Supporting tool for tailor-welding of front side of frame of rail grinding wagon and process method for tailor-welding by adopting tool

Abstract

The invention provides a steel rail grinding wagon frame front face tailor-welding supporting tool and a tailor-welding process method adopting the tool, and belongs to the technical field of track engineering machinery manufacturing. Comprising a plurality of special supporting tools fixed to a tailor-welding platform in the length direction of a vehicle frame, and the special supporting tools comprise a vehicle frame center position supporting tool, a sleeper beam position supporting tool and a traction beam position supporting tool; the vehicle frame center position supporting tool is provided with a main beam supporting face and a side beam supporting face which are used for supporting a vehicle frame main beam and a side beam, and is further provided with a downward pressing mechanism used for pressing a beam body from the upper portion and a side pushing mechanism used for abutting against the beam body from the side direction. The sleeper beam position supporting tool is provided with a sleeper beam supporting face which is arranged according to the height of a frame sleeper beam and used for supporting the frame sleeper beam. The traction beam position supporting tool is provided with a traction beam supporting face which is arranged according to the height of the frame traction beam and used for supporting the frame traction beam. The positioning, supporting and fixing problems of the non-planar structure frame on the tailor-welding platform are effectively solved, and the tailor-welding precision and quality are guaranteed.

Description

Technical Field

[0001] This invention belongs to the field of rail engineering machinery manufacturing technology, specifically relating to a special support fixture for the front welding of the frame of a rail grinding vehicle and the welding process using the fixture. Background Technology

[0002] Rail grinding vehicles are crucial equipment in railway maintenance. Their frames, serving as the load-bearing foundation for the entire vehicle, are complex in structure and require high precision. The grinding vehicle frame typically consists of major components such as the traction beam, sleeper beam, main beam, and side beams. Unlike conventional railcar frames, these major components of the grinding vehicle frame are often not located in the same plane, forming a complex spatial structure.

[0003] Currently, mature welding processes exist for conventional planar frame structures, where beams are placed directly on a large cast iron welding platform, tack-fixed, and welded according to drawings. However, for non-planar frame structures with height differences between traction beams, bolster beams, main beams, and side beams, traditional platform welding methods cannot be directly applied. If traditional methods are used, the suspended beams cannot be stably positioned and supported, making it difficult to guarantee the relative positional accuracy between components. Furthermore, stress release during welding can easily lead to structural deformation, failing to meet the dimensional and geometric tolerance requirements of the frame. Therefore, a dedicated tooling and process method is urgently needed to solve the welding and manufacturing challenges of such complex spatial frame structures. Summary of the Invention

[0004] The technical problem solved by this invention is to provide a front welding support fixture for a rail grinding vehicle frame and a welding process using the fixture. The purpose of this invention is to overcome the shortcomings of the prior art and effectively solve the problems of positioning, supporting and fixing non-planar frame structures on the welding platform, ensuring welding accuracy and quality.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: The rail grinding vehicle frame front welding support fixture includes multiple special support fixtures fixed to the welding platform along the length of the frame. The special support fixtures include three types: frame center position support fixture, sleeper beam position support fixture and traction beam position support fixture. The frame center support fixture is provided with a main beam support surface and a side beam support surface for supporting the main beam and side beam of the frame, and is provided with a pressing mechanism for pressing the beam from above and a pushing mechanism for pressing the beam from the side. The bolster beam support fixture is provided with a bolster beam support surface that is set according to the height of the bolster beam of the vehicle frame to support it; The traction beam position support fixture is provided with a traction beam support surface that is set according to the height of the traction beam of the vehicle frame to support it. The frame center support fixture, the bolster beam support fixture, and the traction beam support fixture are arranged according to the spatial distribution of each beam of the frame, together forming a three-dimensional support system for supporting and positioning the non-planar frame assembly.

