Rail vehicle roof skeleton welding system

Abstract

The present application relates to the field of rail vehicle technology, and more particularly to a rail vehicle roof framework welding system, which comprises a plurality of sets of support driving mechanisms, the plurality of sets of support driving mechanisms being arranged at intervals along a first direction; a support bracket, the curvature of the support bracket being adapted to the curvature of the roof framework, the support bracket being arranged on the plurality of sets of support driving mechanisms, the support bracket being provided with a plurality of parallel and interval transverse grooves and a plurality of parallel and interval longitudinal grooves, and a clearance hole being arranged at the intersection of the transverse grooves and the longitudinal grooves; a first clamping mechanism, the first clamping mechanism being arranged on the support bracket; a second clamping mechanism, the second clamping mechanism being arranged on the support bracket; two sets of third clamping mechanisms, the two sets of third clamping mechanisms being arranged at intervals on the two sides of the support bracket; and a welding mechanism, the welding mechanism being arranged on one side of the support bracket. The present application can improve the assembly efficiency of the roof framework of the vehicle, ensure the assembly quality, and improve the automation level.

Description

Technical Field

[0001] This invention relates to the field of rail vehicle technology, and in particular to a rail vehicle roof frame welding system. Background Technology

[0002] In the manufacturing process of rail vehicles, car body welding is one of the core processes. Its welding quality and assembly efficiency directly determine the manufacturing precision, structural strength, and production cycle of the rail vehicle. As a key load-bearing component of the rail vehicle body, the roof frame is composed of multiple cross-welded horizontal and vertical frames. Its assembly and welding process places stringent requirements on the positioning accuracy, support stability, and ease of replacement of tooling fixtures.

[0003] Existing welding fixtures for rail vehicle roof frames generally suffer from the following technical defects: First, the fixture brackets mostly adopt planar or fixed-curve structures, making it difficult to precisely match the specific curvature of the rail vehicle roof frame. This results in poor support and fit, easily causing elastic or plastic deformation of the frame during support, which in turn affects the alignment accuracy of subsequent welding nodes, ultimately leading to dimensional deviations in the roof frame and failure to meet assembly requirements. Second, the frame assembly positioning structure is poorly designed, lacking a precise directional assembly guide structure. Repeated adjustments are required when assembling the horizontal and vertical frames, resulting in low assembly efficiency. Third, welding operations are easily interfered with by the fixture structure. Existing fixtures lack dedicated avoidance structures for welding nodes, making it easy for the welding torch to collide with the fixture body during welding, affecting the smoothness of the welding operation. Fourth, the frame fixing structure is complex, often employing cumbersome methods such as bolt fastening. This not only involves numerous and time-consuming steps, leading to low fixture changeover efficiency and difficulty in adapting to the fast-paced production demands of automated production lines, but also makes the disassembly process of the fixing structure equally cumbersome. Fifth, the overall structural strength of the tooling is insufficient. After long-term bearing of the frame and the vibration and heat of welding operations, it is prone to deformation, affecting the positioning accuracy. At the same time, the existing tooling lacks a moving guide structure that is compatible with automated production lines, making it difficult to achieve rapid transfer and replacement of the tooling.

[0004] Therefore, a rail vehicle roof frame welding system is needed to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a welding system for the roof frame of a rail vehicle, which can improve the assembly efficiency of the roof frame, ensure the assembly quality, and improve the level of automation.

[0006] To achieve this objective, the present invention adopts the following technical solution: The rail vehicle roof frame welding system includes: Multiple sets of support and drive mechanisms are arranged at intervals along a first direction; A support bracket, the curvature of which is adapted to the curvature of the roof frame, is mounted on several sets of support drive mechanisms, which can drive the support bracket to move along the first direction. The support bracket has multiple parallel and spaced horizontal slots and parallel and spaced vertical slots. A clearance hole is provided at the intersection of the horizontal slots and the vertical slots. The horizontal slots are used to place the horizontal frame, and the vertical slots are used to place the vertical frame. A first clamping mechanism is disposed on the support bracket and is used to clamp and fix the cross frame; The second clamping mechanism is disposed on the support bracket and is used to clamp the longitudinal frame located in the middle. Two sets of third clamping mechanisms are spaced apart on both sides of the support bracket. The third clamping mechanisms are used to clamp the longitudinal frame located at the end. A welding mechanism is provided on one side of the support bracket and is used to weld the transverse frame and the longitudinal frame.

