Metal material integrated forming tooling and method of use

Abstract

This invention provides a one-piece metal forming fixture and its usage method. The one-piece metal forming fixture includes: a fixture base, which provides an overall support platform for the parts; a fixture module, which is disposed on the fixture base and is used for dimensional calibration and positioning hole inspection of the parts in the unwelded state; and a welding and fixing module, which is located outside the fixture module and is partially used to lock the parts and their counterparts in a preset relative position after the parts have been calibrated, to support welding operations. This application solves the problem of the limited functionality of traditional fixtures in the prior art.

Description

Technical Field

[0001] This invention relates to the field of component tooling manufacturing technology, and more specifically, to a one-piece molding tooling based on metal materials and its usage method. Background Technology

[0002] In the existing technology, during the production process of metal parts, it is necessary to use inspection fixtures to calibrate the relative positions of the parts' dimensions and critical gaps, and to use calibration fixtures to verify the matching of key points of the parts, especially when it comes to welding processes.

[0003] Currently, the common processes used for metal sheet metal parts are stamping, forming, welding, gauge dimensional calibration, and calibration. During the parts production process, gauges can only be used for parts dimensional calibration, and calibration tools can only be used for parts verification. Switching between tooling during the manufacturing process consumes a lot of production time and cycle time. The development cost of major tools is too high, and it is impossible to have tooling that can simultaneously meet the requirements of both forming and welding processes to meet production delivery needs.

[0004] There is currently no effective solution to the aforementioned technical problems. Summary of the Invention

[0005] The main objective of this invention is to provide a one-piece molding tooling based on metal materials and its usage method, so as to solve the problem of the single function of traditional tooling in the prior art.

[0006] To achieve the above objectives, according to one aspect of the present invention, a one-piece forming fixture based on metal material is provided, comprising: a fixture base for providing an overall support platform for components; a fixture module disposed on the fixture base for performing dimensional calibration and positioning hole inspection on the components in an unwelded state; and a welding fixing module located outside the fixture module, which is partially used to lock the components and their counterparts in a preset relative position after the components have been calibrated, in order to support welding operations.

[0007] Furthermore, the inspection tool module is formed by a first component section, a second component section, a third component section, and a fourth component section, wherein the first component section and the third component section are arranged opposite to each other, the second component section and the fourth component section are arranged opposite to each other, and the upper surface of the inspection tool module forms a working platform for placing parts.

[0008] Furthermore, at least one of the first, second, third, and fourth components includes: a positioning element, wherein multiple positioning elements are provided and spaced apart circumferentially along the inspection module, and the positioning elements pass through positioning holes on the component to position the component.

[0009] Furthermore, the inspection module also includes: a measuring component, which has multiple measuring components located on the outside of the first, second, third, and fourth component sections respectively; the measuring component includes: a support column, which is vertically fixed on the tooling base; and a measuring probe assembly, which is installed on the top of the support column, with the probe end of the measuring probe assembly extending above the component, and the measuring probe assembly is used to detect the overall size of the component and the size of the positioning hole.

[0010] Furthermore, the welding fixing module includes multiple clamping assemblies, which are spaced apart on the outside of the inspection module. Each clamping assembly has a clamping position for clamping parts and a releasing position for releasing parts. When the clamping assembly is in the clamping position, it is used to perform welding operations on the parts.

[0011] Furthermore, the fixture assembly includes: a support member, which is vertically fixed on the tooling base and has a drive mechanism inside; a rotating shaft, which is located above the support member, with one end of the rotating shaft connected to the drive mechanism and the other end of the rotating shaft having a fixture body, and the fixture body switching between a clamping position and a releasing position by rotating the rotating shaft; wherein the fixture body is rotatably configured with respect to the rotating shaft.

[0012] Furthermore, the clamp body has a clamping surface on the side facing the component that matches the curved contour of the component. When the clamp assembly is in the clamping position, the clamp body is fitted to the component.

[0013] Furthermore, the bottom of the tooling base is provided with multiple rollers, each roller being arranged along the circumference of the tooling base.

[0014] Furthermore, the integrated fixture also includes a calibration module, which includes an X-axis reference component and a Y-axis reference component. The X-axis reference component and the Y-axis reference component are fixed to the surface of the fixture base by laser etching or embedding metal rulers.

[0015] According to another aspect of the present invention, a method for using a one-piece molding fixture based on metal materials is provided. The method involves using the one-piece molding fixture as described above, including: mounting the part to be tested on the fixture base; detecting the dimensional deviations of the part in the X, Y, and Z directions and the positions of the positioning holes based on the inspection module, and recording the dimensional data that does not meet the standards; after the part to be tested has been dimensionally calibrated, if relative dimensional deformation caused by stamping or cutting is detected, controlling the alignment position of the part and the counterpart to meet the welding tolerance requirements, and performing a calibration reset; after the calibration reset is completed, activating the welding fixing module to rigidly fix the part and the counterpart on the fixture base; with the part rigidly fixed and locked in position by the welding fixing module, the construction personnel perform welding operations; after welding is completed, releasing the clamping assembly of the welding fixing module, removing the welded part from the fixture base, and restoring the fixture to its initial standby state for the cyclic operation of the next batch of parts.

