WO2024103498A1 - Chassis assembly and welding method - Google Patents

Chassis assembly and welding method Download PDF

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Publication number
WO2024103498A1
WO2024103498A1 PCT/CN2022/142631 CN2022142631W WO2024103498A1 WO 2024103498 A1 WO2024103498 A1 WO 2024103498A1 CN 2022142631 W CN2022142631 W CN 2022142631W WO 2024103498 A1 WO2024103498 A1 WO 2024103498A1
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WO
WIPO (PCT)
Prior art keywords
positioning
unit
seat
welding
pressure
Prior art date
Application number
PCT/CN2022/142631
Other languages
French (fr)
Chinese (zh)
Inventor
袁志伟
姜明
朱黎明
程希金
刘军
朱文兴
恽峰
王斌
潘云德
时衡镜
鞠程波
韩爱东
Original Assignee
中车戚墅堰机车有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 中车戚墅堰机车有限公司 filed Critical 中车戚墅堰机车有限公司
Publication of WO2024103498A1 publication Critical patent/WO2024103498A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work

Definitions

  • the invention relates to the technical field of welding technology, in particular to a frame assembly welding method.
  • the frame is the main skeleton of the running part of the locomotive. Its quality is directly related to the safe operation of the locomotive. Therefore, the quality of the frame welding must be strictly controlled, especially the quality of the overall welding.
  • the frame of a diesel locomotive is a brand-new design structure. Its main frame consists of left and right side beams, the first middle beam, the second middle beam, and the front and rear end beams. They all adopt a box-type structure and are welded from thick steel plates. During the overall assembly, the entire frame needs to control many points, which is difficult to manufacture. Without process equipment, its overall assembly quality cannot be guaranteed.
  • All components of the rack are welded box-type structures, and the same components may also have deviations within the control of size or position tolerance due to welding deformation.
  • a reasonable gap should be kept between the components, and the groove spacing at the weld should be controlled to 3-5mm to ensure that the weld is welded through, but not too large to prevent the weld from being too wide.
  • the relative positions of the components should be controlled to ensure the overall size of the product after welding and the subsequent finishing allowance of key positions.
  • the present invention provides a frame assembly welding method.
  • a frame assembly welding method using a frame flexible assembly tire
  • the frame flexible assembly tire is provided with a tire seat for installing each assembly tire component unit, and also includes:
  • a support unit used to provide stable support for the bottom of each component of the rack
  • a positioning unit is used to abut against a side wall of each component and provide a horizontal positioning reference for it, and is provided with a plurality of positioning columns installed by threaded connection;
  • the side pressure unit is used to press the other side wall of each component to limit the horizontal displacement of each component, and is provided with a plurality of side pressure columns installed by threaded connection;
  • the top pressing unit is used to press the top of each component to limit the displacement of each component in the vertical direction, and is provided with a number of top pressing columns installed by threaded connection;
  • An alignment unit used to align the marking references on the upper surfaces of the left beam, the right beam, the first middle beam and the second middle beam to align the installation position of the components, including a plurality of alignment seats;
  • the alignment seat is provided with two seat bodies and a ruler distributed on both sides of each component, and a backrest is provided on the top surface of each seat body.
  • the ruler is respectively placed on the top surface of two opposite seat bodies across the top of each component, and one side thereof abuts against the backrest on the two seat bodies;
  • S1 assemble the first center beam and the second center beam in any order, respectively hoist the first center beam or the second center beam to the corresponding support unit, so that its side abuts against the positioning column of the positioning unit to achieve front-to-back positioning, then install the ruler, adjust the left and right positions of the positioning column and the first center beam or the second center beam, so that the longitudinal marking reference on the first center beam or the second center beam is aligned with the side of the ruler in the vertical projection direction, and then lock the corresponding side pressure unit and top pressure unit;
  • S2 assemble the two side beams in any order, hoist the two side beams to the corresponding support units respectively, so that the sides thereof abut against the positioning columns of the positioning units, first adjust the positions of the positioning columns on the sides, adjust the gaps at the welds between the first middle beam and the second middle beam and the side beams, and realize the positioning of the side beams in the left and right directions, then install the ruler, adjust the positions of the positioning columns on the end faces, adjust the longitudinal marking reference of the side beams to align with the side edges of the ruler in the vertical projection direction, and then lock the corresponding side pressure units and top pressure units;
  • tack welds are welded at both ends of the butt groove of the lower cover of each component.
  • the length of each tack weld is not less than 50mm, and the distance from the end of the weld is more than 10mm.
  • the thickness of the tack weld is at least 5mm;
  • S6 assemble the front end beam, hoist the front end beam to the corresponding support unit, make its side abut against the positioning column of the positioning unit, adjust the gap between it and the two side beams at the weld, and then lock the corresponding side pressure unit and top pressure unit;
  • the positioning column, side pressure column and top pressure column installed by threaded connection facilitate the positioning unit, side pressure unit and top pressure unit to adjust according to the actual error of each component, control the relative position of each component, and ensure the size of the product after welding.
  • a positioning reference is provided for the first middle beam and the second middle beam, which is convenient for adjusting the position of the left beam and the right beam.
  • the design of the two bases and the ruler facilitates the removal of the ruler during hoisting and demoulding, which is convenient for operation and avoids interference.
  • the facade surfaces of its flange plate are respectively abutted against the positioning columns of the positioning unit to realize the left and right positioning of the open front end beam, and then its front and rear positions are adjusted, and the gap at the weld between it and the two side beams is adjusted.
  • said support unit is a front beam diagonal brace and a rear beam diagonal brace freely placed on the tire seat, and there is an angle between the top surface of said front beam diagonal brace and the rear beam diagonal brace and the top surface of the tire seat, and the relative positions of the front beam diagonal brace and the front beam, and the rear beam diagonal brace and the rear beam are adjusted to make the lower cover plates of the front beam and the rear beam flush with the lower cover plates of the two side beams.
  • step S8 further comprises the following sub-steps:
  • the vertical plate, upper cover plate and lower cover plate are welded in turn.
  • the alternating welding arrangement continuously enhances the overall strength of the frame during the welding process, and the welding deformation can be effectively controlled under the current clamping and clamping arrangement.
  • the support unit comprises a side beam support, a first middle beam support, a second middle beam support, a front beam diagonal brace and a rear beam diagonal brace, the top surfaces of the front beam diagonal brace and the rear beam diagonal brace have an angle with the top surface of the tire seat, and are freely placed on the tire seat
  • the positioning unit comprises a side beam side backer, a side beam end face backer, a first middle beam backer, a second middle beam backer, a front beam backer and a rear beam backer
  • the front beam backer comprises a closed front beam backer and abutting flange plate
  • An open front end beam backer wherein at least three positioning columns are arranged on the open front end beam backer
  • the side pressure unit comprises the side pressure of the side beam side, the side pressure of the side beam end, the side pressure of the first middle beam, the side pressure of the second middle beam, the side pressure of the front end beam and the side pressure of the rear end beam, the side pressure of the
  • the marking reference is the marking lines measured and engraved on the upper surfaces of the left beam, the right beam, the first middle beam and the second middle beam before assembly, each including two horizontal and vertical center lines.
  • the support unit is a welded bar, the bottom surface and the top surface of the bar are parallel, and a suitable length is set according to the width of each component.
  • the beneficial effects of the present invention are that a set of frame flexible assembly tires can be used to handle the assembly and welding operations of frames of two models with different approximate specifications.
  • the tooling manufacturing cost is low, the space occupied is small, and the management is convenient.
  • the overall layout is streamlined, the position of the welding components is convenient and accurate to adjust, the support positioning is sufficient, the clamping is reliable, and the demoulding is fast and convenient.
  • the relative distance of each component is convenient to adjust, and the positioning problem of separated welding components is solved.
  • each component and the weld gap are effectively controlled to ensure full penetration at the weld, control the frame welding deformation, ensure the weld connection strength after welding, control the dimensional accuracy of the frame after welding, effectively ensure the welding accuracy, avoid rework, and improve the welding efficiency.
  • Fig. 1 is a schematic structural diagram of the utility model.
  • FIG. 2 is a schematic diagram of the structure of the utility model when the closed frame is installed.
  • FIG. 3 is an enlarged view of point E in FIG. 2 .
  • FIG. 4 is an enlarged view of point F in FIG. 2 .
  • FIG. 5 is an enlarged view of point G in FIG. 2 .
  • FIG. 6 is an enlarged view of point H in FIG. 2 .
  • FIG. 7 is a schematic diagram of the structure of the utility model when an open frame is installed.
  • FIG8 is an enlarged view of point L in FIG7 .
  • FIG9 is an enlarged view of point M in FIG7 .
  • FIG. 10 is another schematic diagram of the structure of the utility model when the open frame is installed.
  • FIG. 11 is an enlarged view of point N in FIG. 10 .
  • FIG. 12 is a partial cross-sectional schematic diagram of a surface contact backrest.
  • FIG. 13 is a schematic diagram of the structure of the middle seat of the open front end beam.
  • the rack includes two categories, both of which are symmetrical structures, including open racks and closed racks.
  • the components are all box-type structural components.
  • the box-type structural components are equipped with a lower cover plate, an upper cover plate and two side vertical plates.
  • the closed rack includes a closed left beam a1, a closed right beam a2, a closed first middle beam a3, a closed second middle beam a4, a closed front beam a5, and a closed rear beam a6.
  • the open rack includes an open left beam b1, an open right beam b2, an open first middle beam b3, an open second middle beam b4, an open front beam b5, and an open rear beam b6.
  • the open front beam b5 is divided into left and right parts, and both are equipped with flange plates b51.
  • the open rack and the closed rack have a variety of specifications with different local sizes.
  • the lower cover of each box-type structural component is located on the outside, that is, the upper cover plate abuts against each support unit.
  • the process lining plate at each weld c is fixed on the small side of the groove of weld c.
  • the left beam and the right beam are collectively called side beams.
  • a schematic diagram of the structure of the present invention is a frame assembly welding method, using a frame flexible assembly tire, the frame flexible assembly tire is provided with a tire seat 1 for mounting each assembly tire component unit, and further includes:
  • a support unit used to provide stable support for the bottom of each component of the rack
  • a positioning unit used to abut against a side wall of each component and provide a horizontal positioning reference for it, and provided with a plurality of positioning columns 81 installed by threaded connection;
  • the side pressure unit is used to press the other side wall of each component to limit the displacement of each component in the horizontal direction, and is provided with a plurality of side pressure columns 82 installed by threaded connection;
  • the top pressing unit is used to press the top of each component to limit the displacement of each component in the vertical direction, and is provided with a plurality of top pressing columns 83 installed by threaded connection;
  • An alignment unit used to align the marking references on the upper surfaces of the left beam, the right beam, the first middle beam and the second middle beam to align the installation position of the components, including a plurality of alignment seats;
  • the alignment seat is provided with two seat bodies and a ruler 60 distributed on both sides of each component.
  • the top surfaces of the seat bodies are provided with backrests.
  • the ruler 60 is placed on the top surfaces of two opposite seat bodies across the top of each component, and one side thereof abuts against the backrests on the two seat bodies.
  • the order is not limited, hoist the two side beams to the corresponding support units respectively, so that the sides thereof abut against the positioning columns 81 of the positioning units, first adjust the positions of the positioning columns 81 on the sides, adjust the gaps at the welds c between the first middle beam and the second middle beam and the side beams, and realize the positioning of the side beams in the left and right directions, then install the ruler 60, and then adjust the positions of the positioning columns 81 on the end faces, adjust the longitudinal marking reference of the side beams to align with the side edges of the ruler 60 in the vertical projection direction, and then lock the corresponding side pressure units and top pressure units;
  • tack welds are welded at both ends of the butt groove of the lower cover of each component.
  • the length of each tack weld is not less than 50mm, and the distance from the end of the weld c is more than 10mm.
