Side wall assembly aid

Abstract

The utility model relates to auxiliary frock field provides a kind of side wall assembly auxiliary frock.Side wall assembly auxiliary frock includes upper profile adjustment assembly, and upper profile adjustment assembly includes side wall jigs and at least one upper pull device, and side wall jigs has the contact surface matched with the upper profile of the side wall to be assembled, and upper pull device is connected to side wall jigs, for exerting force to the upper portion of side wall to adjust the profile of side wall upper portion;Lower gap adjustment assembly, and lower gap adjustment assembly includes beam jigs and at least one lower pull device, and beam jigs are suitable for with the cooperation of the chassis beam of vehicle body, and lower pull device is connected to beam jigs, for adjusting the gap between the lower end of side wall and chassis beam.The side wall assembly auxiliary frock can effectively correct the local deformation after side wall welding, ensure that side wall upper profile and end wall profile are completely adapted, reduce profile adaptation error, and guarantee the consistency of motor train unit vehicle body shape size.

Description

Technical Field

[0001] This utility model relates to the field of auxiliary tooling, and provides an auxiliary tooling for sidewall assembly. Background Technology

[0002] In the final assembly process of high-speed trains, the welding of end walls and side walls is one of the key steps. However, in actual production, especially after the welding of end walls and side walls, local deformation is often encountered. This deformation not only affects the fit between the contours of the end walls and side walls, making subsequent prefabrication and clamping operations extremely difficult and increasing assembly time, but also requires repeated adjustments and repairs during assembly, wasting a significant amount of time and manpower. In addition, the excessive welding gap at the connection between the side walls and the underframe due to deflection mismatch, sometimes exceeding 8 mm, leads to defects such as weld discontinuities and porosity during welding, greatly affecting welding quality, increasing the cost and time of subsequent repairs, and thus reducing the overall production efficiency and product quality stability of the high-speed trains.

[0003] Existing technologies offer limited solutions to these problems, lacking a method that can effectively control deformation after welding of end walls and side walls while ensuring high-quality welding standards. This is especially true in the production of high-speed trains, where the requirements for welding quality and assembly precision are even higher, and existing solutions struggle to meet the demands of high-quality, high-efficiency train production. Utility Model Content

[0004] This utility model provides an auxiliary tooling for side wall assembly to solve the problems of poor fit between the end wall and side wall contours and excessive welding gap between the side wall and the underframe in the EMU assembly process, so as to ensure the assembly quality and production efficiency of the EMU.

[0005] This utility model embodiment provides a sidewall assembly auxiliary tooling, including: An upper contour adjustment assembly includes a side wall backing mold and at least one upper pulling device. The side wall backing mold has a contact surface that matches the upper contour of the side wall to be assembled. The upper pulling device is connected to the side wall backing mold and is used to apply a force to the upper part of the side wall to adjust the upper contour of the side wall. The lower clearance adjustment assembly includes a side beam template and at least one lower pull device. The side beam template is adapted to cooperate with the underframe side beam of the vehicle body, and the lower pull device is connected to the side beam template for adjusting the clearance between the lower end of the side wall and the underframe side beam.

[0006] According to an embodiment of the present invention, the side wall backing is an arc-shaped structural member extending along the upper contour of the side wall, and the inner surface of the arc-shaped structural member constitutes the contact surface.

[0007] According to an embodiment of the present invention, the side wall backing mold is provided with a plurality of connection points for connecting the upper backing device, so as to achieve uniform force application to the upper part of the side wall.

[0008] According to an embodiment of the present invention, the upper contour adjustment component and the lower gap adjustment component are independent of each other.

[0009] According to an embodiment of the present invention, the side beam template is a linear structural component, and the side beam template is provided with a positioning mechanism for fixing the side beam template on the base frame side beam.

[0010] According to an embodiment of the present invention, the upper pulling device includes a first upper pulling device and a second upper pulling device; the lower pulling device includes a first lower pulling device and a second lower pulling device.

[0011] According to an embodiment of the present invention, both the upper pulling device and the lower pulling device are length-adjustable mechanisms.

[0012] According to an embodiment of the present invention, the length-adjustable mechanism includes a screw and a screw sleeve screw adjustment mechanism.

[0013] According to an embodiment of the present invention, both the side wall backing mold and the side beam backing mold are provided with hooks or hanging rings for detachable connection with the upper backing device or the lower backing device.

[0014] According to an embodiment of the present invention, one end of the lower bracing device is connected to the side beam support mold, and the other end is connected to the lower end of the side wall. The welding gap between the lower end of the side wall and the side beam of the base frame is controlled by adjusting the length of the lower bracing device.

