Exhaust pipe welding tooling die

Abstract

The utility model discloses a kind of tooling moulds for exhaust pipe welding, including bottom plate, positioning flange is sequentially installed on the bottom plate along bottom plate length direction, support plate one, support plate two, limit plate and support plate three, the limit plate is located at the rear side position close to support plate two, support plate four and end face positioning block are also installed on the bottom plate, support plate three, support plate four and end face positioning block are obliquely arranged along bottom plate width direction, positioning hole is equipped on the positioning flange, positioning pin shaft is equipped in positioning hole, arc-shaped notch is respectively opened in the top end of support plate one, support plate two and support plate four, half U-shaped groove is opened in the top end of support plate three, limit pin and positioning block are fixed on the limit plate.The utility model can realize the synchronous welding of multistage pipeline, positioning is accurate, anti-deformation and easy to operate, shorten production cycle, reduce on-site space occupation and handling waste, reduce production cost.

Description

Technical Field

[0001] This utility model relates to the field of exhaust pipe manufacturing technology for fuel-powered engineering vehicles, and in particular to a tooling mold for welding exhaust pipes, which meets the requirements of high-precision and high-efficiency welding operations for irregularly shaped exhaust pipes. Background Technology

[0002] Existing exhaust pipe welding fixtures have the following disadvantages: 1. Low positioning accuracy and easy deformation. The current tooling uses general-purpose clamps for clamping and positioning, and lacks a special positioning structure for exhaust pipe flanges and round pipes. When manually adjusting the position of the workpiece to be welded, it is easy to cause displacement. In addition, the tooling base plate has no reinforcement design, and under long-term high temperature and external force during welding, it is easy to undergo dimensional deformation, which further leads to misalignment of the welding interface and affects the docking accuracy of the exhaust pipe and the cylinder.

[0003] 2. Low welding efficiency and long production cycle. The existing tooling only supports the "segmented welding" mode of exhaust pipes - it is necessary to clamp and spot weld a single section of the pipe first, and then remove the tooling and move it to the next station to weld the second section. The process of repeatedly switching tooling and moving the parts to be welded is not only time-consuming, but also prone to displacement of the spot-welded parts due to bumps during handling; in addition, after welding a single section, it is necessary to wait for it to cool down before proceeding to the next section, which extends the overall production cycle by more than 30%.

[0004] 3. Cumbersome operation and large waste of space. Segmented welding requires multiple sets of special tooling (corresponding to different pipeline sections), which occupies a lot of space on the production site; at the same time, the clamping of the fixtures requires repeated manual calibration of the position, and the clamping time for a single segment is as long as 5-8 minutes, which is labor-intensive and inefficient. Utility Model Content

[0005] The purpose of this invention is to overcome the shortcomings of existing exhaust pipe welding fixtures, such as low positioning accuracy, only segmented welding capability, long production cycle, cumbersome operation, and easy deformation. This invention provides an exhaust pipe welding fixture mold that enables simultaneous welding of multiple pipe segments, with accurate positioning, resistance to deformation, and simple operation. It shortens the production cycle, reduces on-site space occupation and transportation waste, and lowers production costs.

[0006] This utility model is achieved through the following technical solution: A tooling mold for welding exhaust pipes includes a base plate. A positioning flange, a first support plate, a second support plate, a limiting plate, and a third support plate are sequentially installed on the base plate along its length. The limiting plate is located near the rear side of the second support plate. A fourth support plate and an end-face positioning block are also installed on the base plate. The third support plate, the fourth support plate, and the end-face positioning block are arranged obliquely along the width of the base plate. A positioning hole is provided on the positioning flange, and a positioning pin is provided within the positioning hole. Arc-shaped grooves are respectively opened at the top of the first, second, and fourth support plates, and a semi-U-shaped groove is opened at the top of the third support plate. A limiting pin and a positioning block are fixed on the limiting plate.

[0007] A crosshair with millimeter-level precision is engraved along the length of the center of the base plate, and the positioning flange, support plate one, support plate two, limit plate and support plate three are installed along the crosshair.

[0008] The positioning flange is fixed to the base plate by a short support block.

[0009] Side support blocks are fixed to the sides of support plate one, support plate two, and support plate four, respectively.

[0010] The limiting plate is fixed to the base plate by a long support block.

[0011] Wide ribs and long ribs are fixed on the lower side of the base plate. The wide ribs are arranged parallel to the width direction of the base plate, and the long ribs are arranged parallel to the length direction of the base plate. Both the wide ribs and long ribs are fully welded to the base plate.

[0012] The upper end face of the positioning flange is provided with a contour positioning surface, which is perfectly matched with the lower end face and outer peripheral face of the flange-like weldment, with a contouring accuracy of ≤0.08mm.

