A welding workbench for automotive turbochargers based on standardized processing

Abstract

This invention discloses a welding workbench for automotive turbochargers based on standardized processing, belonging to the field of turbocharger welding technology. It includes a base, on which a rotary chuck is slidably mounted. A pneumatic chuck is mounted on the side of the base away from the rotary chuck via a bracket. A first electro-hydraulic rod, connected at one end to the rotary chuck, is mounted on the side of the base away from the pneumatic chuck. Through the design of the base, chuck, auxiliary unit, and positioning unit, the invention precisely solves the technical pain points of traditional workbench use, such as cumbersome processing of extruded plastic metal and unstable clamping. The corresponding arrangement of the rotary chuck and pneumatic chuck achieves precise docking of the turbine shaft and turbine impeller. In conjunction with the second electro-hydraulic rod of the positioning unit, the upper pressure seat, the lower clamping seat, and the transmission engagement of the gear and rack, the turbine impeller, fixed by the pneumatic chuck, can be clamped in a wrap-around manner, effectively preventing radial runout of the impeller during high-speed rotational friction.

Description

Technical Field

[0001] This invention relates to the field of turbocharger welding technology, and more particularly to a welding workbench for automotive turbochargers based on standardized processing. Background Technology

[0002] Turbochargers are core components for improving engine power performance and fuel economy. The welding quality of the turbine impeller and turbine shaft directly determines the service life and operational reliability of the turbocharger. Friction welding has become one of the mainstream welding processes for turbine impellers and turbine shafts due to its advantages such as narrow heat-affected zone, good bonding performance of dissimilar metals, and no need for filler materials. This process generates heat through relative rotational friction between workpieces, and after the contact surface metals reach a plastic state, upsetting pressure is applied to achieve metallurgical bonding.

[0003] With the standardization and automation of the automotive parts manufacturing industry, higher requirements are placed on the precision, versatility, and integration of friction welding worktables. However, existing automotive turbocharger friction welding worktables still have many shortcomings that urgently need to be addressed:

[0004] Firstly, the process of removing burrs during friction welding is redundant and inconsistent. During the upsetting stage of friction welding between the turbine impeller and the turbine shaft, the ductile metal at the contact surface is extruded. In existing technologies, the extruded ductile metal is usually removed by cutting with grinding equipment after welding. This method increases the process flow time and reduces production efficiency. Moreover, the processing accuracy of manual grinding or general grinding equipment is difficult to control, which can easily lead to uneven shaft diameter and fail to meet the dimensional requirements of standardized processing. In addition, in some application scenarios, it is necessary to process the extruded ductile metal into a frustum shape to improve the connection tightness between the impeller and the shaft. However, traditional equipment cannot perform the shaping process of the extruded ductile metal during welding, which limits the diversified application of the process.

[0005] Secondly, the turbine impeller clamping stability is insufficient, which affects the welding quality. Traditional tooling only clamps the end of the turbine impeller with a pneumatic chuck. During high-speed rotation and friction, the blade part of the impeller lacks effective support, which easily causes chatter. This leads to uneven distribution of frictional heat on the welding contact surface and inconsistent thickness of the plastic layer, which in turn causes fluctuations in the weld bonding strength and makes it impossible to guarantee the stability of the welding quality of batch products. Summary of the Invention

[0006] The purpose of this invention is to address the problem that in the existing technology, the processing of extruded plastic metal is mostly done by cutting and removing it separately using grinding equipment after welding, which increases the process flow time and reduces production efficiency. Therefore, this invention proposes a welding workbench for automotive turbochargers based on standardized processing.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] A welding workbench for automotive turbochargers based on standardized processing includes a base, on which a rotary chuck is slidably mounted. A pneumatic chuck is mounted on the side of the base away from the rotary chuck via a bracket. A first electro-hydraulic rod, connected at one end to the rotary chuck, is mounted on the side of the base away from the pneumatic chuck. An auxiliary unit is provided in the middle of the base, and the auxiliary unit includes a support seat mounted on the base. A telescopic component is connected inside the support seat via a mounting ring.