  • the thickness of the tack weld is at least 5mm;
  • S6 assemble the front end beam, hoist the front end beam to the corresponding support unit, make its side abut against the positioning column 81 of the positioning unit, adjust the gap between it and the weld c between the two side beams, and then lock the corresponding side pressure unit and top pressure unit;
  • a marking unit may also be provided, which is used to mark the upper surface of the closed front beam a5 and the rear beam as a marking reference, and includes a plurality of marking seats; the marking seats are each provided with two seats and a ruler 60 distributed on both sides of each component, and a backrest is provided on the top surface of each seat body, and the ruler 60 is placed on the top surface of two opposite seats across the top of each component, and one side of the ruler 60 abuts against the backrest on the two seats.
  • the marking unit includes a closed front beam marking seat 65a and a rear beam marking seat 66.
  • part of the positioning column 81 , the side pressure column 82 and the top pressure column 83 are shown.
  • the side of the closed front end beam a5 is abutted against the positioning column 81 of the positioning unit to achieve the front-to-rear positioning of the closed front end beam a5, and then the left and right positions thereof are adjusted to adjust the gap at the weld c between the closed front end beam a5 and the two side beams.
  • the outer facades of its flange plate b51 are respectively abutted against the positioning columns 81 of the positioning unit to achieve left and right positioning of the open front end beam b5, and then its front and rear positions are adjusted to adjust the gap at the weld c between it and the two side beams.
  • the supporting unit is a front end beam diagonal brace 25 and a rear end beam diagonal brace 26 freely placed on the tire seat 1, and there is an angle between the top surface of the front end beam diagonal brace 25 and the rear end beam diagonal brace 26 and the top surface of the tire seat 1.
  • the relative positions of the front end beam diagonal brace 25 and the front end beam, and the rear end beam diagonal brace 26 and the rear end beam are adjusted so that the lower cover plates of the front end beam and the rear end beam are flush with the lower cover plates of the two side beams.
  • the step S8 includes the following sub-steps:
  • the support unit includes a side beam support 21, a first middle beam support 23, a second middle beam support 24, a front beam diagonal brace 25 and a rear beam diagonal brace 26, the top surfaces of the front beam diagonal brace 25 and the rear beam diagonal brace 26 have an angle with the top surface of the tire seat 1, and are freely placed on the tire seat 1,
  • the positioning unit includes a side beam side backer 31, a side beam end face backer 32, a first middle beam backer 33, a second middle beam backer 34, a front beam backer 35 and a rear beam backer 36
  • the front beam backer 35 includes a closed front beam backer 35a and an open front beam backer 35a abutting against the flange plate b51 b.
  • the side pressure unit includes a side beam side pressure 41, a side beam end pressure 42, a first middle beam side pressure 43, a second middle beam side pressure 44, a front beam side pressure 45 and a rear beam side pressure 46.
  • the front beam side pressure 45 is used to press the side wall of the closed front end beam a5.
  • the top pressure unit includes a side beam top pressure 51, a first middle beam top pressure 53, a second middle beam top pressure 54, a front beam top pressure 55 and a rear beam top pressure 56.
  • the alignment unit includes a side beam alignment seat 61, a first middle beam alignment seat 63 and a second middle beam alignment seat 64.
  • the open front end beam backer 35 b is a surface contact backer 9, which includes a backer seat 91, a sliding sleeve 92, a sliding shaft 93 and a tapered pin 94.
  • At least three sliding sleeves 92 are horizontally fixed on the backer seat 91.
  • the sliding shaft 93 is slidably installed in the sliding sleeve 92 and is provided with at least one radial tapered hole 931.
  • the sliding sleeve 92 is provided with a locking hole matching the tapered hole 931.
  • the tapered pin 94 passes through the locking hole and is inserted into one of the tapered holes 931.
  • the positioning contact surface is larger and the positioning is more stable.
  • the tapered pin structure is used for connection, which is convenient for quick installation and disassembly, and the avoidance space is large, which is convenient for demoulding.
  • the top pressing units are all rotary quick pressing components.
  • the use of rotary quick pressing components is convenient and fast, and has a relatively large adjustment range, providing a larger demoulding avoidance space.
  • the side pressure units are all flip-type quick-pressing components.
  • an open front beam intermediate seat 65b which includes an intermediate seat body 65b2 and a plurality of upper and lower reference blocks 65b1, and the left side of the reference block 65b1 is located in the same plane.
  • the installation position of the open front beam intermediate seat is determined and fixed, which serves as the positioning reference of the flange surface of the subsequent open front beam.
  • the first center beam backer 33 includes two groups, namely a closed first center beam backer 33a and an open first center beam backer 33b.
  • the second center beam backing 34 includes two groups, namely a closed second center beam backing 34a and an open second center beam backing 34b.
  • the open second center beam backing 34b is a surface contact backing 9.
  • the second center beam alignment seat 64 includes two groups, namely a closed second center beam alignment seat 64a and an open second center beam alignment seat 64b.
  • the two groups of alignment seats have different heights, so that the ruler 60 is closer to the marking reference, and the positioning adjustment is more convenient and accurate.
  • a plurality of rulers 60 are provided according to the spacing between the alignment seat and the marking seat.
  • the marking reference is the marking lines measured and carved on the upper surfaces of the left beam, the right beam, the first middle beam and the second middle beam before assembly, and each includes two horizontal and vertical center lines thereof.
  • the support unit is a welded bar, the bottom surface and the top surface of which are parallel, and a suitable length is set according to the width of each component.
  • the bottom of the closed first middle beam a3 abuts against two first middle beam supports 23, and its side wall abuts against two closed first middle beam backers 33a.
  • the side edge of the ruler 60 on the first middle beam alignment seat 63 is aligned with the closed frame marking reference a7 on the closed first middle beam a3 in the vertical projection direction.
  • the other side is pressed by a first middle beam side pressure 43, and the top is pressed by two first middle beam top pressures 53.
  • the bottom of the closed second center beam a4 abuts against two second center beam supports 24, and its side wall abuts against two closed second center beam backers 34a.
  • the side edge of the ruler 60 on the closed second center beam alignment seat 64a is aligned with the closed frame marking reference a7 on the closed second center beam a4 in the vertical projection direction.
  • the other side is pressed by a second center beam side pressure 44, and the top is pressed by two second center beam top pressures 54.
  • the bottoms of the closed left side beam a1 and the closed right side beam a2 are respectively abutted against two side beam supports 21, and the outer side walls thereof are respectively abutted against two side beam side backings 31, and the ruler 60 on the side beam alignment seat 61 spans the closed left side beam a1 and the closed right side beam a2, and the side edges thereof are aligned with the corresponding closed frame marking references a7 on the closed left side beam a1 and the closed right side beam a2 in the vertical projection direction, and the other side walls are respectively pressed by two side beam side pressures 41, one end thereof is respectively abutted against a side beam end face backing 32, and the other end is pressed by a side beam end face side pressure 42, and the top thereof is respectively pressed by two side beam top pressures 51;
  • the bottom of the closed front end beam a5 abuts against two front end beam diagonal braces 25, its side wall abuts against two closed front end beam backings 35a, the other side is pressed by a front end beam side pressure 45, and its top is pressed by two front end beam top pressures 55.
  • the closed front end beam a5 is marked along the vertical projection direction of the side of the ruler 60 on the closed front end beam marking seat 65a;
  • the bottom of the closed rear end beam a6 abuts against two rear end beam diagonal braces 26, its side wall abuts against two rear end beam backings 36, the other side is pressed by a rear end beam side pressure 46, and the top is pressed by two rear end beam top pressures 56.
  • the closed rear end beam a6 is marked along the vertical projection direction of the side of the ruler 60 on the rear end beam marking seat 66.
  • the bottom of the open first middle beam b3 abuts against two first middle beam supports 23, and its side wall abuts against two open first middle beam backers 33b.
  • the side edge of the ruler 60 on the first middle beam alignment seat 63 is aligned with the open frame marking reference b7 on the open first middle beam b3 in the vertical projection direction.
  • the other side is pressed by a first middle beam side pressure 43, and the top is pressed by two first middle beam top pressures 53.
  • the bottom of the open second center beam b4 abuts against two second center beam supports 24, and its side wall abuts against two open second center beam backrests 34b.
  • the side edge of the ruler 60 on the open second center beam alignment seat 64b is aligned with the open frame marking reference b7 on the open second center beam b4 in the vertical projection direction.
  • the other side is pressed by a second center beam side pressure 44, and the top is pressed by two second center beam top pressures 54.
  • the bottoms of the open left beam b1 and the open right beam b2 are respectively abutted against two side beam supports 21, and the outer side walls thereof are respectively abutted against two side beam side backings 31, and the ruler 60 on the side beam alignment seat 61 spans the open left beam b1 and the open right beam b2, and the side edges thereof are aligned with the corresponding open frame marking references b7 on the open left beam b1 and the open right beam b2 in the vertical projection direction, and the other side walls are respectively pressed by two side beam side pressures 41, one end thereof is respectively abutted against a side beam end face backing 32, and the other end is pressed by a side beam end face side pressure 42, and the top thereof is respectively pressed by two side beam top pressures 51;
  • the bottoms of the two parts of the open front beam b5 are respectively against a front beam diagonal brace 25, and the side walls of its flange plate b51 are respectively against an open front beam backer 35b, and the tops are respectively pressed by a front beam top press 55.
  • the open front beam middle seat 65b is installed so that the side of its reference block 65b1 is located at the middle surface position of the side walls of the two flange plates b51.
  • the side of the reference block 65b1 can be used as the installation reference of the open front beam b5 later.
  • the bottom of the open rear end beam b6 abuts against two rear end beam diagonal braces 26, its side wall abuts against two rear end beam backings 36, the other side is pressed by a rear end beam side pressure 46, and the top is pressed by two rear end beam top pressures 56.
  • the open rear end beam b6 is marked along the vertical projection direction of the side of the ruler 60 on the rear end beam marking seat 66.
  • Each ruler 60 can be removed after use.
  • the above-mentioned support unit, positioning unit, side pressure unit and top pressure unit are all common welding tooling accessories.
  • the positioning unit can provide horizontal positioning, and is positioned by abutting the positioning column 81 against the side wall of each component.
  • the positioning column 81 is a bolt installed in the horizontal direction to facilitate the adjustment of the position of the positioning surface. Multiple positioning columns 81 of different heights can be set.
  • the top pressure unit is provided with a cantilever that can rotate around a vertical axis. The cantilever can be locked and fixed on the axis. A bolt installed in the vertical direction is installed below the other end of the cantilever, which serves as a top pressure column 83, and can quickly adjust and press the welding parts downward.
  • the side pressure unit is provided with a flippable rocker arm, on which a bolt is installed, which serves as a side pressure column 82, and the rocker arm is fixed by a locking pin.

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Abstract

A chassis assembly and welding method, which uses a chassis flexible assembly jig. The chassis flexible assembly jig is provided with a jig base (1) for mounting each assembly jig component unit, and further comprises: a supporting unit, a positioning unit, a side pressing unit, a top pressing unit, an aligning unit and a scribing unit. The welding method specifically comprises: assembling a first middle beam and a second middle beam, assembling two side beams, assembling a rear end beam, checking gaps, welding positioning welds, assembling a front end beam, welding positioning welds, and completing final welding.

Description

一种机架组装焊接方法A frame assembly welding method 技术领域Technical Field
本发明涉及焊接工艺技术领域，尤其是一种机架组装焊接方法。The invention relates to the technical field of welding technology, in particular to a frame assembly welding method.
