Electric bicycle frame splicing welding tooling

Abstract

This invention belongs to the field of tooling technology for electric bicycle frame manufacturing, and discloses a splicing and welding tooling for electric bicycle frames. It is used for shaping and welding frame components, including main side tubes, secondary side tubes, outer and inner plates of the center plate, and attached metal parts. The splicing and welding tooling includes: a base; and a clamping assembly arranged on the base for spatial shaping of the main side tubes, secondary side tubes, and attached metal parts. This invention uses a clamping assembly on the base for the main side tubes, secondary side tubes, and attached metal parts, combined with pneumatic push rods, pneumatic side pushers, manual clamps, and pneumatic flipping clamps to partition and position different tube sections and attached metal parts. This allows the main side tubes, secondary side tubes, outer and inner plates of the center plate, connecting plates, and multiple attached metal parts to be stably clamped according to the actual spatial contour of the frame, thereby reducing lateral offset and angular deviation before and after welding of irregularly shaped frames and improving the consistency of frame component welding positioning.

Description

Technical Field

[0001] This invention belongs to the field of tooling technology for electric bicycle frame manufacturing, specifically to tooling for splicing and welding electric bicycle frames. Background Technology

[0002] Electric bicycle frames are typically formed by welding together multiple irregularly shaped tubing, plates, and attached metal parts. For frame structures that include main side tubes, secondary side tubes, inner and outer plates of the center plate, connecting plates, and multiple attached metal parts, each component needs to be accurately positioned according to the spatial contour of the frame before welding. Otherwise, problems such as tubing angle deviation, insufficient plate fit, and unstable welding positions of attached metal parts may occur.

[0003] Existing welding fixtures mostly use fixed limiting blocks, single-point pressure plates, or universal clamps for positioning. For main and secondary pipes with multiple bends and multi-dimensional tilting shapes, it is difficult to simultaneously provide height support, lateral limiting, and local clamping for different pipe sections. At the same time, the inner and outer plates of the middle plate are prone to deformation under the action of welding heat input and weld shrinkage. After welding, they may also get stuck with the positioning components, making it difficult to remove the parts or causing secondary deformation.

[0004] Therefore, there is an urgent need for a splicing and welding fixture that can partition and position irregularly shaped tubular parts, plates, and attached metal parts of electric bicycle frames, and can reduce interference during part removal and facilitate welding deformation compensation after welding. Summary of the Invention

[0005] The purpose of this invention is to provide a welding fixture for splicing electric bicycle frames to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an electric bicycle frame splicing and welding fixture, used for shaping and welding frame components including main side tubes, secondary side tubes, outer plate of the center plate, inner plate of the center plate, and attached metal parts, wherein the splicing and welding fixture includes:

[0007] Base;

[0008] A clamping assembly, arranged on the base, is used to spatially shape the main side tube, the secondary side tube, and the attached metal part;

[0009] A linear translation clamp assembly is disposed on the base. The linear translation clamp assembly includes a base, a first cylinder, a guide rail, a movable seat, a second cylinder, and a positioning block. The base is fixed to the base, the guide rail is mounted on the base, and the movable seat is slidably connected to the guide rail. The piston rod of the first cylinder is connected to the movable seat to drive the movable seat to move linearly along the guide rail. The second cylinder is disposed on the movable seat, and the positioning block is connected to the end of the piston rod of the second cylinder. The second cylinder is used to drive the positioning block to clamp the outer piece of the intermediate plate. The first cylinder is configured to drive the movable seat to move along the guide rail to a preset demolding position after welding is completed, so as to actively separate the clamped outer piece of the intermediate plate from the welding area.

[0010] A support assembly is provided on the base. The support assembly includes a third cylinder and a support block. The third cylinder is used to drive the support block to support the inner sheet of the middle plate from below during the welding process, and to drive the support block to detach from the inner sheet of the middle plate after welding to assist in demolding.

[0011] As a further technical solution of the present invention, the linear translation clamp assembly also includes an assembly frame fixed on the movable seat, the second cylinder is mounted on the assembly frame, the positioning block is a universal adjustable positioning block, and shims are added to the three-dimensional coordinate axis directions of the positioning block to adjust the clamping angle and position of the outer piece of the middle plate according to the expected direction of the welding thermal deformation of the frame, so as to pre-compensate for the amount of thermal deformation generated during the welding process.

[0012] As a further technical solution of the present invention, the support assembly further includes a support rod, the third cylinder is fixed on the base, and the top end of the piston rod of the third cylinder is connected to the support block through the support rod.

[0013] As a further technical solution of the present invention, the clamping assembly includes:

[0014] Pneumatic push rod and pneumatic side push rod;

[0015] Manual clamps, including No. 1 manual clamp, No. 2 manual clamp and No. 3 manual clamp;

[0016] And pneumatic flip clamps, including No. 1 pneumatic flip clamp, No. 2 pneumatic flip clamp, No. 3 pneumatic flip clamp, No. 4 pneumatic flip clamp, No. 5 pneumatic flip clamp, No. 6 pneumatic flip clamp, No. 7 pneumatic flip clamp, No. 8 pneumatic flip clamp and No. 9 pneumatic flip clamp.

[0017] The fourth pneumatic flipping clamp is equipped with a positioning plate, which is used to place the fourth attached metal part.

[0018] As a further technical solution of the present invention, the main side tube includes non-parallel segments A, B, C, D and E, and the secondary side tube includes non-parallel segments X, Y and Z; two sets of pneumatic push rods are respectively arranged below the matching segment B and below the matching segment X; the pneumatic side push is arranged at the common position matching the matching segment Y and the matching segment Z, for laterally pressing the secondary side tube.

