阅读说明：本技术 一种新型铝合金型材拼焊的车顶结构及其组焊工艺 (Novel aluminum alloy section bar tailor-welded roof structure and assembly welding process thereof ) 是由 张健彬 窦卿 于 2019-11-29 设计创作，主要内容包括：本发明公开了一种新型铝合金型材拼焊的车顶结构,采用铝合金型材拼焊而成,并采用分部件焊接调型再总成焊接的方式组装；包括圆顶、车顶空调、边缘悬垂机构和型材组件,车顶空调设在车顶结构中央,圆顶包括多块圆顶板依次焊接而成,圆顶设在车顶空调两端；型材组件包括依次连接的第三型材、空调平顶和第四型材,型材组件设在车顶空调和圆顶的两侧,边缘悬垂机构分别设在车顶结构两侧,边缘悬垂机构上接型材组件、下接交通工具的侧墙板。本发明还公开了一种组焊工艺,通过特定的组装顺序和焊接工艺来控制车顶焊后尺寸和焊接质量；通过采用双头龙门焊接设备焊接车顶长直焊缝大大提升了焊接效率,减小了焊接变形,为铝合金车顶提供了很好的工艺参照。(The invention discloses a novel roof structure formed by welding aluminum alloy sections in a splicing manner, which is formed by welding the aluminum alloy sections in a splicing manner, and is assembled in a sub-component welding and shape-adjusting manner and then in an assembly welding manner; the roof air conditioner is arranged in the center of a roof structure, the dome comprises a plurality of dome plates which are welded in sequence, and the dome is arranged at two ends of the roof air conditioner; the section bar assembly comprises a third section bar, an air conditioner flat top and a fourth section bar which are sequentially connected, the section bar assembly is arranged on two sides of an air conditioner roof and a dome, the edge suspension mechanisms are respectively arranged on two sides of a roof structure, and the edge suspension mechanisms are connected with the section bar assembly and connected with a side wall plate of a vehicle. The invention also discloses an assembly welding process, which controls the size and welding quality of the welded roof through a specific assembly sequence and a welding process; the welding efficiency is greatly improved by adopting the double-end gantry welding equipment to weld the long straight welding seam of the car roof, the welding deformation is reduced, and a good process reference is provided for the aluminum alloy car roof.)

1. A novel roof structure formed by welding aluminum alloy sections is characterized in that the roof structure is formed by welding the aluminum alloy sections, and the roof structure is assembled in a mode of welding sub-components and then assembling; the roof structure comprises a dome, a roof air conditioner, an edge suspension mechanism and a profile component, wherein the roof air conditioner is arranged in the center of the roof structure, the dome comprises a plurality of dome plates which are welded in sequence, the dome and the edge suspension mechanism are connected by adopting an adjustable lap joint structure, the adjustable lap joint structure comprises an extension end, a buffer platform and a contact cavity which are arranged in pairs, the extension end, the buffer platform and the contact cavity of the edge suspension mechanism and the extension end, the buffer platform and the contact cavity of the dome are in central symmetry, and the extension end, the buffer platform and the contact cavity are matched with each other and are in sliding lap joint to realize that the; the domes are arranged at two ends of the roof air conditioner; the profile component comprises a third profile, an air conditioner flat top and a fourth profile which are sequentially connected, the profile component is arranged on two sides of the roof air conditioner and the dome, and the edge suspension mechanisms are respectively arranged on two sides of the roof structure.

2. The novel tailor welded aluminum alloy roof structure as set forth in claim 1, wherein said extension end extends from the end of the dome or edge suspension device, and the extension end and the buffer platform are respectively located on the front side or the back side of the dome or edge suspension device, i.e. they are not located on the same plane; viewed from the thickness direction, the setting height of the buffer platform is lower than the thickness of the dome or the edge suspension mechanism to form a clamping platform, so that the extending end can be conveniently lapped with the clamping platform; there may be a gap between the dome and the edge suspension, i.e. the contact cavity, and the curvature of the roof structure is finally adjusted by adjusting the mutual sliding overlap position between the dome and the edge suspension, i.e. the size of the contact cavity.