[0013] The arc of the arc-shaped groove is consistent with the arc of the outer circumference of the round tube to be welded.

[0014] Working principle: First, the flange, bellows, and various pipe sections are positioned on the corresponding fixtures using hole positioning or mold positioning. Parts with holes are positioned using pins, while round pipes and flanges are positioned using contour positioning, ensuring that each section of the exhaust pipe fits snugly and is fixed in position. At this point, all parts are reliably limited and clamped. After all parts to be welded are positioned and clamped, the operator can simultaneously perform full welding operations on the interfaces of multiple pipe sections (such as flange and round pipe interfaces, and round pipe and round pipe interfaces) without needing to switch fixtures or move the parts to be welded. After welding is completed, the pins and locating pins are removed, and the finished exhaust pipe is taken out.

[0015] The advantages of this utility model are: 1. This utility model enables simultaneous welding of multiple sections, significantly shortening the production cycle. Compared to the existing technology of "segmented welding + multiple tooling changes", this utility model can complete the simultaneous welding of multiple pipe sections with a single positioning and clamping, eliminating the need to move the parts to be welded and reducing the production cycle by 40%-50%.

[0016] 2. Contour-based positioning design improves positioning efficiency and accuracy. The contour-based surface of the positioning flange perfectly matches the flange workpiece to be welded, and the contour-based groove of the support plate fits snugly against the round pipe workpiece to be welded. During manual material feeding, there is no need to repeatedly adjust the position, reducing feeding time by 60%. With the double clamping of pin positioning and pin positioning, the positioning accuracy can reach within 0.1mm, which is far higher than the positioning accuracy of existing fixtures (usually ≥0.5mm), ensuring the docking accuracy of the exhaust pipe and the hydraulic cylinder after welding.

[0017] 3. Reinforcing ribs on length and width prevent long-term tooling deformation. The wide and long ribs on the lower surface of the base plate form a reinforcing structure, dispersing the high temperature of welding and external stress. The deformation of the tooling after long-term use (≥5000 welding operations) is ≤0.05mm, avoiding welding deviations caused by tooling deformation and extending the service life of the tooling.

[0018] 4. This utility model effectively solves the problems of insufficient positioning accuracy and easy deformation of traditional tooling by using multiple support plates and limiting plates for coordinated positioning, a reinforcing rib structure on the base plate, and a high-precision contour positioning surface. It has the advantages of improving the sealing performance of welding assembly, reducing the number of workpiece transfers, and reducing equipment investment costs. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a side view of the present invention; Figure 3 This is a schematic diagram illustrating the application of this utility model.

[0020] Numbering on the map: 1. Base plate; 2. Positioning flange; 3. Support plate 1; 4. Limiting plate; 5. Support plate 2; 6. Positioning pin; 7. Support plate 3; 8. Semi-U-shaped groove; 9. Limiting pin; 10. Long support block; 11. Short support block; 12. End face positioning block; 13. Support plate 4; 14. Side support block; 15. Positioning block; 16. Wide rib; 17. Long rib. Detailed Implementation

[0021] like Figure 1 , 2The tooling mold for welding exhaust pipes shown in Figure 3 includes a base plate 1. On the base plate 1, a positioning flange 2, a first support plate 3, a second support plate 5, a limiting plate 4, and a third support plate 7 are installed sequentially along the length of the base plate 1. The limiting plate 4 is located near the rear side of the second support plate 5. A fourth support plate 13 and an end face positioning block 12 are also installed on the base plate 1. The third support plate 7, the fourth support plate 13, and the end face positioning block 12 are arranged obliquely along the width of the base plate 1. The positioning flange 2 has a positioning hole, and a positioning pin 6 is provided in the positioning hole. Arc-shaped grooves are opened at the top of the first support plate 3, the second support plate 5, and the fourth support plate 13, respectively. A semi-U-shaped groove 8 is opened at the top of the third support plate 7. A limiting pin 9 and a positioning block 15 are fixed on the limiting plate 4.

[0022] The base plate 1 refers to the base structure that supports the various positioning components. It can be fabricated from steel plates and provides an installation reference for the overall tooling. The positioning flange 2 is a component used to fix flange-like workpieces; its positioning holes cooperate with the positioning pins 6 to achieve axial positioning. The arc-shaped grooves at the top of support plates 1 (3), 2 (5), and 4 (13) are grooves that match the outer diameter of the round pipe. They can be formed by CNC milling and are used to constrain the circumferential displacement of the round pipe. The semi-U-shaped groove of support plate 3 is an upward-opening groove, fabricated by wire cutting, used to support pipe sections at specific angles. The limiting pin of the limiting plate 4 is a vertically installed cylindrical positioning component that, together with the positioning block 15, forms a three-dimensional limiting reference. The obliquely arranged support components refer to support structures arranged at non-orthogonal angles, which can be adjusted by changing the installation angle to adapt to the spatial orientation of multiple pipe sections.

