Moving tool for assembling top cover of air conditioner module unit

Abstract

The invention provides a moving tool for assembling a top cover of an air conditioner module unit, and relates to the technical field of air conditioner production. The moving tool for assembling the top cover of the air conditioner module unit comprises a base and a bearing operation assembly; a moving assembly is arranged on the base, and the moving assembly is used for moving the base; the bearing operation assembly is arranged on the base and used for bearing the top cover. The bearing operation assembly comprises a middle supporting piece and a plurality of supporting frames. The multiple supporting frames are arranged at intervals in the length direction of the base, a bearing area is defined by the multiple supporting frames together, and at least one supporting frame is hollowed out; the middle supporting piece is arranged on the base and located in the bearing area, and the middle supporting piece is used for supporting the middle of the top cover. The problems that in the prior art, the assembling precision is low due to the fact that the top cover bearing stability is poor, the assembling efficiency is low due to the fact that the working space is limited, the transferring risk is high, and rhythm production cannot be achieved are solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of air conditioner production, and in particular to a mobile tool for assembling a top cover of an air conditioner module. BACKGROUND

[0002] In the production process of an air conditioner module, the fan top cover is a key component with a large size and a relatively complex structure, and the assembly quality of the fan top cover directly affects the performance and reliability of the entire machine. A plurality of components such as a stand and a cross beam need to be pre-assembled on the top cover to form a complete top cover assembly, and then the top cover assembly is transferred to an assembly line.

[0003] At present, the industry generally adopts a traditional manual carrying method combined with a simple platform or a general flat pallet to perform the pre-assembly process of the top cover. However, the traditional method has the following problems:

[0004] 1. Poor stability, affecting assembly accuracy. The air conditioner top cover is usually a large thin plate structure with a certain span. When the top cover is carried manually or placed on an ordinary flat pallet, the middle region of the top cover is prone to deflection and deformation due to its own weight because of the lack of targeted and effective support. In this deformed state, the pre-assembly of components will cause deviations in the relative positions of the components, uneven assembly stress, and serious impact on the final assembly accuracy and quality consistency.

[0005] 2. Limited working space, assembly efficiency and quality difficult to guarantee. When the top cover is placed on a solid working platform or a flat pallet, the platform or the pallet itself will physically interfere with the work of the operator. The operator's arms and tightening tools cannot easily reach the side or specific areas of the top cover, making it difficult to install and tighten the torque of components such as the stand and the cross beam. This not only forces workers to adopt awkward and inefficient working postures, increasing labor intensity, but also makes it difficult to effectively guarantee the tightening quality of critical bolts.

[0006] 3. High risk of transportation, unable to achieve paced production. Relying on manual carrying of large top covers not only has high labor intensity, but also has the risk of bumps and falls during movement, which can easily cause product scratches or personal injury. Using a general flat pallet for transportation solves part of the carrying problem, but since the top cover cannot be precisely positioned on the flat pallet, vibration and start-stop during transportation can still cause it to shift, making it difficult to accurately dock with the subsequent workstations and not conducive to efficient and paced flow on the production line.

[0007] Therefore, it is necessary to improve the existing air conditioner module top cover carrying technology to overcome the defects of the prior art. SUMMARY

[0008] In order to overcome the problems in the prior art, the mobile tool for air conditioner module top cover assembly is provided, which sets a bearing work assembly composed of a plurality of interval distributed support frames and an intermediate support, and at least one of the support frames is provided with a hollow, so as to overcome the problems of poor bearing stability of the top cover, low assembly precision, limited work space, low assembly efficiency, high transfer risk and inability to realize beat production in the prior art.

[0009] A mobile tool for air conditioner module top cover assembly, comprising:

[0010] a base provided with a moving assembly for moving the base;

[0011] a bearing work assembly provided on the base for supporting the top cover, the bearing work assembly comprising:

[0012] a plurality of support frames, the plurality of support frames being interval arranged along the length direction of the base, and the plurality of support frames defining a bearing area together, and at least one of the support frames being provided with a hollow;

[0013] an intermediate support provided on the base and located in the bearing area, the intermediate support being used for supporting the middle part of the top cover.

[0014] The base and the moving assembly replace the lifting and carrying of manpower with mechanical bearing and rolling friction, and eliminate the falling and collision risks caused by fatigue and mistakes of personnel. The plurality of interval arranged support frames construct a large span stable bearing platform, and the top cover placed thereon will not shake or overturn, so as to ensure the stability. The intermediate support provides key support for the middle area of the top cover, resists the deflection deformation caused by gravity, and ensures the flatness and geometric precision of the top cover in the assembly process. The hollow structure of the support frame provides an unobstructed work channel for the arms and tools of the workers, so that the fastening operation on the side and inside of the top cover is possible. The hollow structure of the support frame provides an unobstructed work channel for the arms and tools of the workers, so that the fastening operation on the side and inside of the top cover is possible. Finally, the operation safety is improved, the labor intensity of the workers is greatly reduced, the assembly precision and consistency are reliably guaranteed, and a plurality of workpieces can be processed at a time, so that the beat efficiency of the production line is doubled.

[0015] Further, the support frame is provided with two, and the two support frames are respectively located on the two sides of the intermediate support.