[0007] In some embodiments, the support drive mechanism includes a support base plate, a lifting drive component, and a rotating component. The lifting drive component is disposed on the support base plate, and the rotating component is rotatably disposed at the output end of the lifting drive component. The rotating component supports the support bracket and is capable of driving the support bracket to move.

[0008] In some embodiments, the rotating assembly includes a wheel frame, a motor, and a roller. The wheel frame is disposed at the output end of the lifting drive component, the roller is rotatably disposed on the wheel frame, the motor is disposed on the wheel frame, and the motor is drively connected to the roller.

[0009] In some embodiments, the first clamping mechanism includes a baffle and an elastic clamping assembly, the baffle and the elastic clamping assembly being disposed at opposite intervals at both ends of the support bracket along the first direction, and the cross frame being clamped between the baffle and the elastic clamping assembly.

[0010] In some embodiments, the elastic clamping assembly includes a clamping plate, an elastic element, and a guide rod. The guide rod is disposed along the first direction, and one end of the guide rod is connected to the support bracket. The elastic element and the clamping plate are both sleeved on the guide rod. One end of the elastic element abuts against the end of the guide rod, and the other end of the elastic element abuts against the clamping plate.

[0011] In some embodiments, the second clamping mechanism includes a first electric push rod, a first connecting rod, and a top pressing rod. The first electric push rod is disposed on the support bracket, the first connecting rod is connected to the output end of the first electric push rod, and the top pressing rod is connected to the first connecting rod. The first electric push rod can drive the top pressing rod to rise and fall.

[0012] In some embodiments, a positioning rod is provided on the side of the top pressure rod facing the support bracket, and the support bracket has a positioning hole opposite to the positioning rod, into which the positioning rod can be inserted.

[0013] In some embodiments, the third clamping mechanism includes a second electric push rod, a side-pressure rotating rod, and a side-pressure rod. One end of the second electric push rod is rotatably connected to the bracket, and the output end of the second electric push rod is rotatably connected to the side-pressure rotating rod. The side-pressure rod is arranged along the first direction, and the side-pressure rotating rod is connected to the side-pressure rod.

[0014] In some embodiments, the welding mechanism includes a base, a robotic arm, a welding torch, and a camera. The robotic arm is mounted on the base, and the welding torch and the camera are both mounted on the output end of the robotic arm.

[0015] In some embodiments, the lower end of the support bracket is provided with a reinforcing rib along the first direction, and the reinforcing rib cooperates with the support drive mechanism.

[0016] The beneficial effects of this invention are: This invention provides a welding system for the roof frame of a rail vehicle. Multiple sets of support drive mechanisms are spaced apart along a first direction. The curvature of the support bracket matches the curvature of the roof frame. The support bracket is mounted on several of the support drive mechanisms, which can drive the support bracket to move along the first direction. The support bracket has multiple parallel, spaced-apart horizontal slots and parallel, spaced-apart vertical slots. Clearance holes are provided at the intersections of the horizontal and vertical slots. The horizontal slots are used to hold horizontal frames, and the vertical slots are used to hold vertical frames. A first clamping mechanism is mounted on the support bracket to clamp and fix the horizontal frames. A second clamping mechanism is mounted on the support bracket to clamp the vertical frames located in the middle. Two sets of third clamping mechanisms are spaced apart on both sides of the support bracket, and the third clamping mechanisms are used to clamp the vertical frames located at the ends. A welding mechanism is mounted on one side of the support bracket for welding the horizontal and vertical frames. By matching the curvature of the support bracket to the curvature of the roof frame, the curvature of the subsequently welded roof frame can be guaranteed to meet design requirements. By creating transverse and longitudinal slots, the horizontal and vertical frames are easily positioned. A first clamping mechanism clamps and secures the horizontal frame, preventing it from moving relative to the transverse slot. Second and third clamping mechanisms clamp the vertical frame, preventing it from shifting relative to the longitudinal slot. A welding mechanism automates welding at the junction of the horizontal and vertical frames; clearance holes on the support bracket ensure smooth welding. Multiple support drive mechanisms move the support bracket along a first direction, enabling welding operations at different locations. This approach improves the assembly efficiency of the vehicle roof frame, ensures assembly quality, and enhances automation. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the content of the embodiments of the present invention and these drawings without creative effort.

