Multi-angle multi-length short positioning bending jig for tail gas temperature sensor

Abstract

The utility model discloses a kind of tail gas temperature sensor multi-angle multi-length short positioning bending jig, including bottom plate, the left and right ends of bottom plate are equipped with micro guide rail, angle adjusting mechanism for bending and adjusting bending angle is slidably connected on left end micro guide rail, length adjusting mechanism is slidably connected on right end micro guide rail;Angle adjusting mechanism inside includes the first quick clip installed on the upper end of bottom plate, first quick clip lower end is equipped with first quick clip bar.The utility model has the advantages of structure stable and reliable, convenient and efficient operation, bending mode science, positioning accurate, bending precision and consistency are high, suitable for small diameter thin-walled tubular product and compatibility is extensive, significantly improve the efficiency, precision, yield and adaptability of tail gas temperature sensor bending processing, while reducing comprehensive production cost.

Description

Technical Field

[0001] This utility model relates to the field of automotive sensor processing technology, specifically a multi-angle, multi-length, short-positioning bending fixture for exhaust gas temperature sensors. Background Technology

[0002] The exhaust gas temperature sensor needs to be bent during the manufacturing process, which requires a special fixture; existing bending fixtures are mainly divided into manual and automatic types.

[0003] Manual bending fixtures are mainly used in the construction industry for bending steel bars. The principle is based on simple mechanics: two fixed fulcrums, and a third fulcrum rotates around one of the fixed fulcrums to complete the bending. They are mainly used for bending solid round steel bars and are not suitable for bending thin-walled pipes for temperature sensors.

[0004] Existing manual pipe bending fixtures require bending lengths that are far greater than the actual bending dimensions of the material used in temperature sensors, making it impossible to bend the hot end of existing temperature sensors.

[0005] When the hot end of the exhaust gas temperature sensor is bent, a positioning ring accessory has been welded on it due to the requirements of the process. Common manual pipe bending fixtures cannot bend pipes with such accessories.

[0006] Common manual pipe bending fixtures generally lack control over the bending angle, relying on the coordination of the human hand and eye; they cannot meet the high precision, short positioning, and multiple length requirements of exhaust gas temperature sensor bending.

[0007] The old bending fixture in the factory consisted of two U-groove bearings mounted on the bending actuator, with a third support point mounted on the base plate. The bending arm of the actuator had a groove at its end, with a groove width of 8mm less than the outer diameter of the positioning ring (Φ10mm). Two U-groove bearings were mounted on top. During bending, the hot end passed through the groove of the bending arm, and then one U-groove bearing was moved to clamp the hot end. The positioning ring was kept close to the side of the bending arm. The bending arm was rotated to perform the bending. After completion, the bending arm and the clamping U-groove bearings needed to be released before the bent hot end could be removed. This fixture could not adjust the bending positioning distance, and because the end of the positioning ring could not completely follow the plane when the bending arm rotated, the positioning ring would make side line contact with the bending arm, causing deformation at the welded joint of the positioning ring, and in severe cases, cracking.

[0008] There are also automated bending equipment in the industry, but they are expensive, technically complex, and not suitable for small-batch, multi-part-number production modes that require frequent parameter changes. Utility Model Content

[0009] The purpose of this utility model is to provide a multi-angle, multi-length, short positioning and bending fixture for exhaust gas temperature sensors. It has the advantages of stable and reliable structure, convenient and efficient operation, scientific bending method, accurate positioning, high bending accuracy and consistency, applicability to small-diameter thin-walled pipes and wide compatibility, and solves the problems in the prior art.

[0010] To achieve the above objectives, this utility model provides the following technical solution:

[0011] A multi-angle, multi-length short positioning bending fixture for exhaust gas temperature sensors includes a base plate. Miniature guide rails are mounted on both the left and right ends of the base plate. An angle adjustment mechanism for bending and adjusting the bending angle is slidably connected to the left miniature guide rail, and a length adjustment mechanism is slidably connected to the right miniature guide rail. The angle adjustment mechanism includes a first quick clamp mounted on the upper end of the base plate, and a first quick clamp rod is mounted on the lower end of the first quick clamp.

[0012] Preferably, the base plate is provided with a first movable plate, and a first front-middle slider is provided on the outer side of the first movable plate.

[0013] It is worth noting that the first movable plate provides a basic mounting carrier for the angle adjustment mechanism, and together with the first front and middle sliders, it forms the core transmission structure for bending execution. The slot of the first front and middle sliders can accurately squeeze the exhaust gas temperature sensor to ensure accurate bending position. The two work together to achieve stable transmission of bending action. However, it is necessary to ensure that the assembly gap between the first front and middle sliders and the first movable plate is reasonable to avoid excessive gap causing shaking during bending and affecting accuracy.