[0023] This invention achieves precise positioning through a dedicated positioning flange 2 and a multi-directional support structure. Existing tooling base plates lack reinforcement and are prone to deformation; this invention enhances rigidity through rib reinforcement. While existing technologies require segmented welding and multiple clamping operations, this invention achieves simultaneous multi-segment welding through a multi-support layout, reducing the number of clamping operations and handling time. Traditional tooling relies on manual calibration; this invention utilizes a marking system and limit pins to establish a spatial reference, eliminating human adjustment errors.

[0024] This invention achieves precise positioning of flanges and multi-segment circular pipes, effectively preventing interface misalignment caused by welding deformation; it enables simultaneous clamping of multiple pipe segments through multiple support structures, significantly reducing the number of clamping operations and production cycle; the dedicated positioning components and marking system work together to reduce the difficulty of adjustment for operators and improve welding efficiency and finished product consistency.

[0025] A crosshair with millimeter-level precision is engraved along the length of the center of the base plate 1. The positioning flange 2, support plate one 3, support plate two 5, limiting plate 4, and support plate three 7 are installed along the crosshair. This effectively solves the problems of easy misalignment of the parts to be welded due to manual adjustment and welding misalignment caused by base plate deformation. The crosshair provides a unified installation benchmark for each support component, eliminating random errors from manual visual positioning, and the millimeter-level precision ensures the consistency of multi-station collaborative positioning. When the base plate deforms due to heat, operators can quickly identify the amount of deformation and correct the position of the components based on the crosshair, avoiding rework caused by welding interface misalignment.

[0026] The positioning flange 2 is fixed to the base plate 1 by a short support block 11.

[0027] Side support blocks 14 are fixed to the sides of the support plates 1-3, 2-5, and 4-13 respectively. This solves the positioning offset problem caused by insufficient rigidity of the support plates, keeps the round tube to be welded stable during the welding process, reduces misalignment of the joint after welding, and reduces the frequency of repeated manual calibration.

[0028] The limiting plate 4 is fixed to the base plate 1 by the long support block 10. It can effectively suppress the displacement of the limiting plate caused by high welding temperature and external force, reduce the number of manual adjustments, improve the docking accuracy of the exhaust pipe flange and the round pipe, and reduce the rework rate caused by tooling deformation.

[0029] Wide ribs 16 and long ribs 17 are fixed to the lower side of the base plate 1. The wide ribs 16 are arranged parallel to the width direction of the base plate 1, and the long ribs 17 are arranged parallel to the length direction of the base plate 1. Both the wide ribs 16 and long ribs 17 are fully welded to the base plate 1. This effectively solves the problem of dimensional deformation caused by insufficient rigidity of the tooling base plate. The grid layout of the wide and long ribs increases the load-bearing capacity of the base plate by about 2.3 times. The full welding connection process avoids the local stress concentration phenomenon caused by traditional intermittent welding, thereby ensuring that the tooling can maintain stable positioning accuracy after long-term use and extending the service life of the tooling to more than 3 times the original level.

[0030] A contour positioning surface is provided on the upper end face of the positioning flange 2. This contour positioning surface perfectly matches the lower end face and outer peripheral surface of the flange-like workpiece to be welded, with a contouring accuracy of ≤0.08mm. This solves the welding offset problem caused by mismatched positioning structures in existing tooling. The complementary shape characteristics of the contact surfaces between the workpiece to be welded and the tooling allow it to reach the predetermined position in its natural placement state, eliminating the need for additional adjustments during welding and effectively avoiding human error. Simultaneously, the high-precision matching characteristics of the contour positioning surface prevent minor displacements caused by welding thermal deformation, ensuring that the overall coaxiality of the welded multi-section exhaust pipe meets assembly requirements.

[0031] The arc of the aforementioned arc-shaped groove matches the arc of the outer circumference of the round tube to be welded. This solves the problem of welding misalignment caused by easy displacement during round tube clamping, allowing the round tube to achieve self-positioning in its natural state and shortening the clamping time per cycle. During the welding process, the deformation caused by the thermal expansion of the round tube is uniformly constrained by the inner wall of the groove, avoiding weld cracking due to local stress and improving the overall structural stability of the exhaust pipe.

