

[0037] Figure 2 The image shows three views of the simmering insert in a U-shaped hand-simmering device.

[0038] Figure 3 The image shows the three views of the handle in a U-shaped hand-heating device.

[0039] Figure 4 The diagram shows the unfolded form of the U-shaped end post.

[0040] Figure 5 The diagram shows the unfolded area of ​​the U-shaped end column.

[0041] Figure 6 The image shows the three views of the finished U-shaped end post component.

[0042] Figure 7 Displayed as Figure 6 Enlarged schematic diagram of surface AA in the middle.

[0043] Figure 8 The diagram shows the unfolded view of a U-shaped support beam.

[0044] Figure 9 The diagram shows the unfolded area of ​​the U-shaped support beam.

[0045] Figure 10 The three views of the finished component, which is a U-shaped support beam, are shown.

[0046] Figure 11 The images show the front view and sectional view of the U-shaped end post installed in the auxiliary fixture.

[0047] Figure 12 The images show the front view and sectional view of the U-shaped support beam installed in the auxiliary fixture.

[0048] Figure 13 This demonstrates the operating principle of the U-shaped manual simmering device on the U-shaped end column. Figure 1 .

[0049] Figure 14 This demonstrates the operating principle of the U-shaped manual simmering device on the U-shaped end column. Figure 2 .

[0050] Figure 15 This demonstrates the operating principle of the U-shaped manual simmering device on the U-shaped end column. Figure 3 .

[0051] Figure 16 This demonstrates the operating principle of the U-shaped manual simmering device on the U-shaped end column. Figure 4 .

[0052] Component designation explanation

[0053] 1-U-shaped end post U-shaped groove shaping block, 2-U-shaped end post flange, 3-U-shaped end post U-shaped groove elevation, 4-U-shaped end post U-shaped groove vertical surface, 5-U-shaped support beam U-shaped groove shaping block, 6-U-shaped support beam flange, 7-U-shaped support beam U-shaped groove elevation, 8-U-shaped support beam U-shaped groove vertical surface, 9-Shaped insert, 91-Arc working surface, 92-Horizontal block, 93-Slot, 94-Adjustment space, 95-Weight reduction hole, 10-Handle, 11-Auxiliary tooling, 111-Base plate, 112-L-shaped plate. Detailed Implementation

[0054] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0055] Please see Figures 1 to 16 It should be understood that the structures, proportions, sizes, etc., illustrated in the accompanying drawings are merely for illustrative purposes to aid those skilled in the art and to facilitate understanding and reading. They are not intended to limit the scope of the invention and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of the invention, should still fall within the scope of the technical content disclosed in this invention. Furthermore, the terms such as "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention's implementation.

[0056] Example 1

[0057] Please see Figure 1-311-12 This invention provides a manual shaping device for thin-plate U-shaped beams in grain hopper carts, comprising a shaping insert 9 and a handle 10. The shaping insert 9 is laser-cut and machined with M16 threaded holes; the handle 10 is made of ordinary φ20 round steel and machined with M16 threads. The shaping insert 9 and the handle 10 are detachably connected by screwing the threads on the handle 10 into the threaded holes of the shaping insert 9, facilitating the installation and removal of the shaping insert 9 and the handle 10 of the manual shaping device, thereby facilitating the maintenance or replacement of the shaping insert 9 and / or the handle 10. Furthermore, the entire manual shaping device weighs only 1.43 kg, is lightweight, and is easy for workers to operate manually, reducing the labor intensity of workers.

[0058] In this embodiment, the shaped insert 9 includes an insert body. The end of the insert body furthest from the handle 10 protrudes outward to form an arc-shaped working surface 91. The radius of the arc-shaped working surface 91 is equal to the radius of the U-shaped beam shaped product. Horizontal blocks 92 are connected to the upper and lower ends of the insert body, respectively. The horizontal blocks 92 are integrally formed with the insert body. An adjustment space 94 is provided between the suspended end of the upper horizontal block 92 and the arc top of the arc-shaped working surface 91 to adjust the distance between the U-shaped groove shaped block and the arc space on both sides of the U-shaped groove vertical surface when the angle of the shaped insert 9 is insufficient or the shaped section is over-shaped. A slot 93 is formed between the lower horizontal block 92 and the bottom of the arc-shaped working surface 91 for securing the U-shaped groove shaped block.

[0059] The length of the shaped insert 9 is m1, where m1 = m2;

[0060] The width of the shaped insert 9 is m2, where m2 ≤ a - 30 mm, and a is the maximum inner spacing of the U-shaped groove; specifically:

[0061] In U-shaped end post type U-groove, a1 is the inner spacing of U-shaped end post type U-groove, which is commonly 60mm and 72mm.

