Closed front bumper and method of manufacturing the same

Abstract

The embodiment of the application relates to the technical field of automobile safety, in particular to a closed front bumper and a manufacturing method thereof, the closed front bumper comprises a front bumper body, a left side reinforcing plate and a right side reinforcing plate, the front bumper body has a closed area; the left side reinforcing plate and the right side reinforcing plate are arranged on the inner side of the front bumper body and correspondingly arranged at preset welding point positions on the inner side of the front bumper body, the left side reinforcing plate and the right side reinforcing plate are connected with the front bumper body through ultrasonic welding, so that the front bumper body, the left side reinforcing plate and the right side reinforcing plate form a whole structure subjected to force in cooperation. The closed area of the front bumper body is effectively internally supported, the problem of insufficient rigidity of an easy pressing part is improved, the pressing rigidity and compression resistance of the closed area are improved, and obvious welding marks are avoided on the outer surface.

Description

Technical Field

[0001] This application relates to the technical field of automotive safety, and more particularly to a closed front bumper and its manufacturing method. Background Technology

[0002] As car front-end designs continue to evolve towards a more integrated and enclosed aesthetic, the application of closed-off front bumpers is increasing. These bumpers typically eliminate the traditional open grille structure, resulting in a cleaner front appearance and meeting the requirements of overall vehicle design, aerodynamics, and the recognizability of new energy vehicles.

[0003] However, closed-off front bumpers, lacking the structural dispersion effect of traditional grille openings in certain areas, tend to create relatively weak closed areas over larger, continuous outer surfaces. During production, assembly, transportation, daily use, or when pressed by personnel, these closed areas are prone to localized dents, insufficient rebound, or inadequate rigidity due to concentrated stress, affecting the overall vehicle appearance and user tactile experience. Especially in areas prone to pressure, without effective internal support, the front bumper itself is susceptible to localized deformation under localized external forces, making it difficult to meet high requirements for appearance quality and structural strength.

[0004] In related technologies, the problem of insufficient local strength in the front bumper is usually addressed by thickening the body material, increasing the overall frame strength, or adding additional support components. However, thickening the body material often increases material costs and vehicle weight, which is not conducive to lightweight design; while increasing the overall frame strength may lead to complex structures, limited layout, and limited targeted reinforcement of easily pressured areas; using conventional additional support components can easily result in more assembly steps, insufficient connection stability, and susceptibility to aesthetic issues. Summary of the Invention

[0005] One objective of this application is to provide a closed front bumper and a method for manufacturing the same, aiming to solve the problem of the lack of effective solutions in the prior art for insufficient local strength of front bumpers.

[0006] In a first aspect, embodiments of this application provide a closed front bumper, characterized in that it includes a front bumper body, a left reinforcing plate and a right reinforcing plate, wherein the front bumper body has a closed area; The left and right reinforcing plates are disposed on the inner side of the front bumper body and are respectively disposed at the preset welding points on the inner side of the front bumper body. The left and right reinforcing plates are connected to the front bumper body by ultrasonic welding so that the front bumper body, the left and right reinforcing plates form a cohesive structure that shares the load.

[0007] In conjunction with the first aspect, in one possible implementation, the left reinforcing plate and the right reinforcing plate are respectively disposed on the left and right sides inside the enclosed area, and are respectively arranged corresponding to the easily pressed parts of the enclosed area to provide internal support for the enclosed area.

[0008] In conjunction with the first aspect, in one possible implementation, a plurality of left-side weld points are formed between the left-side reinforcing plate and the front bumper body, and a plurality of right-side weld points are formed between the right-side reinforcing plate and the front bumper body. The multiple left-side weld points and the multiple right-side weld points are located in corresponding welding contact areas to transfer the local load on the closed area of ​​the front bumper body to the corresponding reinforcing plate.

[0009] In conjunction with the first aspect, in one possible implementation, the connection points between the left and right reinforcing plates and the front bumper body are both located inside the front bumper body.

[0010] In conjunction with the first aspect, in one possible implementation, the left reinforcing plate and the right reinforcing plate are ultrasonically welded to the front bumper body to form a rigid assembly, so that when the closed area of ​​the front bumper body is subjected to local pressure, the force is diffused through the weld point to the left and right reinforcing plates, thereby converting the local point force into surface load.