[0016] The tooling solution of this invention mainly consists of a tooling base, a fixture module, and a welding and fixing module. The tooling base serves as an overall support platform, supporting the fixture module and the welding and fixing module. The fixture module, located on the tooling base, is specifically used for dimensional calibration and positioning hole inspection of parts in their unwelded state. The welding and fixing module, located outside the fixture module, is used to lock the parts and their corresponding components in a preset relative position after the parts have been calibrated to support welding operations. The core of this solution lies in the integrated layout of the modules, enabling the same part to sequentially perform at least one of the functions of dimensional calibration, deformation verification, and welding and fixing, or simultaneously perform at least two of these functions, achieving the integration of multiple processes on the same tooling fixture. This solves the problem of the single function of traditional tooling in the prior art. Attached Figure Description

[0017] The accompanying drawings, which form part of this application, 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:

[0018] Figure 1 A schematic diagram of a first embodiment of the integral molding tooling according to the present invention is shown;

[0019] Figure 2 A schematic diagram of an embodiment of the clamp assembly according to the present invention in the released position is shown;

[0020] Figure 3 A schematic diagram of a second embodiment of the integral molding tooling according to the present invention is shown;

[0021] Figure 4A flowchart illustrating an embodiment of the method of using the one-piece molding tooling according to the present invention is shown.

[0022] The above figures include the following reference numerals:

[0023] 1. Tooling base; 11. Rollers; 100. Components;

[0024] 2. Inspection fixture module; 21. First component section; 22. Second component section; 23. Third component section; 24. Fourth component section; 25. Measurement assembly; 251. Support column; 252. Measurement probe assembly; 3. Calibration module;

[0025] 4. Welding and fixing module; 40. Fixture assembly; 41. Support component; 42. Rotating shaft; 43. Fixture body. Detailed Implementation

[0026] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0027] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0028] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0029] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0030] Combination Figures 1 to 3 As shown in the specific embodiment of this application, a one-piece molding tooling based on metal material is provided.

[0031] Specifically, the one-piece metal forming fixture includes: a fixture base 1, which provides an overall support platform for the component 100; a fixture module 2, which is mounted on the fixture base 1 and is used for dimensional calibration and positioning hole inspection of the component 100 in the unwelded state; and a welding fixing module 4, which is located outside the fixture module 2 and is partially used to lock the component and the counterspinning parts in a preset relative position after the component is calibrated, so as to support welding construction.

[0032] The tooling base 1 serves as the core load-bearing platform of the entire integrated tooling. Its overall structure is a rigid frame, typically made of high-strength cast iron or welded steel plate to ensure dimensional stability under welding thermal stress and shaping pressure. The upper surface of the tooling base 1 is precision ground to form a high-precision reference plane, which provides a unified coordinate system basis for the installation of the inspection module 2 and the welding fixing module 4.

[0033] The tooling base 1 may have cavities inside for wiring or reinforcement, but its main functional areas are exposed on the upper surface to facilitate the placement and operation of the component 100. The edges of the tooling base 1 are provided with lifting holes or handling interfaces to facilitate the movement and maintenance of the entire tooling. The design of the tooling base 1 allows the component 100 to be placed flat on it, with its bottom surface fitting against the upper surface of the tooling base 1, thereby determining the initial reference position of the component 100 in the Z direction.

[0034] A counterpart (or mating part) refers to another component that is assembled, connected, or forms a relative positional relationship with the "main component" (i.e., component 100) currently being processed, inspected, or welded. The tooling in this application must not only ensure that the dimensions of each individual component (component 100) are qualified, but also that its relative position (such as clearance, surface difference, and overlap) with the counterpart meets the design requirements.

[0035] Furthermore, the tooling base 1, the inspection module 2, and the welding and fixing module 4 are integrated and set together, and the component 100 can sequentially perform at least one of the functions of dimension calibration, deformation verification and welding fixing, and / or the component 100 can simultaneously perform at least two of the functions of dimension calibration, deformation verification and welding fixing.

[0036] The fixture module 2 and the welding fixing module 4 are directly installed or fixed on the same reference plane of the tooling base 1. This means that they share the same spatial coordinate system. This integration eliminates the physical distance between the "fixture station", "calibration station" and "welding station" in traditional processes. Components 100 do not need to be transported between different devices; the entire process can be completed simply by intervening through different modules on the same base.

[0037] Dimensional Calibration is defined as the process of quantitatively inspecting the geometric dimensions of part 100 using fixture module 2.