[0009] During the friction welding process between the turbine impeller and the turbine shaft, the molten metal squeezed to the surface of the shaft is removed from the surface of the shaft by a scraper assembled at the end of the telescopic component, or squeezed into a frustum shape and left on the surface of the shaft.

[0010] As a further description of the above technical solution:

[0011] The telescopic component includes a branch pipe fixed to the ring frame, an extension rod installed inside the branch pipe by a first bolt, and an adjusting rod connected to one end of the extension rod by a second bolt.

[0012] As a further description of the above technical solution:

[0013] One end of the scraper is rotatably connected to the adjusting rod. One end of the adjusting rod is provided with a knob stud. The knob stud passes through the adjusting rod and one end of the scraper and is threaded with a nut, so that the scraper can be fixed inside the adjusting rod after rotation.

[0014] As a further description of the above technical solution:

[0015] The ring frame is rotatably connected to the support base, and a toothed ring is fixed on one side of the ring frame. A drive gear that meshes with the toothed ring is rotatably connected to one side of the support base. A reduction motor with its output end connected to the drive gear is installed on the support base.

[0016] As a further description of the above technical solution:

[0017] A positioning unit is installed on the side of the base surface near the pneumatic chuck. The positioning unit includes a second electro-hydraulic rod fixed to one side of the bracket by a mounting plate, and an upper pressure seat is installed at one end of the second electro-hydraulic rod.

[0018] As a further description of the above technical solution:

[0019] The base surface is fitted with a telescopic rod, and a lower clamp is installed at the top of the telescopic rod. The lower surface of the upper pressure seat and the upper surface of the lower clamp are both provided with limiting cavities adapted to the turbine impeller.

[0020] As a further description of the above technical solution:

[0021] Two rotating shafts are rotatably connected to one side of the bracket, and a transmission gear is fixed at one end of each of the two rotating shafts. Racks that mesh with the transmission gears are installed on both sides of the upper pressure seat and the lower clamp seat.

[0022] As a further description of the above technical solution:

[0023] A receiver box is inserted into one side of the support base through a vertical slot, and the receiver box is fixed in the vertical slot by a third bolt.

[0024] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0025] By setting up a base, chuck, auxiliary unit and positioning unit, the technical pain points of traditional worktables, such as cumbersome processing of extruded plastic metal and unstable clamping, are precisely solved.

[0026] By matching the rotary chuck with the pneumatic chuck, precise docking of the turbine shaft and turbine impeller is achieved. Combined with the second electro-hydraulic rod of the positioning unit, the upper pressure seat, the lower clamping seat, and the transmission gear and rack, the turbine impeller, fixed by the pneumatic chuck, can be clamped in a wrap-around manner, effectively preventing radial runout of the impeller during high-speed rotational friction. Simultaneously, the scraper of the auxiliary unit provides auxiliary support when in contact with the shaft, further ensuring the coaxiality of the workpiece during welding, reducing turbocharger malfunctions caused by coaxiality deviations after welding, and significantly improving the consistency of welding quality for batch products.

[0027] The telescopic components of the auxiliary unit allow for flexible adjustment of the scraper's position and angle. Combined with the transmission structure of the ring frame, gear ring, drive gear, and reduction motor, the scraper can rotate synchronously with the shaft, directly processing the extruded plastic metal during the welding process. This allows the extruded plastic metal to be scraped off to ensure a consistent shaft diameter, or it can be scraped into a frustum shape to improve the connection tightness, eliminating the need for a separate grinding process and significantly shortening the production cycle. Simultaneously, the receiving box of the support base can collect the scraped molten metal for convenient subsequent processing and improve the cleanliness of the processing environment. Attached Figure Description

[0028] Figure 1 A schematic diagram of the overall structure provided according to an embodiment of the present invention is shown;

[0029] Figure 2 A schematic diagram of an auxiliary unit provided according to an embodiment of the present invention is shown from a first perspective;

[0030] Figure 3 A schematic diagram of the auxiliary unit provided according to an embodiment of the present invention is shown in the second perspective;

[0031] Figure 4A schematic diagram of a first usage state provided according to an embodiment of the present invention is shown;

[0032] Figure 5 A schematic diagram of a second usage state provided according to an embodiment of the present invention is shown;

[0033] Figure 6 A schematic diagram of the structure of a positioning unit provided according to an embodiment of the present invention is shown;

[0034] Figure 7 The present invention provides an embodiment of the invention. Figure 4 Enlarged view of point A in the middle;

[0035] Figure 8 The present invention provides an embodiment of the invention. Figure 5 Enlarged view of point B in the middle;

[0036] Figure 9 The present invention provides an embodiment of the invention. Figure 6 Enlarged view of point C in the middle.