[0019] As a further technical solution of the present invention, it also includes a control device installed on the base, the control device including a first switch controller, a second switch controller and a third switch controller;

[0020] The first switch controller is communicatively connected to the first cylinder; the second switch controller is communicatively connected to the second cylinder; and the third switch controller is communicatively connected to the third cylinder.

[0021] An electric bicycle frame, the frame comprising: a main side tube, a secondary side tube, an outer plate of the center plate, an inner plate of the center plate, a connecting plate, and multiple attached metal parts;

[0022] The main side tube and the secondary side tube are connected and shaped by a wrapping welding of the outer plate and the inner plate of the intermediate connecting plate; the outer plate of the intermediate connecting plate is welded across the surfaces of the main side tube and the secondary side tube, the inner plate of the intermediate connecting plate is welded to the surface of the secondary side tube, and the outer plate and the inner plate of the intermediate connecting plate are welded to each other for fixation.

[0023] The connecting plate is welded and fixed between the main side pipe and the secondary side pipe;

[0024] All of the aforementioned metal fittings are welded to the surface of the main side tube.

[0025] As a further technical solution of the present invention, the main side pipe is a multi-dimensional inclined irregular pipe fitting, and its pipe body structure includes segments A, B, C, D and E that are connected in sequence and are not parallel to each other; the secondary side pipe is a multi-dimensional inclined irregular pipe fitting, and its pipe body structure includes segments X, Y and Z that are connected in sequence and are not parallel to each other.

[0026] As a further technical solution of the present invention, the plurality of attached metal parts specifically comprises seven, including: attached metal part No. 1, attached metal part No. 2, attached metal part No. 3, attached metal part No. 4, attached metal part No. 5, attached metal part No. 6 and attached metal part No. 7; wherein, attached metal part No. 2 and attached metal part No. 3 have the same structure.

[0027] As a further technical solution of the present invention, there are three welding positions between the outer plate of the intermediate connecting plate and the main side tube, one welding position between the outer plate of the intermediate connecting plate and the secondary side tube, one welding position between the inner plate of the intermediate connecting plate and the secondary side tube, and two welding positions between the outer plate of the intermediate connecting plate and the inner plate of the intermediate connecting plate.

[0028] The beneficial effects of this invention are as follows:

[0029] 1. This invention uses a clamping assembly on a base for the main side tube, secondary side tube, and attached metal parts. Combined with pneumatic push rods, pneumatic side pushers, manual clamps, and pneumatic flip clamps, different tube sections and attached metal parts are positioned in sections. This allows the main side tube, secondary side tube, outer plate of the middle plate, inner plate of the middle plate, connecting plate, and multiple attached metal parts to be stably clamped according to the actual spatial contour of the frame. This reduces lateral offset and angular deviation before and after welding of irregularly shaped frames and improves the consistency of frame component welding positioning.

[0030] 2. This invention uses a linear translation clamp assembly to adjust the positioning of the outer piece of the center plate and allow it to retract after welding. It also uses a support assembly to support the inner piece of the center plate during welding and release it after welding. This not only maintains the fit between the inner and outer pieces of the center plate and the main and auxiliary side tubes during welding, but also reduces the interference between the center plate area and the tooling after welding. In addition, after the positioning block and shims are finely adjusted, the position of the outer piece of the center plate can be pre-compensated according to the post-weld offset, which helps to improve the post-weld dimensional stability of the connection area in the middle of the frame. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the overall structure of the electric bicycle frame of the present invention in the clamping state on the welding fixture;

[0032] Figure 2 This is a schematic diagram of the individual three-dimensional structure of the welding fixture of the present invention;

[0033] Figure 3 This is a top view schematic diagram of the welding fixture of the present invention.

[0034] Figure 4 This is a separate schematic diagram of the linear translation clamp assembly of the present invention;

[0035] Figure 5 This is a schematic diagram from another perspective of the linear translation clamp assembly of the present invention;

[0036] Figure 6 This is a schematic diagram showing the cooperation state between the support component structure and the inner sheet of the intermediate plate of the present invention;

[0037] Figure 7 This is a separate schematic diagram of the electric bicycle frame of the present invention;

[0038] Figure 8 This is a schematic diagram of the electric bicycle frame of the present invention from another perspective;

[0039] Figure 9 This is a schematic diagram showing the mating state of the positioning block and the gasket of the present invention;

[0040] Figure 10 This is a schematic diagram of the side tube angle of the electric bicycle frame proposed in this invention;

[0041] Figure 11 This is a schematic diagram of stress distribution in the electric bicycle frame when the tooling is not used for welding, as proposed in this invention.

[0042] Figure 12 This is a schematic diagram of stress distribution on the electric bicycle frame when welded using this tooling, as proposed in this invention.

[0043] In the diagram: 1. Base; 21. Pneumatic push rod; 22. Pneumatic side push; 3. Linear translation clamp assembly; 31. Base; 32. First cylinder; 33. Guide rail; 34. Moving seat; 35. Assembly frame; 36. Second cylinder; 37. Positioning block; 4. Support assembly; 41. Third cylinder; 42. Support rod; 43. Support block; 5. Main side tube; 6. Secondary side tube; 7. Outer piece of center plate; 8. Inner piece of center plate; 9. Connecting plate; 101. Metal part No. 1; 102. Metal part No. 2; 103. Metal part No. 3; 104. Metal part No. 4; 105. Metal part No. 5; 106. Metal part No. 6 Accessories; 107. Metal parts No. 7; 11. Switch controller No. 1; 12. Switch controller No. 2; 13. Switch controller No. 3; 141. Manual clamp No. 1; 142. Manual clamp No. 2; 143. Manual clamp No. 3; 151. Pneumatic flip clamp No. 1; 152. Pneumatic flip clamp No. 2; 153. Pneumatic flip clamp No. 3; 154. Pneumatic flip clamp No. 4; 155. Pneumatic flip clamp No. 5; 156. Pneumatic flip clamp No. 6; 157. Pneumatic flip clamp No. 7; 158. Pneumatic flip clamp No. 8; 159. Pneumatic flip clamp No. 9; 16. Positioning plate; 17. Gasket. Detailed Implementation