[0006] Further defining the above solution, the frame center support fixture includes a fixed base I, which is fixed to the welding platform by fixing screws I; vertical columns I are provided on both sides of the upper part of the fixed base I, and a horizontally arranged main beam support beam is fixed in the middle of the two columns I, the upper surface of the main beam support beam forming a main beam support surface for supporting the frame main beam; the lower part of the main beam support beam is supported on the fixed base I by the main beam support column; side beam support blocks are provided on the inner side of the two columns I and above the main beam support beam, the upper surface of the side beam support blocks forming a side beam support surface for supporting the frame side beam; a detachable downward pressure crossbeam is provided on the upper part of the two columns I; multiple downward pressure jacks are also provided, the upper end of the downward pressure jacks rests on the downward pressure crossbeam, and the lower end is used to press the main beam or side beam to form a downward pressure mechanism; a horizontal push jack is provided on the inner side of one of the columns I to form a side push mechanism for pressing the side beam.

[0007] Further defining the above solution, the bolster beam support fixture includes a fixed base II, which is fixed to the welding platform by fixing screws II; vertical columns II are provided on both sides of the upper part of the fixed base II, and bolster beam support columns are provided on the fixed base II. The bolster beam support columns are connected to the columns II through bolster beam connecting beams, and the upper end of the bolster beam support columns is provided with a side support plate for supporting the bolster beam.

[0008] Further defining the above scheme, the traction beam position support fixture includes a fixed base Ⅲ, which is fixed to the welding platform by fixing screws Ⅲ; the fixed base Ⅲ has vertical columns Ⅲ on both sides of its upper part, and the fixed base Ⅲ has traction beam support columns, which are connected to the columns Ⅲ through traction beam connecting beams to support the traction beam.

[0009] To further define the above scheme, the lower part of the side beam support block is reinforced by connecting it to the column I with reinforcing ribs.

[0010] As a further limitation of the above scheme, the two ends of the lower pressure beam pass through the square holes made at the upper end of the column I.

[0011] A method for welding the front of a rail grinding vehicle frame using the aforementioned support fixtures includes the following steps: S1: Welding the traction beam and the sleeper beam into a first assembly, and welding the two main beams into a second assembly via a process support beam; S2: Positioning and fixing multiple of the aforementioned special support fixtures onto the welding platform according to the frame design dimensions, ensuring that the right-side columns of each fixture are in a straight line; S3: Lifting the first assembly onto the sleeper beam support fixture and the traction beam support fixture, adjusting and positioning it, and pressing it firmly with jacks; S4: Lifting the second assembly onto the main beam support beam of the frame center support fixture, and welding it to the first assembly to form a whole; S5: Lifting the side beam onto the side beam support block of the frame center support fixture, adjusting the frame width, pressing it firmly from above with the downward jacks, pressing it firmly from the side with the horizontal push jacks, and tack-fixing the side crossbeam.

[0012] Advantages of this invention compared to existing technologies: 1. This solution solves the problem of non-planar structure welding: through customized chemical fittings, stable and reliable support and precise positioning are provided for beams of different heights, making front welding of complex spatial structure frames possible; 2. This solution improves welding accuracy and quality: the tooling ensures the relative positional accuracy of each component during the welding process, and the jack clamping function effectively controls welding deformation, ensuring that the key dimensions of the frame (such as frame width, center distance between bolster beams, etc.) meet the design requirements; 3. This solution improves production efficiency: The combination of modular pre-assembly (component welding) and systematic final assembly process reduces the time spent adjusting and welding large components at heights, reduces labor intensity, and improves production efficiency; 4. Versatility and Flexibility of this Solution: The tooling body is connected to the standard welding platform via T-bolts, facilitating easy installation and disassembly. One set of tooling can be used to manufacture multiple frames of the same model, offering excellent economic benefits. The tooling design concept can also provide a reference for the manufacturing of other similar complex structural components. 5. This solution has good safety: all components are welded on stable fixtures, avoiding the safety hazards caused by suspended components. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of the support fixture at the center of the vehicle frame of the present invention; Figure 2 This is a schematic diagram of the structure of the support fixture at the center position of the vehicle frame of the present invention without the pressing mechanism; Figure 3 This is a schematic diagram of the support fixture for the pillow beam position of the present invention; Figure 4This is a schematic diagram of the structure of the traction beam support fixture of the present invention; Figure 5 This is a schematic diagram showing the arrangement of the various tooling fixtures of the present invention on the welding platform; Figure 6 This is a structural diagram of the rail grinding vehicle frame.