[0016] The two support frames are the minimum number of sets to achieve stable bearing, avoiding redundant structures and material waste. They are symmetrically arranged on both sides of the intermediate support, forming a classic, stable symmetrical layout. This layout makes the stress of the top cover uniform and centered, and the working conditions faced by the operator are consistent regardless of which side they work from. This minimizes manufacturing costs and maximizes structural efficiency, while providing balanced and symmetrical operating conditions for assembly operations, which is conducive to standardization of operations, further improving the convenience and consistency of operations.

[0017] Further, the support frame is a support frame enclosed by a plurality of rods.

[0018] Using rods (such as square steel) to build a frame is a classic efficient structure in engineering mechanics. It can achieve maximum structural stiffness and strength with the least material, and the overall weight is much lighter than using solid plates. At the same time, the process of enclosing rods naturally forms a large area of hollow area, without the need for secondary processing, perfectly combining the two major needs of bearing function and providing working space in one structure. This makes the mobile tooling structure strong and durable, with light overall weight and easy to move, and low manufacturing cost, perfectly achieving the functional requirements of hollow working.

[0019] Further, the intermediate support includes at least one T-shaped support block.

[0020] The upper beam of the T-shaped structure provides a wider planar support area, which can form face contact or multi-point line contact with the bottom beam of the top cover compared to a single column or narrow beam, greatly increasing the stability of the support and effectively preventing the top cover from rotating or moving laterally during assembly due to stress. It improves the stability of the top cover on the tooling and provides a solid foundation for high-precision assembly operations, further ensuring product quality.

[0021] Further, the intermediate support structure includes two support blocks;

[0022] The length direction of the two support blocks is parallel to the length direction of the base;

[0023] The two support blocks are spaced apart along the width direction of the base;

[0024] The two support blocks are mirror image arranged with the center longitudinal axis in the length direction of the base as the axis of symmetry.

[0025] The structure features two T-shaped support blocks spaced apart and mirrored along the width direction, with each T-shaped support block capable of independently supporting a complete air conditioner top cover. This avoids the use of large support blocks, reducing the overall weight and cost of the moving fixture, and also prevents the impact of support block deformation on placement stability and assembly accuracy caused by sharing a single support block.

[0026] Furthermore, the top surface of the T-shaped support block includes adjacent first and second support surfaces;

[0027] The second support surface protrudes upward relative to the first support surface;

[0028] The first support surface and the second support surface are used to support the bottom of the top cover at different heights, respectively.

[0029] The top surface of the T-shaped support block has adjacent first and second support surfaces with a height difference. This stepped support surface topology precisely matches the height differences of different parts of the top cover's bottom. When the top cover is placed on it, different positions on its bottom simultaneously and separately contact the support surfaces of corresponding heights, ensuring the entire top cover is in a perfectly fitted, stress-free state without external pressure. This solves the problem of stress-free positioning for irregularly shaped or complex bottom surfaces, ensures the accuracy of misaligned assembly, and avoids long-term reliability issues caused by tooling mismatch.

[0030] Furthermore, the support frame and / or the intermediate support member are provided with positioning grooves that mate with the top cover.

[0031] The positioning groove and a protruding feature (such as a crossbeam) on the bottom of the top cover form a locking mechanism (male and female fit). When placing the top cover, the operator only needs to roughly position it, and the top cover will automatically slide into the groove and lock under gravity, achieving limit positioning in the X and Y directions. This is a passive, foolproof design. It achieves zero-error, rapid positioning, greatly shortens loading time, avoids cumulative errors in subsequent assembly caused by inaccurate positioning, and improves product consistency and quality stability.

[0032] Furthermore, the surface of the load-bearing component that contacts the top cover is covered with a flexible protective layer.

[0033] Furthermore, the flexible protective layer is made of velvet or rubber material.

[0034] As an exterior component of the product, the top cover's paint coating is very fragile. Adding a flexible interlayer between the rigid metal tooling and the precision workpiece is crucial. The extremely soft fleece and elastic rubber absorb minor impact energy and disperse contact stress, preventing hard-point contact. This soft armor effectively isolates the two rigid bodies that could potentially cause damage. It effectively protects the product's appearance, reduces rework and scrap rates due to scratches, increases product value, and saves on corresponding quality costs.

[0035] Furthermore, the base is also equipped with push-pull handrails or traction interfaces.

[0036] The base is equipped with push-pull handles or a traction interface. The push-pull handles provide an ergonomic leverage point for manual operation, making short-distance movement more effortless and safer. The traction interface is a standardized connector that allows this tooling to be quickly connected to factory tractors (logistics trains) and other equipment, integrating it into a larger-scale automated logistics system. This effectively enhances the tooling's applicability and ergonomic performance, enabling both flexible stand-alone manual operation and seamless integration into modern production line logistics systems, thus improving overall logistics efficiency.