[0044] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0045] Example 1: Overall structure of the electric bicycle frame splicing and welding fixture

[0046] like Figures 1 to 12 As shown, this embodiment provides a welding fixture for splicing electric bicycle frames, used for positioning, clamping, and shaping welding of frame components including a main side tube 5, a secondary side tube 6, an outer plate 7, an inner plate 8, a connecting plate 9, and multiple attached metal parts. In the frame assembly, both the main side tube 5 and the secondary side tube 6 are irregularly shaped tubes with spatial bending. The main side tube 5 includes segments A, B, C, D, and E connected sequentially and not parallel to each other, while the secondary side tube 6 includes segments X, Y, and Z connected sequentially and not parallel to each other. The outer plate 7 spans the outer regions of the main side tube 5 and the secondary side tube 6, and the inner plate 8 is disposed on the inner or lower corresponding region of the secondary side tube 6. After welding, the two form a wrap-around connection structure with the main side tube 5 and the secondary side tube 6. Because the aforementioned pipe fittings have multiple inclined angles, and the outer plate 7 and inner plate 8 of the middle connecting plate will form a localized covered area after welding, if ordinary fixed positioning blocks and a single clamp structure are used, jamming, deformation, and difficulty in removing the parts are likely to occur after welding shrinkage. The tooling in this embodiment, through the cooperation of the base 1, clamping assembly, linear translation clamp assembly 3, and support assembly 4, achieves spatial shaping of the irregular frame before welding, stable support during the welding process, and active assisted demolding after welding.

[0047] like Figures 1 to 3 As shown, the base 1 serves as the mounting foundation for various positioning, clamping, and support structures, and preferably adopts a rigid base plate or frame platform structure. The upper surface of the base 1 has a pre-reserved mounting area following the contour of the frame to be welded, allowing the main side tube 5, secondary side tube 6, outer plate of the center plate 7, inner plate of the center plate 8, connecting plate 9, and various attached metal parts to fall into their respective positioning positions. The base 1 can be equipped with conventional mounting structures such as positioning pins, limit blocks, mounting holes, or oblong adjustment holes to adjust the relative positions between the clamping components and the workpiece. The specific dimensions, thickness, and material of the base 1 can be determined based on the frame specifications, welding equipment, and production line space, as long as it ensures the stability of each clamping component, linear translation clamp assembly 3, and support assembly 4 during the welding process.

[0048] In this embodiment, the clamping assembly is arranged on the base 1 and is used to spatially shape the main side tube 5, the secondary side tube 6, and the attached metal parts. The clamping assembly includes a pneumatic push rod 21, a pneumatic side push rod 22, a manual clamp, and a pneumatic flip clamp. The pneumatic push rod 21 is used to push the pipe fitting from below or in a partial support direction; the pneumatic side push rod 22 is used to press the secondary side tube 6 from the side; the manual clamp is used to manually press the attached metal parts or in locations where it is inconvenient to install the pneumatic clamp; and the pneumatic flip clamp is used to quickly flip and press the pipe fitting, connecting plate, or attached metal parts after material is released. The installation positions of each clamping assembly are not simply evenly distributed, but are arranged according to the spatial orientation of sections A, B, C, D, and E of the main side tube 5 and sections X, Y, and Z of the secondary side tube 6, so that the clamping force is applied to the position suitable for bearing the pressure, avoiding twisting or local warping of the irregularly shaped pipe fitting due to single-point clamping.

[0049] Specifically, such as Figures 1 to 3 and Figure 10 As shown, two sets of pneumatic push rods 21 are respectively positioned below section B of the matching main side tube 5 and below section X of the matching secondary side tube 6. During clamping, the two sets of pneumatic push rods 21 abut against corresponding parts of the main side tube 5 and the secondary side tube 6, providing a support reference for the main side tube 5 and the secondary side tube 6 in the height direction. A pneumatic side pusher 22 is positioned at the shared location of sections Y and Z of the secondary side tube 6, used to laterally tighten the secondary side tube 6.

[0050] Specifically, the push rod end of the pneumatic side top 22 is hinged with a follower V-shaped top block or a non-circular conforming push plate. The two wing surfaces of the follower V-shaped top block are respectively in contact with the outer surfaces of the Y segment and the Z segment at corresponding angles. When the pneumatic side top 22 extends, the follower V-shaped top block can adapt to the bending angle between the Y segment and the Z segment, and at the same time press against the surfaces of the Y segment and the Z segment with uniform force, which can simultaneously limit the lateral displacement of the secondary side tube 6 in this area and the swing around the tube axis.

[0051] Since there are bends or angle changes between the Y and Z segments of the secondary tube 6, when the pneumatic side top 22 is set in the lateral positioning position shared by the two, it can simultaneously limit the lateral displacement of the secondary tube 6 in this area and the swing around the tube axis, thereby improving the positional stability when the outer piece 7 of the middle connecting plate, the inner piece 8 of the middle connecting plate and the secondary tube 6 are bonded and welded.