[0018] Figure 1 This is an exploded schematic diagram of a support bracket in a rail vehicle roof frame welding system according to the present invention; Figure 2 yes Figure 1 A magnified view of a section at point A in the middle; Figure 3 This is a schematic diagram of a support bracket in a rail vehicle roof frame welding system according to the present invention; Figure 4 yes Figure 3 A magnified view of a section at point B in the middle; Figure 5 This is a schematic diagram from another perspective of the support bracket in the welding system of the roof frame of a rail vehicle according to the present invention; Figure 6 yes Figure 5 A magnified view of a section at point C; Figure 7 This is a schematic diagram of a rail vehicle roof frame welding system according to the present invention; Figure 8 yes Figure 7 A magnified view of a section at point D; Figure 9 This is a schematic diagram of the welding mechanism in a rail vehicle roof frame welding system of the present invention; Figure 10 yes Figure 9 A magnified view of a section at point E in the middle.

[0019] In the picture: 100. Horizontal frame; 200. Vertical frame; 1. Support bracket; 11. Horizontal groove; 12. Vertical groove; 13. Clearance hole; 14. Reinforcing rib; 2. Support drive mechanism; 21. Support base plate; 22. Lifting drive component; 23. First pressure sensor; 24. Wheel frame; 25. Roller; 3. First clamping mechanism; 31. Baffle; 32. Clamping plate; 33. Guide rod; 34. Elastic element; 4. Second clamping mechanism; 41. First electric push rod; 42. First connecting rod; 43. Top pressure rod; 431. Positioning rod; 5. Third clamping mechanism; 51. Second electric push rod; 52. Side pressure rotating rod; 53. Side pressure rod; 6. Welding mechanism; 61. Base; 62. Robotic arm; 63. Welding torch; 64. Camera. Detailed Implementation

[0020] Before explaining any implementation of this application in detail, it should be understood that this application is not limited to its application to the structural details and component arrangements set forth in the following description or shown in the above drawings.

[0021] In this application, the terms "comprising," "including," "having," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0022] In this application, the terms "connection," "combination," "coupling," and "installation" can refer to direct connection, combination, coupling, or installation, or indirect connection, combination, coupling, or installation. For example, a direct connection refers to two parts or components being connected together without the need for an intermediary, while an indirect connection refers to two parts or components each being connected to at least one intermediary, with the connection achieved through the intermediary. Furthermore, "connection" and "coupling" are not limited to physical or mechanical connections or couplings, but can also include electrical connections or couplings.

[0023] In this application, those skilled in the art will understand that the function performed by a component can be performed by one component, multiple components, one part, or multiple parts. Similarly, the function performed by a part can also be performed by one part, one component, or a combination of multiple parts.

[0024] In this application, the directional terms "upper," "lower," "left," "right," "front," and "rear" are used to describe the orientation and positional relationships shown in the accompanying drawings and should not be construed as limiting the embodiments of this application. Furthermore, in the context, it should be understood that when an element is mentioned as being connected "upper" or "lower" to another element, it can be directly connected to the other element "upper" or "lower," or indirectly connected through an intermediate element. It should also be understood that directional terms such as upper side, lower side, left side, right side, front side, and rear side not only represent positive orientation but can also be understood as lateral orientation. For example, "below" can include directly below, lower left, lower right, lower front, and lower rear.

[0025] In the process of welding and manufacturing the roof frame of locomotives and rolling stock, in order to improve the assembly efficiency of the roof frame, ensure the assembly quality, and improve the level of automation, such as... Figures 1-10 As shown, the present invention provides a welding system for the roof frame of a rail vehicle. The welding system for the roof frame of a rail vehicle includes multiple sets of support drive mechanisms 2, support brackets 1, a first clamping mechanism 3, a second clamping mechanism 4, two sets of third clamping mechanisms 5, and a welding mechanism 6.