[0038] Deformation Correction / Shaping is defined as the process of correcting the elastic or plastic deformation of a component 100 during stamping, cutting, or transportation using mechanical force.

[0039] Welding Fixation is defined as the process of rigidly locking component 100 (and its counterpart) in a preset position to resist welding thermal stress and mechanical force.

[0040] The tooling solution of this invention mainly consists of a tooling base, a fixture module, and a welding and fixing module. The tooling base serves as an overall support platform, supporting the fixture module and the welding and fixing module. The fixture module, located on the tooling base, is specifically used for dimensional calibration and positioning hole inspection of parts in their unwelded state. The welding and fixing module, located outside the fixture module, is used to lock the parts and their corresponding components in a preset relative position after the parts have been calibrated to support welding operations. The core of this solution lies in the integrated layout of the modules, enabling the same part to sequentially perform at least one of the functions of dimensional calibration, deformation verification, and welding and fixing, or simultaneously perform at least two of these functions, achieving the integration of multiple processes on the same tooling fixture. This solves the problem of the single function of traditional tooling in the prior art.

[0041] Furthermore, such as Figure 3As shown, the inspection module 2 is formed by a first component segment 21, a second component segment 22, a third component segment 23 and a fourth component segment 24, wherein the first component segment 21 and the third component segment 23 are arranged opposite to each other, the second component segment 22 and the fourth component segment 24 are arranged opposite to each other, and the upper surface of the inspection module 2 forms a working platform for placing the component 100.

[0042] The inspection module 2 is not a single planar structure, but rather consists of four independent components arranged in a specific spatial pattern, thus defining a closed or semi-closed working platform on the upper surface of the inspection module 2 for placing the component 100. This enclosure structure not only provides boundary constraints for component placement but also provides a stable mounting carrier for each inspection reference point.

[0043] Optionally, the fixture module is provided with multiple measurement reference points for contacting the surface of the component. The first component segment 21 serves as a boundary of the fixture module 2, and its top is typically arranged with measurement reference points for key features of the component 100 in a certain direction (such as the front face, rear face, or outer contour on one side). These reference points can be ball-end pins of fixed height, planar probes, or hole positioning pins.

[0044] The third section 23 is positioned opposite to the first section 21, and its top is also provided with measurement reference points for key features of the other end or side of the component 100.

[0045] Similarly, corresponding measurement reference points are also set on the second and fourth sections.

[0046] In summary, the second and fourth sections 22, together with the first and third sections, close the perimeter of the work platform, ensuring that the component 100 is fully surrounded by the reference points around it when placed, thereby achieving complete detection of the component's outline.

[0047] Specifically, the work platform is a flat or slightly undulating horizontal surface (or a slight slope) that conforms to the bottom contour of the component, and its boundary is defined by the upper surfaces and inner walls of the four component sections. When the component 100 is placed on the work platform, its bottom contacts the upper surface of the inspection module 2.

[0048] Furthermore, at least one of the first component segment 21, the second component segment 22, the third component segment 23, and the fourth component segment 24 includes: a positioning element, wherein multiple positioning elements are provided and spaced apart along the circumferential direction of the inspection module 2, and the positioning elements pass through positioning holes on the component 100 to position the component 100.

[0049] The positioning element can cover multiple key control points of the component 100 in the length direction, thereby providing multi-point constraints to ensure the positional accuracy and repeatability of the component when it is placed on the inspection module 2.

[0050] When component 100 is placed on the working platform of fixture module 2, the positioning hole on component 100 is aligned vertically with the corresponding positioning element on fixture module 2. Subsequently, component 100 moves downward, causing the positioning element to insert into the positioning hole of component 100. Through this "pin-hole" fit, the degrees of freedom of component 100 in the X and Y axes are restricted. Since the positioning elements are spaced apart along the length of fixture module 2, the combined action of multiple positioning elements not only determines the translational position of component 100 but also restricts its rotational degree of freedom around the Z-axis, thereby achieving complete positioning of component 100 in the two-dimensional plane.

[0051] By utilizing the precise fit between the positioning component and the positioning hole of the part, the cumulative error of the part during the placement process is eliminated, ensuring the accuracy of the dimensional calibration data.

[0052] Furthermore, the inspection module 2 also includes: a measuring component 25, wherein multiple measuring components 25 are provided, and the multiple measuring components 25 are respectively located on the outside of the first component section 21, the second component section 22, the third component section 23 and the fourth component section 24; the measuring component 25 includes: a support column 251, which is vertically fixed on the tooling base 1; and a measuring probe assembly 252, which is installed on the top of the support column 251, and the probe end of the measuring probe assembly 252 extends above the component 100. The measuring probe assembly 252 is used to detect the overall size and positioning hole size of the component 100.