[0011] In a second aspect, embodiments of this application also propose a method for manufacturing a closed front bumper, the method comprising: Place the left and / or right reinforcing plates on the special fixture or positioning mechanism at the first station, and then place the front bumper body into the equipment; The vacuum suction cup system is activated to adsorb and fix the front bumper body to prevent displacement of the front bumper body during the relocation and processing. The front bumper body is moved to the welding station, and the left and / or right reinforcing plates are positioned at the preset welding points inside the front bumper body. The pre-compression system is activated, and the pre-compression block is driven to descend by the main cylinder to press the welded contact area between the front bumper body and the left and / or right reinforcing plates. The ultrasonic welding unit is activated to apply ultrasonic vibration and pressure to the welding contact area, thereby welding the left and / or right reinforcing plates to the front bumper body. After welding is completed, the weld area is cooled by blowing air. Then the welding head is returned to its original position, the pre-pressure system is reset, the vacuum suction cup system stops adsorption, and the welded front bumper assembly is removed.

[0012] In conjunction with the second aspect, in one possible implementation, the left reinforcing plate and / or the right reinforcing plate are placed on a dedicated fixture or positioning mechanism at the first station. After the front bumper body is placed into the equipment, the vacuum suction cup system is activated synchronously or sequentially to counteract the influence of gravity and prevent the front bumper body from making micro-movements during subsequent relocation and processing, thereby ensuring the accuracy of the processing position.

[0013] In conjunction with the second aspect, in one possible implementation, during the process of transferring the front bumper body to the welding station, the front bumper body is lifted and transported to a position corresponding to the pre-placed left and / or right reinforcing plates by a positioning mold. The preload block presses against the welding contact area between the front bumper body and the left and / or right reinforcing plates to eliminate assembly gaps between the workpieces, provide back support during welding, and ensure consistent welding depth.

[0014] In conjunction with the second aspect, in one possible implementation, when the ultrasonic welding unit is working, a high-frequency electrical energy is generated by an ultrasonic generator. The high-frequency electrical energy is converted into mechanical vibration by a transducer, and the mechanical vibration is transmitted by the welding head to the joint surface of the front bumper body and the left and / or right reinforcing plates. Under the combined action of pressure and vibration, the joint surface generates heat through friction and melts. After mutual penetration, a welded connection is formed. The ultrasonic welding is completed within twenty seconds.

[0015] In conjunction with the second aspect, in one possible implementation, when cooling the weld joint area by blowing air, compressed gas is blown into the weld joint area that has just been welded by blowing air device to cool and shape the weld joint quickly, prevent excessive heat accumulation from causing part deformation and shorten the production cycle. After cooling is complete, the ultrasonic welding head is raised back to its original position, and the main cylinder of the pre-pressure system is raised to release the pre-pressure block from its clamping state. The negative pressure of the vacuum suction cup system is then turned off, and the welded front bumper assembly is removed.

[0016] The embodiments of this application can achieve the following technical effects: On one hand, the enclosed front bumper provided in this application, by setting a left-side reinforcing plate and a right-side reinforcing plate on the inner side of the front bumper body, and connecting the left-side and right-side reinforcing plates to the front bumper body respectively by ultrasonic welding, thereby forming a cohesive structure of the front bumper body, the left-side reinforcing plate, and the right-side reinforcing plate. This structure provides effective internal support for the enclosed area of ​​the front bumper body, especially enhancing the local structural strength of easily pressed areas, thereby improving the pressing stiffness and compressive strength of the enclosed area and reducing the possibility of local dents and deformation.

[0017] On the other hand, the left and right reinforcing plates of this application are respectively arranged on the left and right sides inside the closed area and are set in accordance with the easily pressed parts. Therefore, it is possible to strengthen the local weak areas more effectively, so that when the local load is pressed, it is transferred to the corresponding reinforcing plate through the weld point, realizing the force diffusion, transforming the local point force into surface bearing, and improving the overall force balance and structural stability of the front bumper.