[0052] The manual clamps include manual clamp No. 1 141, manual clamp No. 2 142, and manual clamp No. 3 143. (Combined) Figures 1 to 3As shown, the first manual clamp 141 is preferably arranged near section C of the main side pipe 5 to position the second and third attached metal parts 102 and 103 to be welded in section C; the second manual clamp 142 is preferably arranged on the other side or adjacent area of ​​section C of the main side pipe 5 to position the fifth attached metal part 105 to be welded in section C, and can also be used to position the seventh attached metal part 107 near section C; the third manual clamp 143 is preferably arranged near section D of the main side pipe 5 to position the sixth attached metal part 106 to be welded in section D. The second and third attached metal parts 102 and 103 have the same or similar structure, so they can be clamped by the same clamping direction and similar positioning reference. The manual clamps facilitate the operator to adjust the small attached metal parts independently, avoiding misalignment of the attached metal parts during pneumatic clamping due to their small size and dense weld points.

[0053] The pneumatic tilting clamps include pneumatic tilting clamp No. 1 (151), pneumatic tilting clamp No. 2 (152), pneumatic tilting clamp No. 3 (153), pneumatic tilting clamp No. 4 (154), pneumatic tilting clamp No. 5 (155), pneumatic tilting clamp No. 6 (156), pneumatic tilting clamp No. 7 (157), pneumatic tilting clamp No. 8 (158), and pneumatic tilting clamp No. 9 (159). Combined Figures 1 to 3 As shown, pneumatic flip clamp 151 and pneumatic flip clamp 152 are arranged in section A of the main side tube 5 to clamp the front end or corresponding bending area of ​​the main side tube 5; pneumatic flip clamp 153 is arranged in section B of the main side tube 5 to cooperate with the corresponding pneumatic push rod 21 to form an upper and lower clamp; pneumatic flip clamp 154 ​​is arranged in section C of the main side tube 5, and a positioning plate 16 is installed on pneumatic flip clamp 154. The positioning plate 16 is used to place the fourth attached metal part 104, so that the fourth attached metal part 104 can have a stable resting surface and lateral reference before welding; pneumatic flip clamp 155 is arranged in the end area of ​​section E of the main side tube 5 to... The No. 6 pneumatic flip clamp 156 is positioned at the rear end or end of the main side tube 5; its clamping end does not directly contact the main side tube 5, but is used to clamp and position the No. 1 attached metal part 101; the No. 7 pneumatic flip clamp 157 is positioned near the B section of the main side tube 5, and is used to press the outer piece 7 of the middle connecting plate onto the surface of the B section of the main side tube 5; the No. 8 pneumatic flip clamp 158 and the No. 9 pneumatic flip clamp 159 are positioned near the X section of the secondary side tube 6, wherein the No. 8 pneumatic flip clamp 158 is used to press the outer piece 7 of the middle connecting plate onto the surface of the X section of the secondary side tube 6, and the No. 9 pneumatic flip clamp 159 is used to position the relative position between the connecting plate 9 and the X section of the secondary side tube 6. When the above-mentioned pneumatic tilting clamps are in operation, they are initially in the open state to facilitate the insertion of pipes and attached metal parts; after the workpiece is placed in place, each pneumatic tilting clamp flips and clamps the corresponding part, so that the frame assembly maintains its spatial position during the welding process.

[0054] Example 2: Linear translation positioning and pre-compensation structure of the outer sheet of the middle plate

[0055] like Figure 4 and Figure 5 As shown, the linear translation clamp assembly 3 is mounted on the base 1 and located in the welding positioning area corresponding to the outer piece 7 of the center plate. The linear translation clamp assembly 3 includes a base 31, a first cylinder 32, a guide rail 33, a movable seat 34, an assembly frame 35, a second cylinder 36, and a positioning block 37. The base 31 is fixed to the base 1, the guide rail 33 is mounted on the base 31, and the movable seat 34 is slidably connected to the guide rail 33. The cylinder body of the first cylinder 32 can be fixed to the base 31, and the piston rod of the first cylinder 32 is connected to the movable seat 34, or connected to the movable seat 34 through intermediate parts such as connecting blocks and lugs; when the first cylinder 32 extends or retracts, the movable seat 34 moves linearly along the guide rail 33. The extension direction of the guide rail 33 is preferably set to be consistent with the demolding direction where jamming is likely to occur after welding the outer piece 7 of the center plate, or consistent with the preset yielding direction of the frame being removed from the tooling. Thus, the first cylinder 32 can drive the moving seat 34 to the preset demolding position after welding is completed, so that the linear translation clamp assembly 3 can retract from the area where the outer piece 7 of the middle plate is located. Alternatively, while the second cylinder 36 maintains a slight clamping force, the pull force of the first cylinder 32 can be used to overcome the local biting and jamming caused by post-weld shrinkage, so that the positioning block 37 is forcibly disengaged from the outer piece 7 of the middle plate, thereby reducing the interference between the post-weld covered area and the tooling when removing parts.

