Intercooler double-track servo system welding equipment of heat exchanger

Abstract

The utility model relates to double-track servo system welding equipment for an intercooler of a heat exchanger. The equipment comprises a double-track and double-gun automatic welding device used for welding a workpiece, a lower working table and an upper working table, wherein the lower working table and the upper working table can move relatively and press the workpiece; the automatic welding equipment further comprises a rotating mechanism used for turning over the whole workpiece. The rotating mechanism comprises rotating spindles coaxially arranged on the two sides of the workpiece, the opposite ends of the rotating spindles on the two sides are connected with the workpiece through rotating plates respectively, and the rotating mechanism further comprises a servo system in driving connection with the rotating spindles. Compared with an existing device based on manual turn-over and positioning adjustment, the work efficiency is higher, and operation is easier and more convenient.

Description

Technical Field

[0001] The present invention relates to the technical field of automotive component welding, and particularly to a welding device for a charge air cooler double-track servo system of a heat exchanger. Background Art

[0002] The charge air cooler of an automotive heat exchanger is an essential component in the cooling system of a turbocharged engine. With the country's advocacy of energy conservation, low carbon, environmental protection, etc., current family sedans, SUVs and other vehicle models are also equipped with charge air coolers of heat exchangers. As Figure 1 shown, it is a schematic diagram of the welding structure of the core body and the air chamber of the charge air cooler. Existing welding equipment still has manual adjustment links. For example, it relies on manual positioning of the fixed positions of the core body and the air chamber, and after one side of the welding is completed, it is still necessary to operate the handwheel to flip the workpiece and then weld the other side, etc. Summary of the Invention

[0003] The object of the present invention is to overcome the defects of the above-mentioned existing technologies and provide a welding device and method for a charge air cooler double-track servo system of a heat exchanger.

[0004] The object of the present invention can be achieved by the following technical solutions:

[0005] An automatic welding device for a double-track servo system of a heat exchanger, the device includes a double-track and double-gun automatic welding device for welding workpieces, and a lower workbench surface and an upper workbench surface that can move relative to each other and press the workpieces;

[0006] The automatic welding device further includes a rotating mechanism for flipping the entire workpiece; the rotating mechanism includes rotating main shafts coaxially arranged on both sides of the workpiece, and the opposite ends of the rotating main shafts on both sides are respectively connected to the workpiece through rotating plates, and the rotating mechanism further includes a servo system drivingly connected to the rotating main shafts.

[0007] As a preferred technical solution, lower positioning posts are provided on the air chamber of the workpiece, and rotating positioning holes matching the lower positioning posts of the air chamber are provided on the rotating plates on both sides, and the lower positioning posts of the air chamber are arranged in the rotating positioning holes.

[0008] As a preferred technical solution, the rotating mechanism further includes a sliding positioning cylinder for positioning the workpiece.

[0009] As a preferred technical solution, an insert block for fixing the workpiece is arranged in the sliding positioning cylinder.

[0010] As a preferred technical solution, the sliding positioning cylinder includes a horizontal sliding cylinder and a vertical sliding cylinder arranged perpendicular to each other, the horizontal sliding cylinder is used to drive the vertical sliding cylinder to move horizontally, and an insert block is arranged at the output end of the vertical sliding cylinder and the workpiece is fixed through the insert block.

[0011] As a preferred technical solution, heat insulation plates are respectively arranged on one side of the two side sliding positioning cylinders facing the workpiece.

[0012] As a preferred technical solution, a servo system for driving the rotating main shaft on the same side is arranged on one side of the workpiece of the rotating mechanism, and the rotating main shaft on the side opposite to the servo system serves as a driven shaft.

[0013] As a preferred technical solution, a lower pressing cylinder and an upper pressing cylinder are respectively arranged on the sides of the lower workbench surface and the upper workbench surface facing away from each other.

