Box Structure Welding Support for Real-Time Deformation Control
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Solution Overview
Problem
The bolster beam structure in high-speed train manufacturing experiences severe welding deformations due to its asymmetric welded design, complex welding structures, and high thermal expansion of aluminum alloys, leading to inefficiencies in production and automation, as well as the need for post-weld repair, which increases costs and reduces manufacturing accuracy.
Innovation Solution
An apparatus and method providing multi-point flexible supports and real-time monitoring of the bolster beam's deformation, allowing for dynamic adjustment of positioning and force application during welding, using a combination of sensors and actuators to regulate deformation and eliminate the need for post-weld repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional welding methods are used on the bolster beam structure, then the welding process can be completed, but severe welding deformations occur due to the asymmetric welded design, complex welding structures, and high thermal expansion of aluminum alloys
Solution Approach 1:
The patent applies preliminary action by pre-positioning multiple adjustable support devices at predetermined locations on the bolster beam structure before welding begins. These supports are configured in advance to counteract expected deformation forces, and the support forces are pre-adjusted to appropriate levels. This preliminary setup enables the structure to maintain manufacturing precision throughout the welding process without requiring post-weld repair operations, thereby resolving the contradiction between deformation control and production efficiency.
Solution Approach 2:
The patent employs parameter changes by dynamically adjusting the support force magnitudes and positions of the multiple support devices during the welding process. Based on real-time monitoring of deformation parameters, the control system modifies the force applied by each support and their positional coordinates to counteract evolving deformation trends. This dynamic parameter adjustment maintains manufacturing precision while allowing continuous welding operations, eliminating the need for post-weld repair and improving productivity.
2Manufacturing precision
If post-weld flame heat straightening repair is performed to meet assembly requirements, then manufacturing accuracy can be improved, but production efficiency is reduced and strength loss and performance degradation occur
Solution Approach 1:
The patent applies preliminary anti-action by using the multiple adjustable support devices to counteract welding-induced deformations in real-time during the welding process. The supports generate opposing forces that balance the thermal expansion and contraction forces, preventing deformation from occurring in the first place. This eliminates the need for post-weld flame heat straightening repair, thereby preserving the material strength and performance without the damage caused by subsequent thermal processing operations.
Solution Approach 2:
The patent converts the harmful effect of thermal expansion and contraction forces into a beneficial control mechanism. By using sensors to detect the deformation forces generated during welding, the system calculates the counter-forces needed and applies them through the adjustable supports. This transforms the potentially harmful thermal effects into a controllable parameter, maintaining manufacturing accuracy while avoiding the strength loss associated with post-weld repair operations.
3Manufacturing precision
If multi-point flexible supports with real-time monitoring are implemented, then manufacturing accuracy and deformation control are improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the support system into multiple independent adjustable support devices, each equipped with its own sensor and control capabilities. Rather than using a single complex support mechanism, the system employs several simpler modular units positioned at different locations on the bolster beam. Each unit can be independently adjusted and controlled, which simplifies the design of individual components while achieving overall high precision through their coordinated operation.
Solution Approach 2:
The patent employs feedback mechanisms where sensors mounted on the adjustable support devices continuously monitor the deformation state of the bolster beam structure during welding. This real-time data is fed back to the control system, which automatically adjusts the support forces and positions to maintain manufacturing accuracy. The feedback loop enables the complex system to self-regulate, reducing the need for manual intervention and complex pre-programming, thereby managing system complexity through intelligent control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach improves manufacturing accuracy, reduces production costs, and enhances efficiency by dynamically regulating deformation in real-time, eliminating the need for post-weld repair and improving the overall quality of the bolster beam structure.
Implementation Method 1
the adjustment portion regulates a flatness of the to-be-welded box body by adjusting action force magnitude and/or a force application position on the welding surface of the to-be-welded box body
Implementation Method 2
a supporting portion (30), wherein the supporting portion is formed with a supporting surface that supports a to-be-welded box body
Data Source
AI summary
An apparatus for regulating the welding deformation of a box-shaped structure, said apparatus comprising: a supporting part and a regulating part; a supporting surface that supports a box to be welded is formed on the supporting part; the regulating part is connected to the supporting part and at least abuts against a welding surface of said box; during the welding process, the regulating part regulates the flatness of said box by means of regulating the magnitude and/or force application position of a force acting on the welding surface of said box. In the regulation apparatus, multi-point flexible support is arranged on a bolster box-shaped structure, so as to achieve real-time dynamic regulation and step-by-step precision regulation, thereby improving the manufacturing precision of a bolster, and eliminating post-welding modification and repair of the bolster box-shaped structure. Also disclosed is a method for regulating the welding deformation of a box-shaped structure.