[0015] According to the side wall assembly auxiliary tooling provided in this embodiment of the utility model, the arc-shaped structure and contact surface design of the side wall template enable the upper part of the side wall to achieve precise fitting with the template as a reference. Combined with the controllable force of the upper pulling device, it can effectively correct local deformation after side wall welding, ensuring that the upper contour of the side wall is completely matched with the contour of the end wall. This avoids the problem of "repeated adjustments still failing to meet contour requirements" in traditional assembly, reduces contour matching errors, and ensures the consistency of the train body's external dimensions. The upper pulling device is evenly distributed along the side wall template, and the force is evenly transmitted through threaded adjustment, preventing excessive force on a single part from causing new deformation of the side wall. The high-strength rigidity design of the side wall template also disperses the local load borne by the upper part of the side wall, protecting the structural integrity of the upper part of the side wall and ensuring long-term stability of the adjusted contour without springback. The adjustable length structure of the lower bracing device allows for minute adjustments to the gap. Combined with the fixed reference of the side beam template, it precisely controls the gap between the lower end of the side wall and the underframe side beam within the required process range. This avoids defects such as incomplete weld penetration and porosity caused by excessive gaps in traditional assembly, or weld buildup caused by excessive gaps, improving weld quality stability and reducing post-weld repair workload and costs. The force of the lower bracing device is evenly transmitted to the lower end of the side wall through the side beam template, preventing localized stress that could lead to dents or cracks. This is particularly suitable for side walls with localized stress after welding, reducing secondary damage to the lower side wall structure during adjustment and ensuring the connection strength between the side wall and the underframe side beam. The upper contour adjustment component and the lower gap adjustment component are independent of each other, allowing for priority adjustment of key parts according to side wall assembly needs. This eliminates the need for overall disassembly or repeated adjustments, significantly shortening the assembly time of a single EMU side wall compared to the traditional "overall adjustment, multiple trial and error" approach, and reducing the manpower and time investment required for repeated adjustments. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0017] Figure 1 This is a schematic perspective view of the auxiliary tooling for side wall assembly provided by this utility model.

[0018] Figure 2 This is a schematic side view of the auxiliary tooling for assembling the side wall provided by this utility model.

[0019] Figure label: 100. Side wall; 102. Base frame side beam; 104. Upper contour adjustment assembly; 106. Side wall template; 108. Upper bracing device; 110. Lower gap adjustment assembly; 112. Side beam template; 114. Lower bracing device; 116. Connection point. Detailed Implementation

[0020] The embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of this utility model.

[0021] like Figures 1 to 2 As shown, this utility model embodiment provides a sidewall assembly auxiliary tooling, including: The upper contour adjustment assembly 104 includes a side wall backing mold and at least one upper pulling device 108. The side wall backing mold has a contact surface that matches the upper contour of the side wall 100 to be assembled. The upper pulling device 108 is connected to the side wall backing mold and is used to apply force to the upper part of the side wall 100 to adjust the upper contour of the side wall 100. The lower clearance adjustment assembly 110 includes a side beam template 112 and at least one lower pull device 114. The side beam template 112 is adapted to cooperate with the underframe side beam 102 of the vehicle body. The lower pull device 114 is connected to the side beam template 112 and is used to adjust the clearance between the lower end of the side wall 100 and the underframe side beam 102.

[0022] According to the side wall assembly auxiliary tooling provided in this embodiment of the utility model, the arc-shaped structure and contact surface design of the side wall template enable the upper part of the side wall 100 to achieve precise fitting with the template as a reference. Combined with the controllable force of the upper pulling device 108, it can effectively correct local deformation of the side wall 100 after welding, ensuring that the upper contour of the side wall 100 is completely matched with the contour of the end wall. This avoids the problem of "repeated adjustments still failing to meet contour requirements" in traditional assembly, reduces contour matching errors, and ensures the consistency of the train body's external dimensions. The upper pulling device 108 is evenly distributed along the side wall template, and the force is evenly transmitted through threaded adjustment, preventing excessive force on a single part from causing new deformation of the side wall 100. The high-strength rigidity design of the side wall template also disperses the local load borne by the upper part of the side wall 100, protecting the structural integrity of the upper part of the side wall 100 and ensuring long-term stability of the adjusted contour without springback. The adjustable length structure of the lower bracing device 114 allows for minute adjustments to the gap. Combined with the fixed reference of the side beam template 112, it precisely controls the gap between the lower end of the side wall 100 and the base frame side beam 102 within the required process range. This avoids defects such as incomplete weld penetration and porosity caused by excessively large gaps in traditional assembly, or weld accumulation caused by excessively small gaps, thus improving weld quality stability and reducing post-weld repair workload and costs. The force of the lower bracing device 114 is evenly transmitted to the lower end of the side wall 100 through the side beam template 112, preventing localized stress that could cause dents or cracks at the lower end of the side wall 100. This is particularly suitable for side walls 100 with localized stress after welding, reducing secondary damage to the lower structure of the side wall 100 during adjustment and ensuring the connection strength between the side wall 100 and the base frame side beam 102. The upper contour adjustment component 104 and the lower gap adjustment component 110 are independent of each other. They can prioritize the adjustment of key parts according to the assembly requirements of the side wall 100 without disassembling the whole or making repeated adjustments. Compared with the traditional method of "overall adjustment and multiple trial and error", the assembly time of the side wall 100 of a single EMU is greatly shortened, and the manpower and time investment for repeated adjustments are reduced.