[0037] The beneficial effects of this invention are as follows:

[0038] This invention provides a mobile tooling for assembling the top cover of an air conditioning module. This mobile tooling comprises multiple spaced-apart support frames and an intermediate support component, forming a load-bearing assembly. The support frames have openwork sections, and the entire device is a mobile tooling. Multiple support frames spaced apart on a base form a large-span stable support surface, firmly supporting the top cover. Simultaneously, the intermediate support component provides a crucial support point for the central area of ​​the top cover, which is most prone to sagging under its own weight, forming a multi-point, balanced load-bearing system. This effectively resists bending deformation caused by gravity, maintaining the designed shape of the top cover during assembly. The openwork design on the support frames eliminates the physical interference of traditional solid platforms or material carts, making previously inaccessible mounting points on the sides and inside of the top cover readily accessible. The combination of the base and the mobile component transforms the entire tooling into a mobile work unit, achieving integrated flow between the workpiece and the workstation. By fixing the top cover to a dedicated mobile fixture for assembly and transfer, the risks of manual handling and displacement problems during general material cart transportation are avoided, enabling the workpiece to be quickly, safely, and smoothly transferred between workstations, and effectively ensuring the rhythmic production of the production line. Attached Figure Description

[0039] Fig. 1 This is a three-dimensional schematic diagram of the movable tooling for assembling the top cover of the air conditioning module provided in this application;

[0040] Fig. 2 This is a side view of the movable tooling for assembling the top cover of the air conditioning module provided in this application;

[0041] Fig. 3 This is a schematic diagram of the bottom surface of the movable tooling for assembling the top cover of the air conditioning module provided in this application.

[0042] Figure label:

[0043] 100, Base; 110, Moving component; 200, Load-bearing component; 210, Support frame; 211, Positioning groove; 220, Intermediate support; 221, Support block; 300, Push-pull handrail. Detailed Implementation

[0044] Preferred embodiments of the invention will now be described in more detail with reference to the accompanying drawings. While preferred embodiments of the invention are shown in the drawings, it should be understood that the invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the invention will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0045] Example 1

[0046] like Figs. 1-3 As shown, the mobile tooling for assembling the top cover of the air conditioning module in this embodiment has the following core components: a base 100, a mobile component 110 that enables it to move, and a load-bearing work component 200 for performing core functions.

[0047] The base 100 is the chassis and frame of the entire tooling, providing a stable mounting foundation for all upper components.

[0048] The movable component 110 is installed at the bottom of the base 100, enabling the entire tooling equipment to move freely within the production site.

[0049] The load-bearing assembly 200 is mounted on the base 100 and is the part that directly contacts the workpiece to be processed (the top cover of the air conditioning module) and provides it with support and working space. This assembly consists of multiple support frames 210 and an intermediate support member 220. The multiple support frames 210 are arranged separately along the length of the base 100, forming a load-bearing area for placing the top cover, and at least one support frame 210 is designed with a hollow structure. The intermediate support member 220 is located inside this load-bearing area and provides additional support to the center of the top cover.

[0050] Traditional manual handling of large covers, especially in complex workshop environments, poses a high risk of falls, collisions, and collapses, and is extremely physically demanding on workers. By using a sturdy base 100 to support the cover and utilizing the rolling friction of movable components 110 (such as casters) to replace manual lifting, the main safety hazards during handling are fundamentally eliminated, and the heavy physical labor is transformed into an easy pushing and pulling operation, significantly reducing labor intensity.

[0051] Manual handling is characterized by unstable speed and rhythm, heavily influenced by factors such as worker physical strength and coordination, posing a bottleneck to production line flow. Movable tooling allows the top cover to function as a mobile workstation, smoothly and rapidly moving between pre-assembly processes, providing a physical basis for achieving a highly efficient and balanced production line.

[0052] Air conditioning module top covers are typically large, thin-plate structures. If placed on ordinary flatbed trucks or end supports, the central section will experience significant deflection due to its own weight. Installing components such as columns and beams under this deformed state leads to uneven assembly stress and misalignment of parts, severely impacting the final product quality. In this solution, multiple support frames 210 are spaced apart on the base 100, providing a large-span stable support surface for the top cover. Simultaneously, the crucial intermediate support 220 provides a key support point for the central area of ​​the top cover, which is most prone to sagging. This multi-point, balanced load-bearing system effectively resists deflection caused by gravity, ensuring the top cover maintains its designed flat shape throughout the assembly process, thus providing a reliable guarantee for high-precision assembly.

[0053] Traditional solid workbenches or flatbed carts create physical barriers, hindering operators from accessing the sides and bottom of the top cover. Workers struggle to reach their arms and fastening tools (such as torque wrenches) to the installation points, forcing them into awkward positions. This not only reduces efficiency but also makes it difficult to ensure the tightening torque of critical bolts. The openwork design of the support frame 210 creates an open working window, eliminating physical interference and making previously inaccessible installation points readily accessible. Workers can operate conveniently and comfortably, significantly improving assembly efficiency and fastening quality.

[0054] The manufacturing process of the mobile tooling in this embodiment is as follows: Based on the design drawings, lightweight and high-strength square steel is selected as the main material for the base 100 and the load-bearing work assembly 200. The materials are precisely cut to the required dimensions and quantities as specified in the drawings. Argon welding is used to weld the cut square steel into a frame structure for the base 100 and the support frame 210. Right-angle connections are mostly used to ensure the stability and robustness of the structure. The intermediate support 220 is also welded to the designated position on the base 100. The mobile assembly 110 is installed at the bottom of the base 100, typically by bolting four industrial-grade swivel casters to the mounting plates pre-installed at the four corners of the base 100. The completed tooling is then ground, rust-removed, and coated with anti-rust paint and topcoat to improve durability and aesthetics.

