Method for processing a bed frame structure

Abstract

This invention relates to the field of metal structure welding technology, and more particularly to a method for processing a bed frame structure. The method involves cutting tubing according to design drawings; positioning the cut tubing using tooling to prepare for welding; and providing two sets of through holes on the side of the connection between the side beam and the crossbeam, corresponding to the installation position at one end of each crossbeam, each set including two through holes forming a strain bridge. The processing method includes: attaching strain gauges to the inner wall of the hollow cavity of the side beam at the positions corresponding to the strain bridges; spot welding positioning the crossbeam at four points on the strain bridges at both ends of the crossbeam along its length; releasing the tooling from the crossbeam after welding; monitoring the data of each strain gauge; and performing full welding at the connection between the side beam and the crossbeam when the data conditions are met. This invention effectively prevents hidden torsional deformation at the connection between the crossbeam and the side beam after spot welding, thereby avoiding problems such as diagonal deviations and abnormal noises caused by subsequent full welding curing defects.

Description

Technical Field

[0001] This invention relates to the field of metal structure welding and processing technology, and in particular to a method for processing a bed frame structure. Background Technology

[0002] In the existing bed frame manufacturing method, the first step is to cut the tubing into sections of the required length according to the dimensions in the drawings. During the welding and assembly process, the cut and shaped parts are initially positioned and fixed on the welding fixture by spot welding, and then the welding is carried out automatically and securely.

[0003] In the above process, spot welding followed by full welding can reduce the probability of obtaining defective products with distortion or out-of-tolerance dimensions. In the manufacturing of iron bed frames, the implicit torsional deformation after spot welding of tubing is a common problem leading to poor product consistency, as detailed below:

[0004] During spot welding, uneven release of thermal stress causes invisible torsional deformation inside the pipe, which cannot be detected by traditional calipers. The minute torsion in the spot welding stage is solidified in the subsequent full welding, eventually leading to structural defects such as "diagonal deviation" or "uneven legs" when the whole bed is assembled. Summary of the Invention

[0005] This invention provides a method for processing a bed frame structure, which can effectively solve the problems in the background art.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] A method for processing a bed frame structure involves cutting tubing according to design drawings and positioning the cut tubing using tooling to prepare for welding.

[0008] The bed frame structure includes side beams on both sides and at least two crossbeams connecting the side beams. The side beams are hollow, and the inner and outer contours of the crossbeams are both hollow rectangles. The outer contour of the crossbeams is rectangular. On the side where the side beams connect to the crossbeams, two sets of through holes are provided corresponding to the installation position at one end of each crossbeam. Each set includes two through holes forming a strain bridge between them. The two strain bridges are located on both sides of one end of the crossbeam and are used as spot welding positions for the side beams and crossbeams.

[0009] Processing methods include:

[0010] Strain gauges are attached to the hollow cavity inner wall of the side beam at the positions corresponding to the strain bridge.

[0011] At both ends of the crossbeam along its length, four-point spot welding is performed on the strain bridge to position the crossbeam. After welding is completed, the tooling is released from positioning the crossbeam.

[0012] Monitor the data of each strain gauge, and when the data conditions are met, perform full welding at the connection position of the side beam and the cross beam.

[0013] Furthermore, the fully welded cladding zone covers the strain bridge and the through hole.

[0014] Furthermore, the strain gauge is attached and fixed to the inner wall of the hollow cavity of the side beam.

[0015] Furthermore, the through hole is a waist-shaped hole, and the length of the waist-shaped hole is set along the length direction of the side beam.

[0016] Furthermore, the strain bridges on both sides of one end of the crossbeam correspond to the center position of the edge of the crossbeam.

[0017] Furthermore, the data conditions include:

[0018] The monitored values ​​of the four strain gauges corresponding to each of the beams are all within a first set range, and the variance between the four monitored values ​​is within a second set range.

[0019] Furthermore, the data conditions include:

[0020] Within a set time range, the variance of the rate of change of the real-time data of the four strain gauges is within a third set range.

[0021] Furthermore, the tooling includes an object detection device, which performs detection at least before the tooling is released from positioning of the crossbeam, and both the release from positioning and full welding are performed when the detection result shows that no object is near the predetermined range around the tooling.

[0022] Furthermore, the spacing between the through holes in the same group is 5-15mm.