背景技术Background technique
机架是机车走行部分的主骨架，其质量好坏直接关系着机车的安全运行，因此必须严格控制机架组焊质量，尤其是总组焊质量。某内燃机车机架是全新设计结构，其主框架由左右侧梁、第一中梁、第二中梁和前后端梁组成，它们均采用箱型结构，由厚钢板焊接而成，总组装时，整个机架需要控制的项点较多，制作难度大，没有工艺装备无法保证其总组装质量。The frame is the main skeleton of the running part of the locomotive. Its quality is directly related to the safe operation of the locomotive. Therefore, the quality of the frame welding must be strictly controlled, especially the quality of the overall welding. The frame of a diesel locomotive is a brand-new design structure. Its main frame consists of left and right side beams, the first middle beam, the second middle beam, and the front and rear end beams. They all adopt a box-type structure and are welded from thick steel plates. During the overall assembly, the entire frame needs to control many points, which is difficult to manufacture. Without process equipment, its overall assembly quality cannot be guaranteed.
机架的各构成组件均为焊接的箱型结构，相同组件也会因焊接变形出现尺寸或位置公差控制内的偏差。机架组装时各组件之间要保留合理间隙，控制焊缝处坡口间距3-5mm，保证焊缝处焊透，也不易过大，防止焊缝过宽。要控制各组件相对位置，保证焊接后产品总体尺寸及关键位置后续精加工余量。All components of the rack are welded box-type structures, and the same components may also have deviations within the control of size or position tolerance due to welding deformation. When assembling the rack, a reasonable gap should be kept between the components, and the groove spacing at the weld should be controlled to 3-5mm to ensure that the weld is welded through, but not too large to prevent the weld from being too wide. The relative positions of the components should be controlled to ensure the overall size of the product after welding and the subsequent finishing allowance of key positions.
由于机架组件尺寸较大、重量较大，行车吊装时不稳，吊装难度大，需要焊接前和焊接完成后均有较大的避让空间，方便组件吊装，方便整个机架脱模。Due to the large size and weight of the rack components, they are unstable when hoisted by a crane and are difficult to hoist. Therefore, a large avoidance space is required before and after welding to facilitate the hoisting of the components and the demoulding of the entire rack.
不同型号机车配置有结构类似的机架，全部使用专用工装会导致工装制造成本高、占用空间较大、不易管理的问题。Different models of locomotives are equipped with frames with similar structures. Using dedicated tooling for all of them will lead to problems such as high tooling manufacturing costs, large space occupation, and difficulty in management.
技术问题technical problem
为了克服上述现有问题的不足，本发明提供了一种机架组装焊接方法。In order to overcome the above-mentioned shortcomings of the prior art, the present invention provides a frame assembly welding method.
技术解决方案Technical Solutions
本发明解决其技术问题所采用的技术方案是：一种机架组装焊接方法，使用机架柔性组装胎，所述机架柔性组装胎设有用于安装各组装胎组成单元的胎座，还包括：The technical solution adopted by the present invention to solve the technical problem is: a frame assembly welding method, using a frame flexible assembly tire, the frame flexible assembly tire is provided with a tire seat for installing each assembly tire component unit, and also includes:
支撑单元，用于为机架各组件的底部提供稳定支撑；A support unit, used to provide stable support for the bottom of each component of the rack;
定位单元，用于抵接各组件的一侧壁，并为其提供水平方向的定位基准，且设有若干螺纹连接安装的定位柱；A positioning unit is used to abut against a side wall of each component and provide a horizontal positioning reference for it, and is provided with a plurality of positioning columns installed by threaded connection;
侧压单元，用于压紧各组件的另一侧壁，限制各组件在水平方向的位移，且设有若干螺纹连接安装的侧压柱；The side pressure unit is used to press the other side wall of each component to limit the horizontal displacement of each component, and is provided with a plurality of side pressure columns installed by threaded connection;
顶压单元，用于压紧各组件的顶部，限制各组件在竖直方向的位移，且设有若干螺纹连接安装的顶压柱；The top pressing unit is used to press the top of each component to limit the displacement of each component in the vertical direction, and is provided with a number of top pressing columns installed by threaded connection;
找正单元，用于对准左侧梁、右侧梁、第一中梁及第二中梁上表面的划线基准以找正组件的安装位置，包括若干找正座；An alignment unit, used to align the marking references on the upper surfaces of the left beam, the right beam, the first middle beam and the second middle beam to align the installation position of the components, including a plurality of alignment seats;
所述找正座设有分布于各组件两侧的两个座体及靠尺，所述座体的顶面上均设有靠山，所述靠尺分别跨过各组件的上方放置于两个相对座体的顶面上，且其一侧抵接两个座体上的靠山；The alignment seat is provided with two seat bodies and a ruler distributed on both sides of each component, and a backrest is provided on the top surface of each seat body. The ruler is respectively placed on the top surface of two opposite seat bodies across the top of each component, and one side thereof abuts against the backrest on the two seat bodies;
具体焊接方法如下：The specific welding methods are as follows:
S1，组装第一中梁及第二中梁，先后顺序不限，分别吊装第一中梁或第二中梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱，实现前后方向的定位，然后安装靠尺，调整定位柱及第一中梁或第二中梁的左右位置，使第一中梁或第二中梁上的纵向划线基准与靠尺的侧边在竖直投影方向对齐，再锁紧相应的侧压单元及顶压单元；S1, assemble the first center beam and the second center beam in any order, respectively hoist the first center beam or the second center beam to the corresponding support unit, so that its side abuts against the positioning column of the positioning unit to achieve front-to-back positioning, then install the ruler, adjust the left and right positions of the positioning column and the first center beam or the second center beam, so that the longitudinal marking reference on the first center beam or the second center beam is aligned with the side of the ruler in the vertical projection direction, and then lock the corresponding side pressure unit and top pressure unit;
S2，组装两个侧梁，先后顺序不限，分别吊装两个侧梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱，先调整侧面的定位柱的位置，调整第一中梁及第二中梁与侧梁之间焊缝处的间隙，实现侧梁左右方向的定位，然后安装靠尺，再调整端面的定位柱的位置，调整侧梁的纵向划线基准与靠尺的侧边在竖直投影方向对齐，再锁紧相应的侧压单元及顶压单元；S2, assemble the two side beams in any order, hoist the two side beams to the corresponding support units respectively, so that the sides thereof abut against the positioning columns of the positioning units, first adjust the positions of the positioning columns on the sides, adjust the gaps at the welds between the first middle beam and the second middle beam and the side beams, and realize the positioning of the side beams in the left and right directions, then install the ruler, adjust the positions of the positioning columns on the end faces, adjust the longitudinal marking reference of the side beams to align with the side edges of the ruler in the vertical projection direction, and then lock the corresponding side pressure units and top pressure units;
S3，组装后端梁，吊装后端梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱，实现前后方向的定位，然后调整其左右位置，调整其与两个侧梁之间焊缝处的间隙，再锁紧相应的侧压单元及顶压单元；S3, assemble the rear end beam, hoist the rear end beam to the corresponding support unit, make its side abut against the positioning column of the positioning unit, realize the positioning in the front and rear direction, then adjust its left and right position, adjust the gap between it and the two side beams at the weld, and then lock the corresponding side pressure unit and top pressure unit;
S4，检查各焊接工艺衬板与机架各组件的间隙，不能大于2mm；S4, check the gap between each welding process liner and each component of the frame, which cannot be greater than 2mm;
S5，各组件下盖板的对接坡口两端焊接定位焊缝，每段定位焊缝长不小于50mm，且距离焊缝端部距离10mm以上，定位焊缝厚度至少5mm；S5, tack welds are welded at both ends of the butt groove of the lower cover of each component. The length of each tack weld is not less than 50mm, and the distance from the end of the weld is more than 10mm. The thickness of the tack weld is at least 5mm;
S6，组装前端梁，吊装前端梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱，调整其与两个侧梁之间焊缝处的间隙，再锁紧相应的侧压单元及顶压单元；S6, assemble the front end beam, hoist the front end beam to the corresponding support unit, make its side abut against the positioning column of the positioning unit, adjust the gap between it and the two side beams at the weld, and then lock the corresponding side pressure unit and top pressure unit;
S7，焊接前端梁与两个侧梁之间的定位焊缝，定位焊缝焊接要求同S5；S7, welding the tack weld between the front beam and the two side beams. The requirements for the tack weld are the same as those for S5.
S8，依次完成机架各组件之间的所有焊缝的最终焊接。S8, completing the final welding of all welds between the components of the frame in sequence.
具体的，通过设置稳定的支撑、充分的定位保证各组件安装精度，同时可靠的压紧保证各组件稳定固定。螺纹连接安装的定位柱、侧压柱及顶压柱，方便定位单元、侧压单元及顶压单元根据各组件的实际误差进行调整，控制各组件相对位置，保证焊接后产品尺寸。通过设置找正单元，为第一中梁及第二中梁提供定位基准，方便调整左侧梁、右侧梁的位置。两个座体及靠尺的设计，方便在吊装和脱模时移除靠尺，方便操作，避免干涉。通过特定的组装顺序，便于快速定位各组件，控制各组件相对位置及机架外形尺寸。通过设置特殊的定位焊缝，对机架进行整体初步连接固定，且保证适当的连接强度，减小后续焊接位置调整时或全面焊接时机架整体变形。在焊接过程中方便通过调整组装胎的位置和角度，调整焊接角度，提高焊接质量，控制焊接变形。Specifically, by setting stable support and sufficient positioning, the installation accuracy of each component is ensured, and reliable clamping is used to ensure the stable fixation of each component. The positioning column, side pressure column and top pressure column installed by threaded connection facilitate the positioning unit, side pressure unit and top pressure unit to adjust according to the actual error of each component, control the relative position of each component, and ensure the size of the product after welding. By setting the alignment unit, a positioning reference is provided for the first middle beam and the second middle beam, which is convenient for adjusting the position of the left beam and the right beam. The design of the two bases and the ruler facilitates the removal of the ruler during hoisting and demoulding, which is convenient for operation and avoids interference. Through a specific assembly sequence, it is convenient to quickly locate each component, control the relative position of each component and the overall size of the frame. By setting a special positioning weld, the frame is preliminarily connected and fixed as a whole, and the appropriate connection strength is ensured to reduce the overall deformation of the frame during subsequent welding position adjustment or comprehensive welding. During the welding process, it is convenient to adjust the position and angle of the assembly tire, adjust the welding angle, improve the welding quality, and control welding deformation.
根据本发明的另一个实施例，进一步包括，所述S6中，对于闭式前端梁，使其侧面抵接定位单元的定位柱，实现闭式前端梁前后方向的定位，然后调整其左右位置，调整其与两个侧梁之间焊缝处的间隙。According to another embodiment of the present invention, further comprising: in said S6, for the closed front end beam, making its side face abut against the positioning column of the positioning unit to realize the front-to-rear positioning of the closed front end beam, and then adjusting its left and right position and adjusting the gap at the weld between it and the two side beams.
根据本发明的另一个实施例，进一步包括，所述S6中，对于开式前端梁，使其法兰板的外立面分别抵接定位单元的定位柱，实现开式前端梁左右方向的定位，然后调整其前后位置，调整其与两个侧梁之间焊缝处的间隙。According to another embodiment of the present invention, further comprising: in said S6, for the open front end beam, the facade surfaces of its flange plate are respectively abutted against the positioning columns of the positioning unit to realize the left and right positioning of the open front end beam, and then its front and rear positions are adjusted, and the gap at the weld between it and the two side beams is adjusted.