[0055] The process of using the mobile tooling in this embodiment is as follows: The operator places the top cover of the air conditioning module to be pre-installed from the material area onto the load-bearing component 200 of the mobile tooling using a simple lifting tool or with the cooperation of two people. The two ends of the top cover rest on two support frames 210 respectively, while the middle is firmly supported by the intermediate support 220. The operator pushes the tooling cart to the pre-installation station. When installing components such as columns and beams, the operator can easily reach their hands and tools to the side or bottom of the top cover to perform bolt tightening, torque checking, and other operations using the open areas of the support frames 210. After completing one process, the operator directly pushes the tooling cart to move it along the production line to the next station, or directly into the final assembly line waiting area. The entire process does not require secondary handling of the top cover.

[0056] The mobile fixture in this embodiment integrates load-bearing, operation, and transfer functions, reducing repetitive handling and waiting time. The open working space makes assembly operations faster, shortens production line cycle time, and significantly improves line balance and overall output efficiency. Multi-point balanced support effectively prevents deformation of the top cover during assembly, ensuring the installation accuracy and consistency of components, and improving the final performance and reliability of the product from the source.

[0057] In addition to square steel, the base 100 can also be constructed using round tubes, channel steel, or aluminum profiles. Aluminum profiles are lighter, more corrosion-resistant, and easier to assemble in a modular fashion, but they are more expensive. Structurally, in addition to welding, high-strength bolts can also be used for connection, facilitating later maintenance, replacement, or adjustment.

[0058] In addition to swivel casters, the mobile component 110 can also utilize a combination of two fixed casters and two swivel casters for production lines with fixed routes to achieve better straight-line stability. In workshops with higher levels of automation, it can even integrate AGV (Automated Guided Vehicle) modules to achieve unmanned automated transfer.

[0059] Regarding the number and form of the support frame 210, although the most common implementation is two support frames 210, three or more support frames 210 can be set for extra-long or irregularly shaped top covers. Besides rectangular, the openwork shape can also be circular, trapezoidal, etc., as long as sufficient working space is provided.

[0060] In addition to a simple crossbeam structure, the intermediate support component 220 can also be a liftable jack to accommodate different models and heights of roofs. Its material can also be a high-polymer wear-resistant material to reduce scratches on the roof without requiring a flexible layer.

[0061] Example 2

[0062] like Figs. 1-3 As shown, this embodiment further optimizes and limits the number, layout, and specific construction of the support frame 210 based on the basic structure disclosed in Embodiment 1. This solution aims to provide a more rational structure, lower manufacturing cost, and more stable and convenient use.

[0063] In this embodiment, two support frames 210 are provided. These two support frames 210 are not randomly arranged, but follow a principle of symmetry and stability, specifically, the two support frames 210 are located on both sides of the intermediate support member 220. From a top view, the entire load-bearing assembly 200 forms a stable layout similar to an H, with the two support frames 210 forming the two vertical sides of the H, and the intermediate support member 220 and its connected base 100 forming the horizontal bar in the middle.

[0064] In this embodiment, the internal structure of each support frame 210 is not a solid platform or a heavy plate, but rather a support frame formed by multiple rods. Specifically, it is constructed by using multiple square steel bars (as rods) connected by welding or bolting to form a three-dimensional frame structure with an internal hollow area. This frame is both a load-bearing structure and its enclosed internal space naturally forms a hollow structure.

[0065] For a long, narrow workpiece (such as an air conditioner top cover), supports are provided at both ends, and an additional support point is added in the middle, forming a classic three-point stabilizing support system (two support frames 210 + a middle support 220). This layout is the most economical and effective way to achieve planar stability, and can prevent the workpiece from warping or swaying along its length to the greatest extent.

[0066] By symmetrically arranging the two support frames 210 on both sides of the middle support member 220, the weight of the entire top cover can be evenly distributed on the base 100, avoiding tooling tilting or instability caused by eccentric loading, and ensuring absolute safety during operation.

[0067] A symmetrical layout means that the working conditions and operating space faced by the operator are the same regardless of which side of the tooling they work from. This is conducive to the formation of standardized work instructions, reduces the difficulty of training, and ensures the consistency of operation.

[0068] The support frame, composed of multiple struts, integrates the two core functions of load-bearing and providing working space (openwork) into a single structural form. The use of struts inevitably results in a hollow frame. Compared to manufacturing a solid platform first and then carving a hole in it, this design fulfills the functional requirements from the outset, avoiding material waste and additional processing steps.

[0069] Meanwhile, hollow tubular or frame structures can achieve strength similar to or even higher than solid structures with less material when subjected to bending and torsion. Using square steel members to build the frame can significantly reduce the weight of the support frame 210 itself while ensuring sufficient load-bearing capacity, thereby reducing the weight of the entire tooling and making it easier and less strenuous to move.

[0070] The manufacturing process of the movable tooling in this embodiment is as follows: Based on the dimensions of the air conditioner top cover, determine the length, width, and height of the two support frames. Select suitable rod specifications, such as 40mm×40mm square steel with a wall thickness of 2mm. Cut the square steel according to the design dimensions. Use welding fixtures to position the rods, ensuring their verticality and flatness, and then use argon welding to firmly connect them into a rectangular, hollow support frame. Repeat this step to produce two identical support frames. Weld the two fabricated support frames to the base 100 according to the positions required by the design drawings, ensuring they are parallel to each other and located on both sides of the predetermined position of the intermediate support 220. After welding, perform surface treatment processes such as grinding and painting.