[0037] Legend:

[0038] 10. Base; 11. Rotary chuck; 12. Pneumatic chuck; 13. First electro-hydraulic rod;

[0039] 20. Auxiliary unit; 21. Support base; 22. Ring frame; 23. Telescopic component; 231. Branch pipe; 232. Extension rod; 233. Adjusting rod; 24. Scraper; 25. Receiver box; 26. Gear ring; 27. Drive gear; 28. Gear motor;

[0040] 30. Positioning unit; 31. Second electro-hydraulic rod; 32. Upper pressure seat; 33. Telescopic rod; 34. Lower clamp; 35. Transmission gear; 36. Rack. Detailed Implementation

[0041] 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0042] like Figure 1 - Figure 9 As shown, the present invention provides:

[0043] A welding workbench for automotive turbochargers based on standardized processing includes a base 10. A rotary chuck 11 is slidably mounted on the base 10. Specifically, a slide rail is fixed on the surface of the base 10, and the rotary chuck 11 is slidably mounted on the slide rail. In particular, the rotary chuck 11 is used to fix the turbine shaft and can drive the fixed turbine shaft to rotate. The rotary chuck 11 is a known technology, and its specific structure will not be described in detail here. A pneumatic chuck 12 is mounted on the side of the base 10 away from the rotary chuck 11 via a bracket. In particular, the pneumatic chuck 12 is used to clamp and fix the turbine impeller to ensure stability during the welding process between the turbine shaft and the turbine impeller. The pneumatic chuck 12 is also a known technology, and its specific structure will not be described in detail here. A first electro-hydraulic rod 13 is mounted on the side of the base 10 away from the pneumatic chuck 12, one end of which is connected to the rotary chuck 11. Preferably, there is one first electro-hydraulic rod 13, but two first electro-hydraulic rods 13 can also be used to drive the rotary chuck 11 to move.

[0044] Specifically, after the turbine shaft is fixed in the rotating chuck 11 and the turbine impeller is fixed, the first electro-hydraulic rod 13 pushes the rotating chuck 11 to move the turbine shaft towards one end of the turbine impeller, so that the end of the turbine shaft contacts the end of the turbine impeller. At this time, the rotation of the turbine shaft generates friction with the end of the turbine impeller. The frictional heat causes the metal temperature at the contact surface to rise rapidly to the plastic temperature range. At this time, the metal is in a plastic flow state, but will not reach a completely molten liquid phase state. At the same time, the plastic flow generated by friction will remove the oxide scale and impurities on the contact surface, exposing a fresh metal surface. When the contact surface temperature and the thickness of the plastic layer reach the preset value, the axial pressure is kept constant, and the workpiece rotation is quickly stopped or kept rotating while the axial pressure is increased. The turbine shaft is moved by the first electro-hydraulic rod 13 to apply a higher upsetting pressure, which tightly compacts the metal in the plastic state, reducing the interatomic distance of the metal at the contact surface to the range of interatomic force, thus achieving metallurgical bonding.

[0045] like Figure 1 , Figure 4 , Figure 5 , Figure 6 and Figure 9 As shown, a positioning unit 30 is installed on the side of the base 10 near the pneumatic chuck 12. The positioning unit 30 includes a second electro-hydraulic rod 31 fixed to one side of the bracket by a mounting plate. An upper pressure seat 32 is installed at one end of the second electro-hydraulic rod 31.

[0046] The base 10 is equipped with a telescopic rod 33. In particular, the telescopic rod 33 is a known technology and will not be described in detail here. A lower clamping seat 34 is installed at the top of the telescopic rod 33. The lower surface of the upper pressure seat 32 and the upper surface of the lower clamping seat 34 are both provided with limiting cavities that are compatible with the turbine impeller.