[0014] Preferably, the upper end of the first quick clamp is fixedly connected to a handle for operating the linkage mechanism.

[0015] It is worth noting that the handle efficiently transmits manual operating force to the bending actuator through the linkage mechanism, enabling quick clamping and bending actions, which saves effort, is convenient to operate, and improves work efficiency; however, it is important to ensure that the connection between the handle and the first quick clamp is secure to prevent loosening after long-term use.

[0016] Preferably, a U-groove bearing is installed on the base plate, and the exhaust gas temperature sensor is bent by the groove of the first front-middle slider in the handle-driven angle adjustment mechanism through the U-groove bearing and the handle.

[0017] It is worth noting that the U-groove bearing reduces the frictional resistance when the handle drives the first front and middle slider, making the bending action smoother. At the same time, it disperses the axial force during the bending process, avoids excessive local stress that may cause wear or deformation of parts, and extends the service life of the fixture. However, it is important to note that the U-groove bearing needs to be lubricated regularly to prevent jamming that may affect the accuracy of the action.

[0018] Preferably, the length adjustment mechanism includes a second quick clamp mounted on the base plate, and a second quick clamp rod is mounted on the lower end of the second quick clamp.

[0019] It is worth noting that the second quick clamp and the second quick clamp rod constitute the clamping component of the length adjustment mechanism. Through the dead point positioning principle of the quick clamp, reliable clamping of the exhaust gas temperature sensor is achieved. The operation is simple and the clamping force is stable, ensuring that the material does not loosen during bending and improving positioning accuracy. However, it should be noted that the length of the second quick clamp rod must match the clamping stroke to ensure that the clamping is in place.

[0020] Preferably, the base plate is provided with a second movable plate, and a second front-middle slider is provided on the outer side of the second movable plate to cooperate in completing the bending-related actions.

[0021] It is worth noting that the second movable plate provides a moving carrier for the length adjustment mechanism, and works with the second front and middle slider to assist in the positioning and guidance of the sensor, ensuring the accuracy of the bending length adjustment, while adapting to the positioning requirements of materials of different specifications; however, it is necessary to ensure that the sliding cooperation between the second front and middle slider and the second movable plate is smooth to avoid jamming that may affect the length adjustment.

[0022] Preferably, the base plate is provided with a hot end fixing block that cooperates with the linkage mechanism to fix the hot end of the exhaust gas temperature sensor.

[0023] It is worth noting that the fixing block at the hot end works in conjunction with the linkage mechanism to specifically fix the hot end of the exhaust gas temperature sensor, ensuring that the hot end is stable in position during bending and avoiding bending deformation due to the hot end shaking, thus protecting the precision structure of the hot end; however, it should be noted that the contact part between the fixing block and the hot end should be made of flexible material or have an arc design to prevent damage to the surface of the hot end.

[0024] Preferably, the base plate is equipped with a corner bracket whose position can be adjusted and fixed, and the corner bracket has a U-shaped groove that can limit the insertion length of the exhaust gas temperature sensor.

[0025] It is worth noting that the corner code achieves positional adjustment through the U-shaped groove, flexibly limiting the length of the sensor extending into the bending actuator, adapting to multiple length bending requirements, and improving the compatibility of the fixture; however, it is necessary to ensure that the size of the U-shaped groove matches the fixing bolt to ensure that the corner code is not loose after being fixed.

[0026] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0027] This invention utilizes the lever principle of a quick clamp to achieve rapid clamping and releasing of the sensor, making operation convenient and efficient, and reducing auxiliary work time. The first quick clamp rod acts as a transmission component, stably transmitting the clamping force to the bending part, ensuring reliable clamping and preventing sensor slippage during bending. The angle adjustment mechanism is specifically designed for adjusting the bending angle, and combined with the sliding function of the micro guide rail, it can precisely adjust the bending position to meet multi-angle bending needs. In conjunction with the quick clamp assembly, it achieves an efficient cycle of "clamping-bending-releasing," improving work efficiency while ensuring the consistency of bending angles and reducing angle deviations caused by manual operation. The length adjustment mechanism can adapt to the bending length requirements of different sensors. It operates independently from the angle adjustment mechanism to avoid mutual interference, ensuring accurate length positioning, solving the problem of poor adaptability of existing fixtures to bending lengths, meeting special needs such as short positioning, improving the fixture's adaptability to multiple product specifications, reducing the cost and time of fixture replacement, and increasing the flexibility of small-batch, multi-variety production.