[0062] In a U-shaped support beam with a U-shaped groove, a2 is the inner spacing of the U-shaped support beam with a U-shaped groove, which is commonly 74mm or 80mm.

[0063] In this embodiment, to ensure a wider range of applications for the shaped insert 9, the value of 'a' is calculated based on the maximum inner spacing of the U-shaped groove being 80mm, i.e., a = 80mm, and the width of the shaped insert 9, m2 = 50mm. At this point, the shaped insert 9 is suitable for U-shaped beams with inner spacing of 50mm, 60mm, 72mm, 74mm, 80mm, etc., thus broadening its applicability. Furthermore, with a width of 50mm, the shaped insert 9 can move freely between the two inner surfaces 3 of the U-shaped groove, enabling rapid and smooth shaping of the shaped surface.

[0064] The height of the shaped insert 9 is n1, where n1 = 2m2;

[0065] The width of the slot 93 is t1, where t1 = t + 0.5 mm, and t is the thickness of the U-shaped groove molding block;

[0066] The distance of the adjustment space 94 is m3, where m3 = 1.5t.

[0067] In this embodiment, to reduce the weight of the manual shaping device, a weight-reducing hole 95 is provided in the middle of the shaping insert 9. Meanwhile, the total weight of the shaping device is ≤1.5Kg.

[0068] In this embodiment, in order to fix the U-shaped beam during the manual shaping process, the U-shaped beam manual shaping device also includes an auxiliary tooling 11. The auxiliary tooling 11 includes a base plate 111 and an L-shaped plate 112 that is detachably connected to the base plate 111 by screws. A fixing groove is formed between the L-shaped plate 112 and the base plate 111.

[0069] Specifically, a number of threaded holes are evenly provided on the base plate 111, and a number of threaded holes are provided at the bottom of the vertical end of the L-shaped plate 112. The base plate 111 and the L-shaped plate 112 are connected by screws passing through the threaded holes on the base plate 111 and the L-shaped plate 112, so that different sizes of L-shaped plates 112 can be replaced as needed to meet different usage requirements.

[0070] This device is used very frequently on the production site. Each aluminum alloy (stainless steel) grain hopper car requires about 24 U-shaped beams for shaping. The total weight of the shaping inserts and handles of the device used in the actual production process is 1.43 kg, which is comparable to the weight of a regular hand hammer. This will not increase the labor intensity of employees due to excessive weight.

[0071] Example 2

[0072] U-shaped beams mainly include thin-plate bent-shaped components such as side beams, end columns, columns, longitudinal beams, and support beams.

[0073] This embodiment describes the shaping of the U-shaped end column of the aluminum alloy grain hopper cart.

[0074] Please see Figure 4-7 13-16, A method for manually shaping thin U-shaped end posts of grain hopper carts, mainly including the following steps:

[0075] S1. Prepare a semi-finished product of thin plate U-shaped end column for grain funnel cart, the semi-finished product of U-shaped beam includes a shaped U-shaped beam body and U-shaped end column U-shaped groove molded block 1;

[0076] Please refer to Figure 4-7 In this step, the semi-finished product of thin-plate U-shaped end posts for grain funnel carts is prepared. The process flow is as follows:

[0077] (1) According to Figure 6 The finished product drawing of the parts is laid out and unfolded into a plan view, and a CAD program drawing is created, including tolerance processing, crack-resistant holes at the position of the bending line, and other details. Figure 4 ;

[0078] (2) Using CNC programming software, import the unfolded part drawings into the programming software, and automatically (with manual fine-tuning) generate the product. Figure 4 The laser cutting program shown;

[0079] (3) Laser cutting blanking: The cutting program is copied into the laser equipment using a dedicated USB flash drive. The equipment automatically runs according to the programmed sequence, direction, micro-connections, etc., cutting out blanks on the sheet material. Figure 4 Same semi-finished parts;

[0080] (4) Leveling: Most semi-finished parts have varying degrees of bending deformation after laser cutting, plasma cutting, or shearing, and need to be leveled on a dedicated leveling machine. Unleveled parts pose a significant quality risk, such as excessive flatness or dimensional deviations, when drilled, bent, or assembled (welded) with other parts in the next process.

[0081] (5) Folding and pressing: On specialized folding and pressing equipment, the leveled semi-finished parts are folded and pressed to become new semi-finished parts. Generally, this requires four folding and pressing operations. Figure 4 ① and ② represent the folding sequence on the same side, while ③ and ④ represent the sequence after folding ① and ②, where the workpiece is flipped over and folded again. After folding, the result is as follows: Figure 5 The molded U-shaped beam body and U-shaped end column U-shaped groove molded block 1 are shown.