[0023] Please refer to the inspection report. Figures 1 to 2 The auxiliary tooling for side wall assembly provided in this utility model embodiment addresses the pain points of "poor fit between the end wall and the side wall 100 contour and excessive welding gap between the side wall 100 and the underframe side beam 102" during the assembly of the EMU side wall 100. Through the independent collaborative design of "upper contour adjustment component 104 + lower gap adjustment component 110", it achieves precise adjustment of the upper contour and lower gap of the side wall 100.

[0024] The upper contour adjustment component 104 serves as the core for adjusting the upper contour of the side wall 100. Through the cooperation of the side wall template and the upper pull device 108, it provides a reference support and controllable force for the upper part of the side wall 100.

[0025] The side wall template is an arc-shaped structural component made of high-strength alloy. Its arc contour perfectly matches the upper contour of the side wall 100 to be assembled, extending continuously along the upper contour of the side wall 100 without any breaks or protrusions, ensuring that it covers the main contour area of ​​the upper part of the side wall 100. The inner surface of the side wall template is the contact surface that contacts the upper part of the side wall 100. This contact surface has undergone ultra-precision grinding, and the surface is flat and smooth, without burrs, dents or impurities, so that it can completely fit the upper surface of the side wall 100, avoiding adjustment deviations caused by fitting gaps.

[0026] The side wall template has integrally formed fixing lugs at both ends, with mounting holes on the lugs. The side wall template can be temporarily fixed to the vehicle body end wall or other fixed structures by bolts or clips, ensuring that the side wall template is stable during adjustment and does not shift under the force of the upper pulling device 108. At the same time, the thickness of the side wall template remains uniform along the arc extension direction, ensuring that it has sufficient rigidity and does not bend or deform when subjected to the force of the upper pulling device 108, providing a stable reference for contour adjustment.

[0027] The upper support device 108 is a rigid mechanism with adjustable length. There is at least one such device (usually two or three, evenly distributed along the side wall support mold). One end is fixed to the preset connection point 116 of the side wall support mold by a threaded connection or hook structure, and the other end is connected to the preset connection seat on the upper part of the side wall 100 by a hook or bolt, forming a force transmission link of "side wall support mold - upper support device 108 - side wall 100".

[0028] The adjustable length structure of the upper pulling device 108 consists of an outer rod, an inner rod, and a locking nut. The outer rod is a hollow tubular structure with internal threads on its inner wall; the inner rod is a solid rod-like structure with external threads on its outer wall. One end of the inner rod is inserted into the hollow cavity of the outer rod, and the length is adjusted through thread engagement. Once the length is adjusted to the preset value, tightening the locking nut locks the relative position of the inner and outer rods, preventing the length from changing on its own. During adjustment, rotating the inner or outer rod changes the engagement length between the two, thereby changing the magnitude and direction of the force exerted by the upper pulling device 108 on the upper part of the side wall 100, pushing or pulling the upper part of the side wall 100 towards the contact surface of the side wall template, ultimately correcting the contour of the upper part of the side wall 100.

[0029] The lower gap adjustment component 110 serves as the core for controlling the gap between the lower end of the side wall 100 and the base frame side beam 102. Through the cooperation of the side beam template 112 and the lower pull device 114, it provides a fixed reference and controllable force for gap adjustment.

[0030] The side beam template 112 is a linear structural component made of high-strength alloy. Its length is adapted to the length of the chassis side beam 102 and extends along the length of the chassis side beam 102. One side surface of the template is a mating surface that fits with the chassis side beam 102. The mating surface is flattened so that it can fit tightly with the outer surface of the chassis side beam 102 without gaps or looseness.

[0031] The side beam template 112 is equipped with a positioning mechanism, which includes elastic buckles and threaded holes: the elastic buckles are U-shaped structures made of metal, which are spaced apart on one side of the contact surface of the side beam template 112 and can be directly snapped into the preset slots of the base frame side beam 102 to achieve quick initial fixation of the side beam template 112; the threaded holes are opened at both ends and the middle of the side beam template 112, with a minimum of three. After initial fixation, the side beam template 112 is firmly fixed to the base frame side beam 102 by passing bolts through the threaded holes and screwing them into the preset threaded holes of the base frame side beam 102, ensuring that the side beam template 112 does not shift laterally or longitudinally during the gap adjustment process.

[0032] The lower support device 114 is also a rigid mechanism with adjustable length. There is at least one (usually two, symmetrically distributed along the side beam support mold 112). One end is connected to the preset hanging ring of the side beam support mold 112 by a hook or bolt, and the other end is connected to the mounting ear plate at the lower end of the side wall 100 by a bolt or hook, forming a force transmission link of "side beam support mold 112 - lower support device 114 - side wall 100".