根据本发明的另一个实施例，进一步包括，所述S3及S6中，所述支撑单元为自由放置在胎座上的前端梁斜撑及后端梁斜撑，所述前端梁斜撑及后端梁斜撑的顶面与胎座顶面之间有夹角，调整前端梁斜撑与前端梁、后端梁斜撑与后端梁的相对位置，分别使前端梁、后端梁的下盖板均与两个侧梁的下盖板齐平。通过设置自由放置的前端梁斜撑及后端梁斜撑，适应前端梁斜撑及后端梁斜撑组件的焊接误差，且调整方便，两种机架换型时不用拆装。According to another embodiment of the present invention, further comprising: in said S3 and S6, said support unit is a front beam diagonal brace and a rear beam diagonal brace freely placed on the tire seat, and there is an angle between the top surface of said front beam diagonal brace and the rear beam diagonal brace and the top surface of the tire seat, and the relative positions of the front beam diagonal brace and the front beam, and the rear beam diagonal brace and the rear beam are adjusted to make the lower cover plates of the front beam and the rear beam flush with the lower cover plates of the two side beams. By setting the freely placed front beam diagonal brace and the rear beam diagonal brace, the welding error of the front beam diagonal brace and the rear beam diagonal brace assembly is adapted, and the adjustment is convenient, and the two frames do not need to be disassembled when changing models.
根据本发明的另一个实施例，进一步包括，所述S8中，包括如下子步骤：According to another embodiment of the present invention, the step S8 further comprises the following sub-steps:
S81，调整胎座至机架位于竖直方向立放，焊接各立板之间的焊缝，依次焊接后端梁、第一中梁、第二中梁、前端梁与侧梁立板的对接处焊缝；S81, adjusting the tire seat until the frame is in a vertical position, welding the welds between the vertical plates, and sequentially welding the welds at the joints of the rear end beam, the first middle beam, the second middle beam, the front end beam and the side beam vertical plates;
S82，调整胎座至机架位于水平方向侧放，且两个侧梁位于竖直方向，焊接各侧梁立板与前端梁立板对接处焊缝；S82, adjust the tire seat so that the frame is placed sideways in the horizontal direction and the two side beams are in the vertical direction, and weld the welds at the joints between the side beam upright plates and the front end beam upright plates;
S83，调整胎座至机架位于水平方向平放，焊接前端梁与两侧梁的上盖板对接处焊缝；S83, adjust the tire seat until the frame is horizontally placed, and weld the welds at the joints between the front beam and the upper cover plates of the two side beams;
S84，焊接后端梁、第二中梁与两侧梁的上盖板对接处焊缝；S84, welding the welds at the joints between the rear end beam, the second middle beam and the upper cover plates of the beams on both sides;
S85，焊接第一中梁与两侧梁的上盖板对接处焊缝；S85, welding the welds at the joints between the first middle beam and the upper cover plates of the beams on both sides;
S86，焊接前端梁、第一中梁、第二中梁、后端梁与两侧梁的下盖板对接处焊缝。S86, welding the welds at the joints between the front end beam, the first middle beam, the second middle beam, the rear end beam and the lower cover plates of the beams on both sides.
通过合适的焊缝焊接顺序安排，依次对立板、上盖板、下盖板对接焊缝进行焊接，交替式的焊接安排在焊接过程中不断增强机架整体强度，在当前的装夹压紧的安排下即可有效控制焊接变形。Through the appropriate welding sequence arrangement, the vertical plate, upper cover plate and lower cover plate are welded in turn. The alternating welding arrangement continuously enhances the overall strength of the frame during the welding process, and the welding deformation can be effectively controlled under the current clamping and clamping arrangement.
根据本发明的另一个实施例，进一步包括，所述支撑单元包括侧梁支撑、第一中梁支撑、第二中梁支撑、前端梁斜撑及后端梁斜撑，所述前端梁斜撑及后端梁斜撑的顶面与胎座顶面之间有夹角，且在胎座上自由放置，所述定位单元包括侧梁侧边靠山、侧梁端面靠山、第一中梁靠山、第二中梁靠山、前端梁靠山及后端梁靠山，所述前端梁靠山包括闭式前端梁靠山及抵接法兰板的开式前端梁靠山，所述开式前端梁靠山上设有至少三个定位柱，所述侧压单元包括侧梁侧面侧压、侧梁端面侧压、第一中梁侧压、第二中梁侧压、前端梁侧压及后端梁侧压，所述前端梁侧压用于压紧闭式前端梁的侧壁，所述顶压单元包括侧梁顶压、第一中梁顶压、第二中梁顶压、前端梁顶压及后端梁顶压，所述找正单元包括侧梁找正座、第一中梁找正座、第二中梁找正座。According to another embodiment of the present invention, further comprising: the support unit comprises a side beam support, a first middle beam support, a second middle beam support, a front beam diagonal brace and a rear beam diagonal brace, the top surfaces of the front beam diagonal brace and the rear beam diagonal brace have an angle with the top surface of the tire seat, and are freely placed on the tire seat, the positioning unit comprises a side beam side backer, a side beam end face backer, a first middle beam backer, a second middle beam backer, a front beam backer and a rear beam backer, the front beam backer comprises a closed front beam backer and abutting flange plate An open front end beam backer, wherein at least three positioning columns are arranged on the open front end beam backer, the side pressure unit comprises the side pressure of the side beam side, the side pressure of the side beam end, the side pressure of the first middle beam, the side pressure of the second middle beam, the side pressure of the front end beam and the side pressure of the rear end beam, the side pressure of the front end beam is used to press the side wall of the closed front end beam, the top pressure unit comprises the top pressure of the side beam, the top pressure of the first middle beam, the top pressure of the second middle beam, the top pressure of the front end beam and the top pressure of the rear end beam, and the alignment unit comprises the side beam alignment seat, the first middle beam alignment seat and the second middle beam alignment seat.
根据本发明的另一个实施例，进一步包括，所述划线基准为左侧梁、右侧梁、第一中梁及第二中梁上表面在组装前测量并刻画的划线，均包括沿其横向、竖向的两道中心线。According to another embodiment of the present invention, the marking reference is the marking lines measured and engraved on the upper surfaces of the left beam, the right beam, the first middle beam and the second middle beam before assembly, each including two horizontal and vertical center lines.
根据本发明的另一个实施例，进一步包括，所述支撑单元为焊接而成的条块，其底面和顶面平行，根据各组件的宽度设置合适长度。According to another embodiment of the present invention, the support unit is a welded bar, the bottom surface and the top surface of the bar are parallel, and a suitable length is set according to the width of each component.
有益效果Beneficial Effects
本发明的有益效果是，可应用一套机架柔性组装胎处理两种机型的不同近似规格的机架的组装焊接操作，工装制造成本低、占用空间较小、方便管理，切换两种机型时仅更换个别工装单元即可投入应用，整体布置精简，焊接组件位置调整方便、准确，支撑定位充分、压紧可靠，脱模快速方便，组装时方便调整各组件相对距离，解决彼此分离的焊接组件的定位问题，有效控制各组件相对位置及焊缝间隙，确保焊缝处焊透，控制机架焊接变形，保证焊接后焊缝连接强度，控制机架焊接后尺寸精度，有效保证焊接精度，避免返工，提高焊接效率。The beneficial effects of the present invention are that a set of frame flexible assembly tires can be used to handle the assembly and welding operations of frames of two models with different approximate specifications. The tooling manufacturing cost is low, the space occupied is small, and the management is convenient. When switching between two models, only individual tooling units need to be replaced to put into use. The overall layout is streamlined, the position of the welding components is convenient and accurate to adjust, the support positioning is sufficient, the clamping is reliable, and the demoulding is fast and convenient. During assembly, the relative distance of each component is convenient to adjust, and the positioning problem of separated welding components is solved. The relative position of each component and the weld gap are effectively controlled to ensure full penetration at the weld, control the frame welding deformation, ensure the weld connection strength after welding, control the dimensional accuracy of the frame after welding, effectively ensure the welding accuracy, avoid rework, and improve the welding efficiency.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
下面结合附图和实施例对本发明进一步说明。The present invention is further described below in conjunction with the accompanying drawings and embodiments.
图1是本实用新型的结构示意图。Fig. 1 is a schematic structural diagram of the utility model.
图2是本实用新型安装闭式机架时的结构示意图。FIG. 2 is a schematic diagram of the structure of the utility model when the closed frame is installed.
图3是图2中E处放大图。FIG. 3 is an enlarged view of point E in FIG. 2 .
图4是图2中F处放大图。FIG. 4 is an enlarged view of point F in FIG. 2 .
图5是图2中G处放大图。FIG. 5 is an enlarged view of point G in FIG. 2 .
图6是图2中H处放大图。FIG. 6 is an enlarged view of point H in FIG. 2 .
图7是本实用新型安装开式机架时的结构示意图。FIG. 7 is a schematic diagram of the structure of the utility model when an open frame is installed.
图8是图7中L处放大图。FIG8 is an enlarged view of point L in FIG7 .
图9是图7中M处放大图。FIG9 is an enlarged view of point M in FIG7 .
图10是本实用新型安装开式机架时的另一结构示意图。FIG. 10 is another schematic diagram of the structure of the utility model when the open frame is installed.
图11是图10中N处放大图。FIG. 11 is an enlarged view of point N in FIG. 10 .
图12是面接触式靠山的局部剖视示意图。FIG. 12 is a partial cross-sectional schematic diagram of a surface contact backrest.
图13是开式前端梁中间座的结构示意图。FIG. 13 is a schematic diagram of the structure of the middle seat of the open front end beam.
图中，胎座1，侧梁支撑21，第一中梁支撑23，第二中梁支撑24，前端梁斜撑25，后端梁斜撑26，侧梁侧边靠山31，侧梁端面靠山32，第一中梁靠山33，闭式第一中梁靠山33a，开式第一中梁靠山33b，第二中梁靠山34，闭式第二中梁靠山34a，开式第二中梁靠山34b，前端梁靠山35，闭式前端梁靠山35a，开式前端梁靠山35b，后端梁靠山36，侧梁侧面侧压41，侧梁端面侧压42，第一中梁侧压43，第二中梁侧压44，前端梁侧压45，后端梁侧压46，侧梁顶压51，第一中梁顶压53，第二中梁顶压54，前端梁顶压55，后端梁顶压56，靠尺60，侧梁找正座61，第一中梁找正座63，第二中梁找正座64，闭式第二中梁找正座64a，开式第二中梁找正座64b，闭式前端梁划线座65a，开式前端梁中间座65b，基准块65b1，中间座体65b2，后端梁划线座66，定位柱81，侧压柱82，顶压柱83，面接触式靠山9，靠山座91，滑套92，滑轴93，锥孔931，锥形销94，闭式左侧梁a1，闭式右侧梁a2，闭式第一中梁a3，闭式第二中梁a4，闭式前端梁a5，闭式后端梁a6，闭式机架划线基准a7，开式左侧梁b1，开式右侧梁b2，开式第一中梁b3，开式第二中梁b4，开式前端梁b5，法兰板b51，开式后端梁b6，开式机架划线基准b7，焊缝c。In the figure, the tire seat 1, the side beam support 21, the first middle beam support 23, the second middle beam support 24, the front end beam diagonal support 25, the rear end beam diagonal support 26, the side beam side support 31, the side beam end support 32, the first middle beam support 33, the closed first middle beam support 33a, the open first middle beam support 33b, the second middle beam support 34, the closed second middle beam support 34a, the open second middle beam support 34b, the front end beam support 35 , closed front beam backing 35a, open front beam backing 35b, rear beam backing 36, side beam side pressure 41, side beam end pressure 42, first middle beam side pressure 43, second middle beam side pressure 44, front beam side pressure 45, rear beam side pressure 46, side beam top pressure 51, first middle beam top pressure 53, second middle beam top pressure 54, front beam top pressure 55, rear beam top pressure 56, ruler 60, side beam alignment seat 61, first middle beam Beam alignment seat 63, second middle beam alignment seat 64, closed second middle beam alignment seat 64a, open second middle beam alignment seat 64b, closed front end beam marking seat 65a, open front end beam middle seat 65b, reference block 65b1, middle seat body 65b2, rear end beam marking seat 66, positioning column 81, side pressure column 82, top pressure column 83, surface contact backing 9, backing seat 91, sliding sleeve 92, sliding shaft 93, tapered hole 931 , tapered pin 94, closed left side beam a1, closed right side beam a2, closed first middle beam a3, closed second middle beam a4, closed front end beam a5, closed rear end beam a6, closed frame marking reference a7, open left side beam b1, open right side beam b2, open first middle beam b3, open second middle beam b4, open front end beam b5, flange plate b51, open rear end beam b6, open frame marking reference b7, weld c.