[0026] Multiple sets of support drive mechanisms 2 are spaced apart along a first direction. The curvature of the support bracket 1 matches the curvature of the roof frame. The support bracket 1 is mounted on several sets of support drive mechanisms 2, which can drive the support bracket 1 to move along the first direction. The support bracket 1 has multiple parallel and spaced horizontal grooves 11 and parallel and spaced vertical grooves 12. A clearance hole 13 is provided at the intersection of the horizontal grooves 11 and the vertical grooves 12. The horizontal grooves 11 are used to place the horizontal frame 100, and the vertical grooves 12 are used to place the vertical frame 200. A first clamping mechanism 3 is mounted on the support bracket 1 and is used to clamp and fix the horizontal frame 100. A second clamping mechanism 4 is mounted on the support bracket 1 and is used to clamp the vertical frame 200 located in the middle. Two sets of third clamping mechanisms 5 are spaced apart on both sides of the support bracket 1 and are used to clamp the vertical frame 200 located at the ends. The welding mechanism 6 is located on one side of the support bracket 1, and the welding mechanism 6 is used to weld the horizontal frame 100 and the vertical frame 200.

[0027] By matching the curvature of the support bracket 1 with that of the roof frame, the curvature of the roof frame formed by subsequent welding can be guaranteed to meet design requirements. The horizontal slots 11 and 12 facilitate the positioning of the horizontal frame 100 and the vertical frame 200. The first clamping mechanism 3 clamps and fixes the horizontal frame 100, ensuring it does not move relative to the horizontal slot 11. The second clamping mechanism 4 and the third clamping mechanism 5 clamp the vertical frame 200, preventing it from shifting relative to the vertical slot 12. The welding mechanism 6 performs automated welding at the junction of the horizontal frame 100 and the vertical frame 200. The presence of clearance holes 13 on the support bracket 1 ensures smooth welding. Multiple sets of support drive mechanisms 2 drive the support bracket 1 to move along a first direction, enabling the welding mechanism 6 to perform welding operations at different positions. This approach improves the assembly efficiency of the vehicle roof frame, ensures assembly quality, and enhances the level of automation.

[0028] In some embodiments, the support bracket 1, adapted to the curvature of the roof frame of the rail vehicle, can provide precise and close support to the roof frame, replacing the traditional tooling structure with poor adaptability. This solves the problems of uneven force distribution and unstable support of irregularly shaped frames, effectively suppressing frame bending and misalignment deformation during welding, and ensuring the overall welding dimensional accuracy and forming consistency of the roof frame from a load-bearing perspective. The frame groove group is composed of horizontal grooves 11 and vertical grooves 12 vertically arranged on the surface of the support bracket 1. With the rational design of the groove depth parameters, the depth of the vertical groove 12 is set to one-third of the thickness of the support bracket 1, and the depth of the horizontal groove 11 is half the width of the horizontal frame 100. This enables the directional and rapid alignment and embedding assembly of the horizontal frame 100 and the vertical frame 200, ensuring the positioning stability of the roof frame after assembly, eliminating assembly offset problems, and reserving a reasonable assembly tolerance margin to reduce the difficulty of assembly operations.

[0029] In some embodiments, the clearance hole 13 at the connection between the transverse groove 11 and the longitudinal groove 12 allows the nodes to be welded on the transverse frame 100 and the longitudinal frame 200 to be precisely within the clearance hole 13, completely avoiding the obstruction and interference of the support bracket 1 on the welding operation area, and ensuring smooth welding operations. At the same time, it can concentrate the welding heat in the core area of ​​the node, greatly reducing the thermal impact of the high welding temperature on the support bracket 1 and the non-welded areas of the roof frame, effectively avoiding thermal deformation and material damage in non-welded parts, ensuring uniform weld pool formation, significantly improving the connection strength and forming quality of the welded node, and reducing the welding defect rate.

[0030] In some embodiments, four transverse grooves 11 are provided on the surface of the support bracket 1, and the four transverse grooves 11 are respectively located on both sides, one-third and two-thirds of the support bracket 1. In this embodiment, by providing four transverse grooves 11 at specific positions on both sides, one-third and two-thirds of the support bracket 1, the installation position of the transverse frame 100 is matched with the actual stress and structural distribution of the roof frame, so as to achieve uniform support for the roof frame and further improve the structural stability of the roof frame after assembly. At the same time, the standardized distribution design of the transverse grooves 11 can adapt to the installation requirements of transverse frames 100 of different sizes of roof frames of the same type, enhance the versatility of the tooling, reduce the design and manufacturing cost of special tooling, and improve the adaptability of the tooling.