[0018] Furthermore, this application also provides a manufacturing method for a closed front bumper. Through a combination of processes including vacuum adsorption fixing, transfer positioning, pre-pressurization, ultrasonic welding, and air cooling, a stable connection between the reinforcing plate and the front bumper body is achieved. Compared to existing technologies, the manufacturing method provided in this application offers more accurate positioning, higher welding efficiency, effectively reduced workpiece assembly gaps, improved welding quality consistency, reduced risk of part deformation, and shorter production cycles, making it suitable for mass production applications. Attached Figure Description

[0019] The accompanying drawings, which form part of this specification, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 A front view of a front bumper assembly provided in an embodiment of this application; Figure 2 A diagram showing the mounting positions of a front bumper assembly and left / right side reinforcement plates, provided as an embodiment of this application. Figure 3 A cross-sectional view of the front bumper assembly and the left / right side reinforcement plates provided in an embodiment of this application; Figure 4 A schematic flowchart illustrating a method for manufacturing a closed front bumper provided in an embodiment of this application; Figure 5 This is a schematic diagram of the structure of a computer device provided in an embodiment of this application. Detailed Implementation

[0020] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0021] The following detailed description is exemplary and intended to provide further detailed explanation of the invention. Unless otherwise specified, all technical terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used in this invention is for describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention.

[0022] It should be noted that in this specification, the terms "left side," "right side," "inner side," "outer side," "above," and "below" are used with reference to the installation or observation state shown in the accompanying drawings. They are only used to facilitate understanding of the technical solution of the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0023] like Figures 1 to 3 As shown, this embodiment provides a closed front bumper, including a front bumper body, a left reinforcing plate and a right reinforcing plate, wherein the front bumper body has a closed area; The left and right reinforcing plates are disposed on the inner side of the front bumper body and are respectively disposed at the preset welding points on the inner side of the front bumper body. The left and right reinforcing plates are connected to the front bumper body by ultrasonic welding so that the front bumper body, the left and right reinforcing plates form a cohesive structure that shares the load.

[0024] The front bumper body is part of the vehicle's front exterior covering, and its outer surface constitutes the main visible area of ​​the vehicle's front fascia. Unlike traditional front fascia structures with large open air intake grilles, the front bumper body in this embodiment has a closed area. This closed area appears as a continuous, smooth, integrated surface when viewed from the front of the vehicle, making it suitable for new energy vehicles and some models with closed front fascia designs. Because this closed area is relatively large and aims for a simple and complete appearance, it is more prone to insufficient rigidity and softness under pressure during routine car washing, inspection, handling, assembly, and light manual pressing.

[0025] Therefore, in this embodiment, a left-side reinforcing plate and a right-side reinforcing plate are provided on the inner side of the front bumper body. The left-side reinforcing plate and the right-side reinforcing plate can be arranged to correspond to the left and right parts inside the enclosed area, respectively, and together they form an internal support structure for the enclosed area.

[0026] Preferably, both the left and right reinforcing plates can be made of plastic materials that are compatible with the front bumper body, and can be molded to obtain a predetermined shape so as to match the local contours, welding contact areas and installation space of the inner surface of the front bumper body.

[0027] In this embodiment, the left and right reinforcing plates are disposed on the inner side of the front bumper body and are respectively disposed at the preset welding point positions on the inner side of the front bumper body.

[0028] The preset weld point location refers to the welding connection part pre-designed based on the stress characteristics of the enclosed area, the distribution of easily pressed areas, the inner surface contour, and the welding process requirements. There can be multiple preset weld point locations, distributed in the contact area where the reinforcing plate and the front bumper body are in contact with each other or adjacent to each other, so as to form multiple weld points after welding, thereby improving the stability of the connection and the load transfer capacity.

[0029] Furthermore, the left and right reinforcing plates are connected to the front bumper body via ultrasonic welding. In this way, the front bumper body, the left and right reinforcing plates form a cohesive structural unit that shares the load. When the enclosed area is subjected to localized external pressure, the localized force is no longer borne solely by the thin-walled area of ​​the front bumper body. Instead, it is transmitted and diffused through the weld points to the left and right reinforcing plates, transforming the force originally concentrated at a single point or in a small area into a shared load over a larger area. This effectively improves the pressing stiffness and compressive strength of the enclosed area and reduces the drum-like effect.

[0030] like Figure 2 As shown, in some preferred embodiments, the left and right reinforcing plates are respectively disposed on the left and right sides inside the enclosed area and are arranged corresponding to the easily pressed parts of the enclosed area to provide internal support for the enclosed area.