本发明的实施方式Embodiments of the present invention
机架包括两大类，均为左右对称结构，包括开式机架及闭式机架，其构成组件均为箱型结构组件，箱型结构组件均设有下盖板、上盖板及两侧立板，其对接处设有四处焊缝c，焊缝c分别位于下盖板、上盖板及两侧立板的连接处。闭式机架包括闭式左侧梁a1、闭式右侧梁a2、闭式第一中梁a3、闭式第二中梁a4、闭式前端梁a5、闭式后端梁a6。开式机架包括开式左侧梁b1、开式右侧梁b2、开式第一中梁b3、开式第二中梁b4、开式前端梁b5、开式后端梁b6，开式前端梁b5分为左右两部分，且均设有法兰板b51。开式机架及闭式机架又有局部尺寸不同的多种规格。组装焊接时，各箱型结构组件的下盖板位于外侧，即由上盖板抵接各支撑单元。各焊缝c处工艺衬板固定于焊缝c坡口的小口一侧。左侧梁与右侧梁统称侧梁。The rack includes two categories, both of which are symmetrical structures, including open racks and closed racks. The components are all box-type structural components. The box-type structural components are equipped with a lower cover plate, an upper cover plate and two side vertical plates. There are four welds c at the joints, and the welds c are respectively located at the connection between the lower cover plate, the upper cover plate and the two side vertical plates. The closed rack includes a closed left beam a1, a closed right beam a2, a closed first middle beam a3, a closed second middle beam a4, a closed front beam a5, and a closed rear beam a6. The open rack includes an open left beam b1, an open right beam b2, an open first middle beam b3, an open second middle beam b4, an open front beam b5, and an open rear beam b6. The open front beam b5 is divided into left and right parts, and both are equipped with flange plates b51. The open rack and the closed rack have a variety of specifications with different local sizes. During assembly and welding, the lower cover of each box-type structural component is located on the outside, that is, the upper cover plate abuts against each support unit. The process lining plate at each weld c is fixed on the small side of the groove of weld c. The left beam and the right beam are collectively called side beams.
如图1-13是本发明的结构示意图，一种机架组装焊接方法，使用机架柔性组装胎，所述机架柔性组装胎设有用于安装各组装胎组成单元的胎座1，还包括：As shown in Figures 1-13, a schematic diagram of the structure of the present invention is a frame assembly welding method, using a frame flexible assembly tire, the frame flexible assembly tire is provided with a tire seat 1 for mounting each assembly tire component unit, and further includes:
支撑单元，用于为机架各组件的底部提供稳定支撑；A support unit, used to provide stable support for the bottom of each component of the rack;
定位单元，用于抵接各组件的一侧壁，并为其提供水平方向的定位基准，且设有若干螺纹连接安装的定位柱81；A positioning unit, used to abut against a side wall of each component and provide a horizontal positioning reference for it, and provided with a plurality of positioning columns 81 installed by threaded connection;
侧压单元，用于压紧各组件的另一侧壁，限制各组件在水平方向的位移，且设有若干螺纹连接安装的侧压柱82；The side pressure unit is used to press the other side wall of each component to limit the displacement of each component in the horizontal direction, and is provided with a plurality of side pressure columns 82 installed by threaded connection;
顶压单元，用于压紧各组件的顶部，限制各组件在竖直方向的位移，且设有若干螺纹连接安装的顶压柱83；The top pressing unit is used to press the top of each component to limit the displacement of each component in the vertical direction, and is provided with a plurality of top pressing columns 83 installed by threaded connection;
找正单元，用于对准左侧梁、右侧梁、第一中梁及第二中梁上表面的划线基准以找正组件的安装位置，包括若干找正座；An alignment unit, used to align the marking references on the upper surfaces of the left beam, the right beam, the first middle beam and the second middle beam to align the installation position of the components, including a plurality of alignment seats;
所述找正座设有分布于各组件两侧的两个座体及靠尺60，所述座体的顶面上均设有靠山，所述靠尺60分别跨过各组件的上方放置于两个相对座体的顶面上，且其一侧抵接两个座体上的靠山；The alignment seat is provided with two seat bodies and a ruler 60 distributed on both sides of each component. The top surfaces of the seat bodies are provided with backrests. The ruler 60 is placed on the top surfaces of two opposite seat bodies across the top of each component, and one side thereof abuts against the backrests on the two seat bodies.
具体焊接方法如下：The specific welding methods are as follows:
S1，组装第一中梁及第二中梁，先后顺序不限，分别吊装第一中梁或第二中梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱81，实现前后方向的定位，然后安装靠尺60，调整定位柱81及第一中梁或第二中梁的左右位置，使第一中梁或第二中梁上的纵向划线基准与靠尺60的侧边在竖直投影方向对齐，再锁紧相应的侧压单元及顶压单元；S1, assemble the first center beam and the second center beam in any order, respectively hoist the first center beam or the second center beam to the corresponding support unit, so that its side abuts against the positioning column 81 of the positioning unit to achieve front-to-back positioning, then install the ruler 60, adjust the left and right positions of the positioning column 81 and the first center beam or the second center beam, so that the longitudinal marking reference on the first center beam or the second center beam is aligned with the side of the ruler 60 in the vertical projection direction, and then lock the corresponding side pressure unit and top pressure unit;
S2，组装两个侧梁，先后顺序不限，分别吊装两个侧梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱81，先调整侧面的定位柱81的位置，调整第一中梁及第二中梁与侧梁之间焊缝c处的间隙，实现侧梁左右方向的定位，然后安装靠尺60，再调整端面的定位柱81的位置，调整侧梁的纵向划线基准与靠尺60的侧边在竖直投影方向对齐，再锁紧相应的侧压单元及顶压单元；S2, assemble the two side beams, the order is not limited, hoist the two side beams to the corresponding support units respectively, so that the sides thereof abut against the positioning columns 81 of the positioning units, first adjust the positions of the positioning columns 81 on the sides, adjust the gaps at the welds c between the first middle beam and the second middle beam and the side beams, and realize the positioning of the side beams in the left and right directions, then install the ruler 60, and then adjust the positions of the positioning columns 81 on the end faces, adjust the longitudinal marking reference of the side beams to align with the side edges of the ruler 60 in the vertical projection direction, and then lock the corresponding side pressure units and top pressure units;
S3，组装后端梁，吊装后端梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱81，实现前后方向的定位，然后调整其左右位置，调整其与两个侧梁之间焊缝c处的间隙，再锁紧相应的侧压单元及顶压单元；S3, assemble the rear end beam, hoist the rear end beam to the corresponding support unit, make its side abut against the positioning column 81 of the positioning unit, realize the front and rear direction positioning, then adjust its left and right position, adjust the gap between it and the two side beams at the weld c, and then lock the corresponding side pressure unit and top pressure unit;
S4，检查各焊接工艺衬板与机架各组件的间隙，不能大于2mm；S4, check the gap between each welding process liner and each component of the frame, which cannot be greater than 2mm;
S5，各组件下盖板的对接坡口两端焊接定位焊缝，每段定位焊缝长不小于50mm，且距离焊缝c端部距离10mm以上，定位焊缝厚度至少5mm；S5, tack welds are welded at both ends of the butt groove of the lower cover of each component. The length of each tack weld is not less than 50mm, and the distance from the end of the weld c is more than 10mm. The thickness of the tack weld is at least 5mm;
S6，组装前端梁，吊装前端梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱81，调整其与两个侧梁之间焊缝c处的间隙，再锁紧相应的侧压单元及顶压单元；S6, assemble the front end beam, hoist the front end beam to the corresponding support unit, make its side abut against the positioning column 81 of the positioning unit, adjust the gap between it and the weld c between the two side beams, and then lock the corresponding side pressure unit and top pressure unit;
S7，焊接前端梁与两个侧梁之间的定位焊缝，定位焊缝焊接要求同S5；S7, welding the tack weld between the front beam and the two side beams. The requirements for the tack weld are the same as those for S5.
S8，依次完成机架各组件之间的所有焊缝c的最终焊接。S8, completing the final welding of all welds c between the components of the frame in sequence.
还可设有划线单元，用于作为划线基准在闭式前端梁a5及后端梁的上表面划线，包括若干划线座；所述划线座均设有分布于各组件两侧的两个座体及靠尺60，所述座体的顶面上均设有靠山，所述靠尺60分别跨过各组件的上方放置于两个相对座体的顶面上，且其一侧抵接两个座体上的靠山。所述划线单元包括闭式前端梁划线座65a及后端梁划线座66。A marking unit may also be provided, which is used to mark the upper surface of the closed front beam a5 and the rear beam as a marking reference, and includes a plurality of marking seats; the marking seats are each provided with two seats and a ruler 60 distributed on both sides of each component, and a backrest is provided on the top surface of each seat body, and the ruler 60 is placed on the top surface of two opposite seats across the top of each component, and one side of the ruler 60 abuts against the backrest on the two seats. The marking unit includes a closed front beam marking seat 65a and a rear beam marking seat 66.
如图3所示，展示了部分定位柱81，侧压柱82及顶压柱83。As shown in FIG. 3 , part of the positioning column 81 , the side pressure column 82 and the top pressure column 83 are shown.
优选的，所述S6中，对于闭式前端梁a5，使其侧面抵接定位单元的定位柱81，实现闭式前端梁a5前后方向的定位，然后调整其左右位置，调整其与两个侧梁之间焊缝c处的间隙。Preferably, in S6, the side of the closed front end beam a5 is abutted against the positioning column 81 of the positioning unit to achieve the front-to-rear positioning of the closed front end beam a5, and then the left and right positions thereof are adjusted to adjust the gap at the weld c between the closed front end beam a5 and the two side beams.
优选的，所述S6中，对于开式前端梁b5，使其法兰板b51的外立面分别抵接定位单元的定位柱81，实现开式前端梁b5左右方向的定位，然后调整其前后位置，调整其与两个侧梁之间焊缝c处的间隙。Preferably, in S6, for the open front end beam b5, the outer facades of its flange plate b51 are respectively abutted against the positioning columns 81 of the positioning unit to achieve left and right positioning of the open front end beam b5, and then its front and rear positions are adjusted to adjust the gap at the weld c between it and the two side beams.
优选的，所述S3及S6中，所述支撑单元为自由放置在胎座1上的前端梁斜撑25及后端梁斜撑26，所述前端梁斜撑25及后端梁斜撑26的顶面与胎座1顶面之间有夹角，调整前端梁斜撑25与前端梁、后端梁斜撑26与后端梁的相对位置，分别使前端梁、后端梁的下盖板均与两个侧梁的下盖板齐平。Preferably, in S3 and S6, the supporting unit is a front end beam diagonal brace 25 and a rear end beam diagonal brace 26 freely placed on the tire seat 1, and there is an angle between the top surface of the front end beam diagonal brace 25 and the rear end beam diagonal brace 26 and the top surface of the tire seat 1. The relative positions of the front end beam diagonal brace 25 and the front end beam, and the rear end beam diagonal brace 26 and the rear end beam are adjusted so that the lower cover plates of the front end beam and the rear end beam are flush with the lower cover plates of the two side beams.