[0031] In some embodiments, the longitudinal slots 12 are specifically arranged at equal intervals on the support bracket 1. In this embodiment, the design of the equally spaced longitudinal slots 12 allows the longitudinal frames 200 to be evenly distributed among the transverse frames 100, conforming to the structural design specifications of the roof frame of rail vehicles and ensuring the overall stress balance of the roof frame. Simultaneously, the equally spaced layout facilitates the rapid positioning and assembly of the longitudinal frames 200, eliminating the need for individual alignment adjustments and improving frame assembly efficiency. Furthermore, the standardized spacing design can accommodate the installation of longitudinal frames 200 of various roof frame specifications, further enhancing the versatility of the support bracket 1 and reducing the complexity of replacement and adjustment.

[0032] In some embodiments, the longitudinal frame 200 installed in the longitudinal groove 12 is a three-section arc-shaped plate component, with both ends of the arc-shaped plate component located on the surfaces of the two transverse frames 100 respectively. Designing the longitudinal frame 200 as a three-section arc-shaped plate component, with both ends overlapping the surfaces of the two transverse frames 100, provides a tighter connection between the longitudinal frame 200 and the transverse frames 100, improving the overall rigidity of the assembled roof frame and reducing the risk of node displacement during welding. Furthermore, the segmented longitudinal frame 200 design facilitates individual disassembly and replacement, reducing the difficulty of frame assembly and maintenance. Simultaneously, the structure of the arc-shaped plate component matches the curvature of the support bracket 1 and the roof frame, further ensuring the fit and dimensional accuracy of the assembled frame and improving subsequent welding quality.

[0033] In some embodiments, the support drive mechanism 2 includes a support base plate 21, a lifting drive component 22, and a rotating assembly. The lifting drive component 22 is mounted on the support base plate 21, and the rotating assembly is rotatably mounted at the output end of the lifting drive component 22. The rotating assembly supports the support bracket 1 and can drive the support bracket 1 to move. The support base plate 21 provides stable support for the lifting drive component 22, which provides lifting power to adapt to the working height requirements of the welding mechanism 6. The rotating assembly can precisely control the transfer position of the support bracket 1, ensuring accurate docking of the welding station. The lifting drive component 22 can be a hydraulic cylinder, which can effectively adjust the height of the support bracket 1.

[0034] In some embodiments, the rotating assembly includes a wheel frame 24, a motor, and rollers 25. The wheel frame 24 is disposed at the output end of the lifting drive 22, the rollers 25 are rotatably mounted on the wheel frame 24, and the motor is mounted on the wheel frame 24 and is drively connected to the rollers 25. The wheel frame 24 facilitates the installation of the motor and rollers 25. The motor drives the rollers 25 to rotate, thereby driving the support bracket 1 to move along a first direction. Using a motor drive ensures control precision, effectively cooperating with the welding mechanism 6 to ensure smooth welding operations.

[0035] In some embodiments, a first pressure sensor 23 is provided between the output end of the lifting drive component 22 and the wheel frame 24. The first pressure sensor 23 can monitor the bearing pressure in real time, avoid overload that could damage the support drive mechanism 2, and ensure production safety.

[0036] In some embodiments, the first clamping mechanism 3 includes a baffle 31 and an elastic clamping assembly. The baffle 31 and the elastic clamping assembly are disposed at opposite intervals at both ends of the support bracket 1 along a first direction, and the transverse frame 100 is clamped between the baffle 31 and the elastic clamping assembly. By cooperating with the baffle 31, the elastic clamping assembly can limit the transverse frame 100 in the first direction, thereby ensuring that the position of the transverse frame 100 relative to the support bracket 1 remains stable, ensuring that the welding work can proceed smoothly, and thus ensuring the quality of the welded roof frame.