[0033] The adjustable length structure of the lower bracing device 114 is the same as that of the upper bracing device 108 (outer rod, inner rod, locking nut). During adjustment, if the gap between the lower end of the side wall 100 and the base frame side beam 102 is too large, rotate the screw sleeve of the lower bracing device 114 clockwise to shorten the length of the bracing device and pull the lower end of the side wall 100 closer to the base frame side beam 102 to reduce the gap; if the gap is too small, rotate the screw sleeve counterclockwise to extend the length of the bracing device and push the lower end of the side wall 100 away from the base frame side beam 102 to widen the gap; after adjustment, tighten the locking nut to fix the length and ensure that the gap is kept within the process requirements range.

[0034] The upper contour adjustment assembly 104 and the lower gap adjustment assembly 110 are independent of each other, with no shared structure or connecting parts: when adjusting the upper contour of the side wall 100, only the upper pulling device 108 needs to be operated, without moving or adjusting the lower gap adjustment assembly 110; when adjusting the lower gap of the side wall 100, only the lower pulling device 114 needs to be operated, without disassembling the upper contour adjustment assembly 104. The installation positions of the two do not interfere with each other spatially. The upper contour adjustment assembly 104 is concentrated near the upper part of the side wall 100 and the end wall, while the lower gap adjustment assembly 110 is concentrated at the lower end of the side wall 100 and the base frame side beam 102. They can be operated simultaneously or in stages to adapt to different assembly scenarios.

[0035] According to an embodiment of the present invention, the side wall backing is an arc-shaped structural member extending along the upper contour of the side wall 100, and the inner surface of the arc-shaped structural member forms a contact surface.

[0036] In this embodiment of the invention, the sidewall template is an arc-shaped structural component made of high-strength alloy. Its arc-shaped contour perfectly matches the upper contour of the sidewall 100 to be assembled, extending continuously along the upper contour of the sidewall 100 without any breaks or protrusions. The inner surface of the arc-shaped structural component is precision-polished, resulting in a smooth, flat surface free of burrs or depressions. This inner surface is the contact surface that contacts the upper part of the sidewall 100.

[0037] The side wall template has fixed lugs at both ends, with mounting holes on the lugs. The side wall template can be temporarily fixed to the end wall of the vehicle body or other fixed structures using bolts or clips, ensuring the stability of the side wall template position during adjustment. The arc-shaped structural component has a uniform thickness, maintaining consistency along its extension direction to ensure sufficient rigidity and prevent deformation under tension, thus guaranteeing the support and adjustment accuracy of the upper part of the side wall 100. When the side wall template mates with the side wall 100, the contact surface completely fits against the upper surface of the side wall 100 without gaps, providing a uniform force base for the subsequent application of force by the upper tensioning device 108.

[0038] The inner surface of the arc-shaped structural component perfectly matches and closely fits the upper contour of the side wall 100, serving as a direct adjustment reference for the upper contour of the side wall 100. This avoids adjustment deviations caused by loose contact between the template and the side wall 100, ensuring that the upper contour of the side wall 100 accurately matches the end wall contour and reducing the workload of repeated adjustments. The arc-shaped structural component extends continuously along the upper part of the side wall 100, and with its flat contact surface, it evenly distributes the force of the upper pull device 108 to all areas of the upper side wall 100, preventing excessive local stress that could cause new deformation of the side wall 100 and ensuring the integrity of the upper structure of the side wall 100.

[0039] The high-strength alloy material and uniform thickness design give the side wall template excellent resistance to deformation. It is not easy to bend or be damaged when subjected to tensile forces for a long time. It can be repeatedly used for the assembly of side walls of multiple EMUs, extending the service life of the tooling and reducing production costs.

[0040] According to an embodiment of the present invention, the side wall backing is provided with a plurality of connection points 116 for connecting the upper backing device 108, so as to achieve uniform force application to the upper part of the side wall 100.

[0041] In an embodiment of this utility model, a plurality of connection points 116 are provided on the outer surface of the side wall back mold (the side facing away from the contact surface). The connection points 116 are evenly spaced along the extension direction of the arc-shaped structural member. The number is determined according to the length of the side wall back mold, and is at least three, to ensure that the main stress area on the upper part of the side wall 100 can be covered.

[0042] Each connection point 116 is a boss structure with internal threads. The boss is integrally formed with the side wall template, and the axis of the boss is perpendicular to the outer surface of the side wall template so that the upper pulling device 108 can apply force in a direction perpendicular to the surface of the side wall 100. The internal thread of the connection point 116 is compatible with the external thread of the connector of the upper pulling device 108. The upper pulling device 108 is fixed to the side wall template by the threaded connection, ensuring a firm connection without the risk of loosening. At the same time, each connection point 116 is surrounded by reinforcing ribs to enhance the connection strength between the boss and the side wall template and prevent the boss from breaking under force.