[0053] The measuring component 25 is the core execution unit in the fixture module 2 responsible for high-precision dimensional inspection. Multiple measuring components 25 are not distributed within the internal working area enclosed by the fixture module 2, but are uniformly arranged on the outside of the first section 21, the second section 22, the third section 23, and the fourth section 24. This "outer layout" strategy has clear structural advantages: it allows the measuring components 25 to be spatially independent of the direct placement area of ​​the component 100, avoiding mechanical interference with the measuring probe when placing or removing the component 100, and also facilitating operator readings and routine maintenance.

[0054] The support column 251 extends vertically and its bottom is rigidly fixed to the fixture base 1 via a connection method such as bolting, welding, or integral molding. This vertical fixation ensures the high stability of the support column 251 in the Z-axis direction, providing an absolutely static and highly rigid reference platform for the measuring probe assembly 252 above it. The support column 251 extends upward from the fixture base 1, and its height is precisely designed so that the measuring probe assembly 252 mounted on top of it can accurately reach the critical detection height position of the component 100. The structure of the support column 251 must have sufficient bending stiffness to withstand the reaction force that may be generated when the probe contacts the component, ensuring the repeatability and accuracy of the measurement data.

[0055] The measuring probe assembly 252 is the functional terminal of the measuring assembly 25, directly involved in the dimensional inspection of the component 100. The measuring probe assembly 252 is mounted on top of the support column 251. This mounting position allows the probe to cover the space above the component 100 via the most direct path. The measuring probe assembly 252 includes a probe end that extends downwards and is suspended above the component 100. After the component 100 is placed on the work platform of the fixture module 2, the probe end maintains a specific spatial relative position with key feature points on the surface of the component 100 (such as planes, arc surfaces, edges, or near holes).

[0056] The measuring probe assembly 252 is used to detect the overall external dimensions of the component 100. By contacting (or proximity sensing) the probe tip with the surface of the component, the coordinates of key contour points of the component in the X, Y, and Z directions can be detected. For example, the probe can detect the flatness of the upper surface of the component, the perpendicularity of the side, or the height difference (Z-axis dimension) of a specific feature point relative to a reference plane.

[0057] In addition to measuring the surface profile, the measuring probe assembly 252 is also used to detect the size of the positioning holes on the component 100. This can be achieved in two ways: first, the probe end is designed as a plug gauge, inserted into the positioning hole to detect the hole diameter and position accuracy; second, the probe end is designed as a contact probe, contacting the inner wall or edge of the positioning hole, and indirectly reflecting the positional accuracy of the hole by measuring the position of the hole center relative to other reference points.

[0058] Because multiple measuring components 25 are distributed around the outer perimeter of the fixture module 2, they can perform omnidirectional inspection of the component 100 from different angles and directions. For example, a probe located outside the first component section 21 may detect the front end dimensions of the component, while a probe located outside the second component section 22 may detect the side dimensions of the component. This distributed layout ensures comprehensive and thorough calibration of the overall dimensions of the component 100 and the dimensions of the positioning holes.

[0059] Furthermore, the welding fixing module 4 includes multiple clamping assemblies 40, which are spaced apart on the outside of the inspection module 2. Each clamping assembly 40 has a clamping position for clamping the component 100 and a releasing position for releasing the component 100. When the clamping assembly 40 is in the clamping position, it is used to perform welding operations on the component 100.

[0060] The welding fixing module 4 consists of multiple independent clamping assemblies 40. These clamping assemblies 40 are not continuously distributed, but are spaced apart along the outer side of the fixture module 2. This spaced distribution design strategy allows the clamping assemblies 40 to fix key welding points or stress points on the component 100 at specific points, while avoiding unnecessary obstruction or interference on the surface of the component or the welding area. The multiple clamping assemblies 40 form a distributed, multi-point constraint network around the periphery of the fixture module 2, ensuring that the component 100 can be uniformly and firmly locked in its preset relative position during the welding process.

[0061] Each fixture assembly 40 has two distinct working states: a "clamping position" and a "released position." These two states are switched through the movement of the mechanical structure to adapt to different process stages of the parts.

[0062] When the clamping assembly 40 is in the released position, the constraint force it exerts on the component 100 is released or weakened to the extent that the component can be moved or disassembled. In this state, the component 100 can be freely placed, adjusted, or removed from the work platform of the fixture module 2. The released position typically corresponds to the component's dimensional calibration stage or the preparation stage before calibration, or the unloading stage after welding. At this time, the clamping components of the clamping assembly 40 (such as pressure plates, pressure heads, or jaws) are in a raised, opened, or retracted state, without interfering with the contour or positioning holes of the component 100.

[0063] When the clamping assembly 40 is in the clamped position, it applies sufficient positive pressure or lateral restraint force to the component 100, rigidly fixing the component 100 in its designed position. In this state, the component 100 is securely locked and cannot undergo relative displacement or vibration. The clamped position is a necessary state for welding operations, ensuring that the component 100 maintains dimensional stability under the action of welding thermal stress and mechanical forces.