[0037] In some embodiments, the elastic clamping assembly includes a clamping plate 32, an elastic element 34, and a guide rod 33. The guide rod 33 is arranged along a first direction, and one end of the guide rod 33 is connected to the support bracket 1. The elastic element 34 and the clamping plate 32 are both sleeved on the guide rod 33. One end of the elastic element 34 abuts against the end of the guide rod 33, and the other end of the elastic element 34 abuts against the clamping plate 32. Specifically, one end of the guide rod 33 is welded to the end of the support bracket 1. Under the action of the elastic element 34, the clamping plate 32 tends to move towards the baffle 31. The elastic force of the elastic element 34 is used to automatically compress and fix the cross frame 100, eliminating the need for complex operations such as manually tightening bolts, simplifying the fixing process of the cross frame 100, and significantly improving assembly efficiency. At the same time, the elastic clamping method has a certain buffer margin, which can adapt to cross frames 100 with different dimensional deviations, avoid damage to the cross frame 100 caused by rigid clamping, and can continuously provide a stable clamping force to ensure the positioning stability of the cross frame 100 during welding. The design of the elastic element 34 being sleeved outside the guide rod 33 makes the extension and retraction movement of the elastic element 34 smoother, avoids the twisting and deformation of the elastic element 34, and ensures stable output of elastic force. The elastic clamping assembly has a reasonable structural design, is easy to disassemble and assemble, facilitates maintenance and replacement, and extends the service life of the transverse clamping mechanism. In addition, the first clamping structure 3 can realize the rapid clamping and release of the transverse frame 100, further improving the tooling change efficiency.

[0038] In some embodiments, the second clamping mechanism 4 includes a first electric push rod 41, a first connecting rod 42, and a pressing rod 43. The first electric push rod 41 is mounted on the support bracket 1, the first connecting rod 42 is connected to the output end of the first electric push rod 41, and the pressing rod 43 is connected to the first connecting rod 42. The first electric push rod 41 can drive the pressing rod 43 to rise and fall. By controlling the rope of the first electric push rod 41, the pressing rod 43 can be raised and lowered via the first connecting rod 42, thereby clamping or releasing the longitudinal frame 200 located in the middle. During the welding process of the roof frame, the pressing rod 43 presses the longitudinal frame 200 in the middle, ensuring that the longitudinal frame 200 does not move relative to the support bracket 1, thus ensuring smooth welding.

[0039] In some embodiments, a positioning rod 431 is provided on the side of the top pressure rod 43 facing the support bracket 1, and the support bracket 1 has a positioning hole opposite to the positioning rod 431, into which the positioning rod 431 can be inserted. By cooperating with the positioning hole, the top pressure rod 43 can be prevented from shaking, thereby ensuring effective clamping of the longitudinal frame 200.

[0040] In some embodiments, a second pressure sensor is provided between the output end of the first electric push rod 41 and the first connecting rod 42. By providing the second pressure sensor, the force applied to the longitudinal frame 200 by the top pressure rod 43 can be collected in real time, thereby facilitating the adjustment of the pressure of the top pressure rod 43 on the longitudinal frame 200 according to actual needs, effectively avoiding welding misalignment caused by excessively loose clamping, or deformation of the longitudinal frame 200 caused by excessively tight clamping.

[0041] In some embodiments, the third clamping mechanism 5 includes a second electric push rod 51, a side-pressure rotating rod 52, and a side-pressure rod 53. One end of the second electric push rod 51 is rotatably connected to the bracket, and the output end of the second electric push rod 51 is rotatably connected to the side-pressure rotating rod 52. The side-pressure rod 53 is arranged along a first direction, and the side-pressure rotating rod 52 is connected to the side-pressure rod 53. By controlling the third electric push rod, the two ends of the longitudinal frame 200 can be precisely side-pressed and fixed respectively.

[0042] In some embodiments, a third pressure sensor is provided between the output end of the second electric push rod 51 and the side pressure rotating rod 52. By providing the third pressure sensor, the force applied by the side pressure rotating rod 52 to the side pressure rod 53 can be collected in real time, thereby facilitating the adjustment of the pressure of the side pressure rod 53 on the longitudinal frame 200 according to actual needs, effectively avoiding welding misalignment caused by excessively loose clamping, or deformation of the longitudinal frame 200 caused by excessively tight clamping.