3. A novel tailor welded aluminum alloy vehicle roof structure as claimed in claim 1 or 2 wherein said dome, profile assembly and edge suspension mechanism are welded and shaped separately and then assembled to said roof structure.

4. The novel tailor-welded roof structure made of aluminum alloy sections according to claim 1 or 2, wherein the long straight weld seam, i.e. the transverse weld seam, in the roof structure is welded by a double-head gantry welding device to form a front weld seam and a back weld seam; and the longitudinal welding seam in the car roof structure adopts gas shielded welding.

5. The novel tailor-welded aluminum alloy roof structure according to claim 4, wherein the edge suspension mechanism and the dome plates are assembled by welding front and back weld seams with a double-head gantry welding device; and the sectional material components are assembled and welded, and the dome and the roof air conditioner are welded by adopting gas shield welding.

6. A novel tailor welded roof structure made of aluminum alloy sections according to claim 1 or 2, wherein said edge suspension structure comprises two welded sections, which are a first section and a second section, the second section is bent, the lower end of the second section is connected to the side wall panel of the vehicle, and the upper end of the first section is connected to said section assembly.

7. The utility model provides a novel roof structure assembly welding technology of aluminum alloy ex-trusions tailor-welding which characterized in that, the roof structure adopts and assembles welded mode again after the part welding transfers the type and accomplishes the assembly welding: firstly, respectively completing the welding and shaping of the dome, the edge suspension structure and the profile component, and then assembling and welding the roof air conditioner, the dome, the edge suspension structure and the profile component on a tool; when welding, the sequence of welding the transverse welding seam in the roof structure and then welding the longitudinal welding seam is adopted.

8. The assembly welding process of claim 7, wherein the freedom of curvature of the roof structure is ultimately achieved by adjusting the sliding overlap position of the dome and rim overhang mechanisms relative to each other, i.e., adjusting the size of the cavity in the adjustable overlap structure.

9. The assembly welding process according to claim 7 or 8, wherein the transverse welding seams in the roof structure are both front and back welding seams welded by double-head gantry welding equipment; and the longitudinal welding seam in the car roof structure adopts gas shielded welding.

10. The assembly welding process of claim 9, wherein the splicing assembly of the profiles in the edge suspension mechanism and the splicing assembly of the dome plates in the dome are performed by welding front and back weld seams by using a double-head gantry welding device; and the sectional material components are assembled and welded, and the dome and the roof air conditioner are welded by gas shield welding.

Technical Field

The invention relates to a vehicle roof structure assembling and welding process based on single-rail vehicle aluminum alloy vehicle type section bar tailor welding, in particular to a novel vehicle roof structure based on aluminum alloy section bar tailor welding and an assembling and welding process thereof, and belongs to the field of rail transit vehicle body part manufacturing.

Background

Currently, the attention range of the three major problems of energy, environment and safety in the world is increasing day by day. In the transportation industry, light weight, energy conservation, consumption reduction and pollution reduction are listed as three general war subjects of the industry.

For industrial practitioners, in the process of developing a novel green transportation tool which is safe, reliable, high-speed, comfortable, energy-saving and environment-friendly, the light weight of the transportation tool becomes a primary task and a target. Because the aluminum section material has a series of advantages of light weight, high strength, low density, corrosion resistance, recoverability, easy forming, environmental protection and the like, the aluminum section material is widely applied to traffic transportation and becomes an important path for realizing light weight in the world.

The total length of the roof structure of the current transportation means is more than 10m, and the conventional special manual welding machine and the single-head gantry welding machine are difficult to meet the requirement of long straight welding seams for splicing a plurality of sectional materials. In addition, the number of structural sections of the car roof is large, and the whole deformation of the car roof structure after welding cannot be controlled due to the adoption of the traditional one-time assembly welding process.

Disclosure of Invention

In order to overcome the defects and shortcomings in the prior art, the invention aims to provide a novel aluminum alloy section bar tailor-welded roof structure which has the advantages of high welding efficiency, difficulty in deformation and the like and ensures the size and welding quality of a roof after welding.