[0014] (In the diagram: P - Welding platform; 1 - Support fixture at the center of the frame; 1-1 - Fixed base I; 1-2 - Fixing screw I; 1-3 - Column I; 1-4 - Main beam support beam; 1-5 - Main beam support column; 1-6 - Side beam support block; 1-7 - Reinforcing rib; 1-8 - Lowering crossbeam; 1-9 - Lowering jack; 1-10 - Process support beam; 1-11 - Horizontal push jack; 2 - Support fixture at the bolster beam position; 2- 1-Fixed base II; 2-2-Fixing screw II; 2-3-Column II; 2-4-Pillow beam support column; 2-5-Pillow beam connecting crossbeam; 2-6-Side bearing support plate; 3-Traction beam position support fixture; 3-1-Fixed base III; 3-2-Fixing screw III; 3-3-Column III; 3-4-Traction beam support column; 3-5-Traction beam connecting crossbeam; M-Main beam; S-Side beam; B-Pillow beam; D-Traction beam). Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0017] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0018] Please see Figure 1-6 The embodiments of the present invention are described in detail below.

[0019] Example: Welding support fixture for the front of the rail grinding vehicle frame, see reference. Figure 5 As shown, it includes multiple special support fixtures fixed to the welding platform P along the length of the vehicle frame. The special support fixtures include three types: vehicle frame center position support fixture 1, bolster beam position support fixture 2, and traction beam position support fixture 3.

[0020] See Figure 1 , Figure 2 As shown, the frame center position support fixture 1 is provided with a main beam support surface and a side beam support surface for supporting the main beam M and the side beam S of the frame, and is provided with a pressing mechanism for pressing the beam from above and a pushing mechanism for pressing the beam from the side.

[0021] For details, please refer to Figure 1 As shown, the frame center support fixture 1 includes a fixed base I1-1, which is fixed to the welding platform P by fixing screws I1-2. Vertical columns I1-3 are provided on both sides of the upper part of the fixed base I1-1. A horizontally arranged main beam support beam 1-4 is fixed in the middle of the two columns I1-3. The upper surface of the main beam support beam 1-4 forms a main beam support surface for supporting the frame main beam. The lower part of the main beam support beam 1-4 is supported on the fixed base I1-1 by main beam support columns 1-5. Side beam support blocks 1-6 are provided inside the two columns I1-3 and above the main beam support beam 1-4. The upper surface of the side beam support blocks 1-6 forms a side beam support surface for supporting the frame side beams. The lower part of the side beam support blocks 1-6 is connected and reinforced to the columns I1-3 by reinforcing ribs 1-7. The upper part of each of the two columns I1-3 is provided with a detachable downward pressure beam 1-8; both ends of the downward pressure beam 1-8 pass through square holes made at the upper end of the column I1-3. Multiple downward pressure jacks 1-9 are also provided, with the upper end of each jack abutting against the downward pressure beam 1-8, and the lower end used to press the main beam M or the side beam S, forming a downward pressure mechanism; a horizontal push jack 1-11 is provided on the inner side of one side of the column I1-3, forming a side push mechanism for pressing the side beam S.

[0022] See Figure 3As shown, the bolster beam position support fixture 2 is provided with a bolster beam support surface that is set according to the height of the bolster beam B of the frame. Specifically, the bolster beam position support fixture 2 includes a fixed base II2-1, which is fixed to the welding platform P by fixing screws II2-2. The fixed base II2-1 has vertical columns II2-3 on both sides of its upper part, and a bolster beam support column 2-4 is provided on the fixed base II2-1. The bolster beam support column 2-4 is connected to the column II2-3 through a bolster beam connecting beam 2-5. The upper end of the bolster beam support column 2-4 is provided with a side support plate 2-6 for supporting the bolster beam B.

[0023] See Figure 4 As shown, the traction beam position support fixture 3 is provided with a traction beam support surface that is set according to the height of the traction beam D of the vehicle frame. Specifically, the traction beam position support fixture 3 includes a fixed base Ⅲ3-1, which is fixed to the welding platform P by fixing screws Ⅲ3-2. The fixed base Ⅲ3-1 has vertical columns Ⅲ3-3 on both sides of its upper part, and a traction beam support column 3-4 is provided on the fixed base Ⅲ3-1. The traction beam support column 3-4 is connected to the column Ⅲ3-3 through a traction beam connecting beam 3-5, and is used to support the traction beam D.