[0014] As a preferred technical solution, a notch for positioning the core of the workpiece is arranged on the lower workbench surface.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] 1) The present invention is provided with a rotating mechanism. After welding is completed on one side of the workpiece, the left main shaft is driven by the rotating servo system, and then the left workpiece rotating plate is driven by the left main shaft. Together with the workpiece, the right workpiece rotating plate is driven to drive the right main shaft, so that the workpiece is turned over, and then the other side of the workpiece is welded. Compared with the existing manual turning and positioning adjustment, the working efficiency is higher and the operation is more convenient.

[0017] 2) The present invention considers and arranges each positioning module of the core and the air chamber on the tooling equipment, and realizes the positioning of the workpiece by setting the sliding positioning cylinder. Compared with the traditional manual positioning scheme, the positioning efficiency of the workpiece is higher.

[0018] 4) The present invention uses a protective sleeve made of heat insulation material for heat insulation, so that the cylinder can prevent the transfer of fire splashes and heat, and avoid the situation that the sliding positioning cylinder is easily deformed and difficult to slide after being heated.

[0019] 5) The present invention presses the welded core with the cylinders connected by the upper and lower workbench surfaces, and then after the positioning cylinder withdraws, the cylinders of the upper and lower workbench surfaces are loosened to remove the workpiece. It solves the problem that after welding the core and the air chamber, the product will be deformed, and it is difficult for the positioning cylinder to withdraw, making it difficult to remove the product. Description of the Drawings

[0020] Figure 1 It is a schematic diagram of the welding structure of the core and the air chamber;

[0021] Figure 2 It is a schematic diagram of the overall structure of the equipment of the present invention;

[0022] Figure 3 It is a schematic diagram of the assembly, air chamber and core of the present invention;

[0023] Figure 4For the present invention, the upper cylinder presses down to start welding;

[0024] Figure 5 It is a schematic diagram of the structure where the upper and lower cylinders of the present invention loosen and the core body flips;

[0025] Figure 6 It is a schematic diagram of the structure where the upper and lower cylinders of the present invention press down to start welding the other side;

[0026] Figure 7 It is a schematic diagram of the structure where the upper and lower cylinders of the present invention loosen and the core body flips;

[0027] Figure 8 It is a schematic diagram of the structure where the core body is positioned and pressed, and the upper positioning cylinders in the left and right air chambers retract;

[0028] Figure 9 It is a schematic diagram of the structure where the upper cylinder retracts and the workpiece is taken off after welding is completed;

[0029] Figure 10 It is a schematic diagram of the structure where the core body and the air chamber are positioned;

[0030] Figure 11 It is a schematic diagram of the rotation structure of the present invention;

[0031] In the figure: 1. Left main shaft, 2. Servo system, 3. Left rotating plate, 4. Left positioning cylinder, 5. Upper left air chamber positioning block, 6. Lower left air chamber positioning block, 7. Left welding torch, 8. Workpiece, 9. Upper pressing cylinder, 10. Lower pressing cylinder, 11. Lower supporting plate, 12. Lower workbench surface, 13. Upper workbench surface, 14. Right welding torch, 15. Lower right air chamber positioning plate, 16. Heat insulation plate, 17. Upper right air chamber positioning block, 18. Right rotating plate, 19. Right positioning cylinder, 20. Right main shaft. Specific embodiments

[0032] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment is implemented on the premise of the technical solution of the present invention, and the detailed implementation manners and specific operation processes are given, but the protection scope of the present invention is not limited to the following embodiments.

[0033] Embodiment 1

[0034] As one of the implementation manners of the present invention, this embodiment provides a welding device for the intercooler double-track servo system of a heat exchanger, as Figure 2 shown. This device uses a double-track and double-gun automatic welding device to achieve double-track welding. The left and right frames are erected to run the left and right welding torches along the tracks, and the welding torches are run to the starting position of the workpiece 8 to start welding. After one side of the welding is completed, the rotation servo system 2 drives the left main shaft, and then the left main shaft 1 drives the left workpiece rotating plate 3. Together with the workpiece 8, it drives the right workpiece rotating plate 18 and then drives the right main shaft 20 to flip the workpiece.