[0071] Besides square steel (rectangular tubes), other cross-sectional shapes such as circular steel tubes and C-shaped steel can also be used to enclose the support frame. Circular steel tubes may be superior in certain stress directions, but welding and positioning are relatively complex. Although welding is the optimal choice in terms of cost and strength, high-strength bolts with flanges can be used to connect the members and fix the support frame to the base 100 in designs requiring detachability or adjustability. For non-standard rectangular top covers, the support frame can be designed in trapezoidal, U-shaped, or other irregular shapes to better match the workpiece's contour. In some designs, the vertical members of the support frame 210 can extend directly to the bottom, serving as part of the base 100, thus forming a more integrated, unified frame structure, rather than strictly distinguishing the base 100 and support frame 210 as two separate components.

[0072] Example 3

[0073] like Figs. 1-3 As shown, this embodiment, based on the aforementioned embodiments, provides a more specific and optimized design for the structure of the intermediate support member 220. The core of this embodiment lies in solving the problem of providing high-precision, stress-free support for the top cover of an air conditioning module with a complex or non-planar bottom structure through a support structure of a special shape and layout.

[0074] In this embodiment, the intermediate support 220 is no longer a simple beam or pillar, but a complex structure with precise design. The intermediate support 220 includes at least one T-shaped support block 221. This T-shaped structure consists of a vertical column and a horizontal top beam, forming a stable and reliable support unit.

[0075] In a preferred embodiment, the intermediate support structure includes two support blocks 221. These two T-shaped support blocks 221 are not arbitrarily arranged; their lengths are parallel to the length of the base 100. The two support blocks 221 are spaced apart along the width of the base 100. The two support blocks 221 are arranged in a mirror image with respect to the central longitudinal axis of the base 100. This arrangement forms two parallel, symmetrical support tracks in the middle of the base 100.

[0076] The top surface of the T-shaped support block 221 is not a flat plane. The top surface of the T-shaped support block 221 includes an adjacent first support surface and a second support surface. There is a height difference between these two support surfaces; specifically, the second support surface protrudes upwards relative to the first support surface, forming a stepped or boss-like profile. This special profile is not arbitrarily designed; its function is for the first and second support surfaces to support portions of the top cover at different heights.

[0077] Compared to single-point supports or narrow crossbeams, the T-shaped top crossbeam provides a wider contact surface. When the top cover's crossbeam is placed on it, a stable surface contact or multi-point line contact is formed, rather than an unstable point contact. This greatly increases the stability of the support, effectively resisting slight rotation or lateral displacement that may occur during external force operations such as tightening bolts, providing a solid foundation for high-precision assembly.

[0078] For large roofs, a single central support beam may cause the roof to sag to both sides or experience uneven stress. Using two parallel, mirror-symmetrical support blocks 221 can evenly distribute the weight of the roof's center onto the two support lines, forming a stable and balanced load-bearing system. This minimizes the risk of twisting or warping deformation caused by improper support. Compared to using a single, large, solid support plate, using two independent support blocks 221 can significantly reduce material usage while maintaining support performance, thereby lowering the overall weight and manufacturing cost of the tooling.

[0079] The bottom structure of an air conditioning module's top cover is not a perfect plane; it often features staggered features such as reinforcing ribs, crossbeam connections, and mounting bosses. If a flat supporting surface is used to support it, only the lowest point will be in contact, leaving the entire top cover in a suspended, stressed state of being forcibly leveled. Assembly under these conditions will cause internal stress between components, severely affecting assembly accuracy and the long-term reliability of the product.

[0080] The stepped support surface in this embodiment is designed in reverse engineering based on the actual contour of the bottom of the top cover, precisely matching the height differences of different parts of the bottom of the top cover. When the top cover is placed on it, different positions on its bottom (such as the main plane and the raised crossbeam) will simultaneously and separately perfectly fit with the first and second support surfaces of corresponding heights. This allows the entire top cover to be in a completely relaxed, stress-free natural state without any external force intervention, which is an ideal prerequisite for achieving high-precision misaligned assembly.

[0081] The manufacturing process of the mobile tooling in this embodiment is as follows: By 3D scanning or reading the original digital model of the product, the 3D contour data of the bottom of the air conditioning module's top cover is accurately obtained to determine the key positions requiring support and their precise height differences. Suitable steel is selected, and the top surface of the T-shaped support block 221 with precise stepped height is manufactured through machining (such as milling) or welding. For example, a basic T-shaped structure is first made, and then a steel plate of precise thickness (as a second support surface) is welded to the designated position on the top beam. Using a laser scribing instrument or precision measuring tools, the two manufactured T-shaped support blocks 221 are precisely welded to the base 100 according to the design drawings, strictly ensuring their parallelism and mirror symmetry.

[0082] During use, the operator places the top cover onto the fixture. Because the stepped contour of the T-shaped support block 221 matches the bottom contour of the top cover, the top cover naturally falls into the correct position, with its different height sections fitting against the first and second support surfaces respectively. At this point, the top cover is stably and stress-free supported. The operator can then proceed with the pre-assembly of subsequent components such as columns and beams. Due to the stable and stress-free reference, all components can be installed in their precisely designed positions, ensuring the quality of the final assembly.

