Frame Structure Welding Under Elastic Bending for Geometric Accuracy
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Solution Overview
Problem
Existing methods for attaching connecting members to frame structures face challenges in maintaining geometrical accuracy due to thermal distortion during welding and shape correction deformations, particularly in bent frame members, leading to difficulties in achieving precise alignment and increased weight.
Innovation Solution
A method involving temporarily fixing a connecting member to a frame member while elastically deforming it, followed by final-welding under controlled conditions to counteract thermal distortion and shape deviations, using a device with supporting, bending, and welding parts to ensure high geometrical accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If connecting members are attached to frame member by welding, then the number of components is reduced and weight is decreased, but thermal distortion during welding causes deformation of joining surfaces and reduces geometrical positional accuracy
Solution Approach 1:
The patent applies preliminary action by temporarily fixing the connecting member to the frame member at the desired position before welding. This preliminary positioning ensures that the connecting member is correctly placed, and subsequent welding is performed without causing displacement or geometrical inaccuracies. The temporary fixing acts as a precursor that prevents the harmful effect of thermal distortion from affecting the final position accuracy.
Solution Approach 2:
The patent introduces a temporary fixing mechanism as an intermediary between the connecting member and the welding process. This intermediary temporarily holds the connecting member in the correct position during the welding operation, allowing the welding to proceed without causing displacement. After welding, the temporary fixing is removed, leaving the connecting member securely welded at the precise intended location.
2Shape
If frame member undergoes bending to achieve desired shape, then the frame structure can be formed, but shape correction causes large deformation amount and spring back, making it difficult to maintain accuracy within given range
Solution Approach 1:
The patent applies preliminary action by performing temporary fixing of the connecting member before the frame member undergoes bending or shape correction. This ensures that the connecting member is already positioned correctly, and subsequent shape adjustments to the frame member do not cause relative displacement or spring back that would affect the final geometrical accuracy of the assembled structure.
Solution Approach 2:
The patent utilizes parameter changes by controlling the timing and state of the frame member during bending operations. By performing temporary fixing at a specific stage before bending, and by managing the elastic deformation parameters during bending, the patent achieves the desired shape while minimizing spring back and maintaining dimensional accuracy within the given range.
3Manufacturing precision
If mechanical joining means such as bolts are used to attach connecting members, then positional accuracy can be regulated by forming attachment holes, but the number of steps increases and the overall weight of frame structure increases
Solution Approach 1:
The patent replaces the mechanical joining system (bolts, nuts, and attachment holes) with a welding system. Instead of using mechanical fasteners that require multiple steps for drilling and assembly, the patent uses welding to directly join the connecting member to the frame member. This substitution eliminates the need for additional components and reduces the overall weight while maintaining attachment position accuracy through the temporary fixing method.
Solution Approach 2:
The patent discards the temporary fixing mechanism after it has served its purpose of positioning the connecting member during welding. The temporary fixing is removed after welding is complete, leaving only the permanent welded joint. This eliminates the need for permanent mechanical fasteners and their associated components, thereby reducing weight while maintaining manufacturing precision.
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
The method effectively eliminates the influence of thermal distortion and shape deformations, resulting in a frame structure with high geometrical accuracy and reduced weight.
Implementation Method 1
imposing a bending load on an axial-direction intermediate portion of the frame member to elastically deform the frame member
Implementation Method 2
final-welding the connecting member to the frame member while keeping the frame member in an elastically deformed state
Data Source
AI summary
Provided are a method and a device for producing a frame structure, in which influences of both a thermal distortion due to welding and a decrease in the accuracy of the frame member itself are eliminated and high geometrical accuracy is obtained. The method for producing a frame structure includes supporting both ends of a long frame member, temporarily fixing a connecting member to somewhere along a longitudinal direction of the frame member, and final-welding the connecting member to the frame member while keeping the frame member in an elastically deformed state by imposing a bending load on an intermediate portion along the longitudinal direction of the frame member.