[0047] Two rotating shafts are rotatably connected to one side of the bracket, and a transmission gear 35 is fixed at one end of each of the two rotating shafts. Racks 36 that mesh with the transmission gear 35 are installed on both sides of the upper pressure seat 32 and the lower clamp seat 34.

[0048] Specifically, in the initial state, the upper pressure seat 32 and the lower clamp seat 34 are located away from the axis of the pneumatic chuck 12. After the turbine impeller is fixed in the pneumatic chuck 12, the second electric hydraulic rod 31 is activated to drive the upper pressure seat 32 to move downward. During the process, the lower clamp seat 34 is driven to move upward under the action of the transmission gear 35 and the rack 36. With the cooperation of the upper pressure seat 32 and the lower clamp seat 34, the turbine impeller can be covered, so that after the shaft end is fixed in the pneumatic chuck 12, the impeller body can be fixed by the upper pressure seat 32 and the lower clamp seat 34 to improve its stability during the welding process with the turbine shaft.

[0049] like Figure 1 , Figure 2 , Figure 3 and Figure 9 As shown, an auxiliary unit 20 is provided in the middle of the base 10. The auxiliary unit 20 includes a support base 21 mounted on the base 10. A telescopic member 23 is connected to the support base 21 through a mounting ring 22.

[0050] During the friction welding process between the turbine impeller and the turbine shaft, the molten metal squeezed to the surface of the shaft is removed from the surface of the shaft by the scraper 24 assembled at the end of the telescopic component 23 or squeezed into a frustum shape and left on the surface of the shaft.

[0051] The telescopic component 23 includes a branch pipe 231 fixed to the ring frame 22. An extension rod 232 is installed inside the branch pipe 231 by a first bolt. One end of the extension rod 232 is connected to an adjusting rod 233 by a second bolt. Specifically, the surface of the extension rod 232 is provided with a plurality of first screw holes corresponding to the first bolt. In actual use, by loosening the first bolt, the fixing of the extension rod 232 can be released. At this time, the position of the adjusting rod 233 at its end can be adjusted by moving the extension rod 232, so that the position of the scraper 24 can be adapted to the position of the joint between the turbine shaft and the turbine impeller.

[0052] Meanwhile, multiple second screw holes corresponding to the second bolts are provided on the outer wall of the adjusting rod 233. In actual use, the restriction on the adjusting rod 233 can be released by loosening the second bolts. At this time, the scraper 24 can gradually contact the outer wall of the shaft by moving the adjusting rod 233 inward.

[0053] like Figure 1 , Figure 2 and Figure 3As shown, one end of the scraper 24 is rotatably connected to the adjusting rod 233. One end of the adjusting rod 233 is provided with a knob stud. The knob stud passes through the adjusting rod 233 and is threaded with a nut on one end of the scraper 24, so that the scraper 24 can be fixed in the adjusting rod 233 after rotation.

[0054] It should be noted that, initially, the end of scraper 24 is parallel to the end of adjusting rod 233, as shown below. Figure 3 As shown, in this state, after the turbine shaft is placed in the rotating chuck 11 and fixed, the scraper 24 located below is controlled to contact the shaft surface, while the other scrapers 24 need to be kept away from the shaft. This state can be applied to processes that require ensuring that the diameter of the turbine impeller and the turbine shaft is consistent after welding (in this process, if it is necessary to keep the diameter of the shaft consistent after welding, the conventional method is to grind off the part that exceeds the diameter of the shaft after welding).

[0055] Specifically, during use, during the friction welding process between the turbine shaft and the turbine impeller, the molten metal generated under the upsetting pressure and squeezed to the surface of the shaft will be scraped off the surface of the shaft by the scraper 24 that is in contact with the shaft to ensure that no excess metal remains on the surface of the shaft after welding. During this process, the scraper 24 rotates together with the ring frame 22.