优选的，所述S8中，包括如下子步骤：Preferably, the step S8 includes the following sub-steps:
S81，调整胎座1至机架位于竖直方向立放，焊接各立板之间的焊缝c，依次焊接后端梁、第一中梁、第二中梁、前端梁与侧梁立板的对接处焊缝c；S81, adjust the tire seat 1 until the frame is in a vertical position, weld the welds c between the vertical plates, and sequentially weld the welds c at the joints of the rear end beam, the first middle beam, the second middle beam, the front end beam and the side beam vertical plates;
S82，调整胎座1至机架位于水平方向侧放，且两个侧梁位于竖直方向，焊接各侧梁立板与前端梁立板对接处焊缝c；S82, adjust the tire seat 1 until the frame is placed sideways in the horizontal direction, and the two side beams are in the vertical direction, and weld the weld c at the joint between the side beam upright plate and the front end beam upright plate;
S83，调整胎座1至机架位于水平方向平放，焊接前端梁与两侧梁的上盖板对接处焊缝c；S83, adjust the tire seat 1 until the frame is horizontally placed, and weld the weld c at the joint between the front end beam and the upper cover plate of the two side beams;
S84，焊接后端梁、第二中梁与两侧梁的上盖板对接处焊缝c；S84, welding the weld c at the joint between the rear end beam, the second middle beam and the upper cover plate of the two side beams;
S85，焊接第一中梁与两侧梁的上盖板对接处焊缝c；S85, welding the weld c at the joint between the first middle beam and the upper cover plates of the two side beams;
S86，焊接前端梁、第一中梁、第二中梁、后端梁与两侧梁的下盖板对接处焊缝c。S86, weld the weld c at the joint between the front end beam, the first middle beam, the second middle beam, the rear end beam and the lower cover plates of the beams on both sides.
优选的，所述支撑单元包括侧梁支撑21、第一中梁支撑23、第二中梁支撑24、前端梁斜撑25及后端梁斜撑26，所述前端梁斜撑25及后端梁斜撑26的顶面与胎座1顶面之间有夹角，且在胎座1上自由放置，所述定位单元包括侧梁侧边靠山31、侧梁端面靠山32、第一中梁靠山33、第二中梁靠山34、前端梁靠山35及后端梁靠山36，所述前端梁靠山35包括闭式前端梁靠山35a及抵接法兰板b51的开式前端梁靠山35b，所述开式前端梁靠山35b上设有至少三个定位柱81，所述侧压单元包括侧梁侧面侧压41、侧梁端面侧压42、第一中梁侧压43、第二中梁侧压44、前端梁侧压45及后端梁侧压46，所述前端梁侧压45用于压紧闭式前端梁a5的侧壁，所述顶压单元包括侧梁顶压51、第一中梁顶压53、第二中梁顶压54、前端梁顶压55及后端梁顶压56，所述找正单元包括侧梁找正座61、第一中梁找正座63、第二中梁找正座64。Preferably, the support unit includes a side beam support 21, a first middle beam support 23, a second middle beam support 24, a front beam diagonal brace 25 and a rear beam diagonal brace 26, the top surfaces of the front beam diagonal brace 25 and the rear beam diagonal brace 26 have an angle with the top surface of the tire seat 1, and are freely placed on the tire seat 1, the positioning unit includes a side beam side backer 31, a side beam end face backer 32, a first middle beam backer 33, a second middle beam backer 34, a front beam backer 35 and a rear beam backer 36, the front beam backer 35 includes a closed front beam backer 35a and an open front beam backer 35a abutting against the flange plate b51 b. At least three positioning columns 81 are provided on the open front end beam backrest 35b. The side pressure unit includes a side beam side pressure 41, a side beam end pressure 42, a first middle beam side pressure 43, a second middle beam side pressure 44, a front beam side pressure 45 and a rear beam side pressure 46. The front beam side pressure 45 is used to press the side wall of the closed front end beam a5. The top pressure unit includes a side beam top pressure 51, a first middle beam top pressure 53, a second middle beam top pressure 54, a front beam top pressure 55 and a rear beam top pressure 56. The alignment unit includes a side beam alignment seat 61, a first middle beam alignment seat 63 and a second middle beam alignment seat 64.
优选的，如图12所示，所述开式前端梁靠山35b为面接触式靠山9，所述面接触式靠山9包括靠山座91、滑套92、滑轴93及锥形销94，至少三个所述滑套92水平固定在靠山座91上，所述滑轴93滑动安装在滑套92内，且设有至少一个径向的锥孔931，所述滑套92上设有与锥孔931匹配的锁定孔，所述锥形销94穿过锁定孔***其中一个锥孔931内。通过设置面接触式靠山，定位接触面更大，定位更稳定，同时采用锥形插销结构连接，方便快速安装、拆卸，且避让空间大，方便脱模。Preferably, as shown in FIG. 12 , the open front end beam backer 35 b is a surface contact backer 9, which includes a backer seat 91, a sliding sleeve 92, a sliding shaft 93 and a tapered pin 94. At least three sliding sleeves 92 are horizontally fixed on the backer seat 91. The sliding shaft 93 is slidably installed in the sliding sleeve 92 and is provided with at least one radial tapered hole 931. The sliding sleeve 92 is provided with a locking hole matching the tapered hole 931. The tapered pin 94 passes through the locking hole and is inserted into one of the tapered holes 931. By setting a surface contact backer, the positioning contact surface is larger and the positioning is more stable. At the same time, the tapered pin structure is used for connection, which is convenient for quick installation and disassembly, and the avoidance space is large, which is convenient for demoulding.
优选的，所述顶压单元均为旋转式快压组件。使用旋转式快压组件方便快速压紧，且调整范围比较大，提供更大脱模避让空间。Preferably, the top pressing units are all rotary quick pressing components. The use of rotary quick pressing components is convenient and fast, and has a relatively large adjustment range, providing a larger demoulding avoidance space.
所述侧压单元均为翻转式快压组件。The side pressure units are all flip-type quick-pressing components.
优选的，如图9、图13所示，还包括开式前端梁中间座65b，所述开式前端梁中间座65b包括中间座体65b2及若干上下设置的基准块65b1，所述基准块65b1的左侧面位于同一平面内。通过设置开式前端梁中间座，在调试第一个产品后，确定并固定开式前端梁中间座的安装位置，作为后续开式前端梁的法兰面的定位基准。Preferably, as shown in Fig. 9 and Fig. 13, it also includes an open front beam intermediate seat 65b, which includes an intermediate seat body 65b2 and a plurality of upper and lower reference blocks 65b1, and the left side of the reference block 65b1 is located in the same plane. By setting the open front beam intermediate seat, after debugging the first product, the installation position of the open front beam intermediate seat is determined and fixed, which serves as the positioning reference of the flange surface of the subsequent open front beam.
第一中梁靠山33包括两组，分别为闭式第一中梁靠山33a及开式第一中梁靠山33b。The first center beam backer 33 includes two groups, namely a closed first center beam backer 33a and an open first center beam backer 33b.
第二中梁靠山34包括两组，分别为闭式第二中梁靠山34a及开式第二中梁靠山34b。所述开式第二中梁靠山34b为面接触式靠山9。The second center beam backing 34 includes two groups, namely a closed second center beam backing 34a and an open second center beam backing 34b. The open second center beam backing 34b is a surface contact backing 9.
第二中梁找正座64包括两组，分别为闭式第二中梁找正座64a及开式第二中梁找正座64b。两组找正座的高度不同，使靠尺60更接近划线基准，定位调整更方便、准确。The second center beam alignment seat 64 includes two groups, namely a closed second center beam alignment seat 64a and an open second center beam alignment seat 64b. The two groups of alignment seats have different heights, so that the ruler 60 is closer to the marking reference, and the positioning adjustment is more convenient and accurate.
各靠尺60根据找正座及划线座的间距设置多个。A plurality of rulers 60 are provided according to the spacing between the alignment seat and the marking seat.
优选的，所述划线基准为左侧梁、右侧梁、第一中梁及第二中梁上表面在组装前测量并刻画的划线，均包括沿其横向、竖向的两道中心线。Preferably, the marking reference is the marking lines measured and carved on the upper surfaces of the left beam, the right beam, the first middle beam and the second middle beam before assembly, and each includes two horizontal and vertical center lines thereof.
优选的，所述支撑单元为焊接而成的条块，其底面和顶面平行，根据各组件的宽度设置合适长度。Preferably, the support unit is a welded bar, the bottom surface and the top surface of which are parallel, and a suitable length is set according to the width of each component.
组装闭式机架时，拆除开式前端梁靠山35b、开式前端梁中间座65b，安装闭式前端梁靠山35a；When assembling the closed frame, remove the open front end beam backing 35b and the open front end beam middle seat 65b, and install the closed front end beam backing 35a;
闭式第一中梁a3的底部抵接两个第一中梁支撑23，其侧壁抵接两个闭式第一中梁靠山33a，第一中梁找正座63上的靠尺60的侧边与闭式第一中梁a3上的闭式机架划线基准a7在竖向投影方向对齐，另一侧由一个第一中梁侧压43压紧，其顶部由两个第一中梁顶压53压紧；The bottom of the closed first middle beam a3 abuts against two first middle beam supports 23, and its side wall abuts against two closed first middle beam backers 33a. The side edge of the ruler 60 on the first middle beam alignment seat 63 is aligned with the closed frame marking reference a7 on the closed first middle beam a3 in the vertical projection direction. The other side is pressed by a first middle beam side pressure 43, and the top is pressed by two first middle beam top pressures 53.
闭式第二中梁a4的底部抵接两个第二中梁支撑24，其侧壁抵接两个闭式第二中梁靠山34a，闭式第二中梁找正座64a上的靠尺60的侧边与闭式第二中梁a4上的闭式机架划线基准a7在竖向投影方向对齐，另一侧由一个第二中梁侧压44压紧，其顶部由两个第二中梁顶压54压紧；The bottom of the closed second center beam a4 abuts against two second center beam supports 24, and its side wall abuts against two closed second center beam backers 34a. The side edge of the ruler 60 on the closed second center beam alignment seat 64a is aligned with the closed frame marking reference a7 on the closed second center beam a4 in the vertical projection direction. The other side is pressed by a second center beam side pressure 44, and the top is pressed by two second center beam top pressures 54.
闭式左侧梁a1及闭式右侧梁a2的底部分别抵接两个侧梁支撑21，其外侧侧壁分别抵接两个侧梁侧边靠山31，侧梁找正座61上的靠尺60横跨闭式左侧梁a1及闭式右侧梁a2，其侧边与闭式左侧梁a1及闭式右侧梁a2上的相应的闭式机架划线基准a7在竖向投影方向对齐，另一侧侧壁分别由两个侧梁侧面侧压41压紧，其一端分别抵接一个侧梁端面靠山32，另一端由一个侧梁端面侧压42压紧，其顶部分别由两个侧梁顶压51压紧；The bottoms of the closed left side beam a1 and the closed right side beam a2 are respectively abutted against two side beam supports 21, and the outer side walls thereof are respectively abutted against two side beam side backings 31, and the ruler 60 on the side beam alignment seat 61 spans the closed left side beam a1 and the closed right side beam a2, and the side edges thereof are aligned with the corresponding closed frame marking references a7 on the closed left side beam a1 and the closed right side beam a2 in the vertical projection direction, and the other side walls are respectively pressed by two side beam side pressures 41, one end thereof is respectively abutted against a side beam end face backing 32, and the other end is pressed by a side beam end face side pressure 42, and the top thereof is respectively pressed by two side beam top pressures 51;
闭式前端梁a5的底部抵接两个前端梁斜撑25，其侧壁抵接两个闭式前端梁靠山35a，另一侧由一个前端梁侧压45压紧，其顶部由两个前端梁顶压55压紧。焊接后，沿闭式前端梁划线座65a上的靠尺60的侧边的竖向投影方向在闭式前端梁a5上进行划线；The bottom of the closed front end beam a5 abuts against two front end beam diagonal braces 25, its side wall abuts against two closed front end beam backings 35a, the other side is pressed by a front end beam side pressure 45, and its top is pressed by two front end beam top pressures 55. After welding, the closed front end beam a5 is marked along the vertical projection direction of the side of the ruler 60 on the closed front end beam marking seat 65a;
闭式后端梁a6的底部抵接两个后端梁斜撑26，其侧壁抵接两个后端梁靠山36，另一侧由一个后端梁侧压46压紧，其顶部由两个后端梁顶压56压紧。焊接后，沿后端梁划线座66上的靠尺60侧边的竖向投影方向在闭式后端梁a6上进行划线。The bottom of the closed rear end beam a6 abuts against two rear end beam diagonal braces 26, its side wall abuts against two rear end beam backings 36, the other side is pressed by a rear end beam side pressure 46, and the top is pressed by two rear end beam top pressures 56. After welding, the closed rear end beam a6 is marked along the vertical projection direction of the side of the ruler 60 on the rear end beam marking seat 66.