[0056] The assembly frame 35 is fixed on the movable seat 34, and the second cylinder 36 is mounted on the assembly frame 35. The positioning block 37 is connected to the piston rod end of the second cylinder 36, which drives the positioning block 37 to move toward or away from the outer plate 7 of the intermediate plate. When the workpiece is clamped, the second cylinder 36 pushes the positioning block 37 closer to the outer plate 7 of the intermediate plate, so that the positioning block 37 provides a pressing, clamping, or positioning effect on the outer plate 7 of the intermediate plate. When release is required, the second cylinder 36 can first depressurize or retract, so that an initial gap is formed between the positioning block 37 and the outer plate 7 of the intermediate plate. For products with obvious jamming after welding, the second cylinder 36 can also maintain the clamping or abutting state of the outer plate 7 of the intermediate plate within a limited stroke, and then the first cylinder 32 drives the movable seat 34 to move along the guide rail 33 to the preset demolding position, so that the area where the outer plate 7 of the intermediate plate is located is actively separated from the welding positioning area of ​​the tooling. The term "separation" here refers to the outer piece 7 of the center plate separating from the positioning block, support surface, or welding positioning area on the tooling along with the welded frame assembly. It does not refer to the separation of the weld seams already formed between the outer piece 7 of the center plate and the main side tube 5 and the secondary side tube 6. Based on the above explanation, the linear translation clamp assembly 3 can achieve precise positioning before welding and provide active assisted demolding function after welding.

[0057] The positioning block 37 is preferably a universally adjustable positioning block. For example... Figure 9 As shown, an orthogonal groove is provided at the connection between the assembly frame 35 and the positioning block 37. Shims 17 are inserted into the gaps of the orthogonal groove. By changing the thickness and number of shims 17 in the transverse, longitudinal, and height directions within the orthogonal groove, the positioning block 37 can be finely adjusted in translation within the three-dimensional coordinate system. Furthermore, the clamping end of the positioning block 37 is movably connected to the main body via a spherical adjustment seat or an arc-shaped oval hole with a fastening bolt. When wedge-shaped shims 17 are added or removed locally on one side of the clamping end of the positioning block 37, the tilt angle of the clamping surface of the positioning block 37 can be finely adjusted by coordinating the rotational allowance of the spherical adjustment seat or the arc-shaped oval hole. After adjustment, the positioning block 37 is fixed as a whole by tightening the lock nut, ensuring its rigidity and stability during welding.

[0058] Before mass production, the first frame can be clamped and welded according to the theoretical position. Then, the relative offset direction and amount of the outer plate 7, inner plate 8, main side tube 5, and auxiliary side tube 6 after welding are measured. If the outer plate 7 is found to have shifted in a certain direction due to welding heat shrinkage, the initial clamping angle and position of the outer plate 7 can be pre-adjusted in the opposite direction by adjusting the shims 17 of the positioning block 37 in the three-dimensional coordinate axis direction before the next clamping. This ensures that the outer plate 7 has a pre-compensation amount opposite to the trend of post-weld thermal deformation before welding. The heat shrinkage generated during welding will offset part of the pre-compensation amount, making the welded outer plate 7 closer to the design position. This adjustment method does not require changing the structure of the main side tube 5, auxiliary side tube 6, and outer plate 7, nor does it require changing the welding equipment. Thermal deformation compensation can be achieved only by fine-tuning the tooling positioning reference, which is convenient for correction according to different batches of materials, welding processes, or operating habits during mass production.

[0059] Example 3: Floating support and active demolding structure for the inner sheet of the middle plate

[0060] like Figure 6As shown, the support assembly 4 is mounted on the base 1 and located in the support area corresponding to the inner plate 8 of the intermediate plate. The support assembly 4 includes a third cylinder 41, a support rod 42, and a support block 43. The third cylinder 41 is fixed on the base 1, and the top of the piston rod of the third cylinder 41 is connected to the support block 43 through the support rod 42. The support rod 42 is used to transmit the linear motion of the third cylinder 41 to the support block 43, and can be set to one or more rods depending on the position of the inner plate 8 of the intermediate plate. The upper end surface of the support block 43 is adapted to the lower surface or mating surface of the inner plate 8 of the intermediate plate. During the welding process, the third cylinder 41 drives the support rod 42 and the support block 43 to rise, so that the support block 43 supports and fits the inner plate 8 of the intermediate plate from below, preventing the inner plate 8 of the intermediate plate from deforming downward due to welding heat input or clamping pressure. After welding is completed, the third cylinder 41 drives the support block 43 to fall, so that the support block 43 is detached from the inner plate 8 of the intermediate plate, thereby eliminating the lower support interference between the inner plate 8 of the intermediate plate and the tooling. After the support component 4 and the linear translation clamp component 3 are combined, the constraints can be released from the two areas that are prone to jamming, namely the inner plate 8 and the outer plate 7 of the middle plate, respectively, thereby improving the overall smoothness of part removal.

[0061] In this embodiment, the base 1 is also equipped with control devices, including a first switch controller 11, a second switch controller 12, and a third switch controller 13. The first switch controller 11 is communicatively or controllably connected to the first cylinder 32, and is used to control the extension, retraction, and stopping of the first cylinder 32. The second switch controller 12 is communicatively or controllably connected to the second cylinder 36, and is used to control the clamping or releasing of the positioning block 37 onto the outer piece 7 of the center plate. The third switch controller 13 is communicatively or controllably connected to the third cylinder 41, and is used to control the rising support or falling disengagement of the support block 43 onto the inner piece 8 of the center plate. The above-mentioned communication connections can be understood as electrical connections, pneumatic control connections, or indirect control connections achieved through solenoid valves, pneumatic valve assemblies, or control wiring harnesses. The pneumatic push rod 21, pneumatic side push 22 and each pneumatic tilting clamp can also be driven by the corresponding air source, valve group or control button. The air source, air pipe and valve group can be set around the base 1 or on external equipment. Conventional power sources and pipelines not shown in the figure do not affect the connection relationship and working process between the structures in this embodiment.