[0056] Specifically, before friction welding, the restriction on scraper 24 is released by loosening the nut. At this time, scraper 24 is rotated so that the end facing the turbine impeller tilts outward. After tilting to the required angle, the nut is tightened again so that scraper 24 is fixed to the end of adjusting rod 233. Then, the position of scraper 24 is adjusted by extending rod 232 and adjusting rod 233 so that the inward tilted end contacts the outer wall of the shaft body. In particular, this end is arc-shaped to increase the contact area with the shaft body. It should be noted that all scrapers 24 need to be adjusted. After adjustment, the inward tilted end of all scrapers 24 contacts the outer wall of the shaft body. In this state, during friction welding, scraper 24 rotates around the shaft body with ring frame 22, which can scrape the molten metal squeezed to the surface of the shaft body into a frustum shape, improving the connection tightness of turbine shaft and turbine impeller after friction welding. At the same time, the end of scraper 24 that is in contact with the outer wall of the shaft body can also provide auxiliary support for the shaft body to ensure coaxiality after welding.

[0057] like Figure 2 and Figure 3 As shown, the ring frame 22 is rotatably connected to the support base 21, and a toothed ring 26 is fixed on one side of the ring frame 22. A drive gear 27 that meshes with the toothed ring 26 is rotatably connected to one side of the support base 21. A reduction motor 28 whose output end is connected to the drive gear 27 is installed on the support base 21.

[0058] Specifically, during the friction welding process of the turbine shaft and turbine impeller, regardless of the method used to process the molten metal extruded onto the surface of the shaft, the gear motor 28 is started to drive the drive gear 27 to rotate the gear ring 26, which in turn enables the ring frame 22 to drive the scraper 24 to rotate, scraping away or scraping the molten metal extruded onto the surface of the shaft into a frustum shape.

[0059] like Figure 3 and Figure 5 As shown, in order to collect the scraped metal, a receiving box 25 is inserted into one side of the support base 21 through a vertical slot, and the receiving box 25 is fixed in the vertical slot by a third bolt.

[0060] Specifically, in actual use, by unscrewing the third bolt, the restriction on the receiving box 25 can be released. At this time, the receiving box 25 can be moved up and down to adapt to different positions of the adjusting rod 233, so as to avoid affecting the rotation of the adjusting rod 233. After moving, the third bolt is rotated again to fix the position of the receiving box 25, so that the molten metal scraped off by the scraper 24 can be received for subsequent centralized processing.

[0061] Specifically, this automotive turbocharger welding workbench, based on standardized machining, operates / is used as follows:

[0062] 1. Preliminary preparation and initial fixation of the workpiece

[0063] (1) Adjust the equipment according to the workpiece specifications: loosen the third bolt to move the receiving box 25 of the support seat 21 and fix it; loosen the first bolt to adjust the length of the extension rod 232 in the branch pipe 231 and initially position the scraper 24;

[0064] (2) Fix the turbine shaft to the rotary chuck 11 and the turbine impeller to the pneumatic chuck 12 to ensure that the welding end faces are opposite;

[0065] 2. Turbine impeller assisted fixing (positioning unit 30 activated)

[0066] The second electric hydraulic rod 31 of the positioning unit 30 is activated, driving the upper pressure seat 32 to move downward; through the rack 36 and the transmission gear 35, the lower clamp 34 is driven to move upward along the telescopic rod 33, so that the limiting cavity of the upper pressure seat 32 and the lower clamp 34 covers the impeller, completing the auxiliary fixation;

[0067] 3. Scraper 24 position and angle adjustment (to adapt to metal extrusion processing requirements)

[0068] (1) Scrape off the extruded plastic metal (keep the shaft diameter consistent): Keep the scraper 24 parallel to the adjusting rod 233, loosen the second bolt to adjust the extension of the adjusting rod 233 so that the lower scraper 24 contacts the shaft and the rest moves away, and tighten the bolt to fix it;

[0069] (2) Frustum-shaped plastic metal (reinforced connection): Loosen the knob stud nut, rotate the scraper 24 to the preset tilt angle and fix it; adjust all scrapers 24 so that their tilted ends contact the shaft;

[0070] 4. Simultaneous processing of friction welding and flash.