[0043] In some embodiments, the welding mechanism 6 includes a base 61, a robotic arm 62, a welding torch 63, and a camera 64. The robotic arm 62 is mounted on the base 61, and the welding torch 63 and camera 64 are both located at the output end of the robotic arm 62. The application of the robotic arm 62 in the rail vehicle roof frame welding system welding production line achieves precise adaptation between the rail vehicle roof frame welding system and automated welding equipment, solving the problems of traditional manual welding or poor compatibility with the robotic arm 62, and providing a foundation for automated and intelligent welding. Multiple sets of support drive mechanisms 2 provide stable support and movement power for the support bracket 1, enabling automatic transfer of the support bracket 1 without manual handling, reducing labor intensity and improving the automation level of the production line. Simultaneously, the automatic transfer of the support bracket 1 can precisely control the switching of welding stations, ensuring the continuity of the robotic arm 62's operation and improving overall welding production efficiency. The robotic arm 62 is specifically used for welding the nodes of the horizontal frame 100 and the vertical frame 200. Compared with manual welding, it offers higher welding precision, more stable weld quality, and significantly improved welding efficiency. Meanwhile, the robotic arm 62 enables continuous welding operations, reducing production interruptions caused by manual intervention and further increasing production line capacity. The integration of the quick-change mechanism with the robotic arm 62 welding production line achieves an integrated workflow of "quick change-precise positioning-automated welding," significantly shortening the production cycle, reducing production costs, and improving the standardization and scale of rail vehicle body welding production. The robotic arm 62 has a wide range of motion and high flexibility, adapting to the operational needs of welding nodes at different locations. The welding torch 63 precisely targets the welding node, ensuring welding accuracy. The camera 64 allows for real-time image acquisition of the welding process, facilitating operators to monitor the welding status in real time, promptly identify and address welding defects, and improve the controllability of welding quality.

[0044] In some embodiments, a reinforcing rib 14 is provided at the lower end of the support bracket 1 along the first direction, and the reinforcing rib 14 cooperates with the support drive mechanism 2. The reinforcing rib 14 welded to the lower surface of the support bracket 1 realizes a dual-purpose integrated structural design. On the one hand, it effectively improves the overall structural rigidity and load-bearing capacity of the support bracket 1, resists deformation and structural damage caused by long-term workpiece bearing and high-temperature welding impact, extends the service life of the support bracket 1, and reduces maintenance costs; on the other hand, it can be directly used as a guide rail in conjunction with an external drive mechanism to achieve stable and precise overall displacement of the support bracket 1 without the need for additional guide rail components, simplifying the overall structure of the equipment, reducing manufacturing costs, and perfectly adapting to the working conditions of rapid changeover and continuous operation in automated production lines, greatly improving the versatility and automation adaptability of the support bracket 1.

[0045] In some embodiments, the welding mechanism 6 includes a control box. The control box houses an intelligent control module and a data storage and interaction module. The intelligent control module includes a PLC controller and a fuzzy PID control unit. The PLC controller is electrically connected to the fuzzy PID control unit, the lifting drive component 22, the first pressure sensor 23, the robotic arm 62, the welding torch 63, and the camera 64. The fuzzy PID control unit dynamically adjusts the extension and retraction speed of the lifting drive component 22 and the welding current and welding speed parameters of the welding torch 63 based on the pressure data collected by the first pressure sensor 23 and the welding image data collected by the camera 64. The data storage and interaction module includes a local storage unit and a wireless communication unit. The local storage unit stores welding parameters, pressure data, and welding image data. The wireless communication unit enables bidirectional data interaction between the control box and a remote monitoring center, and the remote monitoring center can send parameter adjustment commands to the PLC controller via the wireless communication unit.

[0046] This embodiment effectively solves industry pain points such as poor curvature adaptability, low positioning accuracy, cumbersome replacement process, easy welding interference, easy deformation of workpieces and support brackets 1, and insufficient automation adaptability of traditional rail vehicle roof frame welding support brackets 1 through optimized design and coordinated operation of various functional structures. It has core advantages such as high positioning accuracy, fast replacement speed, good welding quality, stable and durable structure, and excellent integration and adaptability, thus significantly improving the accuracy and efficiency of rail vehicle roof frame welding operations. Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A welding system for the roof frame of a rail vehicle, characterized in that, include: Multiple sets of support drive mechanisms (2) are provided, and the multiple sets of support drive mechanisms (2) are spaced apart along a first direction; A support bracket (1) is provided, the curvature of which is adapted to the curvature of the roof frame. The support bracket (1) is disposed on several sets of support drive mechanisms (2). The support drive mechanism (2) can drive the support bracket (1) to move along the first direction. The support bracket (1) is provided with a plurality of parallel and spaced transverse grooves (11) and parallel and spaced longitudinal grooves (12). A clearance hole (13) is provided at the intersection of the transverse grooves (11) and the longitudinal grooves (12). The transverse grooves (11) are used to place the transverse frame (100), and the longitudinal grooves (12) are used to place the longitudinal frame (200). The first clamping mechanism (3) is disposed on the support bracket (1) and is used to clamp and fix the cross frame (100); The second clamping mechanism (4) is disposed on the support bracket (1) and is used to clamp the longitudinal frame (200) located in the middle. Two sets of third clamping mechanisms (5) are arranged at intervals on both sides of the support bracket (1). The third clamping mechanisms (5) are used to clamp the longitudinal frame (200) located at the end. Welding mechanism (6), which is disposed on one side of the support bracket (1), is used to weld the transverse frame (100) and the longitudinal frame (200).