[0043] Multiple evenly distributed connection points 116 allow the upper bracing device 108 to apply force from different positions on the upper part of the side wall 100. The force is evenly distributed along the upper contour of the side wall 100, avoiding local bulges or depressions in the side wall 100 caused by force applied from a single connection point 116. This ensures that the upper contour of the side wall 100 can be smoothly adjusted to the preset shape, significantly reducing the fitting error with the end wall contour. The evenly distributed force can disperse the load borne by the upper part of the side wall 100, avoiding material damage to the side wall 100 (such as dents or cracks) caused by concentrated loads in local areas. This is especially suitable for side walls 100 with local stress after welding, reducing secondary damage to the side wall 100 structure during the adjustment process.

[0044] Depending on the deformation of the upper part of the side wall 100, some or all of the connection points 116 can be selected to install the upper bracing device 108. For example, the number of bracing devices can be increased in areas with severe deformation, and reduced in areas with slight deformation, so as to flexibly meet different adjustment needs and improve the applicability of the tooling.

[0045] According to an embodiment of the present invention, the upper contour adjustment component 104 and the lower gap adjustment component 110 are independent of each other.

[0046] In the embodiments of this utility model, the upper contour adjustment component 104 and the lower gap adjustment component 110 have no shared structure or connecting parts, and each has an independent template and pulling device: the side wall template and upper pulling device 108 of the upper contour adjustment component 104 are only used to adjust the contour of the upper part of the side wall 100, and the installation positions are concentrated near the upper part of the side wall 100 and the end wall of the vehicle body; the side beam template 112 and lower pulling device 114 of the lower gap adjustment component 110 are only used to adjust the gap between the lower end of the side wall 100 and the underframe side beam 102, and the installation positions are concentrated at the lower end of the side wall 100 and the underframe side beam 102.

[0047] The operation of the two components is independent: when adjusting the upper contour of the side wall 100, the upper support device 108 can be operated independently without moving or adjusting the lower gap adjustment component 110; when adjusting the lower gap of the side wall 100, the lower support device 114 can be operated independently without disassembling or moving the upper contour adjustment component 104. Furthermore, their fixing methods are also independent: the upper contour adjustment component 104 is connected to the vehicle body end wall via the fixing lugs of the side wall support template, and the lower gap adjustment component 110 is connected to the underframe side beam 102 via the positioning mechanism of the side beam support template 112; there is no interdependent fixing relationship.

[0048] The adjustment of key components can be prioritized based on the actual problems of the side wall 100. For example, if the side wall 100 and the end wall contour do not match well, only the upper contour adjustment component 104 needs to be operated; if the gap between the side wall 100 and the base frame is too large, only the lower gap adjustment component 110 needs to be operated, without overall adjustment, reducing unnecessary operation steps and improving assembly efficiency. The independent structural design ensures that the adjustment processes of the two do not affect each other. For example, when adjusting the gap at the lower end of the side wall 100, the upper contour of the side wall 100 will not shift due to the transmission of force; when adjusting the upper contour, the relative position between the lower end of the side wall 100 and the side beam 102 of the base frame will not change, ensuring that the accuracy of both contour adjustment and gap adjustment meets the requirements.

[0049] When a component (such as a pull-back device or a template) is damaged, it can be disassembled and repaired or replaced individually without replacing the entire set of tooling, thus reducing maintenance costs and downtime and ensuring production continuity.

[0050] According to an embodiment of the present invention, the side beam template 112 is a linear structural component, and the side beam template 112 is provided with a positioning mechanism for fixing the side beam template 112 to the base frame side beam 102.

[0051] In the embodiments of this utility model, the side beam template 112 is a linear structural component made of high-strength steel. Its length is adapted to the length of the underframe side beam 102 of the vehicle body to be assembled. It extends along the length direction of the underframe side beam 102 and its surface is treated with anti-rust to adapt to the humid environment of the workshop.

[0052] The positioning mechanism of the side beam template 112 includes multiple clips and threaded holes: the clips are elastic metal parts, spaced apart on one side of the side beam template 112, and can be directly snapped into the pre-set slots of the base frame side beam 102 to achieve quick initial fixation of the side beam template 112; the threaded holes are opened at both ends and the middle of the side beam template 112, with at least three in number. After the clips have completed the initial fixation, bolts are passed through the threaded holes and screwed into the pre-set threaded holes of the base frame side beam 102 to firmly fix the side beam template 112 onto the base frame side beam 102, preventing the side beam template 112 from shifting during adjustment. The upper surface of the side beam template 112 is also provided with hanging rings for connecting the lower support device 114. The hanging rings are evenly distributed along the linear structural members to meet the connection requirements of the lower support device 114.