[0083] While maintaining the core idea of ​​providing multi-height support for non-planar workpieces, it can also be achieved in the following ways:

[0084] The second support surface can be designed as a liftable top pin or replaceable pads of different thicknesses. This method offers greater flexibility, allowing a single fixture to adapt to various top cover models by adjusting or replacing the pads. However, the operation is relatively cumbersome and carries the risk of incorrect settings.

[0085] For top covers with more complex bottom structures, the top surface of the T-shaped support block 221 can be designed to include three or more support surfaces of different heights, forming a more complex multi-level stepped profile to match more complex workpieces.

[0086] The main structure of the support block 221 is not limited to T-shape, but can also adopt I-shaped, box-shaped or any other structural form that can provide a stable base 100. The key is that the top surface must be machined to have a multi-height support surface that matches the workpiece.

[0087] The entire intermediate support component 220 can be designed as a platform with an array of screw holes. Depending on the model of the top cover, customized support columns or support blocks 221 of different heights can be installed at different screw hole positions. This method offers the highest flexibility, but also increases cost and complexity of redesign.

[0088] Example 4

[0089] like Figs. 1-3 As shown, this embodiment, based on the basic moving tooling disclosed in Embodiment 1, adds physical positioning features to transform the workpiece placement process from an alignment process that relies on the operator's experience and attention into an embedding process that is almost error-free.

[0090] In this embodiment, the carrying operation component 200 of the moving tooling specifically has a positioning groove 211 that mates with the top cover machined or installed on the carrying surface of the support frame 210 and / or the intermediate support member 220.

[0091] This positioning groove 211 is not an ordinary recess; its geometry, size, and position are precisely designed. Its design is based on a unique, stable, and easily accessible physical feature on the bottom of the air conditioning module's top cover, such as a reinforcing rib (crossbeam), a folded edge, or a raised mounting base. The contour of the groove forms a mating or locking relationship with the contour of this top cover feature. When the top cover is placed, its bottom male feature fits perfectly into the female groove on the tooling. These grooves can be provided only on the support brackets 210 at both ends to determine the lateral (width) position and rotation of the top cover; they can also be provided on the intermediate support 220 to determine its longitudinal (length) position; or a combination of both can be provided to achieve complete constraint on all degrees of freedom of the top cover in the XY plane.

[0092] The fundamental purpose of this positioning groove 211 is to solve the problems of inefficiency and uncertainty in the workpiece placement process when precise positioning features are not available. When placing a large top cover on a flat fixture without the positioning groove 211, the operator needs to spend extra time visually aligning it and repeatedly fine-tuning its position to ensure it is centered and not tilted. This process is time-consuming and inefficient, directly affecting the work cycle of the loading process. Relying solely on manual alignment will result in inconsistent outcomes. Different operators, and even the same operator at different times, may have slight deviations in the placement of the top cover. This inconsistency is a significant source of variation in the production process, potentially leading to cumulative errors in subsequently installed components. If the initial placement of the top cover is inaccurate, the relative positions of pre-assembled components such as columns and beams will also deviate from the design reference. This not only affects the product's aesthetics but may also cause misalignment of connection holes with other modules during final assembly, generating assembly stress and even affecting the stability and reliability of the entire machine.

[0093] There are several ways to integrate the positioning groove 211 into the mobile tooling:

[0094] The manufacturing process of the movable tooling in this embodiment is as follows: By analyzing the CAD 3D model of the top cover, a bottom protrusion feature that is most suitable as a positioning reference is determined. Then, a matching groove structure is designed at the corresponding position of the tooling support frame 210 or intermediate support 220.

[0095] Processing method 1: Welding. This is the most common and cost-effective method. Two parallel angle steel or square steel bars are welded to the steel surface of the support frame 210 or intermediate support 220. The gap between the two steel bars naturally forms the required positioning groove 211.

[0096] The second processing method is milling. For applications requiring higher precision, a milling machine can be used to directly machine a precise groove on a thicker steel plate, and then this steel plate can be welded to the main body of the tooling as a support surface.

[0097] The processing method involves modular components, or the positioning groove 211 can be made into an independent positioning block and then fixed to the tooling with bolts. This method facilitates subsequent adjustments or replacements based on changes in product design.

[0098] In this embodiment, the use of the movable fixture is as follows: When hoisting or moving the top cover to the fixture, the operator no longer needs to precisely align it with a specific scale line. They only need to roughly place the top cover in the bearing area, then align the positioning feature on the bottom of the top cover with the approximate position of the positioning groove 211 and lower it. Under the action of the top cover's own weight, its raised positioning feature will automatically slide into and completely settle into the groove, emitting a slight knocking sound or providing clear tactile feedback, indicating that the positioning process is completed instantly. The entire process achieves accurate positioning immediately without the need for secondary adjustments.

[0099] In achieving the goal of rapid and accurate positioning, besides the positioning groove 211 (mother feature), there are other functionally equivalent alternatives:

[0100] Locating pins (male features) are one or more cylindrical or rhomboid locating pins installed on the support surface of the tooling, with corresponding locating holes pre-drilled on the bottom of the top cover. For positioning, simply align the holes in the top cover with the pins in the tooling and insert them. This pin-hole fit typically provides higher positioning accuracy.