2. The rail vehicle roof frame welding system according to claim 1, characterized in that, The support drive mechanism (2) includes a support base plate (21), a lifting drive component (22), and a rotating component. The lifting drive component (22) is disposed on the support base plate (21), and the rotating component is rotatably disposed at the output end of the lifting drive component (22). The rotating component supports the support bracket (1) and can drive the support bracket (1) to move.

3. The rail vehicle roof frame welding system according to claim 2, characterized in that, The rotating assembly includes a wheel frame (24), a motor, and a roller (25). The wheel frame (24) is located at the output end of the lifting drive (22). The roller (25) is rotatably mounted on the wheel frame (24). The motor is mounted on the wheel frame (24) and is connected to the roller (25) in a transmission manner.

4. The rail vehicle roof frame welding system according to claim 1, characterized in that, The first clamping mechanism (3) includes a baffle (31) and an elastic clamping assembly. The baffle (31) and the elastic clamping assembly are arranged at opposite intervals at both ends of the support bracket (1) along the first direction. The cross frame (100) is clamped between the baffle (31) and the elastic clamping assembly.

5. The rail vehicle roof frame welding system according to claim 4, characterized in that, The elastic clamping assembly includes a clamping plate (32), an elastic element (34), and a guide rod (33). The guide rod (33) is arranged along the first direction. One end of the guide rod (33) is connected to the support bracket (1). The elastic element (34) and the clamping plate (32) are both sleeved on the guide rod (33). One end of the elastic element (34) abuts against the end of the guide rod (33), and the other end of the elastic element (34) abuts against the clamping plate (32).

6. The rail vehicle roof frame welding system according to claim 1, characterized in that, The second clamping mechanism (4) includes a first electric push rod (41), a first connecting rod (42), and a top pressing rod (43). The first electric push rod (41) is mounted on the support bracket (1). The first connecting rod (42) is connected to the output end of the first electric push rod (41). The top pressing rod (43) is connected to the first connecting rod (42). The first electric push rod (41) can drive the top pressing rod (43) to rise and fall.

7. The rail vehicle roof frame welding system according to claim 6, characterized in that, The top pressure rod (43) is provided with a positioning rod (431) on the side facing the support bracket (1). The support bracket (1) has a positioning hole opposite to the positioning rod (431), and the positioning rod (431) can be inserted into the positioning hole.

8. The rail vehicle roof frame welding system according to claim 1, characterized in that, The third clamping mechanism (5) includes a second electric push rod (51), a side pressure rotating rod (52) and a side pressure rod (53). One end of the second electric push rod (51) is rotatably connected to the bracket, and the output end of the second electric push rod (51) is rotatably connected to the side pressure rotating rod (52). The side pressure rod (53) is arranged along the first direction, and the side pressure rotating rod (52) is connected to the side pressure rod (53).

9. The rail vehicle roof frame welding system according to claim 1, characterized in that, The welding mechanism (6) includes a base (61), a robotic arm (62), a welding torch (63), and a camera (64). The robotic arm (62) is mounted on the base (61), and the welding torch (63) and the camera (64) are both mounted on the output end of the robotic arm (62).

10. The rail vehicle roof frame welding system according to claim 1, characterized in that, The lower end of the support bracket (1) is provided with a reinforcing rib (14) along the first direction, and the reinforcing rib (14) cooperates with the support drive mechanism (2).

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