组装开式机架时，拆除闭式前端梁靠山35a，安装开式前端梁靠山35b、开式前端梁中间座65b；When assembling the open frame, remove the closed front end beam backing 35a, and install the open front end beam backing 35b and the open front end beam middle seat 65b;
开式第一中梁b3的底部抵接两个第一中梁支撑23，其侧壁抵接两个开式第一中梁靠山33b，第一中梁找正座63上的靠尺60的侧边与开式第一中梁b3上的开式机架划线基准b7在竖向投影方向对齐，另一侧由一个第一中梁侧压43压紧，其顶部由两个第一中梁顶压53压紧；The bottom of the open first middle beam b3 abuts against two first middle beam supports 23, and its side wall abuts against two open first middle beam backers 33b. The side edge of the ruler 60 on the first middle beam alignment seat 63 is aligned with the open frame marking reference b7 on the open first middle beam b3 in the vertical projection direction. The other side is pressed by a first middle beam side pressure 43, and the top is pressed by two first middle beam top pressures 53.
开式第二中梁b4的底部抵接两个第二中梁支撑24，其侧壁抵接两个开式第二中梁靠山34b，开式第二中梁找正座64b上的靠尺60的侧边与开式第二中梁b4上的开式机架划线基准b7在竖向投影方向对齐，另一侧由一个第二中梁侧压44压紧，其顶部由两个第二中梁顶压54压紧；The bottom of the open second center beam b4 abuts against two second center beam supports 24, and its side wall abuts against two open second center beam backrests 34b. The side edge of the ruler 60 on the open second center beam alignment seat 64b is aligned with the open frame marking reference b7 on the open second center beam b4 in the vertical projection direction. The other side is pressed by a second center beam side pressure 44, and the top is pressed by two second center beam top pressures 54.
开式左侧梁b1及开式右侧梁b2的底部分别抵接两个侧梁支撑21，其外侧侧壁分别抵接两个侧梁侧边靠山31，侧梁找正座61上的靠尺60横跨开式左侧梁b1及开式右侧梁b2，其侧边与开式左侧梁b1及开式右侧梁b2上的相应的开式机架划线基准b7在竖向投影方向对齐，另一侧侧壁分别由两个侧梁侧面侧压41压紧，其一端分别抵接一个侧梁端面靠山32，另一端由一个侧梁端面侧压42压紧，其顶部分别由两个侧梁顶压51压紧；The bottoms of the open left beam b1 and the open right beam b2 are respectively abutted against two side beam supports 21, and the outer side walls thereof are respectively abutted against two side beam side backings 31, and the ruler 60 on the side beam alignment seat 61 spans the open left beam b1 and the open right beam b2, and the side edges thereof are aligned with the corresponding open frame marking references b7 on the open left beam b1 and the open right beam b2 in the vertical projection direction, and the other side walls are respectively pressed by two side beam side pressures 41, one end thereof is respectively abutted against a side beam end face backing 32, and the other end is pressed by a side beam end face side pressure 42, and the top thereof is respectively pressed by two side beam top pressures 51;
开式前端梁b5的两部分的底部分别抵接一个前端梁斜撑25，其法兰板b51的侧壁分别抵接一个开式前端梁靠山35b，其顶部分别由一个前端梁顶压55压紧。每批开式机架调试好第一个产品后，安装开式前端梁中间座65b，使其基准块65b1的侧面位于两个法兰板b51的侧壁的中间面位置，后续可使用基准块65b1的侧面作为开式前端梁b5的安装基准。The bottoms of the two parts of the open front beam b5 are respectively against a front beam diagonal brace 25, and the side walls of its flange plate b51 are respectively against an open front beam backer 35b, and the tops are respectively pressed by a front beam top press 55. After the first product of each batch of open racks is debugged, the open front beam middle seat 65b is installed so that the side of its reference block 65b1 is located at the middle surface position of the side walls of the two flange plates b51. The side of the reference block 65b1 can be used as the installation reference of the open front beam b5 later.
开式后端梁b6的底部抵接两个后端梁斜撑26，其侧壁抵接两个后端梁靠山36，另一侧由一个后端梁侧压46压紧，其顶部由两个后端梁顶压56压紧。焊接后，沿后端梁划线座66上的靠尺60侧边的竖向投影方向在开式后端梁b6上进行划线。The bottom of the open rear end beam b6 abuts against two rear end beam diagonal braces 26, its side wall abuts against two rear end beam backings 36, the other side is pressed by a rear end beam side pressure 46, and the top is pressed by two rear end beam top pressures 56. After welding, the open rear end beam b6 is marked along the vertical projection direction of the side of the ruler 60 on the rear end beam marking seat 66.
各靠尺60使用后即可移除。Each ruler 60 can be removed after use.
各组件完成组装后，可先进行局部定位焊接，再调整组装胎至合适方位进行全面焊接。After all components are assembled, local positioning welding can be carried out first, and then the assembly tire can be adjusted to the appropriate position for comprehensive welding.
上述支撑单元、定位单元、侧压单元及顶压单元均为常见的焊接工装配件。定位单元可提供水平方向的定位，并通过各组件侧壁抵接定位柱81定位，定位柱81为沿水平方向安装的螺栓方便调整定位面的位置。可设置不同高度的多个定位柱81。顶压单元设有可以绕竖直转轴旋转的悬臂，悬臂在转轴上可以锁紧固定，悬臂的另一端下方安装有竖直方向安装的螺栓，作为顶压柱83，可以快速调整并向下压紧焊接零部件。侧压单元设有可翻转的摇臂，摇臂上安装有螺栓，作为侧压柱82，并通过锁紧销固定摇臂。The above-mentioned support unit, positioning unit, side pressure unit and top pressure unit are all common welding tooling accessories. The positioning unit can provide horizontal positioning, and is positioned by abutting the positioning column 81 against the side wall of each component. The positioning column 81 is a bolt installed in the horizontal direction to facilitate the adjustment of the position of the positioning surface. Multiple positioning columns 81 of different heights can be set. The top pressure unit is provided with a cantilever that can rotate around a vertical axis. The cantilever can be locked and fixed on the axis. A bolt installed in the vertical direction is installed below the other end of the cantilever, which serves as a top pressure column 83, and can quickly adjust and press the welding parts downward. The side pressure unit is provided with a flippable rocker arm, on which a bolt is installed, which serves as a side pressure column 82, and the rocker arm is fixed by a locking pin.
以上说明对本发明而言只是说明性的，而非限制性的，本领域普通技术人员理解，在不脱离所附权利要求所限定的精神和范围的情况下，可做出许多修改、变化或等效，但都将落入本发明的保护范围内。The above description is only illustrative rather than restrictive of the present invention. Those skilled in the art will understand that many modifications, changes or equivalents may be made without departing from the spirit and scope defined by the appended claims, but all will fall within the scope of protection of the present invention.

Claims (8)

  1. 一种机架组装焊接方法，其特征是，使用机架柔性组装胎，所述机架柔性组装胎设有用于安装各组装胎组成单元的胎座（1），还包括：A frame assembly welding method, characterized in that a frame flexible assembly tire is used, the frame flexible assembly tire is provided with a tire seat (1) for mounting each assembly tire component unit, and further comprising:
    支撑单元，用于为机架各组件的底部提供稳定支撑；A support unit, used to provide stable support for the bottom of each component of the rack;
    定位单元，用于抵接各组件的一侧壁，并为其提供水平方向的定位基准，且设有若干螺纹连接安装的定位柱（81）；A positioning unit, used to abut against a side wall of each component and provide a horizontal positioning reference for it, and provided with a plurality of positioning columns (81) installed by threaded connection;
    侧压单元，用于压紧各组件的另一侧壁，限制各组件在水平方向的位移，且设有若干螺纹连接安装的侧压柱（82）；A side pressure unit, used to press the other side wall of each component to limit the displacement of each component in the horizontal direction, and provided with a plurality of side pressure columns (82) installed by threaded connection;
    顶压单元，用于压紧各组件的顶部，限制各组件在竖直方向的位移，且设有若干螺纹连接安装的顶压柱（83）；A top pressing unit, used to press the top of each component to limit the displacement of each component in the vertical direction, and provided with a plurality of top pressing columns (83) installed by threaded connection;
    找正单元，用于对准左侧梁、右侧梁、第一中梁及第二中梁上表面的划线基准以找正组件的安装位置，包括若干找正座；An alignment unit, used to align the marking references on the upper surfaces of the left beam, the right beam, the first middle beam and the second middle beam to align the installation position of the components, including a plurality of alignment seats;
    所述找正座设有分布于各组件两侧的两个座体及靠尺（60），所述座体的顶面上均设有靠山，所述靠尺（60）分别跨过各组件的上方放置于两个相对座体的顶面上，且其一侧抵接两个座体上的靠山；The alignment seat is provided with two seat bodies and a ruler (60) distributed on both sides of each component, and the top surfaces of the seat bodies are provided with a backrest. The ruler (60) is respectively placed on the top surfaces of the two opposite seat bodies across the top of each component, and one side thereof abuts against the backrests on the two seat bodies.
    具体焊接方法如下：The specific welding methods are as follows:
    S1，组装第一中梁及第二中梁，先后顺序不限，分别吊装第一中梁或第二中梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱（81），实现前后方向的定位，然后安装靠尺（60），调整定位柱（81）及第一中梁或第二中梁的左右位置，使第一中梁或第二中梁上的纵向划线基准与靠尺（60）的侧边在竖直投影方向对齐，再锁紧相应的侧压单元及顶压单元；S1, assembling the first center beam and the second center beam in any order, hoisting the first center beam or the second center beam onto the corresponding support unit respectively, so that the side surface thereof abuts against the positioning column (81) of the positioning unit to achieve positioning in the front-rear direction, then installing the ruler (60), adjusting the left-right position of the positioning column (81) and the first center beam or the second center beam, so that the longitudinal marking reference on the first center beam or the second center beam is aligned with the side edge of the ruler (60) in the vertical projection direction, and then locking the corresponding side pressure unit and top pressure unit;
    S2，组装两个侧梁，先后顺序不限，分别吊装两个侧梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱（81），先调整侧面的定位柱（81）的位置，调整第一中梁及第二中梁与侧梁之间焊缝（c）处的间隙，实现侧梁左右方向的定位，然后安装靠尺（60），再调整端面的定位柱（81）的位置，调整侧梁的纵向划线基准与靠尺（60）的侧边在竖直投影方向对齐，再锁紧相应的侧压单元及顶压单元；S2, assembling the two side beams, in any order, hoisting the two side beams onto the corresponding support units respectively, so that the sides thereof abut against the positioning columns (81) of the positioning units, first adjusting the positions of the side positioning columns (81), adjusting the gaps at the welds (c) between the first middle beam and the second middle beam and the side beams, so as to achieve the left-right positioning of the side beams, then installing the ruler (60), adjusting the positions of the end surface positioning columns (81), adjusting the longitudinal marking reference of the side beams to align with the side edges of the ruler (60) in the vertical projection direction, and then locking the corresponding side pressure units and top pressure units;
    S3，组装后端梁，吊装后端梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱（81），实现前后方向的定位，然后调整其左右位置，调整其与两个侧梁之间焊缝（c）处的间隙，再锁紧相应的侧压单元及顶压单元；S3, assembling the rear end beam, hoisting the rear end beam onto the corresponding support unit, making its side face abut against the positioning column (81) of the positioning unit, realizing the positioning in the front-rear direction, then adjusting its left-right position, adjusting the gap between it and the two side beams at the weld (c), and then locking the corresponding side pressure unit and top pressure unit;
    S4，检查各焊接工艺衬板与机架各组件的间隙，不能大于2mm；S4, check the gap between each welding process liner and each component of the frame, which cannot be greater than 2mm;
    S5，各组件下盖板的对接坡口两端焊接定位焊缝，每段定位焊缝长不小于50mm，且距离焊缝（c）端部距离10mm以上，定位焊缝厚度至少5mm；S5, tack welds are welded at both ends of the butt groove of the lower cover of each component. The length of each tack weld is not less than 50mm, and the distance from the end of the weld (c) is more than 10mm. The thickness of the tack weld is at least 5mm;
    S6，组装前端梁，吊装前端梁至相应的支撑单元上，使其侧面抵接定位单元的定位柱（81），调整其与两个侧梁之间焊缝（c）处的间隙，再锁紧相应的侧压单元及顶压单元；S6, assembling the front end beam, hoisting the front end beam onto the corresponding support unit, making its side face abut against the positioning column (81) of the positioning unit, adjusting the gap between it and the weld (c) between the two side beams, and then locking the corresponding side pressure unit and top pressure unit;
    S7，焊接前端梁与两个侧梁之间的定位焊缝，定位焊缝焊接要求同S5；S7, welding the tack weld between the front beam and the two side beams. The requirements for the tack weld are the same as those for S5.