[0082] in,

[0083] a1 is the spacing between the inner sides of the U-shaped end post and the U-shaped groove;

[0084] b1 is the net height of the U-shaped end column and U-shaped groove;

[0085] S2. Place the U-shaped beam body with the U-shaped groove opening facing downwards into the fixed groove of the auxiliary tooling 11. The U-shaped end column U-shaped groove forming block 1 is located on the outer side of the end of the base plate 111, facilitating manual forming operations. Figure 11 As shown;

[0086] S3. Insert the slot 93 of the U-shaped beam manual shaping device into the U-shaped end column U-groove shaping block 1, and turn the handle 10 clockwise to bend the U-shaped end column U-groove shaping block 1 along the arcs on both sides of the U-shaped end column U-groove facade 3, as shown. Figure 13 As shown;

[0087] Among them, the width of the U-shaped end post and U-shaped groove molding block 1 is m2 = 50mm.

[0088] S4. Continue to rotate handle 10 clockwise to make the U-shaped end post U-groove bending block 1 continue to bend along the arc of the U-shaped end post U-groove facade 3, and position weld the tangent point E2 between the U-shaped end post U-groove bending block 1 and the arcs on both sides of the U-shaped end post U-groove facade 3, as shown. Figure 15 As shown;

[0089] S5. Continue to rotate handle 10 clockwise to make the U-shaped end post U-groove bending block 1 continue to bend along the arc of the U-shaped end post U-groove facade 3, and position weld the tangent point E3 between the U-shaped end post U-groove bending block 1 and the arcs on both sides of the U-shaped end post U-groove facade 3. E3 is at the very end corner joint between the U-shaped end post U-groove bending block 1 and the arcs on both sides of the U-shaped end post U-groove facade 3. Figure 16 As shown;

[0090] S6. Complete the shaping and positioning welding, and remove the manual shaping device for the U-shaped beam;

[0091] S7. After the shaping is completed, the fillet weld is fully welded between the U-shaped end column and U-shaped groove shaping block 1 and the two arcs on both sides of the U-shaped end column and U-shaped groove facade 3.

[0092] In this embodiment, during step S3, when the U-shaped end post U-groove bending block 1 is bent along the arcs on both sides of the U-shaped end post U-groove facade 3, the tangent point E1 between the U-shaped end post U-groove bending block 1 and the arcs on both sides of the U-shaped end post U-groove facade 3 can be pre-welded to the tangent point E2 as needed. Figure 14 As shown. E1 is located 5mm in front of the middle of the U-shaped end post and U-shaped groove molding block 1, and E2 is located 5mm behind the middle of the U-shaped end post and U-shaped groove molding block 1.

[0093] Of course, the positions of E1 and / or E2 are not limited to 5mm in front and 5mm behind the middle of the U-shaped end column U-shaped groove molding block 1. They can be adjusted according to the actual construction situation. For example, E1 and / or E2 can be within 5 to 10mm of the middle of the arc on both sides of the U-shaped end column U-shaped groove molding block 1 and the U-shaped end column U-shaped groove facade 3.

[0094] In this embodiment, in step S6, before removing the manual shaping device for the U-shaped beam, the shaping insert 9 is finely adjusted, specifically as follows:

[0095] If the U-shaped groove is not fully formed and the teeth are misaligned, continue rotating the handle clockwise by 10 mm. This will reduce the size of the molded block and ensure a tight fit between the U-shaped groove molded block and the two side surfaces of the U-shaped groove.

[0096] When the U-shaped groove is over-molded and misaligned, rotate the handle counterclockwise by 10, and m3 will increase, making the U-shaped groove molding block fit tightly against the two sides of the U-shaped groove.

[0097] Example 3

[0098] U-shaped beams mainly include thin-plate bent-shaped components such as side beams, end columns, columns, longitudinal beams, and support beams.

[0099] This embodiment describes the shaping of the U-shaped support beam of the aluminum alloy grain hopper cart.

[0100] A method for manually shaping thin-plate U-shaped support beams for grain hopper carts mainly includes the following steps:

[0101] S1. Prepare a semi-finished product of a thin-plate U-shaped support beam for a grain funnel cart. The semi-finished product of the U-shaped support beam includes a shaped U-shaped beam body and a U-shaped channel molded block 5 for the U-shaped support beam.