[0031] Specifically, although the outer surface of a closed front bumper appears as a continuous closed surface overall, the curvature, thickness, back space, and support conditions vary in different areas during actual structural design, resulting in inconsistent pressure resistance. Typically, areas with larger areas, larger back cavities, or greater distance from other support components are more prone to becoming softer under pressure. To enhance the local stiffness of these areas, left and right reinforcing plates can be placed on the corresponding inner sides based on simulation analysis results, empirical evaluation, or prototype testing results. This arrangement allows the reinforcing plates to form a closer support path behind the easily pressured areas, improving the local stress state without significantly increasing the overall weight.

[0032] In this embodiment, the left and right reinforcing plates do not need to be completely identical in structure. Depending on the inner contours of the left and right sides of the front bumper body, the available installation space, and the target support area, the two plates may differ in length, width, thickness, outline, local ribs, or the shape of the mating surface, as long as they can be stably welded to the corresponding areas and achieve a local reinforcement effect.

[0033] like Figure 2 and Figure 3 As shown, in some embodiments, multiple left-side weld points are formed between the left-side reinforcing plate and the front bumper body, and multiple right-side weld points are formed between the right-side reinforcing plate and the front bumper body; the multiple left-side weld points and the multiple right-side weld points are respectively located in the corresponding welding contact areas.

[0034] Specifically, the welding contact area refers to the region where the left or right reinforcing plate is close to or in contact with the inner surface of the front bumper body, suitable for ultrasonic welding. Multiple spaced weld points can be placed in this area to form a distributed connection. The number, spacing, and arrangement of these weld points can be determined comprehensively based on the stress distribution in the enclosed area, the size of the reinforcing plate, the capacity of the welding equipment, and manufacturing cycle requirements. Connecting through multiple weld points improves the reliability of the connection between the reinforcing plate and the front bumper body, and also allows localized pressure to diffuse to the reinforcing plate through multiple connection points, improving force transmission efficiency.

[0035] When a user applies partial pressure to the enclosed area of ​​the front bumper, the deformation tendency of the pressure-bearing part of the front bumper is transmitted to the corresponding left or right reinforcing plate through nearby weld points. Since the reinforcing plate itself has a certain in-plane stiffness and structural support, it can disperse the local load over a larger area, transforming the force on the enclosed area from a local point to a whole surface bearing, thereby reducing the depth of local indentation and improving rebound performance.

[0036] like Figure 3 As shown, in this invention, the connection points between the left and right reinforcing plates and the front bumper body are both located inside the front bumper body. In other words, the weld points formed by ultrasonic welding are located between the inner surface of the front bumper body and the reinforcing plates, rather than on the outer surface of the front bumper body.

[0037] Since a closed front bumper is typically a key styling component of a vehicle's front end, its exterior surface, especially the visible area of ​​the outer surface, requires high standards for flatness, integrity, and tactile feel. This embodiment, employing an internal connection method, ensures that the welding process primarily occurs at the inner joint interface, preventing the formation of noticeable weld marks on the outer surface and minimizing the presence of heavy tactile traces. This helps guarantee the aesthetic matching of the front bumper's outer surface, meeting the design requirements of a closed front end for cleanliness and unity.

[0038] It should be noted that all contact points in this embodiment are located inside the front bumper body, emphasizing the arrangement of the connection positions. As for the specific form of the weld points inside—whether they are dots, approximately circular, grouped, or distributed along a certain area—as long as they are formed on the inner side and can achieve a stable connection between the reinforcing plate and the front bumper body, they can all be considered feasible embodiments of the present invention.

[0039] In some preferred embodiments, the left and right reinforcing plates are ultrasonically welded to the front bumper body to form a rigid assembly. The term "rigid assembly" here does not mean absolutely no deformation, but rather that the integrated assembly formed after welding has significantly higher overall structural rigidity and load-bearing capacity when subjected to localized pressure, compared to structures without reinforcing plates or without stable welded connections.

[0040] It's easy to understand that ultrasonic welding creates a high-strength connection, with the welded area's strength approaching or even exceeding that of the base material itself. This avoids the stress relaxation issues that bolted connections might cause, as well as the aging and embrittlement risks associated with adhesive connections. Therefore, the left and right reinforcing plates can work stably and collaboratively with the front bumper body over a long period.

[0041] When the enclosed area is subjected to localized pressure, the force diffuses through the weld points to the left and right reinforcing plates, transforming the localized point stress into surface load-bearing capacity, significantly improving the dent resistance and rigidity of the enclosed area. Based on this, this embodiment can increase the pressing stiffness of the critical area to more than twice that of the original structure.