[0064] Once the clamping assembly 40 switches to the clamping position and secures the component 100, this state is specifically designed to support welding operations. During welding, the metal expands and contracts when heated, causing the component to deform or shift. The clamping assembly 40, through the strong locking force provided by its clamping position, resists these thermal stresses and mechanical forces, preventing misalignment of the component 100 and its mating components.

[0065] Because the fixture assemblies 40 are spaced apart on the outside of the fixture module 2, they work in conjunction with the positioning elements within the fixture module 2. The fixture module is responsible for guiding the position of the foundation, while the welding fixing module 4 is responsible for maintaining the rigidity of this position during the welding process. This synergy ensures the quality of the weld joint and avoids incomplete welds, misalignments, or dimensional deviations caused by workpiece loosening.

[0066] The structural design of the clamp assembly 40 must be adapted to the welding environment. Its material selection and layout should be able to withstand welding spatter and high-temperature radiation, while ensuring that it does not obstruct the operation path of the welding torch or welding clamp when clamped, so as to ensure that the welding construction can be carried out smoothly.

[0067] Furthermore, the fixture assembly 40 includes: a support member 41, which is vertically fixed on the tooling base 1 and has a drive mechanism inside; a rotating shaft 42, which is located above the support member 41, with one end of the rotating shaft 42 connected to the drive mechanism and the other end of the rotating shaft 42 having a fixture body 43, which switches between a clamping position and a releasing position by rotating the rotating shaft 42; wherein the fixture body 43 is rotatably configured with respect to the rotating shaft 42.

[0068] like Figure 1 , Figure 2 As shown, the support member 41, serving as the basic load-bearing structure of the clamping assembly 40, extends vertically. Its bottom is rigidly fixed to the tooling base 1 via a connection method such as bolting or welding. This vertically fixed structure ensures the absolute stability of the support member 41 in the Z-axis direction, providing a stable mechanical support reference for the transmission assembly above. The support member 41 not only provides support but also forms a spatial cavity inside to accommodate and guide the transmission components.

[0069] The drive mechanism is integrated into the internal structure of the support member 41. This built-in design makes the external structure cleaner and effectively protects the drive component from welding spatter, dust, or mechanical impact. As a power source, the drive mechanism generates rotational torque or linear motion (or converts linear drive to rotation if necessary), and transmits the power to the rotating shaft 42 via a mechanical connection. Although the specific drive method can be pneumatic, hydraulic, or electric, its core function is to controllably drive the rotating shaft 42 to rotate, thereby achieving precise switching of the clamp body 43 between the clamping and releasing positions.

[0070] The rotating shaft 42 is located above the support member 41, spanning the top or upper side of the support member 41, serving as a key transmission shaft connecting the power source and the actuator. One end of the rotating shaft 42 is connected to the drive mechanism inside the support member 41. This connection method allows the output motion of the drive mechanism to be directly transmitted to the rotating shaft 42, driving it to rotate around its own axis. The other end of the rotating shaft 42 is connected to the clamp body 43. This "one-end drive, one-end actuation" structural design constitutes a typical rotary clamping mechanism. The rotation angle of the rotating shaft 42 directly determines the spatial orientation of the clamp body 43.

[0071] The clamp body 43 and the rotating shaft 42 are connected by a rotatable arrangement (i.e., hinged or rotary fit). This rotatable arrangement allows the clamp body 43 to swing or rotate relative to the rotating shaft 42 at a certain angle, or the clamp body 43 as a whole can rotate together with the rotating shaft 42.

[0072] When the drive mechanism drives the rotating shaft 42 to rotate at a certain angle, the rotating shaft 42 drives the clamp body 43 to move. Since the rotation center of the rotating shaft 42 is fixed, the clamp body 43 will move its end from the "release position" away from the component 100 to the "clamping position" that is close to or pressing against the surface of the component 100 during the rotation process. Conversely, when the drive mechanism drives the rotating shaft 42 to rotate in the opposite direction, the clamp body 43 will rotate accordingly, causing it to return from the state of pressing against the component 100 to the "release position" that does not interfere with the placement or removal of the component.

[0073] The drive mechanism drives the rotating shaft 42 to rotate, which enables the fixture to open and close quickly, significantly shortening the clamping and disassembly time of parts and improving the production cycle.

[0074] Furthermore, the clamp body 43 has a clamping surface on the side facing the component 100 that matches the curved contour of the component 100. When the clamp assembly 40 is in the clamping position, the clamp body 43 is fitted against the component 100. Because the clamping surface matches the curved contour of the component 100, when the clamp body 43 is in the clamping position, the locking force is no longer concentrated on the narrow contact area, but is distributed along the curved surface. This avoids indentation, deformation, or damage to the surface of the component 100 due to excessive local stress. This large-area contact is especially important for thin-walled sheet metal parts. During the welding operation, the component 100 may be subjected to minor deformation or vibration caused by thermal stress. The fitted state between the clamp body 43 and the curved surface of the component 100 provides stable support, preventing displacement of the component under the action of welding sparks or arc force. The fitted state ensures that the component 100 is always kept in the precise position positioned by the inspection module 2.