[0101] Edge-mounted and stop blocks are used, with fixed edge-mounted (L-shaped) or flip-up stop blocks installed at the edge of the tooling's load-bearing area. The operator simply pushes the top cover towards a designated corner or both sides, bringing it close to the stop block, to complete the positioning. This method is simple to implement, but may not be as effective as the constraint provided by grooves or pins.

[0102] For steel top covers, magnetic positioning involves embedding permanent magnets or electromagnets at predetermined positions on the tooling support surface. When the top cover approaches, the magnetic force attracts it to the correct position and provides a clamping force to prevent accidental movement during assembly.

[0103] The adjustable positioning mechanism allows the positioning groove 211 or positioning pin to be made on the sliding base 100 if the tooling needs to be compatible with multiple models of top covers. It can be driven by a lead screw or cylinder to adjust to different positions according to the model being produced, thus enhancing the flexibility of the tooling.

[0104] Example 5

[0105] like Figs. 1-3As shown, this embodiment adds a protective measure to the tooling on the basic structure disclosed in Embodiment 1, aiming to fundamentally solve the problem of surface damage caused by direct contact between the workpiece and the rigid tooling during assembly and transportation.

[0106] The surfaces of the load-bearing assembly 200 that come into contact with the top cover are covered with a flexible protective layer. Specifically, this means that all parts of the entire moving fixture that may come into physical contact with the top cover of the air conditioning module, including the top surfaces of the multiple support frames 210 and the intermediate support 220, are covered with a non-rigid material that provides cushioning and protection.

[0107] The flexible protective layer is preferably made of fleece or rubber. Fleece is a soft fabric with a napped surface, while rubber is a highly elastic polymer material. These two materials together constitute the material basis of the protective layer in this embodiment. It acts like a soft armor tailored to the tooling, isolating the metal tooling from hard contact with the metal workpiece.

[0108] The top cover of an air conditioning module unit is one of the unit's exterior components, and the quality of its surface coating (paint) directly affects the overall appearance and market competitiveness of the product. Traditional steel tooling, even after polishing, remains hard. During placement, assembly (which may involve slight movement due to stress), and transportation (which involves bumps and vibrations), friction and impacts occur between the painted surface of the top cover and the steel surface of the tooling, easily resulting in scratches, dents, or paint peeling. These defects can directly lead to product downgrading or require costly rework and repair.

[0109] During the production line process, the starting, stopping, crossing bumps, and turning of the tooling vehicles will generate impacts and vibrations. A flexible protective layer, especially an elastic rubber material, can effectively absorb this dynamic energy, playing a role in buffering and shock absorption, further reducing the minute displacements and friction caused by vibration, and protecting the structural stability and surface integrity of the top cover.

[0110] In addition to the above-described implementation methods, it can also be implemented in the following ways:

[0111] Materials can also include industrial felt, polyurethane (PU) or EPDM foam, and polymer coatings. Industrial felt is thicker, more durable, and provides better cushioning than fleece, making it suitable for heavier workpieces. Polyurethane (PU) or EPDM foam offers excellent elasticity and abrasion resistance and can be molded into specific profiles for direct snap-fit ​​or embedding into tooling recesses. Polymer coatings can be applied by spraying or dip-coating to form a flexible, abrasion-resistant protective layer (e.g., polyurea coating) on ​​the tooling contact surface. This method creates a seamless protective layer with better overall integrity.

[0112] The structure and fixing method can also be achieved through prefabricated sleeves and modular inserts. Prefabricated sleeves (materials such as canvas, leather, and rubber) can be pre-sewn or molded into tubular sleeves that match the cross-section of the tooling beam. They are simply slipped onto the beam and secured with zippers, Velcro, or straps. The advantage of this method is that replacement is extremely convenient and quick. Modular inserts are designed with grooves pre-drilled on the contact surface, and then standard-sized inserts made of flexible materials (such as nylon or TPU) are embedded into them. After wear, only the standardized inserts need to be replaced, resulting in high maintenance efficiency.

[0113] Example 6

[0114] like Figs. 1-3 As shown, this embodiment improves upon the mobile tooling for assembling the top cover of an air conditioning module disclosed in Embodiment 1, focusing on mobility and system integration. The aim is to further enhance the tooling's ease of operation, throughput efficiency, and adaptability to modern logistics systems in actual production environments.

[0115] An additional device for assisting movement is provided on the base 100 described in Embodiment 1. Specifically, this device can be one of the following two forms or a combination thereof:

[0116] The push-pull handrail 300 is a structural component specifically designed for manual operation. It typically takes the form of a rod-shaped or ring-shaped structure fixed to one or both ends of the base 100, with an ergonomic height and gripping habit. Operators can easily apply pushing or pulling forces to the moving tool by gripping this handrail to control its movement and steering.

[0117] A traction interface is a standardized mechanical connection device. Its design purpose is to enable mobile tooling to be towed by powered equipment within the factory (such as electric tractors, logistics trains, AGVs, etc.). It typically takes the form of a robust connecting ring, traction pin, or a hook structure of a specific shape, fixed to the front end of the base 100.