[0023] Furthermore, compressed air is introduced into the interior of the side beam, and the compressed air flow time covers the spot welding process and the strain gauge data monitoring process.

[0024] Furthermore, the compressed air circulates in a vortex pattern.

[0025] The technical solution of this invention can achieve the following technical effects:

[0026] This invention effectively prevents hidden torsional deformation at the connection between the crossbeam and the side beam after spot welding, thus avoiding problems such as diagonal deviations and abnormal noises caused by defects after full welding and curing. During implementation, a temporary sensor structure is obtained through a combination of strain bridges and strain gauges during the spot welding stage. Each crossbeam is fixed relative to the side beam at two spot welding positions at both ends, and the four strain bridges represent the actual beam connection points. Given their relatively small cross-sectional dimensions, they possess more sensitive deformation sensing capabilities, enabling real-time capture of torsional data and achieving quality assessment before full welding. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a structural diagram illustrating how the bed frame structure is fixed using tooling.

[0029] Figure 2 A top view showing the bed frame structure being fixed using tooling;

[0030] Figure 3 This is a top view of the bed frame structure;

[0031] Figure 4 This is a partial schematic diagram of a bed frame structure, showing the different shapes of through holes and the locations of spot welds.

[0032] Figure 5 A partial schematic diagram of the bed frame structure to show the location of the strain gauges;

[0033] Figure 6 A schematic diagram illustrating the process of spot welding to full welding of the bed frame structure;

[0034] Figure 7 This is a flowchart of the bed frame structure manufacturing process.

[0035] Reference numerals: 01, side beam; 011, side surface; 012, through hole; 013, strain bridge; 014, spot weld; 02, crossbeam; 03, tooling; 031, transverse extrusion point; 032, longitudinal extrusion point; 033, limiting point; 04, strain gauge. Detailed Implementation

[0036] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0037] like Figure 1-6 As shown, a method for processing a bed frame structure involves first cutting the tubing according to the design drawings; then positioning the cut tubing using tooling 03 to prepare for welding.

[0038] In this embodiment, the bed frame structure includes side beams 01 on both sides and at least two crossbeams 02 connecting the side beams 01 on both sides. The side beams 01 are hollow and the inner and outer contours of the cross section are both hollow rectangles. The outer contour of the cross section of the crossbeams 02 is rectangular. On the side 011 where the side beams 01 and the crossbeams 02 are connected, two sets of through holes 012 are provided corresponding to the installation position at one end of each crossbeam 02. Each set includes two through holes 012 that form a strain bridge 013 between them. The two strain bridges 013 are located on both sides of one end of the crossbeam 02 and are used as spot welding positions for the side beams 01 and the crossbeams 02.

[0039] like Figure 7 As shown, the processing method includes:

[0040] S1: Install strain gauge 04 on the inner wall of the hollow cavity of the side beam 01 at the position corresponding to strain bridge 013;

[0041] S2: At both ends of the crossbeam 02 along its length, perform four-point spot welding positioning on the strain gauge bridge 013, as follows: Figure 4 As shown, the location of spot weld 014 is displayed. After welding is completed, the tooling 03 is released from positioning the crossbeam 02.

[0042] S3: Monitor the data of each strain gauge 04. When the data conditions are met, perform full welding at the connection position of the side beam 01 and the cross beam 02.

[0043] This invention effectively prevents hidden torsional deformation at the connection between the crossbeam 02 and the side beam 01 after spot welding, thereby avoiding problems such as diagonal deviation and abnormal noise caused by defects after full welding curing. During implementation, a temporary sensor structure is obtained through a combination of strain bridges 013 and strain gauges 04 during the spot welding stage. Each crossbeam 02 is fixed relative to the side beam 01 at two spot welding positions at both ends. The four strain bridges 013 serve as the actual beam connection positions. Given their relatively small cross-sectional dimensions, they possess more sensitive deformation sensing capabilities, enabling real-time capture of torsional data and achieving quality judgment before full welding.