[0102] Please refer to Figure 8-10 In this step, the semi-finished product of the thin-plate U-shaped support beam for the grain funnel cart is prepared. The process flow is as follows:

[0103] (1) According to Figure 10 The finished product drawings of the parts are laid out and unfolded into a plan view, and CAD program drawings are created, including tolerance handling, crack prevention gaps at the position of the folding line, and other details. Figure 8 ;

[0104] (2) Using CNC programming software, import the unfolded part drawings into the programming software, and automatically (with manual fine-tuning) generate the product. Figure 8 The laser cutting program shown;

[0105] (3) Laser cutting blanking: The cutting program is copied into the laser equipment using a dedicated USB flash drive. The equipment automatically runs according to the programmed sequence, direction, micro-connections, etc., cutting out blanks on the sheet material. Figure 8 Same semi-finished parts;

[0106] (4) Leveling: Most semi-finished parts have varying degrees of bending deformation after laser cutting, plasma cutting, or shearing, and need to be leveled on a dedicated leveling machine. Unleveled parts pose a significant quality risk, such as excessive flatness or dimensional deviations, when drilled, bent, or assembled (welded) with other parts in the next process.

[0107] (5) Folding and pressing: On specialized folding and pressing equipment, the leveled semi-finished parts are folded and pressed to become new semi-finished parts. Generally, this requires four folding and pressing operations. Figure 4 ① and ② represent the folding sequence on the same side, while ③ and ④ represent the sequence after folding ① and ②, where the workpiece is flipped over and folded again. After folding, the result is as follows: Figure 9 The molded U-shaped beam body and U-shaped support beam and U-shaped groove molded block 5 are shown.

[0108] in,

[0109] a2 is the spacing between the inner sides of the U-shaped groove of the U-shaped support beam;

[0110] b2 is the net height of the U-shaped support beam and U-shaped channel;

[0111] S2. Place the U-shaped groove of the formed U-shaped beam body with the opening facing downwards into the fixed groove of the auxiliary tooling 11. The U-shaped support beam U-shaped groove forming block 5 is located on the outer side of the end of the base plate 111, which facilitates manual forming operations. Figure 12 As shown;

[0112] S3. Insert the slot 93 of the U-shaped beam manual bending device into the U-shaped support beam U-shaped groove bending block 5, and turn the handle 10 clockwise to make the U-shaped support beam U-shaped groove bending block 5 bend along the arcs on both sides of the U-shaped support beam U-shaped groove vertical surface 7, and position weld the tangent point E1 between the U-shaped support beam U-shaped groove bending block 5 and the arcs on both sides of the U-shaped support beam U-shaped groove vertical surface 7, E1 is located 3mm in front of the middle of the U-shaped support beam U-shaped groove bending block 5;

[0113] Among them, the width m2 of the U-shaped support beam and the U-shaped groove of the shaped block 5 is 50mm.

[0114] S4. Continue to rotate the handle 10 clockwise to make the U-shaped support beam U-shaped groove bending block 5 continue to bend along the arc of the U-shaped support beam U-shaped groove vertical surface 7, and position weld the tangent point E2 between the U-shaped support beam U-shaped groove bending block 5 and the arc on both sides of the U-shaped support beam U-shaped groove vertical surface 7. E2 is located 4mm behind the middle of the U-shaped support beam U-shaped groove bending block 5.

[0115] S5. Continue to rotate the handle 10 clockwise to make the U-shaped support beam U-shaped groove bending block 5 continue to bend along the arc of the U-shaped support beam U-shaped groove vertical surface 7, and position weld the tangent point E3 between the U-shaped support beam U-shaped groove bending block 5 and the arc on both sides of the U-shaped support beam U-shaped groove vertical surface 7. E3 is at the end corner joint of the U-shaped support beam U-shaped groove bending block 5 and the arc on both sides of the U-shaped support beam U-shaped groove vertical surface 7.

[0116] S6. Complete the shaping and positioning welding, and remove the manual shaping device for the U-shaped beam;

[0117] Before removing the manual shaping device for the U-shaped beam, the shaping insert 9 is finely adjusted, specifically as follows:

[0118] If the U-shaped groove is not fully formed and the teeth are misaligned, continue rotating the handle clockwise by 10 mm. This will reduce the size of the molded block and ensure a tight fit between the U-shaped groove molded block and the two side surfaces of the U-shaped groove.

[0119] When the U-shaped groove is over-molded and misaligned, rotate the handle counterclockwise by 10, and m3 will increase, making the U-shaped groove molding block fit tightly against the two sides of the U-shaped groove.

[0120] S7. After the shaping is completed, the fillet weld between the U-shaped support beam U-shaped groove shaping block 5 and the U-shaped support U-shaped groove 7 on both sides of the vertical arc is fully welded.