[0062] Example 4: Electric bicycle frame assembly and welding position arrangement

[0063] This embodiment also provides an electric bicycle frame formed by positioning and welding using the above-described splicing and welding fixture. For example... Figure 7 and Figure 8As shown, the electric bicycle frame includes a main side tube 5, a secondary side tube 6, an outer plate of the center joint 7, an inner plate of the center joint 8, a connecting plate 9, and multiple attached metal parts. Specifically, there are seven attached metal parts: attached metal part 101, attached metal part 102, attached metal part 103, attached metal part 104, attached metal part 105, attached metal part 106, and attached metal part 107. Attached metal part 102 and attached metal part 103 can be symmetrical parts with the same structure or parts of the same specification. The main side tube 5 and the secondary side tube 6 are connected and shaped by a wrapping weld of the outer plate of the center joint 7 and the inner plate of the center joint 8. The outer plate of the center joint 7 is welded across the surfaces of the main side tube 5 and the secondary side tube 6, and the inner plate of the center joint 8 is welded to the surface of the secondary side tube 6. Furthermore, the outer plate of the center joint 7 and the inner plate of the center joint 8 are welded and fixed together. The connecting plate 9 is welded and fixed between the main side tube 5 and the secondary side tube 6 to enhance the connection rigidity between the main side tube 5 and the secondary side tube 6; each attached metal part is welded to the surface of the main side tube 5 to meet the subsequent installation, connection or reinforcement requirements of the frame.

[0064] Combination Figure 7 and Figure 8 As shown, there are three welding positions between the outer plate 7 and the main side tube 5, one welding position between the outer plate 7 and the secondary side tube 6, one welding position between the inner plate 8 and the secondary side tube 6, and two welding positions between the outer plate 7 and the inner plate 8. During welding, the contact positions between the outer plate 7 and the main side tube 5 and the secondary side tube 6 can be tack welded first, and then the contact positions between the inner plate 8 and the secondary tube 6 can be tack welded. Afterwards, the welding positions can be segmented or alternately welded according to the requirements for controlling welding deformation. Specific welding methods can include argon arc welding, carbon dioxide gas shielded welding, or other welding processes suitable for connecting metal pipes and plates, commonly used in electric bicycle frame manufacturing. This embodiment does not uniquely limit the specific welding current, voltage, welding wire specifications, or other process parameters. As long as a reliable weld can be formed at the above welding position, and the main side pipe 5, the secondary side pipe 6, the outer piece 7 of the middle connecting plate, the inner piece 8 of the middle connecting plate, and the connecting plate 9 are fixedly connected, the technical effect of this application can be achieved.

[0065] Example 5: Tooling clamping, welding, and demolding operation process

[0066] The usage process of this embodiment will be described below in conjunction with the clamping, welding and demolding processes.

[0067] The first step is pre-clamping reset. Pneumatic flip clamps 151 through 159 are in the open position, and manual clamps 141, 142, and 143 are in the released position. Using switch controller 11, the first cylinder 32 moves the moving seat 34 to the initial positioning position. Using switch controller 12, the second cylinder 36 and positioning block 37 are positioned to facilitate the placement of the outer piece 7 of the intermediate plate. Using switch controller 13, the third cylinder 41 is positioned to receive or lift the inner piece 8 of the intermediate plate. If there is post-weld offset in the previous batch of products, adjust the shim 17 or adjustment structure at the positioning block 37 according to the offset direction before clamping.

[0068] The second step is to place the main side tube 5 and the auxiliary side tube 6. The operator places the main side tube 5 into the corresponding positioning area on the base 1 according to the spatial orientation of segments A, B, C, D, and E, and places the auxiliary side tube 6 into the corresponding positioning area on the base 1 according to the spatial orientation of segments X, Y, and Z. Two sets of pneumatic push rods 21 are respectively placed under segment B of the main side tube 5 and under segment X of the auxiliary side tube 6, providing height support for both the main side tube 5 and the auxiliary side tube 6; pneumatic side pushers 22 laterally press the auxiliary side tube 6 from the shared position of segments Y and Z, restricting its lateral and angular position.

[0069] The third step involves placing the inner plate 8 and outer plate 7 of the intermediate connecting plate. The inner plate 8 is placed above the support block 43 or in the corresponding support area. The third cylinder 41 is activated by the third switch controller 13, causing the support rod 42 to lift the support block 43 and support the inner plate 8 from below, bringing it close to the surface of the secondary tube 6 to be welded. The outer plate 7 is then placed in the bridging area between the main tube 5 and the secondary tube 6. The second cylinder 36 is activated by the second switch controller 12, causing the positioning block 37 to press against or abut against the outer plate 7. At this point, the outer plate 7 is restricted by the positioning block 37 and related flipping clamps, while the inner plate 8 is supported by the support block 43, maintaining a preset relative position between the inner and outer plates.

[0070] Step 4: Place the connecting plate 9 and all attached metal parts. Place the connecting plate 9 at the preset welding position between the main side tube 5 and the secondary side tube 6, and restrict the position between the connecting plate 9 and the X segment of the secondary side tube 6 using the No. 9 pneumatic flip clamp 159 or an adjacent positioning structure. Place the attached metal parts 101 to 107 in sequence: attached metal part 101 is positioned by the No. 6 pneumatic flip clamp 156; attached metal parts 102 and 103 are positioned by the No. 1 manual clamp 141; attached metal part 104 is placed at the positioning plate 16 on the No. 4 pneumatic flip clamp 154; attached metal parts 105 and 107 are positioned by the No. 2 manual clamp 142; attached metal part 106 is positioned by the No. 3 manual clamp 143. After all attached metal parts are placed, close the relevant manual clamps and pneumatic flip clamps in sequence to make each attached metal part fit against the surface of the main side tube 5.