[0044] The design of the hollow side beam 01 creates a thermal partition between the installation position of the strain gauge 04 on the inner wall and the spot welding position on the outer wall. Data monitoring time can be controlled within 5 minutes, effectively reducing the thermal impact on the strain gauge 04. The tube wall naturally isolates welding spatter, preventing contamination of the strain gauge 04. After data monitoring is completed, the strain gauge 04 can be removed or retained inside the side beam 01. In this application, even if the strain gauge 04 is retained on the inner wall of the side beam 01, it will not affect the aesthetics of the product. Specifically, in this embodiment, the strain gauge 04 is used as a consumable and retained on the inner wall of the side beam 01; its service life at high temperatures only needs to be controlled within the aforementioned 5 minutes.

[0045] See details Figure 1-5 As a specific implementation, this embodiment illustrates a configuration with two side beams 01 and three crossbeams 02, where one crossbeam 02 is located at the foot of the bed and two crossbeams 02 are located at the head of the bed. This configuration is not intended to limit the scope of this invention. During the use of the bed frame structure, the side beams 01 primarily bear the impact bending moment from the human body sitting on it, while the crossbeams 02 bear the uniformly distributed load of the bed board. The joints between the side beams 01 and the crossbeams 02 often need to withstand combined bending and torsional stresses, thus representing a focus of this invention.

[0046] For tooling structure 03, it often includes, for example Figure 1 and 2 The following structures are shown;

[0047] The transverse extrusion point 031 applies extrusion force to the tube from both sides in parallel with the extension direction of the bed frame, and has a dynamic structure.

[0048] The longitudinal extrusion point 032 applies extrusion force perpendicularly to the extension direction of the bed frame, and has a dynamic structure.

[0049] Limit point 033 only limits the pipe material through the tank body, etc., and does not have a power structure.

[0050] The above positioning methods can be flexibly selected according to the actual bed frame structure. In this embodiment, a combined positioning method of transverse pressing point 031 and longitudinal pressing point 032 is used for the side beam 01; the positioning method of transverse pressing point 031 is used only for the crossbeam 02 at the end of the bed. In this case, after welding is completed, releasing the tooling 03 from the positioning of the crossbeam 02 is to release the pressing force of the transverse pressing point 031; the two crossbeams 02 at the head of the bed are positioned by a combined positioning method of limiting point 033 and longitudinal pressing point 032. In this case, after welding is completed, releasing the tooling 03 from the positioning of the crossbeam 02 is to release the pressing force of the longitudinal pressing point 032. Since the limiting point 033 is often clearance fit with the pipe, the torsion of the crossbeam 02 can be manifested even without pressing force.

[0051] Monitor the data of each strain gauge 04. If the data conditions are not met, troubleshooting can be carried out according to the actual situation, including but not limited to pipe material inspection, tooling quality inspection, and welding parameter adjustment. When the data conditions are not met, it is often necessary to separate the crossbeam 02 from the side beam 01. This process can be carried out directly on the tooling 03, maintaining the positioning of the side beam 01 on the tooling 03 while releasing the positioning of the crossbeam 02. Since the welding area of ​​the spot weld 014 is limited, separation is relatively easy to achieve.

[0052] As a preferred embodiment of the above, such as Figure 6 As shown, the fully welded cladding zone covers the strain bridge 013 and the through hole 012; in this way, zero-cost structural restoration can be achieved. The hole is filled with welding material. The surface tension of the molten welding material is relatively low. Under the action of gravity and arc blowing force, it spontaneously penetrates into the through hole 012. The high temperature of the molten pool causes the base material at the edge of the hole to melt slightly, forming a diffusion metallurgical bonding layer.

[0053] As one method of fixing the strain gauge 04, the strain gauge 04 is glued and fixed to the inner surface of the side beam 01. This method can reduce the distortion of strain transmission and is also convenient to operate. In specific installation, the strain gauge 04 with adhesive material can be fixed by a rod-like structure. By moving the rod-like structure into the hollow cavity of the side beam 01, the strain gauge 04 is transferred to the position corresponding to the strain bridge 013, and then pressure bonding is applied. Specifically, the movement position of the strain gauge 04 can be controlled by pre-setting the movement trajectory. This method can be implemented by a predetermined program. Alternatively, a camera and a light can be installed at the end of the rod-like structure, and the final position can be determined by image recognition during the movement of the rod-like structure. All of the above methods are within the protection scope of this invention, and the specific implementation can be selected comprehensively based on factors such as processing equipment and cost.