[0028] The modular design of the fixture facilitates manufacturing and maintenance, while the overall rigidity of each module is good, with strong resistance to deformation, ensuring stability during the bending process. The use of quick-clamping for dead-point positioning and clamping, along with the fixture's opening design, allows for direct removal of the hot-end material from the fixture before and after hot-end bending operations, simplifying operation and saving labor. Compared to the factory's original manual fixtures, which required 20 seconds to bend each product, this represents a 50% increase in efficiency.

[0029] The hot end of the temperature sensor uses a small-diameter thin-walled tube with a diameter of 5mm. It has two metal pins inside, and the space between the pins and the tube is filled with alumina insulating material. A cylindrical positioning ring is assembled and laser-welded onto the hot end, which can significantly improve the efficiency, accuracy, yield and adaptability of the exhaust gas temperature sensor bending process, while reducing the overall production cost. Attached Figure Description

[0030] Figure 1 This is a cross-sectional view of the overall structure of this utility model;

[0031] Figure 2 This is a three-dimensional structural diagram of the overall structure of this utility model;

[0032] Figure 3 This is a three-dimensional structural diagram of the first movable plate of this utility model;

[0033] Figure 4 This is a three-dimensional structural diagram of the second movable plate of this utility model.

[0034] Reference numerals: 1. Base plate; 2. First quick clamp; 3. Second quick clamp; 4. First quick clamp rod; 5. Second quick clamp rod; 6. Second movable plate; 7. First movable plate; 8. Angle code; 9. First front-middle slider; 10. Second front-middle slider; 11. Hot end fixing block; 12. Handle; 13. U-groove bearing; 14. Miniature guide rail. Detailed Implementation

[0035] In the manufacturing process of exhaust gas temperature sensors, bending is a crucial step, as its quality directly affects the assembly accuracy and performance of the sensor. Due to the special structure of the exhaust gas temperature sensor, which uses a small-diameter thin-walled tube with a diameter of 5mm and a wall thickness of only 0.5mm, and contains two metal pins and alumina insulating filler material, and has a 10mm diameter positioning ring attached welded to the hot end, the bending fixture has extremely high requirements. Specialized equipment is needed to achieve precise and non-destructive bending processing.

[0036] Currently, bending fixtures on the market are mainly divided into two categories: manual and automatic. However, both have significant limitations in adapting to the bending requirements of exhaust gas temperature sensors.

[0037] Manual bending fixtures have significant industry limitations in their application scenarios. These fixtures were initially designed for the construction industry, with the core function of bending solid building materials such as steel bars. Their working principle is based on a simple mechanical lever structure: two fixed fulcrums provide support, and a third fulcrum rotates around one of these fixed fulcrums, utilizing the three-point force principle to cause plastic deformation of the material, thus completing the bending. This design is entirely suited to the characteristics of solid round steel, emphasizing the bending capability of high-strength, high-rigidity materials, but it cannot adapt to the thin-walled tube characteristics of exhaust gas temperature sensors. Solid round steel experiences uniform stress during bending and is less prone to deformation due to localized stress concentration. However, the thin-walled tubes of exhaust gas temperature sensors are highly susceptible to uneven stress during bending, leading to tube wall dents, cracks, and even breakage of internal metal pins or detachment of insulation material. Using manual bending fixtures from the construction industry would directly result in product scrapping.

[0038] Existing manual pipe bending fixtures have a fatal flaw in their adaptability to bending length. These fixtures are designed to handle pipes of standard length, requiring a minimum bending length of at least 100mm. However, the bending length of the hot end of the exhaust gas temperature sensor is extremely short, with an actual requirement of only 60-70mm, which is a typical "short positioning" bending scenario. Due to structural limitations, existing manual pipe bending fixtures cannot complete stable clamping and bending within such a short distance. If forced, it can lead to bending position deviation, angle loss of control, or even excessive stretching of the pipe due to insufficient lever arm, damaging the product structure.

[0039] For pipes with positioning ring attachments, common manual pipe bending fixtures are ineffective. The hot end of the exhaust gas temperature sensor has its positioning ring fixed by laser welding before bending, which is a key reference component for subsequent assembly processes. However, the clamping mechanism of existing manual pipe bending fixtures is simple in design and lacks space to avoid the attachment. When clamping, it directly squeezes the positioning ring, causing it to deform or the weld joint to crack. In addition, the presence of the positioning ring changes the stress distribution of the pipe. The three-point bending structure of existing fixtures cannot adapt to this non-uniform stress state, which easily leads to stress concentration at the connection between the positioning ring and the pipe, further increasing the risk of product damage.