[0053] The positioning mechanism, combining snap-fit ​​and bolts, stably fixes the side beam template 112 to the base frame side beam 102, eliminating the risk of lateral or longitudinal displacement. This ensures the positional accuracy of the side beam template 112 as a gap adjustment reference, providing a reliable foundation for the subsequent precise gap adjustment of the lower support device 114. The combination of quick initial fixing with snap-fit ​​and precise locking with bolts allows for the installation of the side beam template 112 without complex measurements or adjustments. Compared to the traditional method of fixing solely with bolts, this significantly reduces installation time and improves assembly efficiency.

[0054] The linear structural components are adapted to the length of the underframe side beam 102. The positions of the buckles and threaded holes of the positioning mechanism can be adjusted according to the structure of the underframe side beam 102 of different train models. There is no need to redesign the main body of the side beam template 112, so it can be adapted to the underframe side beam 102 of various EMUs, enhancing the versatility of the tooling.

[0055] According to an embodiment of the present invention, the upper pulling device 108 includes a first upper pulling device 108 and a second upper pulling device 108; the lower pulling device 114 includes a first lower pulling device 114 and a second lower pulling device 114.

[0056] In the embodiments of this utility model, the first upper pulling device 108 and the second upper pulling device 108 have completely identical structures, both being length-adjustable mechanisms, symmetrically distributed on both sides of the side wall backing mold, near the two ends of the side wall backing mold. One end of the first upper pulling device 108 is fixed to the connection point 116 of the side wall backing mold via a threaded connection, and the other end is connected to the preset connecting seat on the upper part of the side wall 100 via a hook; the installation method of the second upper pulling device 108 is the same as that of the first upper pulling device 108. The two work together to apply force from both sides of the upper part of the side wall 100 to adjust the upper contour of the side wall 100.

[0057] The first lower bracing device 114 and the second lower bracing device 114 have the same structure and are length-adjustable mechanisms. They are symmetrically distributed on both sides of the side beam support mold 112 and spaced apart along the length of the side beam support mold 112. One end of the first lower bracing device 114 is connected to the side beam support mold 112 via a hanging ring, and the other end is fixed to the mounting ear plate at the lower end of the side wall 100 via bolts. The second lower bracing device 114 is installed in the same way as the first lower bracing device 114, and the two work together to adjust the gap between the lower end of the side wall 100 and the base frame side beam 102.

[0058] The symmetrical distribution of the first and second bracing devices allows for the application of balanced forces from both sides or ends of the side wall 100, preventing tilting or displacement of the side wall 100 caused by unilateral force application. This makes the adjustment of the upper contour and lower gap of the side wall 100 smoother and reduces secondary deformation after adjustment. The synergistic effect of the two bracing devices provides a greater total force, which, compared to a single bracing device, can more effectively correct severe deformation of the side wall 100 after welding (such as a large bulge at the upper part of the side wall 100 or an excessive gap at the lower end), expanding the adjustment range of the tooling and adapting to more complex assembly scenarios.

[0059] The two sets of tie-down devices create redundancy. If one set of tie-down devices temporarily fails, the other set can temporarily take over some of the adjustment tasks, avoiding assembly shutdowns due to a single device failure, ensuring production continuity, and facilitating online replacement of faulty devices.

[0060] According to the embodiments of this utility model, both the upper pulling device 108 and the lower pulling device 114 are length-adjustable mechanisms.

[0061] In the embodiments of this utility model, the length-adjustable mechanisms of the upper pulling device 108 and the lower pulling device 114 are both composed of an outer rod, an inner rod, and a locking nut: the outer rod is a hollow tubular structure with internal threads on the inner wall; the inner rod is a solid rod structure with external threads on the outer wall, and one end of the inner rod is inserted into the hollow cavity of the outer rod, and the length is adjusted by thread engagement; the locking nut is sleeved on the connection between the outer rod and the inner rod, and when the length is adjusted to the preset value, tightening the locking nut can lock the relative position of the inner rod and the outer rod, preventing the length from changing on its own.

[0062] The outer rod end of the upper bracing device 108 is provided with a threaded joint adapted to the side wall support connection point 116, and the inner rod end is provided with a hook adapted to the upper connecting seat of the side wall 100; the outer rod end of the lower bracing device 114 is provided with a hook adapted to the hanging ring of the side beam support 112, and the inner rod end is provided with a bolt hole adapted to the mounting ear plate at the lower end of the side wall 100. During adjustment, the engagement length of the inner rod or the outer rod is changed by rotating them, thereby changing the total length of the bracing device and adjusting the force applied to the side wall 100.

[0063] The threaded engagement length adjustment method allows for minute length changes, thereby precisely controlling the force applied to the side wall 100. Whether it's a slight contour deviation at the upper part of the side wall 100 or a minor gap adjustment at the lower end, it can be precisely corrected by adjusting the length of the pull-back device, reducing adjustment errors. The threaded structure has excellent self-locking performance. Combined with the locking nut, once the pull-back device is adjusted to the preset length, its length will not change due to vibration or the reaction force of the side wall 100, ensuring that the contour and gap of the side wall 100 remain stable before positioning welding, guaranteeing assembly accuracy.