[0042] Furthermore, such as Figure 4 As shown, this embodiment provides a method for manufacturing a closed front bumper, including: Step S10: Place the left reinforcing plate and / or the right reinforcing plate on the special fixture or positioning mechanism of the first station, and put the front bumper body into the equipment; Step S20: Activate the vacuum suction cup system to adsorb and fix the front bumper body to prevent the front bumper body from shifting during the relocation and processing process. Step S30: The front bumper body is moved to the welding station, so that the left reinforcing plate and / or the right reinforcing plate are positioned at the preset welding point position inside the front bumper body. Step S40: Start the pre-compression system and drive the pre-compression block to descend through the main cylinder to press the welding contact area between the front bumper body and the left and / or right reinforcing plates. Step S50: Start the ultrasonic welding unit and apply ultrasonic vibration and pressure to the welding contact area to weld the left reinforcing plate and / or the right reinforcing plate to the front bumper body. Step S60: After welding is completed, the weld area is cooled by blowing air, then the welding head is returned to its original position, the pre-pressure system is reset, the vacuum suction cup system stops adsorption, and the welded front bumper assembly is removed.

[0043] The method in this embodiment is used to achieve a stable connection between the left reinforcing plate, the right reinforcing plate and the front bumper body, so as to obtain the closed front bumper in the aforementioned structural embodiment.

[0044] Specifically, in this embodiment, the method first places the left and / or right reinforcing plates on a dedicated fixture or positioning mechanism at the first station, and then places the front bumper body into the equipment. Here, "and / or" indicates that, depending on the actual product configuration, only the left reinforcing plate, only the right reinforcing plate, or both the left and right reinforcing plates may be placed.

[0045] In the preferred embodiment, both the left and right reinforcing plates are placed simultaneously to form a complete double-sided reinforcing structure. Specialized fixtures or positioning mechanisms are used to initially limit the reinforcing plates, ensuring they maintain a predetermined posture and position during subsequent station transitions and welding processes, thus reducing the risk of displacement.

[0046] Subsequently, the vacuum suction cup system is activated to adhere and fix the front bumper body, preventing displacement during repositioning and processing. Since the front bumper body is typically large, has a complex curved surface, and requires high-quality finishes, vacuum suction provides a more stable fixation while avoiding damage to the surface from rigid clamping.

[0047] Next, the front bumper body is moved to the welding station, where the left and / or right reinforcing plates are positioned at the pre-set welding points inside the front bumper body. During this process, the front bumper body can be lifted, moved, and repositioned using a positioning mold or other transfer and positioning device, ensuring accurate alignment between the front bumper body and the pre-positioned reinforcing plates in the fixture.

[0048] After the reinforcing plate and the front bumper body are aligned, the pre-compression system is activated. The main cylinder drives the pre-compression block to descend, pressing down on the welding contact area between the front bumper body and the left and / or right reinforcing plates. The functions of pre-compression include: eliminating any assembly gaps between the front bumper body and the reinforcing plates; providing necessary back support during welding to prevent incomplete welding due to vibration energy loss; and ensuring consistent pressure across all welding points, resulting in more stable welding depth and weld quality.

[0049] After the pre-stressing stabilizes, the ultrasonic welding unit is activated to apply ultrasonic vibration and pressure to the welding contact area, thereby welding the left and / or right reinforcing plates to the front bumper body. This process is the core step of the entire manufacturing method.

[0050] After welding, the weld area is cooled by blowing air. Then, the welding head returns to its original position, the pre-pressure system resets, the vacuum suction system stops adsorption, and the welded front bumper assembly is removed. Air cooling can accelerate the setting of the weld, reduce local heat accumulation, reduce the risk of part deformation, and help shorten the cycle time per part.

[0051] Through the steps described above in this embodiment, the welding and assembly between the reinforcing plate and the front bumper body can be completed stably, which is suitable for the mass production and rhythmic production needs of the modern automotive industry.

[0052] In some preferred embodiments, the left reinforcing plate and / or the right reinforcing plate are placed manually or by a robotic arm onto a dedicated fixture or positioning mechanism at the first station. After the front bumper body is placed into the equipment, the vacuum suction cup system is activated synchronously or sequentially to counteract the influence of gravity and prevent the front bumper body from making micro-movements during subsequent relocation and processing, thereby ensuring the accuracy of the processing position.