[0071] (1) Start the first electric hydraulic rod 13 to push the rotary chuck 11 along the slide rail of the base 10 to move towards the pneumatic chuck 12, so that the turbine shaft contacts the impeller end face;

[0072] (2) Start the rotating chuck 11 to drive the turbine shaft to rotate at high speed and generate frictional heat, so that the metal on the contact surface reaches a plastic state; simultaneously start the reduction motor 28 of the auxiliary unit 20, which drives the ring frame 22 and scraper 24 to rotate through the drive gear 27 and gear ring 26, and simultaneously process the extruded plastic metal.

[0073] (3) When the temperature and plastic layer reach the standard, stop the rotation (or keep the rotation and increase the pressure), apply the upsetting pressure through the first electric hydraulic rod 13 to compact the metal and achieve metallurgical bonding; the scraper 24 continues to process the extruded plastic metal, and the receiving box 25 collects the scraped metal;

[0074] 5. Welding completion and workpiece removal

[0075] After welding is completed, turn off the geared motor 28 and the rotary chuck 11, control the first electro-hydraulic rod 13 to drive the rotary chuck 11 to reset; start the second electro-hydraulic rod 31 to reset the upper pressure seat 32 and the lower clamping seat 34; release the pneumatic chuck 12 and the rotary chuck 11, and take out the workpiece to complete the process.

[0076] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A welding workbench for automotive turbochargers based on standardized processing, comprising a base (10), on which a rotary chuck (11) is slidably mounted, and on the side of the base (10) away from the rotary chuck (11) is a pneumatic chuck (12) mounted via a bracket, and on the side of the base (10) away from the pneumatic chuck (12) is a first electro-hydraulic rod (13) with one end connected to the rotary chuck (11), characterized in that, An auxiliary unit (20) is provided in the middle of the base (10). The auxiliary unit (20) includes a support seat (21) assembled on the base (10). A telescopic component (23) is connected inside the support seat (21) through a mounting ring (22). During the friction welding process between the turbine impeller and the turbine shaft, the molten metal squeezed to the surface of the shaft is removed from the surface of the shaft by the scraper (24) assembled at the end of the telescopic component (23) or squeezed into a frustum shape and left on the surface of the shaft. A positioning unit (30) is installed on the side of the base (10) near the pneumatic chuck (12). The positioning unit (30) includes a second electro-hydraulic rod (31) fixed to one side of the bracket by a mounting plate. An upper pressure seat (32) is installed at one end of the second electro-hydraulic rod (31). The base (10) is equipped with a telescopic rod (33), and a lower clamp (34) is installed at the top of the telescopic rod (33). The lower surface of the upper pressure seat (32) and the upper surface of the lower clamp (34) are both provided with limiting cavities adapted to the turbine impeller. Two rotating shafts are rotatably connected to one side of the bracket, and a transmission gear (35) is fixed at one end of each of the two rotating shafts. Racks (36) that mesh with the transmission gear (35) are installed on both sides of the upper pressure seat (32) and the lower clamp seat (34).

2. The automotive turbocharger welding workbench based on standardized processing according to claim 1, characterized in that, The telescopic component (23) includes a branch pipe (231) fixed on the ring frame (22), an extension rod (232) is installed inside the branch pipe (231) by a first bolt, and an adjusting rod (233) is connected to one end of the extension rod (232) by a second bolt.

3. The automotive turbocharger welding workbench based on standardized processing according to claim 2, characterized in that, One end of the scraper (24) is rotatably connected to the adjusting rod (233). One end of the adjusting rod (233) is provided with a knob stud. The knob stud passes through the adjusting rod (233) and the end of the scraper (24) and is threaded with a nut so that the scraper (24) can be fixed inside the adjusting rod (233) after rotation.

4. The automotive turbocharger welding workbench based on standardized processing according to claim 3, characterized in that, The ring frame (22) is rotatably connected to the support base (21), and a toothed ring (26) is fixed on one side of the ring frame (22). A drive gear (27) meshing with the toothed ring (26) is rotatably connected on one side of the support base (21). A speed reduction motor (28) whose output end is connected to the drive gear (27) is installed on the support base (21).

5. A welding workbench for automotive turbochargers based on standardized processing according to claim 4, characterized in that, A receiver box (25) is inserted into one side of the support base (21) through a vertical slot, and the receiver box (25) is fixed in the vertical slot by a third bolt.

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