[0064] The outer rod, inner rod, and locking nut have a simple structure with no complex transmission components, resulting in a low probability of failure. If thread wear or component damage occurs, the outer rod, inner rod, or locking nut can be replaced individually without replacing the entire tensioning device, thus reducing maintenance costs and difficulty.

[0065] According to an embodiment of the present invention, the length-adjustable mechanism includes a screw and a screw sleeve screw adjustment mechanism.

[0066] In an embodiment of this utility model, the screw adjustment mechanism consists of a screw and a screw sleeve: the screw is a solid rod made of high-strength alloy, with precision external threads machined on its surface. The thread profile is trapezoidal, possessing excellent load-bearing capacity and wear resistance; the screw sleeve is a hollow tubular structure, with internal threads machined on its inner wall to match the external threads of the screw. The material of the screw sleeve is the same as that of the screw, ensuring uniform wear during thread engagement.

[0067] One end of the screw has a connector (hook or threaded connector) for connecting to the template or side wall 100, and the connector is integrally formed with the screw. The other end of the sleeve also has a matching connecting structure (hanging ring or bolt hole), which is welded to the sleeve. The weld is ground to ensure connection strength. During adjustment, rotating the sleeve clockwise will cause the screw to retract into the sleeve, shortening the length of the entire adjustment mechanism; rotating the sleeve counterclockwise will cause the screw to extend out of the sleeve, lengthening the adjustment mechanism. After the length is adjusted to the correct position, the screw and sleeve are locked together by the locking nuts at both ends of the sleeve to prevent relative rotation.

[0068] The trapezoidal thread has a uniform pitch, allowing for precise control of the screw's movement during rotation of the threaded sleeve. This enables millimeter-level or even smaller length adjustments, fully meeting the precision adjustment requirements of the side wall 100 profile and clearance of the EMU. It ensures that the profile mismatch error between the side wall 100 and the end wall, as well as the clearance error between the side wall 100 and the underframe, are controlled within the required process specifications. Compared to ordinary triangular threads, the trapezoidal thread has a larger bearing area and can withstand greater tensile forces. Even when adjusting the side wall 100, which has undergone severe deformation after welding, thread slippage or damage will not occur, ensuring the reliability of the adjustment process.

[0069] The screw and the sleeve are made of the same high-strength alloy material, resulting in uniform wear during thread engagement. The thread accuracy can still be maintained after long-term use, eliminating the need for frequent component replacement, extending the service life of the screw adjustment mechanism, and reducing the cost of tooling.

[0070] According to an embodiment of the present invention, both the side wall backing mold and the side beam backing mold 112 are provided with hooks or hanging rings for detachable connection with the upper backing device 108 or the lower backing device 114.

[0071] In this embodiment of the invention, a hook is provided on the outer surface of the side wall backing mold (at connection point 116). The hook is a U-shaped metal piece, integrally formed with the side wall backing mold. The opening of the hook faces the side wall 100, and the inner wall of the hook is rounded to avoid scratching the connecting parts of the upper pulling device 108. Each connection point 116 corresponds to one hook. The size of the hook is adapted to the size of the connector of the upper pulling device 108. The connector of the upper pulling device 108 can be directly inserted into the hook for quick connection.

[0072] A hanging ring is provided on the upper surface of the side beam template 112. The hanging ring is a circular metal ring, which is fixed to the side beam template 112 by welding. The axis of the hanging ring is perpendicular to the upper surface of the side beam template 112. The inner diameter of the hanging ring is adapted to the size of the hook of the lower pull device 114. The hook of the lower pull device 114 can be directly inserted into the hanging ring to complete the detachable connection. The surfaces of the hook and the hanging ring are rust-proofed to prevent corrosion caused by the humid environment of the workshop and to ensure smooth connection.

[0073] The detachable connection between the hook and the hanging ring allows for tool-free installation and removal of the upper / lower support device 114. Compared to threaded connections, this saves time spent tightening bolts, a significant advantage when frequent adjustments to the support device's position are required, greatly improving the overall assembly efficiency of the side wall 100. The smooth inner wall of the hook and the circular structure of the hanging ring prevent rigid collisions when the support device connects to the template, reducing scratches or deformation of the connecting parts, protecting the connection structure between the support device and the template, and extending their service life.

[0074] The dimensions of the hooks and rings conform to industry standards and can be adapted to the same type of pull-back devices produced by different manufacturers. There is no need to design a separate connection structure for the pull-back device, which enhances the versatility of the tooling and reduces the cost of replacing the pull-back device.

[0075] According to an embodiment of the present invention, one end of the lower bracing device 114 is connected to the side beam backing mold 112, and the other end is connected to the lower end of the side wall 100. The welding gap between the lower end of the side wall 100 and the base frame side beam 102 is controlled by adjusting the length of the lower bracing device 114.