The invention also discloses a novel assembly welding process for the roof structure of the aluminum alloy section.

The technical scheme adopted by the invention for solving the technical problems is as follows:

a novel roof structure formed by welding aluminum alloy sections in a splicing manner is assembled in a manner that sub-components are welded and shaped and then are welded in an assembly manner; the roof structure comprises a dome, a roof air conditioner, an edge suspension mechanism and a profile component, wherein the roof air conditioner is arranged in the center of the roof structure, the dome comprises a plurality of dome plates which are welded in sequence, the dome and the edge suspension mechanism are connected by adopting an adjustable lap joint structure, the adjustable lap joint structure comprises an extension end, a buffer platform and a contact cavity which are arranged in pairs, the extension end, the buffer platform and the contact cavity of the edge suspension mechanism and the extension end, the buffer platform and the contact cavity of the dome are in central symmetry, and the extension end, the buffer platform and the contact cavity are matched with each other and are in sliding lap joint to realize that the; the domes are arranged at two ends of the roof air conditioner; the profile component comprises a third profile, an air conditioner flat top and a fourth profile which are sequentially connected, the profile component is arranged on two sides of the roof air conditioner and the dome, and the edge suspension mechanisms are respectively arranged on two sides of the roof structure.

Further, the extension end extends from an end of the dome or rim overhang, the extension end and the buffer platform being located on a front or back side of the dome or rim overhang, respectively, i.e. not on the same plane hand; viewed from the thickness direction, the setting height of the buffer platform is lower than the thickness of the dome or the edge suspension mechanism to form a clamping platform, so that the extending end can be conveniently lapped with the clamping platform; there may be a gap between the dome and the edge suspension, i.e. the contact cavity, and the curvature of the roof structure is finally adjusted by adjusting the mutual sliding overlap position between the dome and the edge suspension, i.e. the size of the contact cavity.

Further, the dome, the profile assembly and the edge suspension mechanism are respectively welded and shaped and then assembled to the roof structure.

Furthermore, long straight welding seams, namely transverse welding seams in the roof structure are welded with welding seams on the front side and the back side by adopting double-head gantry welding equipment; and the longitudinal welding seam in the car roof structure adopts gas shielded welding. Furthermore, splicing and assembling among the profiles in the edge suspension mechanism and splicing and assembling among the dome plates in the dome adopt double-head gantry welding equipment to weld front and back welding seams; and the sectional material components are assembled and welded, and the dome and the roof air conditioner are welded by adopting gas shield welding.

Furthermore, the edge overhang structure comprises two profiles which are welded together and respectively comprise a first profile and a second profile, the second profile is in a bent curve shape, the lower end of the second profile is connected with a side wall plate of a vehicle, and the upper end of the first profile is connected with the profile component.

The utility model provides a novel roof structure assembly welding technology of aluminum alloy ex-trusions tailor-welding, the roof structure adopts and assembles welded mode again and accomplishes the assembly welding after the part welding transfers the type: firstly, respectively completing the welding and shaping of the dome, the edge suspension structure and the profile component, and then assembling and welding the roof air conditioner, the dome, the edge suspension structure and the profile component on a tool; when welding, the sequence of welding the transverse welding seam in the roof structure and then welding the longitudinal welding seam is adopted.

Further, by adjusting the mutual sliding overlapping position between the dome and the edge suspension mechanism, i.e. adjusting the size of the cavity in the adjustable overlapping structure, the freedom of curvature of the roof structure is finally achieved.

Furthermore, transverse welding seams in the roof structure are welded with front and back welding seams by adopting double-head gantry welding equipment; and the longitudinal welding seam in the car roof structure adopts gas shielded welding. Splicing and assembling among the profiles in the edge suspension mechanism and splicing and assembling among the round top plates in the round tops adopt double-head gantry welding equipment to weld front and back welding seams; and the sectional material components are assembled and welded, and the dome and the roof air conditioner are welded by gas shield welding.