[0053] Specifically, at the beginning of a complete work cycle, the operator can first place the left and right reinforcing plates into their respective fixture positions, or the robotic arm can pick them up from the loading rack and place them into the fixture. The fixture can limit the reinforcing plates in the lateral, longitudinal, and height directions, ensuring that their welding surfaces face the inner surface of the front bumper body to be joined. After the reinforcing plates are placed, the front bumper body is then placed into the designated position on the equipment.

[0054] Considering the large size of the front bumper and its significant impact from its own weight, as well as the possibility of slight swaying due to inertia and vibration during relocation and tooling changes, the vacuum suction cup system is preferably activated as soon as possible after the front bumper is in place. The vacuum suction cup adheres to an appropriate area of ​​the front bumper, flexibly fixing it in place. This fixing method not only suppresses micro-movements but also avoids leaving indentations or damage to the surface like rigid clamps.

[0055] In some implementations, during the process of transferring the front bumper body to the welding station, the front bumper body is lifted and transported to a position corresponding to the pre-placed left and / or right reinforcing plates by a positioning mold; a pre-pressing block is pressed against the welding contact area between the front bumper body and the left and / or right reinforcing plates to eliminate assembly gaps between the workpieces and provide back support during welding, while ensuring consistent welding depth.

[0056] Specifically, during the equipment's working cycle, after the front bumper body has been initially placed and fixed in place, it can be lifted by a positioning mold and moved towards the welding station. The positioning mold can cooperate with the equipment base, guide rails, or transfer mechanism to accurately transport the front bumper body to the position corresponding to the pre-placed reinforcing plate.

[0057] In this embodiment, the corresponding position refers to the position of the left and right reinforcing plates after the bumper body is moved into place, with the left and right reinforcing plates located below or close to the preset welding points on the inner side of the front bumper body, respectively, and the welding contact area of ​​the two plates can meet the energy requirements of the subsequent ultrasonic welding head.

[0058] After the transfer and positioning are completed, the pre-compression system is started.

[0059] Preferably, the pre-compression system includes a main cylinder and a linked pre-compression block. When the main cylinder actuates, it drives the pre-compression block to move downwards, pressing the front bumper body and the reinforcing plate together in the welding contact area. Since certain dimensional and positional deviations are unavoidable in the manufacturing of automotive exterior panels and injection-molded parts, without pre-compression, small gaps may exist in the welding contact area, resulting in insufficient ultrasonic vibration transmission, weak welds, or fluctuations in weld quality. Pre-compression improves the fit between the two components, reduces assembly gaps, and enhances welding stability. The specification also clearly states that pre-compression provides sufficient back support during welding, preventing vibration energy loss and incomplete welding, ensuring consistent weld depth, and improving weld quality.

[0060] In some implementations, when the ultrasonic welding unit is working, the ultrasonic generator generates high-frequency electrical energy, which is converted into mechanical vibration by the transducer. The welding head then transmits the mechanical vibration to the joint surface between the front bumper body and the left and / or right reinforcing plates. Under the combined action of pressure and vibration, the joint surface generates heat through friction and melts, and after mutual penetration, a welded connection is formed.

[0061] Specifically, after the pre-compression system has stabilized and tightened, the ultrasonic welding unit begins operation. The ultrasonic generator outputs high-frequency electrical energy, which is converted into high-frequency mechanical vibration by the transducer. This vibrational energy is then directed through the welding head to the welding contact area between the front bumper body and the reinforcing plate. Under a certain pressure, the materials in the welding contact area undergo high-frequency friction and rapidly heat up. After the local materials reach a molten state, they interpenetrate. Once the vibration stops and appropriate pressure is maintained, solidification is completed, thus forming a stable welded connection.

[0062] The ultrasonic welding method used in this embodiment has several advantages. First, the welding process eliminates the need for additional adhesives, bolts, or rivets, thus reducing the number of additional parts and materials, which is beneficial for weight reduction and process simplification. Second, ultrasonic welding produces high-strength welds with reliable connections, avoiding the stress relaxation problems associated with bolted connections and the aging and embrittlement risks of adhesive connections. Third, this welding method has a short work cycle and a high degree of automation, making it suitable for mass production in the automotive industry.