[0075] Furthermore, the bottom of the tooling base 1 is provided with a plurality of rollers 11, each roller 11 being arranged along the circumference of the tooling base 1.

[0076] At the bottom of the tooling base 1, i.e. the side in contact with the ground or workshop floor, multiple rollers 11 are provided. The multiple rollers 11 jointly bear the total weight of the tooling base 1 and the inspection module 2, welding fixing module 4 and components 100 installed on it. By being distributed at various points in the circumference, the rollers 11 ensure stable support of the tooling's center of gravity, preventing the tooling from tilting or swaying due to uneven ground or uneven force.

[0077] The rollers 11 significantly reduce the coefficient of friction between the tooling base 1 and the ground. This allows operators or auxiliary machinery to move the heavy tooling over long or short distances with relatively small pushing or pulling forces, greatly improving the handling efficiency and flexibility of the tooling.

[0078] Furthermore, the integrated fixture also includes a calibration module 3, which includes an X-axis reference component and a Y-axis reference component. The X-axis reference component and the Y-axis reference component are fixed to the surface of the fixture base 1 by laser etching or embedding metal rulers.

[0079] Calibration module 3, serving as the precision reference system within the integrated tooling, primarily consists of mutually perpendicular or orthogonal X-axis and Y-axis reference components. These two reference components together form a two-dimensional Cartesian coordinate system, providing an absolute physical reference for the dimensional inspection, positioning correction, and relative position verification of component 100 during the welding process. The presence of this module endows the tool with self-checking and calibration capabilities, ensuring the accuracy and consistency of inspection data during long-term use.

[0080] Some or all of the reference components can be formed directly on the surface of the tooling base 1 using laser etching. This method allows the scale lines, numbers, or markings to be directly integrated into the material surface of the tooling base 1, resulting in extremely high wear resistance and corrosion resistance. Furthermore, the components become an integral part of the base, making them less prone to falling off or deforming.

[0081] Another part or all of the reference components are fixed by embedding metal scales. These metal scales have clear and high-precision scale markings and are usually made of wear-resistant metal materials with stable coefficients of thermal expansion. They are embedded or attached to the surface of the tooling base 1 by mechanical fixing or bonding.

[0082] Both laser etching and metal scales provide high-precision length and position references, enabling operators or inspection equipment to quickly and accurately read the dimensional deviations of part 100 relative to the reference coordinate system. Laser etching is integrally molded with the base, and the metal scales offer high wear resistance; both methods resist wear, oil, and corrosion in the production environment, ensuring the accuracy of the reference remains throughout the tooling's entire lifecycle.

[0083] According to another aspect of the invention, such as Figure 4 As shown, a method for using a one-piece molding tooling based on metal materials is provided. The method involves using the one-piece molding tooling described above, and is characterized by including:

[0084] Step S10: Install the part to be tested on the tooling base, and use the inspection module to detect the dimensional deviation of the part in the X, Y and Z directions and the position of the positioning holes, and record the dimensional data that do not meet the standards.

[0085] Specifically, the operator places component 100 on fixture module 2 and uses positioning elements inserted into pre-set positioning holes in component 100 to achieve initial positioning of the component in the X and Y planes. Fixture module 2 simulates the installation state of the component in the vehicle, ensuring that the inspection datum is consistent with the vehicle assembly datum. Using the measuring components 25 distributed on the outside (including measuring probe assembly 252), component 100 is inspected from all angles.

[0086] X and Y direction detection: The measuring probe assembly 252 detects the coordinates of key feature points of the component on the horizontal plane to determine whether the length, width and planar position meet the requirements of the design drawings.

[0087] Z-direction inspection: The measuring probe assembly 252 detects the height of the component surface relative to the reference plane and evaluates flatness, waviness, and contour.

[0088] Positioning hole inspection: Focus on inspecting the center position and diameter of the positioning holes to ensure that they meet the reference requirements for subsequent assembly or welding.

[0089] Operators record all inspection data, compare it with the standard tolerance range, and mark the dimensions that do not meet the standards (such as a point exceeding the Z-axis tolerance by 0.5mm, or a positioning hole deviating by 0.3mm in the Y-axis). This data provides a precise basis for subsequent calibration operations.

[0090] Step S12: After the dimensions of the part to be tested are calibrated, if relative dimensional deformation caused by stamping or cutting is detected, control the alignment position of the part with the hand part to meet the welding tolerance requirements, and perform calibration and resetting.

[0091] After step S10 is completed, if the test results show that the parts have relative dimensional deformation (such as warping or twisting) caused by the previous stamping, cutting or heat treatment process, the correction and reset stage will begin.