[0035] During the welding process, the core needs to be positioned to ensure the installation dimensions of the assembly. Currently, a fixed core height is set on the workbench, and a certain allowance is left within the tolerance range to prevent thermal deformation and facilitate the removal of the workpiece after welding.

[0036] During the welding process, the air chamber needs to be positioned to facilitate correct positioning of the welding and the core. Currently, lower positioning holes are added to the left and right rotating plates for the lower positioning of the air chamber, so that the lower positioning posts on the air chamber are in the rotating positioning holes, which is convenient for product welding, ensures the installation dimensions of the product, and a certain allowance is provided within the tolerance range to facilitate the removal of the product after welding.

[0037] Since the upper positioning of the air chamber is positioned by a sliding cylinder, the cylinder is prone to deformation when heated and is not easy to slide. Currently, a protective sleeve made of heat-insulating material is used for heat insulation to prevent the cylinder from transmitting fire splashes and heat.

[0038] Since the product will be deformed after welding the core and the air chamber, the positioning cylinder is not easy to withdraw, making it difficult to remove the product. Therefore, the welded core is pressed by a cylinder connected to the upper and lower workbenches. Then, after the positioning cylinder withdraws, the cylinder of the upper and lower workbenches is loosened to remove the workpiece.

[0039] The main process flow is as Figures 3 to 9 shown:

[0040] As Figure 3 , Figure 10 shown, after the core of the workpiece 8 is positioned on the welding table, the placement position of the core is determined by the notch of the lower workbench 12. The lower left air chamber positioning block 6 is set in the positioning hole on the left rotating plate 3. The air chamber of the workpiece 8 is provided with a lower positioning post and is positioned and connected to the lower left air chamber positioning block 6. As Figure 10 shown, the upper left air chamber positioning block 5 is installed on the positioning cylinder 4. Similarly, the positioning position of the cylinder on the right is based on the same principle as that on the left.

[0041] Figure 11 As a schematic diagram of the rotating mechanism, the servo system 2 drives the left main shaft 1, and then connects to the left rotating plate 3 to drive the workpiece 8. The workpiece 8 is driven by the lower left positioning block 6 and the upper left air chamber positioning block 5 (which is an insert in the left positioning cylinder 4) to rotate together, and the workpiece 8 drives the lower right air chamber positioning plate 15 and the upper right air chamber positioning block 17. And it is pressed by the right positioning cylinder 19 and rotates together with the right rotating plate 15 and the right main shaft 20 to complete the process of welding one side and then the other side after welding.

[0042] Figure 11Schematic diagram of the rotating structure. During the welding process, the temperature can reach over 600 degrees, and both the workpieces and parts are relatively prone to thermal deformation. Therefore, especially for the left and right sliding positioning cylinders, it is not easy to slide and feed after thermal deformation. For this reason, heat insulation plates 16 are added outside these two parts.

[0043] Figure 8 Schematic diagram of the middle structure. Similarly, due to the influence of thermal deformation, after welding is completed, it is not easy for the left and right positioning cylinders to retract their positions after thermal deformation. For this reason, see Figure 8 It is necessary to drive the upper and lower workbench surfaces of serial numbers 12 and 13 to be pressed by the upper and lower cylinders of serial numbers 9 and 10, and the left and right positioning cylinders of serial numbers 4 and 19 to retract their positions.

[0044] Figure 9 The schematic diagram of the structure is for the upper cylinder to retract its position and remove the workpiece.

[0045] The present invention has the following advantages: 1) Improve the equipment utilization rate and production efficiency; 2) Improve the weld quality of the product. Since the double-track welding is automatically carried out, the weld quality consistency is better; 3) For this automatic double-track welding equipment, after one side of the welding is completed, it is flipped to weld the other side to improve the production efficiency and the operation of the employees is simple; 4) Consider the positioning modules of the core body and the air chamber on the tooling equipment to ensure the installation dimensions of the product; 5) During the equipment design process, consider problems such as easy deformation, stress release, and thermal deformation of the cylinder during the welding process; 6) Due to thermal deformation, it is difficult to remove the workpiece. Consider workpiece positioning and clamping, cylinder retraction, and workpiece fixture loosening on the equipment so that the workpiece can be smoothly removed.