[0040] In terms of bending angle control, common manual pipe bending fixtures have almost no precise adjustment capabilities; their angle accuracy relies entirely on the operator's experience, judging the degree of bending through "hand-eye coordination," with errors typically exceeding ±5°; while the bending angle of exhaust gas temperature sensors needs to be controlled within ±1°, and multiple angle adjustments are required according to the installation needs of different vehicle models; the "unquantitative" adjustment method of existing manual fixtures simply cannot meet the high-precision bending requirements, which will lead to problems such as interference and poor contact during sensor assembly, affecting the final temperature detection accuracy.

[0041] The old bending fixture currently in use in the factory, although modified to some extent, still has many insurmountable defects. This fixture mounts two U-groove bearings on the bending actuator, with a third support point fixed to the base plate, forming a three-point bending structure. The bending arm of the actuator has an 8mm wide slot at its end, while the positioning ring has an outer diameter of 10mm; the slot size is smaller than the positioning ring diameter. During bending, the hot end needs to pass through the slot of the bending arm, and then one of the U-groove bearings is moved to clamp the hot end. At this time, the positioning ring will be tightly against the side of the bending arm. This structural design has three serious problems: First, the bending positioning distance cannot be adjusted, and it can only be adapted to a single product specification, resulting in extremely poor flexibility. Second, when the bending arm rotates, the end of the positioning ring cannot keep a plane following the movement trajectory of the bending arm, causing lateral line contact between the positioning ring and the bending arm, generating lateral friction, which causes deformation at the welded joint of the positioning ring, and in severe cases, direct cracking. Third, when picking up and placing products, the bending arm and the U-groove bearing used for clamping must be loosened first, which is a cumbersome operation and takes more than 20 seconds to bend each product, resulting in low efficiency.

[0042] Compared to manual fixtures, while automated bending equipment in the industry can improve accuracy and efficiency to some extent, it is not suitable for the production scenario of exhaust gas temperature sensors. Such automated equipment is expensive, with the cost of a single unit often exceeding 100,000 yuan. For small-batch, multi-part production models, the return on investment is extremely low. At the same time, the debugging process of automated equipment is complex. When changing product specifications, reprogramming and parameter adjustment are required, which usually takes 1-2 hours, failing to meet the needs of rapid model changeover. In addition, the bending mechanism of automated equipment is highly versatile and lacks special optimization for thin-walled pipes and positioning ring accessories. Risks such as pipe wall dents and positioning ring damage still exist, requiring additional investment for customized modifications, further increasing production costs.

[0043] In summary, neither traditional manual fixtures, outdated in-plant fixtures, nor automated equipment can perfectly meet the bending requirements of exhaust gas temperature sensors. This urgently necessitates a specialized bending fixture designed for small-diameter, thin-walled pipes, with positioning ring accessories, short positioning lengths, and multi-angle adjustments. This fixture would address the pain points of existing equipment in terms of accuracy, compatibility, efficiency, and cost, ensuring the bending quality and production efficiency of exhaust gas temperature sensors.

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

[0045] To address the problems of long material dimensions, large angle deviations during bending, limited material applicability, structural risks to semi-finished products, and low overall bending efficiency in existing technologies, the following technical solution is proposed. Please refer to [link / reference]. Figure 1-4 ;

[0046] A multi-angle, multi-length, short-positioning bending fixture for exhaust gas temperature sensors includes a base plate 1. Miniature guide rails 14 are mounted on both the left and right ends of the base plate 1. An angle adjustment mechanism for bending and adjusting the bending angle is slidably connected to the left miniature guide rail 14, and a length adjustment mechanism is slidably connected to the right miniature guide rail 14. The angle adjustment mechanism includes a first quick clamp 2 mounted on the upper end of the base plate 1, and a first quick clamp rod 4 mounted on the lower end of the first quick clamp 2.

[0047] Miniature guide rails 14 are installed on both the left and right ends of the base plate 1. An angle adjustment mechanism for bending and adjusting the bending angle is slidably connected to the left miniature guide rail 14, and a length adjustment mechanism is slidably connected to the right miniature guide rail 14. The angle adjustment mechanism includes a first quick clamp 2 installed on the upper end of the base plate 1. A first quick clamp rod 4 is installed at the lower end of the first quick clamp 2. A first movable plate 7 is provided on the base plate 1. A first front-middle slider 9 is provided on the outer side of the first movable plate 7. A handle 12 for operating the linkage mechanism is fixedly connected to the upper end of the first quick clamp 2. A U-groove bearing 13 is installed on the base plate 1. The first front-middle slider 9 in the angle adjustment mechanism is driven by the U-groove bearing 13 and the handle 12 to squeeze the exhaust gas temperature sensor to complete the bending.