[0032] Base plate 1: Made of Q235 steel plate, with millimeter-precision crosshairs (extending along the length and width) engraved on the surface. This is used for the pre-installation calibration of positioning and support components to ensure the relative positional accuracy of each component (error ≤ 0.1mm). At the same time, the crosshairs can assist in the initial placement of the parts to be welded, reducing manual adjustment time.

[0033] Wide stiffener 16 and long stiffener 17: Both are made of angle steel and fixed to the lower surface of the base plate 1; the wide stiffener 16 is arranged parallel to the width direction of the base plate 1, and the long stiffener 17 is arranged parallel to the length direction of the base plate 1 at intervals of 200-300mm. The stiffeners are connected to the base plate 1 by full welding, which can effectively disperse the stress of the base plate 1 caused by the high temperature of welding and external force, and avoid warping and deformation of the base plate 1 after long-term use (deformation ≤0.05mm / year).

[0034] Positioning flange 2: Fixed to the top of short support block 11, its upper end face is provided with "contour positioning surface" - the positioning surface is completely matched with the lower end face and outer peripheral face of the flange-type weldment (contour accuracy ≤0.08mm), and can be directly attached to the flange weldment to achieve preliminary positioning; the positioning flange 2 is provided with through hole for pin shaft to be inserted for positioning.

[0035] Positioning pin 6: It is a cylindrical structure with a diameter that matches the center hole of the flange to be welded. After the part to be welded is attached to the contour surface of the positioning flange 2, the positioning pin is inserted into the upper hole of the part to be welded and the through hole of the positioning flange 2 to achieve dual axial and radial positioning of the part to be welded and avoid rotation during welding.

[0036] Support plate: The top is provided with an arc-shaped groove (the arc of the groove is consistent with the arc of the outer circumference of the round tube to be welded), which is fixed to the bottom of the base plate 1 below the round tube to be welded, and is used to support the round tube to be welded to prevent it from sagging due to its own weight and causing the interface to shift.

[0037] The semi-U-shaped plate and end face positioning block 12: The semi-U-shaped plate is fixed to the upper part of the base plate 1, and its U-shaped groove fits with the outer circumferential surface of the round pipe to be welded, which is used to support and limit the displacement of the round pipe; the end face positioning block 12 is fixed to the upper part of the base plate 1 on the side corresponding to the end face of the round pipe, and its positioning surface fits with the end face of the round pipe, which further ensures the axial positioning accuracy of the flange.

[0038] The above description is merely an embodiment of this utility model and is not intended to limit the scope of protection of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the scope of protection of this utility model.

Claims

1. A tooling mold for welding exhaust pipes, characterized in that: The system includes a base plate, on which a positioning flange, a first support plate, a second support plate, a limiting plate, and a third support plate are sequentially installed along the length of the base plate. The limiting plate is located near the rear side of the second support plate. A fourth support plate and an end-face positioning block are also installed on the base plate. The third support plate, the fourth support plate, and the end-face positioning block are arranged obliquely along the width of the base plate. The positioning flange has a positioning hole, and a positioning pin is installed in the positioning hole. Arc-shaped slots are opened at the top of the first support plate, the second support plate, and the fourth support plate, respectively. A semi-U-shaped slot is opened at the top of the third support plate. A limiting pin and a positioning block are fixed on the limiting plate.

2. The tooling mold for welding exhaust pipes according to claim 1, characterized in that: A crosshair with millimeter-level precision is engraved along the length of the center of the base plate, and the positioning flange, support plate one, support plate two, limit plate and support plate three are installed along the crosshair.

3. The tooling mold for welding exhaust pipes according to claim 1, characterized in that: The positioning flange is fixed to the base plate by a short support block.

4. The tooling mold for welding exhaust pipes according to claim 1, characterized in that: Side support blocks are fixed to the sides of support plate one, support plate two, and support plate four, respectively.

5. The tooling mold for welding exhaust pipes according to claim 1, characterized in that: The limiting plate is fixed to the base plate by a long support block.

6. The tooling mold for welding exhaust pipes according to claim 1, characterized in that: Wide ribs and long ribs are fixed on the lower side of the base plate. The wide ribs are arranged parallel to the width direction of the base plate, and the long ribs are arranged parallel to the length direction of the base plate. Both the wide ribs and long ribs are fully welded to the base plate.

7. The tooling mold for welding exhaust pipes according to claim 1, characterized in that: The upper end face of the positioning flange is provided with a contour positioning surface, which is perfectly matched with the lower end face and outer peripheral face of the flange-like weldment, with a contouring accuracy of ≤0.08mm.

8. The tooling mold for welding exhaust pipes according to claim 1, characterized in that: The arc of the arc-shaped groove is consistent with the arc of the outer circumference of the round tube to be welded.

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