[0054] As a preferred embodiment of the above, the through hole 012 is a waist-shaped hole, and the length direction of the waist-shaped hole is set along the length direction of the side beam 01. For example Figure 4 As shown, two magnified views illustrate two cases where the through hole 012 is a round hole and an oblong hole, respectively. The round hole is easier to process, but compared to the oblong hole, the strain bridge 013 can obtain a bridge structure that is more conducive to the installation of strain gauges 04 and adapts to torsional changes, thereby improving the sensitivity of data monitoring.

[0055] As a preferred embodiment of the above, the strain bridges 013 on both sides of one end of the crossbeam 02 correspond to the center position of the edge of the crossbeam 02, thereby maintaining symmetry. Through symmetrical data acquisition, monitoring noise can be reduced, and the influence of spot welding can also be largely self-balanced.

[0056] As a preferred embodiment of the above, the data conditions include:

[0057] The monitoring values ​​of the four strain gauges 04 corresponding to each crossbeam 02 are all within the first set range, and the variance between the four monitoring values ​​is within the second set range. The first set range and the second set range can be set according to experiments or operator experience, and can also be finely adjusted during operation to be more suitable for actual working conditions.

[0058] Regarding the two conditions in the above embodiment, the former ensures that the results monitored by each strain gauge 04 are at an acceptable absolute level, verifying whether the overall deformation of the end of the crossbeam 02 after welding exceeds the safety threshold; the latter ensures that the readings of the four strain gauges 04 are close to each other and evenly distributed, verifying whether the deformation of the end of the crossbeam 02 after welding is uniform and symmetrical, and identifying whether unexpected unilateral bending or twisting has occurred; the qualified state determined by both is more reliable.

[0059] As another implementation method, the data conditions include:

[0060] Within a set time range, the variance of the rate of change of the real-time data from the four strain gauges (04) falls within a third set range. This real-time dynamic capability is achieved through multiple data acquisitions. Similar to the implementation method described above, the specific acquisition frequency and the third set range in this implementation can be set based on experiments or operator experience, and can be finely adjusted during operation to better suit actual working conditions.

[0061] This approach changes the judgment method based on static results to a dynamic monitoring method within a set time period, which can ensure uniform and stable thermodynamic behavior. By selecting a reasonable time range, the entire process from thermal expansion to cooling and contraction can be effectively monitored, further improving the final product quality.

[0062] As a preferred embodiment of the above, the tooling 03 includes an object detection device. The object detection device performs detection at least before the tooling 03 releases its positioning of the crossbeam 02, and both the release of positioning and full welding are performed when the detection result shows that no object is near a predetermined range around the tooling 03. The following is an example description of the object detection implementation method, which can be selected as needed during implementation:

[0063] (1) The object detection device can build a three-dimensional digital twin model of the tooling area in real time by scanning 100,000 to 200,000 point cloud per second. Specifically, it can perform scanning work by installing a 3D-ToF laser radar on the tooling, and automatically classify object types such as people, equipment, and spatter by combining deep learning algorithms. It can also predict collision risks by combining welding trajectory. In this way, it can achieve an emergency stop response within 0.2 seconds for personnel who suddenly break in.

[0064] (2) The object detection device can simultaneously capture the outline of visible light objects and thermal radiation characteristics through a dual-spectrum thermal imager deployed on the tooling frame, automatically release known tools by comparing them with the bill of materials through AI, and quickly respond to intruders, etc.

[0065] (3) The object detection device can monitor objects by linking with the active positioning tags equipped by personnel or equipment through the UWB base station array deployed on the tooling frame, forming a digital fence, thereby dynamically isolating the welding gun working area and quickly responding to objects that intrude into the digital fence.

[0066] In this preferred embodiment, the inclusion of an object detection device ensures safety when the tooling is released from positioning the crossbeam, as the four spot welds may be affected by torque. Even better, the object detection device can begin operating before the tooling positions all the pipes; for example, the device can activate 5 seconds before the tooling positions the pipes, creating protection covering the entire tooling operation cycle. This device makes the welding process more intelligent and safer, enabling rapid response to risks such as personnel intrusion and equipment boundary violations based on real-time spatial awareness of the warning zone. Ultimately, through undisturbed welding environment control, it ensures that strain gauge monitoring data remains undisturbed.

[0067] In the specific implementation process, specific working conditions can be set based on the test results, for example:

[0068] The triggering conditions for tooling release positioning and full welding action are: no object intrusion is detected within the warning zone around tooling 03 for 2 consecutive seconds, and the range of the warning zone can be specifically set according to the actual production space.