[0024] The frame center support fixture 1, the bolster beam support fixture 2, and the traction beam support fixture 3 are arranged according to the spatial distribution of each beam of the frame, and are firmly installed on a universal welding platform through the bottom seat plate and T-bolts, together forming a three-dimensional support system for supporting and positioning the non-planar frame assembly.

[0025] Example 2: A method for welding the front side of a rail grinding vehicle frame using the above-mentioned support fixture, comprising the following steps: First, based on the chassis design drawings, manufacture the various specialized support fixtures (1, 2, 3). The main body of the fixtures is constructed by welding together profiles such as 30# and 20# channel steel to ensure sufficient strength and rigidity. The height and position of each support surface and positioning surface must be machined strictly according to the dimensions in the drawings.

[0026] Then, on the large cast iron welding platform P, the installation positions of each tooling are determined along the length of the chassis. For example... Figure 5 As shown, nine support fixtures are typically placed at key locations such as the center of the frame, 3.5mm to either side of the centerline, the center of the bolster beam, and the traction beam. T-bolts are used to secure the base plates of each fixture to the T-slots of platform P. During installation, a string line must be used to calibrate the right-side uprights (I) of all the support fixtures at the center of the frame, ensuring they are on the same straight line with a straightness deviation of no more than ±2mm, thus guaranteeing the frame's width reference.

[0027] After the tooling is installed, the frame welding begins: 1. Weld the traction beam D and the bolster beam B into the first assembly, and weld the two main beams M into the second assembly through the process support beams 1-10. This facilitates the overall hoisting and welding to ensure dimensional requirements (there is a connecting plate between the two main beams. If the two main beams are placed on the support tooling and then the connecting plate in the middle is welded, the construction will be difficult due to the high placement height of the main beams and the large number of unsupported positions at the bottom. Therefore, the two main beams and the connecting plate in the middle are welded into a whole first, and then hoisted onto the support tooling).

[0028] 2. Hoist the pre-welded bolster-traction beam assembly (first assembly) and place its two ends on the corresponding bolster beam support fixture and traction beam support fixture, respectively. According to process requirements, the required height difference (e.g., 5mm) can be shims at the support points, and allowance should be made for welding shrinkage along the length (e.g., 10-15mm). After accurate positioning, use jacks or additional tools on the fixtures to tighten and secure it.

[0029] 3. Hoist the pre-welded main beam-connecting plate assembly (second assembly) and place it smoothly onto the main beam support beam of the support fixture at the center of the vehicle frame. Then assemble and spot weld this second assembly to the already fixed first assembly.

[0030] 4. Hoist the left and right beams S and place them on the side beam support blocks of the support fixture at the center of each frame. Position the right beam close to the calibrated right side column I, then adjust the position of the left beam to ensure the frame width meets the design requirement of 3100(0,+4)mm. Install the lower crossbeams, using a lower jack to press down on each main beam and side beam from above, and using a horizontal push jack to press down on the left beam from the side to prevent movement. Finally, spot weld the side crossbeams in place. 5. After tack welding of all components is completed, formal welding can be carried out according to the welding process specifications to form a complete frame structure. This invention uses a series of specialized tooling to construct a three-dimensional support and positioning system on a two-dimensional welding platform, matching the frame design. Each tooling is responsible for supporting a specific part of the frame and ensuring it is in the correct three-dimensional spatial coordinates. Using clamping mechanisms such as jacks, thermal stress and deformation tendencies during welding are overcome, firmly fixing the components in the preset positions, thus ensuring that the final welded frame assembly has high precision and good geometric shape. The modular pre-assembly strategy transfers some welding work to the ground or low altitude, simplifying the operational complexity of final assembly, improving overall manufacturing efficiency and quality reliability, and effectively reducing the difficulty and deformation risk of high-altitude operations.

[0031] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0032] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A front welding support fixture for the frame of a rail grinding vehicle, characterized in that: It includes multiple special support fixtures fixed on the welding platform (P) along the length of the frame. The special support fixtures include three types: frame center position support fixture (1), bolster beam position support fixture (2) and traction beam position support fixture (3). The frame center position support fixture (1) is provided with a main beam support surface and a side beam support surface for supporting the main beam (M) and the side beam (S) of the frame, and is provided with a pressing mechanism for pressing the beam from above and a pushing mechanism for pressing the beam from the side. The bolster beam support fixture (2) is provided with a bolster beam support surface that is set according to the height of the bolster beam (B) of the frame to support it; The traction beam position support fixture (3) is provided with a traction beam support surface that is set according to the height of the traction beam (D) of the vehicle frame to support it; The frame center support fixture (1), the bolster beam support fixture (2), and the traction beam support fixture (3) are arranged according to the spatial distribution of each beam of the frame, and together form a three-dimensional support system for supporting and positioning the non-planar frame assembly.