[0071] Step 5: Overall clamping and verification. Close the pneumatic flipping clamps 151, 152, 153, 154, 155, 156, 157, 158, and 159 in sequence, and verify that the main side tube 5, secondary side tube 6, outer plate 7, inner plate 8, connecting plate 9, and all attached metal parts are in a properly fitted state. If a gap is found between the outer plate 7 and the main side tube 5 or secondary side tube 6, the positioning block 37 can be clamped and corrected using the second cylinder 36. If insufficient support is found under the inner plate 8, the lifting position of the support block 43 can be adjusted using the third cylinder 41. After verification, welding can proceed.

[0072] Step 6: Welding. With the clamping assembly, linear translation clamp assembly 3, and support assembly 4 in working condition, welding is performed on three welding positions between the outer plate 7 and the main side tube 5, one welding position between the outer plate 7 and the secondary side tube 6, one welding position between the inner plate 8 and the secondary side tube 6, and two welding positions between the outer plate 7 and the inner plate 8. Welding is also performed on the corresponding positions of the connecting plate 9 and the first to seventh auxiliary metal parts 101. During welding, the pneumatic push rod 21, pneumatic side push 22, and pneumatic flip clamp restrict the positions of the main side tube 5 and the secondary side tube 6. The support block 43 supports the inner plate 8 from below, and the positioning block 37 restricts the position of the outer plate 7, thereby reducing warping and displacement of the inner and outer plates due to welding heat input.

[0073] Step 7: Active Assisted Demolding. After welding is completed and necessary cooling is achieved, first release the No. 1 manual clamp 141, No. 2 manual clamp 142, and No. 3 manual clamp 143, and open all pneumatic flip clamps to release the conventional clamping constraints on the main side tube 5, secondary side tube 6, connecting plate 9, and all attached metal parts. Then, control the retraction of the third cylinder 41 via the No. 3 switch controller 13, causing the support rod 42 and support block 43 to move downwards, and the support block 43 to disengage from the inner plate 8 of the middle connecting plate, thereby releasing the support interference on the lower side of the inner plate 8 of the middle connecting plate. Then, based on the actual jamming situation between the outer plate 7 of the middle connecting plate and the positioning block 37, control the second cylinder 36 via the No. 2 switch controller 12 to depressurize or maintain the limited clamping state; then control the first cylinder 32 via the No. 1 switch controller 11 to drive the moving seat 34 to move along the guide rail 33 to the preset demolding position. When the movable seat 34 moves, it causes the assembly frame 35, the second cylinder 36, and the positioning block 37 to retract synchronously, or, under a limited clamping state, it causes the frame assembly containing the outer piece 7 of the middle plate to undergo a small stroke of pre-disengagement relative to the tooling positioning area, thereby releasing the enveloping jamming at the outer piece 7 of the middle plate. After there is no obvious interference below the inner piece 8 of the middle plate and laterally on the outer piece 7 of the middle plate, the operator can remove the welded electric bicycle frame from the base 1.

[0074] Example 6: Welding Deformation Control Effect and Adaptation Adjustment Method

[0075] like Figure 11 and Figure 12 As shown, when welding is not performed using the tooling of this embodiment, the lack of active demolding and pre-compensation positioning structures in the inner and outer areas of the mid-plate leads to a concentration of local stress in the connection area between the mid-plate and the fittings after frame welding. Furthermore, weld shrinkage may cause the workpiece to become stuck with the fixed positioning block during part removal. With the tooling of this embodiment, the support assembly 4 provides downward support for the inner plate 8 of the mid-plate during welding, the linear translation clamp assembly 3 provides adjustable positioning and active demolding for the outer plate 7 of the mid-plate, and the positioning block 37 and shim 17 can be pre-compensated and adjusted according to the actual thermal deformation direction. Therefore, the stress distribution in the mid-plate area of ​​the welded frame assembly is more balanced, part removal is smoother after welding, and the relative positional consistency between the main side tube 5, the secondary side tube 6, the outer plate 7 of the mid-plate, and the inner plate 8 of the mid-plate is better.

[0076] It should be noted that the pneumatic flipping clamps (numbers 1 to 9), three sets of manual clamps, two sets of pneumatic push rods, and one set of pneumatic side push rods listed in the above embodiments are preferred arrangements given in conjunction with the frame structure shown in the attached drawings. Without changing the core technical concept of this application, for electric bicycle frames of different specifications, the mounting hole positions, clamping directions, clamping end shapes, and action sequences of each clamping component can be adaptively adjusted according to the specific shapes of the main side tube 5, secondary side tube 6, outer plate 7, inner plate 8, and attached metal parts. As long as the spatial shaping of the main side tube 5, secondary side tube 6, and attached metal parts is still achieved through the clamping components, the positioning and active demolding of the outer plate 7 area are achieved through the linear translation clamping clamp component 3, and the welding support and post-weld detachment of the inner plate 8 are achieved through the support component 4, this constitutes an equivalent implementation of the technical solution of this application.