Aiming at the defects that the number of roof sections is large and the integral deformation after welding cannot be controlled due to the adoption of a one-time assembly welding process, the welding deformation is reduced by adopting a mode of welding and shaping sub-components and then welding an assembly.

The total length of the car roof structure is more than or equal to 10m, the defect that the conventional special manual welding machine and the single-head gantry welding machine cannot meet the requirement of long straight welding seams for splicing a plurality of sectional materials is overcome, and the welding seams of the car roof structure are welded by the special double-head gantry long straight welding seam machine, so that the welding quality can be met, and the welding efficiency can be improved.

The roof structure of the invention designs a special assembly welding tool for ensuring the welding quality of components and assemblies, and the welding work of all welding seams is completed on the assembly welding tool.

The adjustable overlapping structure is arranged between the dome and the edge suspension mechanism, and the mutual matching of the dome and the edge suspension mechanism finally realizes the free adjustment of the radian of the roof structure.

In conclusion, the roof structure controls the size and welding quality of the roof after welding through a specific assembly sequence and a specific welding process; the welding efficiency is greatly improved by adopting the double-end gantry welding equipment to weld the long straight weld of the roof, the welding deformation is reduced, and a good process reference is provided for the aluminum alloy roof later.

Drawings

FIG. 1 is a side view of three dome plates assembled to each other;

fig. 2 is a schematic view of the connection of two profiles on each side: (a) a side section bar; (b) the other side section bar;

FIG. 3 is a schematic view of a third profile, an air conditioning deck and a fourth profile in a roof structure;

FIG. 4 is a schematic view of the dome plate in a roof configuration;

FIG. 5 is a top view of the roof structure;

FIG. 6 is an enlarged schematic view of the dome and rim overhang mechanism;

the structure comprises a first section bar 1, a second section bar 2, a third section bar 3, a fourth section bar 4, a dome 5, a first dome plate 5a, a second dome plate 5b, a third dome plate 5c, an air-conditioning flat top 6, a sealing plate 7, an adjustable lap joint structure 8, an extending end 8a, a buffering platform 8b and a contact cavity 8 c.

Detailed Description

The invention is further described below with reference to the accompanying drawings and examples.

The novel roof structure of aluminum alloy section bar tailor-welding of this embodiment, it adopts aluminum alloy section bar, realizes a lightweight roof structure. The roof structure comprises a dome 5, a roof air conditioner, an edge suspension mechanism and a profile assembly, wherein the roof air conditioner is arranged in the center of the roof structure, the dome 5 comprises a plurality of dome plates which are welded in sequence, and the dome 5 is arranged at two ends of the roof air conditioner; the section bar assembly comprises a third section bar 3, an air-conditioning flat top 6 and a fourth section bar 4, the third section bar 3, the air-conditioning flat top 6 and the fourth section bar 4 are sequentially connected, and the section bar assembly is arranged on two sides of the vehicle roof air conditioner and the dome 5. The edge suspension mechanisms are respectively arranged on two sides of the roof structure, the edge suspension structure comprises two sectional materials which are welded and respectively a first sectional material 1 and a second sectional material 2, the second sectional material 2 is integrally bent and curved, the lower end of the second sectional material 2 is connected with a side wallboard of a vehicle, and the upper end of the first sectional material 1 is connected with the sectional material assembly.

In the past, all roof profiles adopt a butt joint structure, and the radian of the roof is difficult to adjust after welding because the sizes of the profiles are fixed. The adjustable overlapping structure 8 is adopted between the dome and the edge suspension mechanism of the embodiment, so that the mutual sliding overlapping position of the dome and the edge suspension mechanism can be freely adjusted according to the radian of the roof when the roof is assembled, as shown in fig. 6.