[0048] The length adjustment mechanism includes a second quick clamp 3 mounted on the base plate 1. A second quick clamp rod 5 is mounted on the lower end of the second quick clamp 3. A second movable plate 6 is provided on the base plate 1. A second front-middle slider 10 is provided on the outer side of the second movable plate 6 to cooperate in completing bending-related actions. A hot end fixing block 11 is provided on the base plate 1 to fix the hot end of the exhaust gas temperature sensor in cooperation with the linkage mechanism. An adjustable corner bracket 8 is installed on the base plate 1. A U-shaped groove is provided on the corner bracket 8 to limit the extension length of the exhaust gas temperature sensor. The corner bracket 8 is position-adjustable through the U-shaped groove, which flexibly limits the length of the sensor extending into the bending actuator, adapts to multiple length bending requirements, and improves the compatibility of the fixture.

[0049] Working principle: First, place the exhaust gas temperature sensor to be bent on the base plate 1. Adjust the position of the fixed corner bracket 8 on the base plate 1, and use the U-shaped groove on the corner bracket 8 to limit the sensor's insertion length. Operate the second quick clamp 3 installed on the base plate 1 in the length adjustment mechanism, so that the second quick clamp rod 5 at its lower end drives the second movable plate 6 on the base plate 1 and the second front-middle slider 10 on the outer side to move, which, together with the fixing block 11 at the hot end, fixes the hot end of the sensor. Next, operate the first quick clamp 2 installed on the upper end of the base plate 1 in the angle adjustment mechanism, so that the first quick clamp rod 4 at its lower end drives the first movable plate 7 on the base plate 1 and the first front-middle slider 9 on the outer side to move. Operate the linkage mechanism through the handle 12 at the upper end of the first quick clamp 2, which, together with the U-shaped groove bearing 13 on the base plate 1, drives the first front-middle slider 9 to squeeze the sensor through the slot. At the same time, use the miniature guide rails 14 on the left and right ends of the base plate 1 to slide and adjust the angle adjustment mechanism and the length adjustment mechanism to the appropriate position. After bending is completed, release the quick clamps and take out the bent sensor.

[0050] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," 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 process, method, article, or apparatus.

[0051] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention.

Claims

1. A multi-angle, multi-length, short-positioning bending fixture for exhaust gas temperature sensors, comprising a base plate (1), characterized in that, Miniature guide rails (14) are installed on both the left and right ends of the base plate (1). An angle adjustment mechanism for bending and adjusting the bending angle is slidably connected on the left miniature guide rail (14), and a length adjustment mechanism is slidably connected on the right miniature guide rail (14). The angle adjustment mechanism includes a first quick clamp (2) installed on the upper end of the base plate (1), and a first quick clamp rod (4) is installed on the lower end of the first quick clamp (2).

2. The multi-angle, multi-length, short-positioning bending fixture for exhaust gas temperature sensors according to claim 1, characterized in that, The base plate (1) is provided with a first movable plate (7), and a first front-middle slider (9) is provided on the outer side of the first movable plate (7).

3. The multi-angle, multi-length, short-positioning bending fixture for exhaust gas temperature sensors according to claim 2, characterized in that, The first quick clamp (2) has a handle (12) fixedly connected to its upper end.

4. The multi-angle, multi-length, short-positioning bending fixture for exhaust gas temperature sensors according to claim 3, characterized in that, A U-groove bearing (13) is installed on the base plate (1).

5. The multi-angle, multi-length, short-positioning bending fixture for exhaust gas temperature sensors according to claim 1, characterized in that, The length adjustment mechanism includes a second quick clamp (3) mounted on the base plate (1), and a second quick clamp rod (5) is mounted on the lower end of the second quick clamp (3).

6. The multi-angle, multi-length, short-positioning bending fixture for exhaust gas temperature sensors according to claim 5, characterized in that, The base plate (1) is provided with a second movable plate (6), and a second front-middle slider (10) is provided on the outside of the second movable plate (6) to cooperate in completing bending-related actions.

7. A multi-angle, multi-length, short-positioning bending fixture for exhaust gas temperature sensors according to claim 6, characterized in that, The base plate (1) is provided with a hot end fixing block (11) that cooperates with the linkage mechanism to fix the hot end of the exhaust gas temperature sensor.

8. The multi-angle, multi-length, short-positioning bending fixture for exhaust gas temperature sensors according to claim 7, characterized in that, An adjustable and fixed corner bracket (8) is installed on the base plate (1). A U-shaped groove is opened on the corner bracket (8) to limit the insertion length of the exhaust gas temperature sensor.

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