Claims

1. An electric bicycle frame splicing and welding fixture, used for shaping and welding frame components including main side tube (5), secondary side tube (6), outer plate of center plate (7), inner plate of center plate (8) and attached metal parts, characterized in that: The splicing and welding fixture includes: Base (1); A clamping assembly is arranged on the base (1) for spatially shaping the main side tube (5), the secondary side tube (6) and the attached metal parts; A linear translation clamp assembly (3) is disposed on the base (1). The linear translation clamp assembly (3) includes a base (31), a first cylinder (32), a guide rail (33), a movable seat (34), a second cylinder (36), and a positioning block (37). The base (31) is fixed on the base (1), the guide rail (33) is mounted on the base (31), and the movable seat (34) is slidably connected to the guide rail (33). The piston rod of the first cylinder (32) is connected to the movable seat (34) to drive the movable seat. The seat (34) moves linearly along the guide rail (33); the second cylinder (36) is disposed on the moving seat (34), and the positioning block (37) is connected to the piston rod end of the second cylinder (36). The second cylinder (36) is used to drive the positioning block (37) to clamp the outer piece (7) of the middle plate; the first cylinder (32) is configured to drive the moving seat (34) to move along the guide rail (33) to a preset demolding position after welding is completed, so as to drive the clamped outer piece (7) of the middle plate to actively separate from the welding area. And a support component (4) is disposed on the base (1). The support component (4) includes a third cylinder (41) and a support block (43). The third cylinder (41) is used to drive the support block (43) to support and adhere to the inner sheet (8) of the middle plate from below during the welding process, and to drive the support block (43) to detach from the inner sheet (8) of the middle plate after welding to assist in demolding.

2. The electric bicycle frame splicing and welding fixture according to claim 1, characterized in that: The linear translation clamp assembly (3) also includes an assembly frame (35) fixed on the moving seat (34), the second cylinder (36) is mounted on the assembly frame (35), the positioning block (37) is a universal adjustable positioning block, and shims (17) are added to all three-dimensional coordinate axes of the positioning block (37) to adjust the clamping angle and position of the outer piece (7) of the middle plate according to the expected direction of the heat deformation of the frame welding, so as to pre-compensate the amount of heat deformation generated during the welding process.

3. The electric bicycle frame splicing and welding fixture according to claim 1, characterized in that: The support assembly (4) also includes a support rod (42), the third cylinder (41) is fixed on the base (1), and the top end of the piston rod of the third cylinder (41) is connected to the support block (43) through the support rod (42).

4. The electric bicycle frame splicing and welding fixture according to claim 1, characterized in that: The clamping assembly includes: Pneumatic push rod (21) and pneumatic side push rod (22); Manual clamps, including manual clamp No. 1 (141), manual clamp No. 2 (142) and manual clamp No. 3 (143). And pneumatic flip clamps, including No. 1 pneumatic flip clamp (151), No. 2 pneumatic flip clamp (152), No. 3 pneumatic flip clamp (153), No. 4 pneumatic flip clamp (154), No. 5 pneumatic flip clamp (155), No. 6 pneumatic flip clamp (156), No. 7 pneumatic flip clamp (157), No. 8 pneumatic flip clamp (158) and No. 9 pneumatic flip clamp (159); The fourth pneumatic flip clamp (154) is equipped with a positioning plate (16), which is used to place the fourth attached metal part (104).

5. The electric bicycle frame splicing and welding fixture according to claim 1, characterized in that: The main side tube (5) includes segments A, B, C, D and E that are not parallel to each other, and the secondary side tube (6) includes segments X, Y and Z that are not parallel to each other; two sets of pneumatic push rods (21) are respectively arranged below segments B and below segments X; the pneumatic side pusher (22) is arranged at the common position of segments Y and Z, and is used to press the secondary side tube (6) from the side.

6. The electric bicycle frame splicing and welding fixture according to claim 1, characterized in that: It also includes control devices installed on the base (1), the control devices including a first switch controller (11), a second switch controller (12) and a third switch controller (13). The first switch controller (11) is connected to the first cylinder (32); the second switch controller (12) is connected to the second cylinder (36); and the third switch controller (13) is connected to the third cylinder (41).

7. An electric bicycle frame, characterized in that: The electric bicycle frame is assembled by positioning and welding using the splicing and welding fixture as described in any one of claims 1 to 6. The frame includes: a main side tube (5), a secondary side tube (6), an outer plate of the middle connecting plate (7), an inner plate of the middle connecting plate (8), a connecting plate (9), and a plurality of attached metal parts. The main side tube (5) and the secondary side tube (6) are connected and shaped by the wrapping welding of the outer plate (7) and the inner plate (8) of the middle connecting plate; the outer plate (7) of the middle connecting plate is welded across the surface of the main side tube (5) and the secondary side tube (6), the inner plate (8) of the middle connecting plate is welded to the surface of the secondary side tube (6), and the outer plate (7) of the middle connecting plate and the inner plate (8) of the middle connecting plate are welded and fixed to each other; The connecting plate (9) is welded and fixed between the main side pipe (5) and the secondary side pipe (6); All of the attached metal parts are welded to the surface of the main side tube (5).

8. The electric bicycle frame according to claim 7, characterized in that: The main side pipe (5) is a multidimensional inclined irregular pipe fitting, and its pipe body structure includes segments A, B, C, D and E that are connected in sequence and are not parallel to each other; the secondary side pipe (6) is a multidimensional inclined irregular pipe fitting, and its pipe body structure includes segments X, Y and Z that are connected in sequence and are not parallel to each other.

9. The electric bicycle frame according to claim 7, characterized in that: The plurality of attached metal parts specifically comprises seven, including: attached metal part No. 1 (101), attached metal part No. 2 (102), attached metal part No. 3 (103), attached metal part No. 4 (104), attached metal part No. 5 (105), attached metal part No. 6 (106), and attached metal part No. 7 (107); wherein, attached metal part No. 2 (102) and attached metal part No. 3 (103) have the same structure.

10. The electric bicycle frame according to claim 7, characterized in that: There are three welding positions between the outer plate (7) of the middle connecting plate and the main side tube (5), one welding position between the outer plate (7) of the middle connecting plate and the secondary side tube (6), one welding position between the inner plate (8) of the middle connecting plate and the secondary side tube (6), and two welding positions between the outer plate (7) of the middle connecting plate and the inner plate (8) of the middle connecting plate.

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