    S8，依次完成机架各组件之间的所有焊缝（c）的最终焊接。S8, complete the final welding of all welds (c) between the components of the frame in sequence.
  2. 根据权利要求1所述的机架组装焊接方法，其特征是，所述S6中，对于闭式前端梁（a5），使其侧面抵接定位单元的定位柱（81），实现闭式前端梁（a5）前后方向的定位，然后调整其左右位置，调整其与两个侧梁之间焊缝（c）处的间隙。The frame assembly welding method according to claim 1 is characterized in that, in S6, for the closed front end beam (a5), its side is abutted against the positioning column (81) of the positioning unit to achieve the front and rear positioning of the closed front end beam (a5), and then its left and right position is adjusted to adjust the gap between it and the two side beams at the weld (c).
  3. 根据权利要求1所述的机架组装焊接方法，其特征是，所述S6中，对于开式前端梁（b5），使其法兰板（b51）的外立面分别抵接定位单元的定位柱（81），实现开式前端梁（b5）左右方向的定位，然后调整其前后位置，调整其与两个侧梁之间焊缝（c）处的间隙。The frame assembly welding method according to claim 1 is characterized in that, in S6, for the open front end beam (b5), the outer facades of its flange plate (b51) are respectively abutted against the positioning columns (81) of the positioning unit to achieve the left and right positioning of the open front end beam (b5), and then its front and rear positions are adjusted to adjust the gap at the weld (c) between it and the two side beams.
  4. 根据权利要求1所述的机架组装焊接方法，其特征是，所述S3及S6中，所述支撑单元为自由放置在胎座（1）上的前端梁斜撑（25）及后端梁斜撑（26），所述前端梁斜撑（25）及后端梁斜撑（26）的顶面与胎座（1）顶面之间有夹角，调整前端梁斜撑（25）与前端梁、后端梁斜撑（26）与后端梁的相对位置，分别使前端梁、后端梁的下盖板均与两个侧梁的下盖板齐平。The frame assembly welding method according to claim 1 is characterized in that, in S3 and S6, the support unit is a front beam diagonal brace (25) and a rear beam diagonal brace (26) freely placed on the tire seat (1), and there is an angle between the top surface of the front beam diagonal brace (25) and the top surface of the tire seat (1), and the relative positions of the front beam diagonal brace (25) and the front beam, and the rear beam diagonal brace (26) and the rear beam are adjusted so that the lower cover plates of the front beam and the rear beam are flush with the lower cover plates of the two side beams.
  5. 根据权利要求1所述的机架组装焊接方法，其特征是，所述S8中，包括如下子步骤：The frame assembly welding method according to claim 1 is characterized in that, in S8, the following sub-steps are included:
    S81，调整胎座（1）至机架位于竖直方向立放，焊接各立板之间的焊缝（c），依次焊接后端梁、第一中梁、第二中梁、前端梁与侧梁立板的对接处焊缝（c）；S81, adjusting the tire seat (1) until the frame is in a vertical position, welding the welds (c) between the vertical plates, and sequentially welding the welds (c) at the joints of the rear end beam, the first middle beam, the second middle beam, the front end beam and the side beam vertical plates;
    S82，调整胎座（1）至机架位于水平方向侧放，且两个侧梁位于竖直方向，焊接各侧梁立板与前端梁立板对接处焊缝（c）；S82, adjusting the tire seat (1) until the frame is placed sideways in the horizontal direction and the two side beams are in the vertical direction, and welding the welds (c) at the joints between the side beam uprights and the front beam uprights;
    S83，调整胎座（1）至机架位于水平方向平放，焊接前端梁与两侧梁的上盖板对接处焊缝（c）；S83, adjust the tire seat (1) until the frame is horizontally placed, and weld the welds (c) at the joints between the front end beam and the upper cover plates of the two side beams;
    S84，焊接后端梁、第二中梁与两侧梁的上盖板对接处焊缝（c）；S84, welding the welds at the joints between the rear end beam, the second middle beam and the upper cover plates of the two side beams (c);
    S85，焊接第一中梁与两侧梁的上盖板对接处焊缝（c）；S85, welding the welds at the joints between the first middle beam and the upper cover plates of the two side beams (c);
    S86，焊接前端梁、第一中梁、第二中梁、后端梁与两侧梁的下盖板对接处焊缝（c）。S86, welding the welds at the joints between the front beam, the first middle beam, the second middle beam, the rear beam and the lower cover plates of the two side beams (c).
  6. 根据权利要求1所述的机架组装焊接方法，其特征是，所述支撑单元包括侧梁支撑（21）、第一中梁支撑（23）、第二中梁支撑（24）、前端梁斜撑（25）及后端梁斜撑（26），所述前端梁斜撑（25）及后端梁斜撑（26）的顶面与胎座（1）顶面之间有夹角，且在胎座（1）上自由放置，所述定位单元包括侧梁侧边靠山（31）、侧梁端面靠山（32）、第一中梁靠山（33）、第二中梁靠山（34）、前端梁靠山（35）及后端梁靠山（36），所述前端梁靠山（35）包括闭式前端梁靠山（35a）及抵接法兰板b51的开式前端梁靠山（35b），所述开式前端梁靠山（35b）上设有至少三个定位柱（81），所述侧压单元包括侧梁侧面侧压（41）、侧梁端面侧压（42）、第一中梁侧压（43）、第二中梁侧压（44）、前端梁侧压（45）及后端梁侧压（46），所述前端梁侧压（45）用于压紧闭式前端梁（a5）的侧壁，所述顶压单元包括侧梁顶压（51）、第一中梁顶压（53）、第二中梁顶压（54）、前端梁顶压（55）及后端梁顶压（56），所述找正单元包括侧梁找正座（61）、第一中梁找正座（63）、第二中梁找正座（64）。The frame assembly welding method according to claim 1 is characterized in that the support unit includes a side beam support (21), a first middle beam support (23), a second middle beam support (24), a front beam diagonal brace (25) and a rear beam diagonal brace (26), the top surfaces of the front beam diagonal brace (25) and the rear beam diagonal brace (26) have an angle with the top surface of the tire seat (1), and are freely placed on the tire seat (1), the positioning unit includes a side beam side backer (31), a side beam end face backer (32), a first middle beam backer (33), a second middle beam backer (34), a front beam backer (35) and a rear beam backer (36), the front beam backer (35) includes a closed front beam backer (35a) and an open backer abutting the flange plate b51 The open front end beam backer (35b) is provided with at least three positioning columns (81), the side pressure unit comprises a side beam side pressure (41), a side beam end surface pressure (42), a first middle beam side pressure (43), a second middle beam side pressure (44), a front end beam side pressure (45) and a rear end beam side pressure (46), the front end beam side pressure (45) is used to press the side wall of the closed front end beam (a5), the top pressure unit comprises a side beam top pressure (51), a first middle beam top pressure (53), a second middle beam top pressure (54), a front end beam top pressure (55) and a rear end beam top pressure (56), and the alignment unit comprises a side beam alignment seat (61), a first middle beam alignment seat (63) and a second middle beam alignment seat (64).
  7. 根据权利要求1所述的机架组装焊接方法，其特征是，所述划线基准为左侧梁、右侧梁、第一中梁及第二中梁上表面在组装前测量并刻画的划线，均包括沿其横向、竖向的两道中心线。The frame assembly welding method according to claim 1 is characterized in that the marking reference is the marking lines measured and engraved on the upper surfaces of the left beam, the right beam, the first middle beam and the second middle beam before assembly, and each includes two horizontal and vertical center lines along the upper surfaces.
  8. 根据权利要求1所述的机架组装焊接方法，其特征是，所述支撑单元为焊接而成的条块，其底面和顶面平行，根据各组件的宽度设置合适长度。According to the frame assembly welding method according to claim 1, it is characterized in that the support unit is a welded bar, the bottom surface and the top surface of which are parallel, and the appropriate length is set according to the width of each component.
PCT/CN2022/142631 2022-11-18 2022-12-28 Chassis assembly and welding method WO2024103498A1 (en)

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Citations (6)

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Publication number Priority date Publication date Assignee Title
CN201960305U (en) * 2011-03-23 2011-09-07 中国北车集团大同电力机车有限责任公司 Locomotive framework assembly tool
CN202291974U (en) * 2011-10-14 2012-07-04 南车戚墅堰机车有限公司 Positioning tool for assembly of locomotive steering frame
RU2680114C1 (en) * 2017-12-21 2019-02-15 Общество с ограниченной ответственностью "Всесоюзный научно-исследовательский центр транспортных технологий" (ООО "ВНИЦТТ") Stand for assembling and welding railcar frame
CN210099350U (en) * 2019-05-07 2020-02-21 中车大同电力机车有限公司 Locomotive framework assembling tool
CN112427874A (en) * 2020-12-11 2021-03-02 中车戚墅堰机车有限公司 Tool for assembling bogie frame
CN113954007A (en) * 2021-11-12 2022-01-21 中车长春轨道客车股份有限公司 Assembling process and assembling tool for frame shaped like Chinese character' yu

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN201960305U (en) * 2011-03-23 2011-09-07 中国北车集团大同电力机车有限责任公司 Locomotive framework assembly tool
CN202291974U (en) * 2011-10-14 2012-07-04 南车戚墅堰机车有限公司 Positioning tool for assembly of locomotive steering frame
RU2680114C1 (en) * 2017-12-21 2019-02-15 Общество с ограниченной ответственностью "Всесоюзный научно-исследовательский центр транспортных технологий" (ООО "ВНИЦТТ") Stand for assembling and welding railcar frame
CN210099350U (en) * 2019-05-07 2020-02-21 中车大同电力机车有限公司 Locomotive framework assembling tool
CN112427874A (en) * 2020-12-11 2021-03-02 中车戚墅堰机车有限公司 Tool for assembling bogie frame
CN113954007A (en) * 2021-11-12 2022-01-21 中车长春轨道客车股份有限公司 Assembling process and assembling tool for frame shaped like Chinese character' yu

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