[0046] Compared with the existing solution, the cost advantage of this equipment is obvious. The cost of the self-designed double-track welding equipment is about 220,000 yuan. If an automatic double-track welding machine is purchased externally, it is about 1.2 million yuan, and the cost only accounts for about 16.7%. The production efficiency is improved. If manual welding is used, the welding of each product takes about 25 minutes. Now, if double-track automatic welding is used, each product only takes about 2 - 4 minutes, and the efficiency is increased by more than 6 times. The weld quality is improved. Since automatic welding machines are used for welding, the weld quality consistency is better, and there are no welding defects such as shrinkage holes and breakpoints. The operation of the employees is simple. As long as the product is placed on the fixed workbench surface according to the operation instruction manual, start the operation button, and after automatically completing a process, the product is automatically released and the workpiece is removed to complete the welding of the entire product.

[0047] The preferred specific embodiments of the present invention have been described in detail above. It should be understood that those of ordinary skill in the art can make many modifications and variations according to the concept of the present invention without creative labor. Therefore, all technical solutions that can be obtained by those skilled in the art in the technical field based on the concept of the present invention through logical analysis, reasoning, or limited experiments on the basis of the existing technology should be within the protection scope determined by the claims.

Claims

1. A welding device for the intercooler double-track servo system of a heat exchanger, the device comprising a double-track and double-gun automatic welding device for welding a workpiece (8), and a lower workbench surface (12) and an upper workbench surface (13) that can move relative to each other and press the workpiece (8); It is characterized in that The welding equipment further includes a rotating mechanism for flipping the entire workpiece (8); the rotating mechanism includes rotating main shafts coaxially arranged on both sides of the workpiece (8), and the opposite ends of the rotating main shafts on both sides are respectively connected to the workpiece (8) through rotating plates. The rotating mechanism further includes a servo system (2) drivingly connected to the rotating main shafts.

2. The welding device for the intercooler double-track servo system of a heat exchanger according to claim 1, characterized in that Lower positioning posts are arranged on the air chamber of the workpiece (8), and rotating positioning holes matching the lower positioning posts of the air chamber are arranged on the rotating plates on both sides. The lower positioning posts of the air chamber are arranged in the rotating positioning holes.

3. The welding device for the intercooler double-track servo system of a heat exchanger according to claim 1, characterized in that The rotating mechanism further includes a sliding positioning cylinder for positioning the workpiece (8).

4. The welding device for the intercooler double-track servo system of a heat exchanger according to claim 3, characterized in that An insert block for fixing the workpiece (8) is arranged inside the sliding positioning cylinder.

5. The welding device for the intercooler double-track servo system of a heat exchanger according to claim 4, characterized in that The sliding positioning cylinder includes a horizontal sliding cylinder and a vertical sliding cylinder arranged perpendicular to each other. The horizontal sliding cylinder is used to drive the vertical sliding cylinder to move horizontally, and an insert block is arranged at the output end of the vertical sliding cylinder and is connected to and fixes the workpiece (8) through the insert block.

6. The welding device for the intercooler double-track servo system of a heat exchanger according to claim 3, characterized in that Heat insulation plates (16) are respectively arranged on one side of the two sliding positioning cylinders facing the workpiece (8).

7. The welding device for the intercooler double-track servo system of a heat exchanger according to claim 1, characterized in that The rotating mechanism is provided with a servo system (2) for driving the rotating main shaft on the same side on one side of the workpiece (8), and the rotating main shaft on the side opposite to the servo system (2) serves as a driven shaft.

8. The welding device for the intercooler double-track servo system of a heat exchanger according to claim 1, characterized in that Lower pressing cylinders (10) and upper pressing cylinders (9) are respectively arranged on the sides of the lower workbench surface (12) and the upper workbench surface (13) facing away from each other.

9. The welding device for the intercooler double-track servo system of a heat exchanger according to claim 1, characterized in that Notches for positioning the core of the workpiece (8) are arranged on the lower workbench surface (12).

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