[0118] By adding these two devices, the mobile tooling in this embodiment is upgraded from a device that can only move passively to a logistics unit that is easier to operate and manage, with an active and convenient mobile interface.

[0119] Although the movable component 110 (casters) in Embodiment 1 enables the tooling to move, in practical applications, how to efficiently and safely drive this movement is a problem that must be solved. This embodiment is designed precisely to solve this problem:

[0120] Without a dedicated handrail, operators can only push the tooling against the base 100 or the frame supporting the work assembly 200. The height, shape, and surface of these locations may not be suitable for applying force, easily leading to awkward operating postures, increased labor intensity, and even the risk of slipping and losing control of the tooling when hands are wet. Providing a suitably sized, easy-to-grip push-pull handrail 300 offers operators a stable and effortless point of leverage, significantly improving ergonomics, reducing labor intensity, and enhancing the safety of manual operation.

[0121] Specialized handrails allow operators to control the tooling more precisely when making short, precise movements (such as aligning workstations).

[0122] In large-scale production, manually pushing tooling carts one by one over long distances between different processes is extremely inefficient and consumes a large amount of manpower. The traction interface allows multiple mobile tooling carts to be linked together by a single tractor, forming a logistics train and enabling the one-time, large-volume transfer of materials / semi-finished products. This aligns perfectly with the just-in-time material delivery model pursued by modern lean manufacturing.

[0123] A standardized traction interface is a prerequisite for mobile tooling to be recognized, connected, and transported by automated equipment such as AGVs. It reserves an interface for the tooling to be seamlessly integrated into more advanced automated production systems in the future, giving it good scalability.

[0124] The push-pull handrail 300 can be designed as a foldable or retractable handrail. It can be folded away when not in use to save storage space or avoid interference in narrow aisles. For production lines with operators of varying heights, the handrail can be designed with a height-adjustable structure to meet individual ergonomic needs. Rubber or soft polymer materials can be wrapped around the grip portion of the metal handrail to increase friction and improve grip comfort.

[0125] In addition to the common pin-hole type, the traction interface can also be designed in different types, such as ball-head type, hook type, or electromagnetic adsorption type, according to the standards of factory traction vehicles. For scenarios involving AGVs, the traction interface can be designed as a complex mechanism with guide grooves and automatic locking / unlocking functions, enabling fully automatic attachment and disengagement of AGVs and further improving the level of automation. The function of the traction interface can be directly integrated into the frame design of the base 100. For example, a reinforced traction hole can be directly formed on the crossbeam at the front end of the base 100 by laser cutting, instead of welding an additional component. This simplifies the manufacturing process and improves the overall structural integrity.

[0126] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of this application. Any specific values ​​in all examples shown and discussed herein should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0127] Furthermore, it should be noted that the use of terms such as "first" and "second" is merely for ease of distinction, and unless otherwise stated, these terms have no special meaning and therefore should not be construed as limiting the scope of protection of this application.

[0128] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A movable tooling for assembling the top cover of an air conditioning module, characterized in that, include: A base (100) is provided with a movable component (110) for moving the base (100); A support assembly (200) is mounted on the base (100) and is used to support the top cover; The carrying operation component (200) includes: Multiple support frames (210) are spaced apart along the length of the base (100), and the multiple support frames (210) together define a bearing area, and at least one of the support frames (210) is provided with a hollow; An intermediate support member (220) is disposed on the base (100) and located within the bearing area, the intermediate support member (220) being used to support the middle part of the top cover.

2. The movable tooling for assembling the top cover of an air conditioning module according to claim 1, characterized in that: There are two support frames (210), which are located on both sides of the intermediate support member (220).

3. The movable tooling for assembling the top cover of an air conditioning module according to claim 1 or 2, characterized in that: The support frame (210) is a support frame formed by multiple rods.

4. The movable tooling for assembling the top cover of an air conditioning module according to claim 1, characterized in that: The intermediate support (220) includes at least one T-shaped support block (221).

5. The movable tooling for assembling the top cover of an air conditioning module according to claim 4, characterized in that: The intermediate support structure includes two support blocks (221); The length direction of the two support blocks (221) is parallel to the length direction of the base (100); The two support blocks (221) are spaced apart along the width direction of the base (100); The two support blocks (221) are arranged in a mirror image with the central longitudinal axis of the base (100) as the axis of symmetry.

6. The movable tooling for assembling the top cover of an air conditioning module according to claim 4, characterized in that: The top surface of the T-shaped support block (221) includes an adjacent first support surface and a second support surface; The second support surface protrudes upward relative to the first support surface; The first support surface and the second support surface are used to support the bottom of the top cover at different heights, respectively.

7. The movable tooling for assembling the top cover of an air conditioning module according to claim 1, characterized in that: The support frame (210) and / or the intermediate support member (220) are provided with positioning grooves (211) that cooperate with the top cover.

8. The movable tooling for assembling the top cover of an air conditioning module according to claim 1, characterized in that: The surface of the load-bearing working component (200) that contacts the top cover is covered with a flexible protective layer.

9. The movable tooling for assembling the top cover of an air conditioning module according to claim 8, characterized in that: The flexible protective layer is made of velvet or rubber material.

10. The movable tooling for assembling the top cover of an air conditioning module according to claim 1, characterized in that: The base (100) is also provided with a push-pull handrail (300) or a traction interface.

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