[0092] Based on the deviation data recorded in step S10, the operator analyzes the deformation trend. For example, if the edge of the component curls inward, the correction direction should be outward stretching or local tapping correction. At this time, the welding fixing module 4 is in a released state and does not interfere with the correction operation. The operator can manually or use auxiliary tools to fine-tune the deformed part until the key feature points of the component are completely aligned with the reference surface of the fixture module 2, or the predetermined correction target value is reached. If multiple components are involved in welding, a "counterpart" needs to be introduced simultaneously. With the assistance of the fixture module 2, the relative position of component 100 and the counterpart is adjusted to ensure that the key matching dimensions such as the gap and misalignment before welding are within the allowable welding tolerance range. This step ensures that the geometric relationship between the components is correct before welding, laying the foundation for high-quality welding.

[0093] Step S14: After the calibration and reset are completed, start the welding and fixing module to rigidly fix the parts and the hand parts on the tooling base. With the parts rigidly fixed and locked in position by the welding and fixing module, the construction personnel shall carry out the welding operation.

[0094] Once the alignment and resetting are complete, and the positional relationship between component 100 and the opposing component meets the welding requirements, the welding and fixing stage begins. The operator activates multiple clamping assemblies 40 in the welding and fixing module 4. The drive mechanism operates, rotating the shaft 42, which in turn drives the clamping body 43 to switch from the "release position" to the "clamping position." The clamping surface of the clamping body 43 tightly adheres to the surfaces of component 100 and the opposing component. Because the clamping surface matches the curved contour of the component, the contact area is large, and the force is uniform, firmly locking the component and the opposing component onto the tooling base 1. With the component and the opposing component rigidly fixed and locked in position, the operator performs the welding operation. Rigid fixing effectively resists the thermal and mechanical stresses generated during welding, preventing secondary deformation or displacement of the component during the welding thermal cycle. Because the component has been calibrated before welding and locked by the clamps during welding, the welded component maintains extremely high dimensional accuracy and geometric tolerances.

[0095] Multiple spaced-apart clamping assemblies 40 work together to ensure the overall stability of large or complex structural components throughout the welding process.

[0096] Step S16: After welding is completed, loosen the clamping assembly of the welding fixing module, remove the welded parts from the tooling base, and restore the tooling to its initial standby state so as to carry out the cycle operation of the next batch of parts.

[0097] After welding is completed and cooled, the process proceeds to the unloading and tooling reset stage. The operator reverses the drive mechanism of the welding fixing module 4, causing the clamp assembly 40 to switch from the "clamping position" to the "release position," releasing the constraints on the component 100 and the hand component. The operator removes the welded component assembly from the tooling base 1. Because the components did not shift during the welding process, the finished product has good dimensional consistency and stable quality. The tooling is then returned to its initial standby state.

[0098] After machining, clean any weld slag and spatter from the tooling surface to ensure the cleanliness of the gauge module 2 and fixture assembly 40. Inspect the condition of the measuring probe assembly 252 and positioning components to ensure they are undamaged or contaminated. Confirm that all modules are in the normal open or reset position to prepare for the next batch of parts. The tooling can be moved to the next workstation or storage area as needed for production logistics.

[0099] Through steps S10 to S16, the integrated process of "inspection-calibration-fixing-welding-unloading" overturns the traditional step-by-step model of inspection, calibration, and welding. Utilizing the multi-functional integration of the integrated tooling, not only is the production cycle significantly shortened and tooling changeover costs reduced, but also, through rigid fixing and precise calibration, the dimensional accuracy and product quality of welded parts are significantly improved, achieving efficient and high-precision automated production.

[0100] The technical solution of this embodiment has the following beneficial technical effects:

[0101] 1. In traditional processes, dimensional calibration requires gauges, form calibration requires calibration gauges, and welding requires welding fixtures. These three types of tools are independent of each other, resulting in a complex variety of tooling. This invention integrates the gauge module 2, the form calibration function (through a specific posture or auxiliary means of the fixture component 40), and the welding fixing module 4 onto the same tooling base 1. Users no longer need to develop, purchase, and maintain three separate sets of tooling, significantly reducing the design, manufacturing, and maintenance costs of tooling. Simultaneously, it reduces tooling storage space and optimizes workshop management.

[0102] 2. Eliminate inter-process transfer losses, significantly improving production efficiency and delivery cycle: In existing technologies, parts need to be moved and re-clamped multiple times between inspection fixtures, calibration fixtures, and clamping bodies. This not only consumes a lot of non-value-adding time but also introduces cumulative errors due to multiple positioning. This invention realizes continuous operation of "inspection-calibration-welding" at the same station and with the same benchmark. Shorten production cycle: After the parts are installed, dimensional inspection is completed directly in place. If calibration is required, it is performed directly in the calibration state without changing tools. After calibration, it is directly switched to the welding clamping state for welding. This seamless connection significantly shortens the production cycle and improves production delivery speed.