[0076] In an embodiment of this utility model, one end of the lower pull-back device 114 is connected to the hanging ring of the side beam backing mold 112 via a hook. The hook can rotate slightly around the hanging ring to adapt to the slight angle change of the side wall 100 during the adjustment process. The other end is fixed to the mounting ear plate at the lower end of the side wall 100 via a bolt. The bolt passes through the bolt hole of the inner rod of the lower pull-back device 114 and is screwed into the threaded hole of the mounting ear plate. After tightening, it is locked by an anti-loosening washer to prevent the bolt from loosening during the adjustment process.

[0077] When adjusting the welding gap between the lower end of the side wall 100 and the base frame side beam 102, first measure the initial gap size. If the gap is too large, rotate the sleeve of the lower pulling device 114 clockwise to shorten the length of the pulling device, pulling the lower end of the side wall 100 closer to the base frame side beam 102 until the gap is reduced to the required range. If the gap is too small, rotate the sleeve counterclockwise to extend the length of the pulling device, pushing the lower end of the side wall 100 away from the base frame side beam 102 until the gap is expanded to the required range. During the adjustment process, the gap size is checked in real time using a feeler gauge to ensure gap control accuracy.

[0078] By adjusting the length of the lower bracing device 114, the gap between the lower end of the side wall 100 and the base frame side beam 102 can be precisely controlled. This avoids defects such as incomplete weld penetration and porosity caused by an excessively large gap, or weld accumulation caused by an excessively small gap. This significantly improves the first-pass weld inspection pass rate and reduces the workload and cost of post-weld repair. The force of the lower bracing device 114 is evenly distributed along the lower end of the side wall 100. Adjusting the gap will not cause local depressions or bulges at the lower end of the side wall 100, protecting the structural integrity of the lower end of the side wall 100 and ensuring that the connection strength between the side wall 100 and the base frame side beam 102 meets the design requirements.

[0079] The operation method of adjusting the length by rotating the screw sleeve and checking the gap by the feeler gauge is intuitive and easy to understand. Operators can master it without complicated training, which lowers the operation threshold, reduces adjustment errors caused by improper operation, and ensures the stability of assembly quality.

[0080] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. An auxiliary tooling for sidewall assembly, characterized in that, include: The upper contour adjustment assembly (104) includes a side wall back mold and at least one upper pull device (108). The side wall back mold has a contact surface that matches the upper contour of the side wall (100) to be assembled. The upper pull device (108) is connected to the side wall back mold and is used to apply force to the upper part of the side wall (100) to adjust the upper contour of the side wall (100). The lower clearance adjustment assembly (110) includes a side beam template (112) and at least one lower pull device (114). The side beam template (112) is adapted to cooperate with the underframe side beam (102) of the vehicle body. The lower pull device (114) is connected to the side beam template (112) and is used to adjust the clearance between the lower end of the side wall (100) and the underframe side beam (102).

2. The auxiliary tooling for sidewall assembly according to claim 1, characterized in that, The sidewall template is an arc-shaped structural member extending along the upper contour of the sidewall (100), and the inner surface of the arc-shaped structural member constitutes the contact surface.

3. The auxiliary tooling for sidewall assembly according to claim 2, characterized in that, The side wall backing is provided with multiple connection points (116) for connecting the upper backing device (108) to achieve uniform force application to the upper part of the side wall (100).

4. The auxiliary tooling for sidewall assembly according to claim 1, characterized in that, The upper contour adjustment component (104) and the lower gap adjustment component (110) are independent of each other.

5. The auxiliary tooling for sidewall assembly according to claim 1, characterized in that, The side beam template (112) is a linear structural component, and the side beam template (112) is provided with a positioning mechanism for fixing the side beam template (112) on the base frame side beam (102).

6. The auxiliary tooling for sidewall assembly according to claim 1, characterized in that, The upper pulling device (108) includes a first upper pulling device (108) and a second upper pulling device (108); the lower pulling device (114) includes a first lower pulling device (114) and a second lower pulling device (114).

7. The auxiliary tooling for sidewall assembly according to any one of claims 1 to 6, characterized in that, Both the upper pulling device (108) and the lower pulling device (114) are length-adjustable mechanisms.

8. The auxiliary tooling for sidewall assembly according to claim 7, characterized in that, The length-adjustable mechanism includes a screw and a screw sleeve with a spiral adjustment mechanism.

9. The auxiliary tooling for sidewall assembly according to any one of claims 1 to 6, characterized in that, Both the side wall support mold and the side beam support mold (112) are provided with hooks or hanging rings for detachable connection with the upper support device (108) or the lower support device (114).

10. The auxiliary tooling for sidewall assembly according to any one of claims 1 to 6, characterized in that, One end of the lower bracing device (114) is connected to the side beam backing mold (112), and the other end is connected to the lower end of the side wall (100). The welding gap between the lower end of the side wall (100) and the base frame side beam (102) can be controlled by adjusting the length of the lower bracing device (114).

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