[0063] It should be noted that during ultrasonic welding, parameters such as amplitude, pressure, and welding time can be adapted to the workpiece material, thickness, number of weld points, and equipment specifications. Those skilled in the art can make appropriate adjustments based on the material combinations of the front bumper body and reinforcing plate for different vehicle models without departing from the concept of this invention.

[0064] In some implementations, when cooling the weld area with air blowing, compressed gas is blown into the weld area that has just been welded by an air blowing device to quickly cool and shape the weld, prevent excessive heat accumulation that could cause part deformation, and shorten the production cycle. After cooling is completed, the ultrasonic welding head is raised back to its original position, and the main cylinder of the pre-pressure system is controlled to rise and drive the pre-pressure block to release the clamping state. The negative pressure of the vacuum suction cup system is turned off, and the welded front bumper assembly is removed.

[0065] Specifically, after the ultrasonic welding timer ends, the weld area still retains a certain amount of heat. If it is not cooled in time, the accumulation of local heat may cause adverse deformation of the front bumper body or reinforcement plate around the weld point, affecting the appearance and flatness, and even affecting the weld point forming quality. Therefore, after welding, the equipment preferably triggers the air blowing device immediately to blow compressed gas into the weld area to quickly cool and shape the weld point, thereby reducing the overall production cycle time.

[0066] After the air cooling process is complete, the ultrasonic welding head first rises back to its original position and exits the working area. Then, the main cylinder of the pre-compression system rises, causing the pre-compression block to move away from the welding contact area between the front bumper body and the reinforcing plate, releasing the pressure and restoring it to a safe height. Afterwards, the vacuum suction system shuts off the negative pressure, ceasing its suction and fixation of the front bumper body. Once the above mechanisms have completed their reset, the welded front bumper assembly can be removed from the first station by an operator or an automated parts-retrieving robot and sent to subsequent assembly, testing, or packaging processes.

[0067] Further, see Figure 5 , Figure 5 This is a schematic diagram of the structure of a computer device provided in an embodiment of this application. This computer device can serve as a production management device or a host computer for implementing the manufacturing methods described in the above embodiments. Based on this understanding, the computer device includes one or more processors 31 and a memory 32. The memory 32 is connected to one or more processors 31, for example, via a bus.

[0068] Processor 31 is configured to support the computer device in performing the corresponding functions in the methods described in the above method embodiments. Processor 31 may be a central processing unit (CPU), a network processor (NP), a hardware chip, or any combination thereof. The aforementioned hardware chip may be an application-specific integrated circuit (ASIC), a programmable logic device (PLD), or a combination thereof. The aforementioned PLD may be a complex programmable logic device (CPLD), a field-programmable gate array (FPGA), a generic array logic (GAL), or any combination thereof.

[0069] Memory 32 is used to store program code, etc. Memory 32 may include volatile memory (VM), such as random access memory (RAM); memory 32 may also include non-volatile memory (NVM), such as read-only memory (ROM), flash memory, hard disk drive (HDD), or solid-state drive (SSD); memory 32 may also include combinations of the above types of memory.

[0070] The memory 32 can be used to store non-volatile software programs, non-volatile computer-executable programs, and modules, such as the program instructions / modules corresponding to the central controller in the embodiments of this application. The processor 31 implements the manufacturing method provided in the above embodiments by running the non-volatile software programs, instructions, and modules stored in the memory 32.

[0071] The memory 32 may include a program storage area and a data storage area. The program storage area may store the operating system and applications required for at least one function. These remote memories can be connected to other component modules via a network. Examples of such networks include, but are not limited to, the Internet, corporate intranets, local area networks, mobile communication networks, and combinations thereof.

[0072] One or more modules are stored in memory 32. When executed by one or more processors 31, they perform the manufacturing method in any of the above method embodiments. For example, they perform the method steps described in the above method embodiments to realize the function of the modules described in the above device embodiments.

[0073] This application also provides a computer-readable storage medium storing a computer program, the computer program including program instructions, which, when executed by a computer, cause the computer to perform the method as described in the foregoing embodiments.

[0074] As is known from common technical knowledge, this invention can be implemented through other embodiments that do not depart from its spirit or essential characteristics. Therefore, the disclosed embodiments described above are merely illustrative in all respects and are not the only ones. All modifications within the scope of this invention or its equivalents are included in this invention.