[0103] 3. The clamping surface design of the clamping assembly 40 matches the curved contour of the part 100, achieving a large-area fit rather than point contact. This not only improves clamping stability but also avoids surface indentations or damage to parts caused by excessive local stress in traditional clamps, making it particularly suitable for automotive sheet metal parts with high requirements for appearance quality.

[0104] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0105] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0106] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0107] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A one-piece molding tooling based on metal materials, characterized in that, include: Tooling base (1), the tooling base (1) is used to provide an overall support platform for the component (100); Inspection module (2), the inspection module (2) is disposed on the tooling base (1), the inspection module (2) is used to perform dimensional calibration and positioning hole detection on the component (100) in the unwelded state; Welding fixing module (4), which is located outside the inspection tool module (2), is used to lock the parts and the counters in a preset relative position after the parts are calibrated, so as to support welding construction.

2. The integral forming tooling based on metal materials according to claim 1, characterized in that, The inspection tool module (2) is formed by a first component section (21), a second component section (22), a third component section (23) and a fourth component section (24), wherein the first component section (21) and the third component section (23) are arranged opposite to each other, the second component section (22) and the fourth component section (24) are arranged opposite to each other, and the upper surface of the inspection tool module (2) forms a working platform for placing the component (100).

3. The integral metal forming tooling according to claim 2, characterized in that, At least one of the first component segment (21), the second component segment (22), the third component segment (23), and the fourth component segment (24) includes: Positioning elements, multiple of which are provided and spaced apart along the circumference of the inspection module (2), the positioning elements pass through positioning holes on the component (100) to position the component (100).

4. The integral metal forming tooling according to claim 3, characterized in that, The inspection module (2) also includes: Measurement components (25), wherein multiple measurement components (25) are provided, and the multiple measurement components (25) are respectively located outside the first component segment (21), the second component segment (22), the third component segment (23) and the fourth component segment (24); The measuring component (25) includes: a support column (251), which is vertically fixed to the tooling base (1); A measuring probe assembly (252) is mounted on the top of the support column (251). The probe end of the measuring probe assembly (252) extends above the component (100). The measuring probe assembly (252) is used to detect the overall size and positioning hole size of the component (100).

5. The one-piece metal forming tooling according to claim 4, characterized in that, The welding fixing module (4) includes multiple clamping assemblies (40), which are spaced apart on the outside of the inspection module (2). Each clamping assembly (40) has a clamping position for clamping the component (100) and a releasing position for releasing the component (100). When the clamping assembly (40) is in the clamping position, it is used to perform welding operations on the component (100).

6. The integral forming tooling based on metal materials according to claim 5, characterized in that, The clamp assembly (40) includes: Support member (41), the support member (41) is vertically fixed on the tooling base (1), and the support member (41) is provided with a driving mechanism; A rotating shaft (42) is located above the support member (41). One end of the rotating shaft (42) is connected to the drive mechanism, and the other end of the rotating shaft (42) is provided with a clamp body (43). The clamp body (43) switches between the clamping position and the releasing position by rotating the rotating shaft (42). The clamp body (43) is rotatably mounted to the rotating shaft (42).

7. The integral forming tooling based on metal materials according to claim 6, characterized in that, The clamp body (43) has a pressing surface on the side facing the component (100) that matches the curved contour of the component (100). When the clamp assembly (40) is in the clamping position, the clamp body (43) is fitted to the component (100).

8. The integral forming tooling based on metal materials according to claim 7, characterized in that, The tooling base (1) is provided with a plurality of rollers (11) at its bottom, and each roller (11) is arranged along the circumference of the tooling base (1).

9. The integral forming tooling based on metal materials according to claim 8, characterized in that, The integrated molding fixture also includes a calibration module (3), which includes an X-axis reference component and a Y-axis reference component. The X-axis reference component and the Y-axis reference component are fixed to the surface of the fixture base (1) by laser etching or embedding metal rulers.

10. A method of using a one-piece molding tooling based on metal materials, wherein the method uses the one-piece molding tooling as described in any one of claims 1 to 9, characterized in that, include: The component to be tested is installed on the tooling base. The dimensional deviation of the component in the X, Y, and Z directions and the position of the positioning hole are detected based on the inspection module. The dimensional data that does not meet the standard are recorded. After the dimensions of the part to be tested are calibrated, if relative dimensional deformation caused by stamping or cutting is detected, the alignment position of the part with the hand part is controlled to meet the welding tolerance requirements, and the shape is corrected and reset. After the calibration and resetting are completed, the welding and fixing module is activated to rigidly fix the parts and the workpieces on the tooling base. With the parts rigidly fixed and locked in position by the welding and fixing module, the construction personnel can carry out the welding operation. After welding is completed, the clamping assembly of the welding fixing module is released, the welded parts are removed from the tooling base, and the tooling is restored to its initial standby state for the next batch of parts to be processed.

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