2. The rail grinding vehicle frame front welding support fixture according to claim 1, characterized in that: The frame center support fixture (1) includes a fixed base I (1-1), which is fixed to the welding platform (P) by fixing screws I (1-2); the fixed base I (1-1) has vertical columns I (1-3) on both sides of its upper part, and a horizontally arranged main beam support beam (1-4) is fixed in the middle of the two columns I (1-3). The upper surface of the main beam support beam (1-4) forms a main beam support surface for supporting the frame main beam; the lower part of the main beam support beam (1-4) is supported on the fixed base I (1-1) by a main beam support column (1-5); the two columns I (1-3) Inside the main beam support beam (1-4), a side beam support block (1-6) is provided. The upper surface of the side beam support block (1-6) forms a side beam support surface for supporting the side beam of the frame. The upper part of the two columns I (1-3) is provided with a detachable downward pressure crossbeam (1-8). Multiple downward pressure jacks (1-9) are also provided. The upper end of the downward pressure jack (1-9) rests on the downward pressure crossbeam (1-8), and the lower end is used to press the main beam (M) or the side beam (S) to form a downward pressure mechanism. A horizontal push jack (1-11) is provided inside the column I (1-3) on one side to form a side push mechanism for pressing the side beam (S).

3. The rail grinding vehicle frame front welding support fixture according to claim 1, characterized in that: The bolster beam support fixture (2) includes a fixed base II (2-1), which is fixed to the welding platform (P) by fixing screws II (2-2); the fixed base II (2-1) has vertical columns II (2-3) on both sides of the upper part, and bolster beam support columns (2-4) are provided on the fixed base II (2-1). The bolster beam support columns (2-4) are connected to the columns II (2-3) through bolster beam connecting beams (2-5). The upper end of the bolster beam support columns (2-4) is provided with a side support plate (2-6) for supporting the bolster beam (B).

4. The rail grinding vehicle frame front welding support fixture according to claim 1, characterized in that: The traction beam position support fixture (3) includes a fixed base Ⅲ (3-1), which is fixed to the welding platform (P) by fixing screws Ⅲ (3-2); the fixed base Ⅲ (3-1) has vertical columns Ⅲ (3-3) on both sides of the upper part, and the fixed base Ⅲ (3-1) has traction beam support columns (3-4), which are connected to the column Ⅲ (3-3) through the traction beam connecting crossbeam (3-5) to support the traction beam (D).

5. The rail grinding vehicle frame front welding support fixture according to claim 2, characterized in that: The lower part of the side beam support block (1-6) is reinforced by connecting the column I (1-3) with the reinforcing rib (1-7).

6. The rail grinding vehicle frame front welding support fixture according to claim 2, characterized in that: The two ends of the lower pressure beam (1-8) are inserted into the square holes made at the upper end of the column I (1-3).

7. A method for fabricating a rail grinding vehicle frame using the support fixture described in any one of claims 1-6, characterized in that: Includes the following steps: S1: Weld the traction beam (D) and the bolster beam (B) into a first assembly, and weld the two main beams (M) into a second assembly via process support beams (1-10); S2: Position and fix multiple special support fixtures according to the frame design dimensions onto the welding platform (P), ensuring that the right-side uprights of each fixture are in a straight line; S3: Hoist the first assembly onto the bolster beam position support fixture (2) and the traction beam position support fixture (3) and adjust their positioning, using a thousand S4: Hoist the second assembly onto the main beam support beam (1-4) of the frame center support fixture (1) and weld it together with the first assembly; S5: Hoist the side beam (S) onto the side beam support block (1-6) of the frame center support fixture (1), adjust the frame width, use the downward jack (1-9) to press and fix it from the top, use the horizontal push jack (1-11) to press and fix it from the side, and fix the side beam.

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