[0075] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0076] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0077] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0078] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0079] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A closed front bumper, characterized in that, It includes a front bumper body, a left reinforcing plate and a right reinforcing plate, wherein the front bumper body has a closed area; The left and right reinforcing plates are disposed on the inner side of the front bumper body and are respectively disposed at the preset welding points on the inner side of the front bumper body. The left and right reinforcing plates are connected to the front bumper body by ultrasonic welding so that the front bumper body, the left and right reinforcing plates form a cohesive structure that shares the load.

2. The enclosed front bumper according to claim 1, characterized in that, The left and right reinforcing plates are respectively disposed on the left and right sides inside the enclosed area and are arranged corresponding to the easily pressed parts of the enclosed area to provide internal support for the enclosed area.

3. The enclosed front bumper according to claim 1, characterized in that, Multiple left-side weld points are formed between the left-side reinforcing plate and the front bumper body, and multiple right-side weld points are formed between the right-side reinforcing plate and the front bumper body. The multiple left-side weld points and the multiple right-side weld points are located in corresponding welding contact areas to transfer the local load on the closed area of ​​the front bumper body to the corresponding reinforcing plate.

4. The enclosed front bumper according to claim 1, characterized in that, The connection points between the left and right reinforcing plates and the front bumper body are both located inside the front bumper body.

5. The enclosed front bumper according to claim 1, characterized in that, The left and right reinforcing plates are ultrasonically welded to the front bumper body to form a rigid assembly. When the closed area of ​​the front bumper body is subjected to local pressure, the force is diffused to the left and right reinforcing plates through the weld points, so as to transform the local point force into surface load.

6. A method for manufacturing a closed front bumper, characterized in that, The method includes: Place the left and / or right reinforcing plates on the special fixture or positioning mechanism at the first station, and then place the front bumper body into the equipment; The vacuum suction cup system is activated to adsorb and fix the front bumper body to prevent displacement of the front bumper body during the relocation and processing. The front bumper body is moved to the welding station, and the left and / or right reinforcing plates are positioned at the preset welding points inside the front bumper body. The pre-compression system is activated, and the pre-compression block is driven to descend by the main cylinder to press the welded contact area between the front bumper body and the left and / or right reinforcing plates. The ultrasonic welding unit is activated to apply ultrasonic vibration and pressure to the welding contact area, thereby welding the left and / or right reinforcing plates to the front bumper body. After welding is completed, the weld area is cooled by blowing air. Then the welding head is returned to its original position, the pre-pressure system is reset, the vacuum suction cup system stops adsorption, and the welded front bumper assembly is removed.

7. The method according to claim 6, characterized in that, The left reinforcing plate and / or the right reinforcing plate are placed on a special fixture or positioning mechanism at the first station. After the front bumper body is placed into the equipment, the vacuum suction cup system is activated synchronously or sequentially to counteract the influence of gravity and prevent the front bumper body from making micro-movements during subsequent relocation and processing, thereby ensuring the accuracy of the processing position.

8. The method according to claim 6, characterized in that, During the process of transferring the front bumper body to the welding station, the front bumper body is lifted and transported to the position corresponding to the pre-placed left and / or right reinforcing plates using a positioning mold. The preload block presses against the welding contact area between the front bumper body and the left and / or right reinforcing plates to eliminate assembly gaps between the workpieces, provide back support during welding, and ensure consistent welding depth.

9. The method according to claim 6, characterized in that, When the ultrasonic welding unit is working, the ultrasonic generator generates high-frequency electrical energy, which is converted into mechanical vibration by the transducer. The welding head then transmits the mechanical vibration to the joint surface between the front bumper body and the left and / or right reinforcing plates. Under the combined action of pressure and vibration, the joint surface generates heat through friction and melts. After mutual penetration, a welded connection is formed. The ultrasonic welding is completed within twenty seconds.

10. The method according to claim 6, characterized in that, When cooling the weld joint area with air blowing, compressed gas is blown into the weld joint area that has just been welded through an air blowing device to quickly cool and shape the weld joint, prevent excessive heat accumulation that could cause part deformation, and shorten the production cycle. After cooling is complete, the ultrasonic welding head is raised back to its original position, and the main cylinder of the pre-pressure system is raised to release the pre-pressure block from its clamping state. The negative pressure of the vacuum suction cup system is then turned off, and the welded front bumper assembly is removed.

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