[0121] In summary, the present invention features a simple structure, convenient manufacturing, low cost, high versatility, and lightweight design, facilitating manual operation. Furthermore, the molding process is easily controlled, preventing surface oil contamination and scratches, and allowing adjustment of the molding surface to prevent misalignment between the molding surface and the two sides of the U-shaped groove, thus effectively ensuring molding quality. Therefore, the present invention effectively overcomes the various shortcomings of existing technologies and possesses high industrial applicability.

[0122] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A method for manually shaping thin-plate U-shaped beams for grain hopper carts, employing a manual shaping device for thin-plate U-shaped beams for grain hopper carts, characterized in that, The device includes a detachably connected shaped insert (9) and a handle (10). The shaped insert (9) includes a main body, and the end of the main body away from the handle (10) protrudes outward to form an arc working surface (91). The radius of the arc working surface (91) is equal to the radius of the U-shaped beam shaped product. Horizontal blocks (92) are connected to the upper and lower ends of the main body of the insert. An adjustment space (94) is left between the suspended end of the upper horizontal block (92) and the arc top of the arc working surface (91). A groove (93) is formed between the lower horizontal block (92) and the arc working surface (91). The device also includes an auxiliary tooling (11), which includes a base plate (111) and an L-shaped plate (112) connected to the base plate (111). A fixing groove is formed between the L-shaped plate (112) and the base plate (111). The method includes the following steps: S1. Prepare a semi-finished product of a thin-plate U-shaped beam for a grain funnel cart, wherein the semi-finished product of the U-shaped beam includes a shaped U-shaped beam body and a U-shaped groove molding block; S2. Place the U-shaped groove of the formed U-shaped beam body with the opening facing downwards into the auxiliary tooling (11); S3. Insert the slot (93) of the U-shaped beam manual bending device into the U-shaped groove bending block, and turn the handle (10) clockwise to make the U-shaped groove bending block bend along the arcs on both sides of the U-shaped groove. During the bending process of the U-shaped groove bending block along the arcs on both sides of the U-shaped groove, position weld the tangent point E1 between the U-shaped groove bending block and the arcs on both sides of the U-shaped groove. S4. Continue to rotate the handle (10) clockwise to make the U-shaped groove bending block continue to bend along the arc of the U-shaped groove vertical surface, and position weld the tangent point E2 between the U-shaped groove bending block and the arc on both sides of the U-shaped groove vertical surface; S5. Continue to rotate the handle (10) clockwise to make the U-shaped groove bending block continue to bend along the arc of the U-shaped groove vertical surface, and position weld the tangent point E3 between the U-shaped groove bending block and the arc on both sides of the U-shaped groove vertical surface; S6. Complete the shaping and positioning welding, and remove the manual shaping device for the U-shaped beam; S7. After the shaping is completed, the fillet weld between the U-shaped groove shaping block and the arc on both sides of the facade is fully welded.

2. The method for manually shaping thin-plate U-shaped beams for grain hopper carts according to claim 1, characterized in that: The width of the shaped insert (9) is m2, m2≤a-30mm, where a is the maximum inner spacing of the U-shaped groove.

3. The method for manually shaping thin-plate U-shaped beams for grain hopper carts according to claim 1, characterized in that: The width of the slot (93) is t1, t1 = t + 0.5 mm, where t is the thickness of the U-shaped groove molded block.

4. The method for manually shaping thin-plate U-shaped beams for grain hopper carts according to claim 1, characterized in that: The distance of the adjustment space (94) is m3, m3=1.5t, where t is the thickness of the U-shaped groove molded block.

5. The method for manually shaping thin-plate U-shaped beams for grain hopper carts according to claim 1, characterized in that: E1 and / or E2 are located 5 to 10 mm from the center of the U-shaped groove molded block.

6. The method for manually shaping thin-plate U-shaped beams for grain hopper carts according to claim 1, characterized in that: E3 is located at the very end of the corner where the U-shaped groove block meets the arc on both sides of the U-shaped groove facade.

7. The method for manually shaping thin-plate U-shaped beams for grain hopper carts according to claim 1, characterized in that: In step S6, before removing the manual shaping device for the U-shaped beam, the shaping insert (9) is finely adjusted, specifically as follows: If the U-shaped groove is not fully formed and the teeth are misaligned, continue to rotate the handle (10) clockwise to ensure that the U-shaped groove forming block fits tightly against the two sides of the U-shaped groove. When the U-shaped groove is over-molded and the teeth are misaligned, rotate the handle (10) counterclockwise to make the U-shaped groove molding block fit tightly against the two sides of the U-shaped groove.

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