[0069] As a preferred embodiment of the above, the spacing between the through holes 012 in the same group is 5-15mm, thereby ensuring that the strain gauge 04 obtains an effective installation position.

[0070] In the above embodiments, although the measurement can be completed within the lifespan of the strain gauge 04 by reasonably controlling the data monitoring time, the temperature rise caused by spot welding may also affect the data monitoring. In order to solve this problem, as a preferred embodiment, compressed air is introduced into the side beam 01, and the compressed air circulation time covers the spot welding process and the data monitoring process of the strain gauge 04.

[0071] In this preferred embodiment, by continuously introducing compressed air into the interior of the side beam 01, a dynamic thermal isolation barrier can be constructed during the cooling process, ensuring that the temperature of the strain gauge 04 substrate remains within an acceptable range, thereby reducing the risks of adhesive layer carbonization, zero-point drift, and other issues caused by spot welding temperature. The compressed air is a room-temperature gas and will not affect the spot welding process during implementation. Its main function is to affect the inner surface temperature of the strain gauge 04 attached to the side beam 01, thus ensuring the accuracy of the monitoring process.

[0072] To prevent compressed air from flowing out of the through hole 012 and affecting the spot welding process, as a preferred embodiment, the compressed air flows in a vortex pattern. This method can be achieved by setting a spiral guide structure at the outlet of the air duct, which generates axial swirling force in the airflow. Combined with the control of the air supply pressure, this can minimize or completely prevent the compressed air from flowing out of the through hole 012. In practice, the cost of obtaining compressed air is low, and it can be freely discharged from the other end of the side beam 01. By increasing the gas flow, the relative stability of the temperature at the installation position of the strain gauge 04 can be maintained, thereby improving the accuracy of monitoring.

[0073] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A method for processing a bed frame structure, comprising cutting tubing according to design drawings; positioning the cut tubing using tooling to prepare for welding; Its features are, The bed frame structure includes side beams on both sides and at least two crossbeams connecting the side beams. The side beams are hollow, and the inner and outer contours of the crossbeams are both hollow rectangles. The outer contour of the crossbeams is rectangular. On the side where the side beams connect to the crossbeams, two sets of through holes are provided corresponding to the installation position at one end of each crossbeam. Each set includes two through holes forming a strain bridge between them. The two strain bridges are located on both sides of one end of the crossbeam and are used as spot welding positions for the side beams and crossbeams. Processing methods include: Strain gauges are attached to the hollow cavity inner wall of the side beam at the positions corresponding to the strain bridge. At both ends of the crossbeam along its length, four-point spot welding is performed on the strain bridge to position the crossbeam. After welding is completed, the tooling is released from positioning the crossbeam. Monitor the data of each strain gauge, and when the data conditions are met, perform full welding at the connection position of the side beam and the cross beam; The fully welded cladding zone covers the strain bridge and the through hole; The data conditions include: The monitored values ​​of the four strain gauges corresponding to each of the crossbeams are all within a first set range, and the variance between the four monitored values ​​is within a second set range; within a set time range, the variance of the real-time data change rate of the four strain gauges is within a third set range.

2. The processing method for the bed frame structure according to claim 1, characterized in that, The strain gauge is attached and fixed to the inner wall of the hollow cavity of the side beam.

3. The processing method for the bed frame structure according to claim 1, characterized in that, The through hole is a waist-shaped hole, and the length of the waist-shaped hole is set along the length of the side beam.

4. The processing method of the bed frame structure according to claim 1, characterized in that, The strain bridges on both sides of one end of the crossbeam correspond to the center position of the edge of the crossbeam.

5. The processing method of the bed frame structure according to claim 1, characterized in that, The tooling includes an object detection device, which performs detection at least before the tooling is released from positioning of the crossbeam, and both the release from positioning and full welding are performed when the detection result shows that no object is near the predetermined range around the tooling.

6. The processing method of the bed frame structure according to claim 1, characterized in that, Compressed air is introduced into the side beam, and the compressed air flow time covers the spot welding process and the strain gauge data monitoring process.

7. The processing method of the bed frame structure according to claim 6, characterized in that, The compressed air flows in a vortex pattern.

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