The adjustable overlapping structure 8 comprises an extending end 8a, a buffering platform 8b and a contact cavity 8c which are arranged in pairs, specifically, the extending end 8a, the buffering platform 8b and the contact cavity 8c of the edge suspension mechanism and the extending end 8a, the buffering platform 8b and the contact cavity 8c of the dome 5 are in central symmetry and are matched and overlapped with each other. An extended end 8a extends from the end of the dome 5 or rim overhang, the extended end 8a and the bumper platform 8b being located on the front or back side of the dome 5 or rim overhang, respectively, i.e. not on the same hand. The height of the bumper platform 8b, as viewed in thickness, is less than the thickness of the dome 5 or the rim overhang, so as to form a snap platform to which the extension 8a is slidably engaged, i.e., slidably adjustable to the left and right (the dome 5 and rim overhang may have a gap, i.e., the contact cavity 8c), while the contact cavity 8c may be adjustable in size. The presence of this contact cavity 8c and its adjustment in size are made to allow for adjustment of the roof camber when the roof is assembled.

The novel aluminum alloy section tailor-welded roof structure of the embodiment is assembled by adopting a mode of welding and adjusting shapes of sub-components and then welding an assembly. Specifically, the dome 5, the profile assembly and the edge suspension mechanism are welded and reshaped respectively and then assembled to the roof structure of the present embodiment.

Preferably, all the long straight welding seams (such as all the transverse seams shown in fig. 3 and 4) in the roof structure of the embodiment adopt a double-head gantry welding device to weld the front and back welding seams, for example, the assembly of the first profile 1 and the second profile 2 in the edge suspension mechanism and the assembly welding of the dome 5 adopt the double-head gantry welding device to weld the front and back welding seams.

Preferably, all the vertical seams in the roof structure of the embodiment shown in fig. 3 and 4 are gas shielded welded, and for example, the sectional components are assembled and welded by gas shielded welding to weld the front and back sides of the vertical seams.

The roof structure of the present embodiment is assembled in the following order:

(1) the dome plates are assembled into a dome 5: sequentially hanging three dome plates (a first dome plate 5a, a second dome plate 5b and a third dome plate 5c) in the middle of the roof onto an automatic dome plate welding tool, adjusting the end parts of the section bars by using a wooden hammer, aligning the end parts of the three section bars, and enabling the misalignment not to exceed 1 mm; and welding front and back welding seams by using double-head gantry welding equipment after the tool is fastened. As shown in fig. 1. (2) Assembling the edge overhang structure: 1 traveling crane is matched with a lifting hook and a hanging strip to sequentially lift 2 sectional materials on each side to an edge suspension structure tool, the 2 sectional materials on each side are a first sectional material 1 and a second sectional material 2 respectively, the first sectional material 1 and the second sectional material 2 are connected with each other, the first sectional material 1 is connected with the tool, and the second sectional material 2 is hung on two sides; and welding front and back welding seams by using double-head gantry welding equipment after the tool is fastened. As shown in fig. 2.

(3) Assembling the profile assemblies, namely assembling the third profile 3, the air-conditioning flat roof 7 and the fourth profile 4: the third section bar 3, the air-conditioning flat top 6 and the fourth section bar 4 are lifted from the one-position end to the section bar assembly tool in sequence (the third section bar 3 and the fourth section bar 4 are not mixed during lifting, the third section bar 3, the air-conditioning flat top 6 and the fourth section bar 4 are connected in sequence, the two-position end is adjusted by a big mallet, so that the end parts of all the section bars at the one-position end are aligned (such as the section bars at the left-side end part of the figure 3), the difference is not more than 0.5mm, and the front and back surface sections of the welding line are welded by gas shielded welding.

(4) And assembling and welding the components on the roof structure tool, as shown in fig. 4. Installation of the dome: and (3) hoisting the domes 5 at a two-position end to corresponding positions of the tool by using 1 crown block matched with a lifting hook, namely respectively installing the domes 5 assembled in the step (1) at two ends of the central area of the roof structure, and welding the welding seams by adopting double-head gantry welding equipment according to a welding process after welding the sections. Such as the installation of profile assemblies and edge overhang structures.

(5) Sealing: and welding the two end seal plates 7 and the drop hanging pieces on the car roof, and welding all welding seams according to the welding process requirement. As shown in fig. 5.

The above description is only a preferred embodiment of the present invention, and should not be construed as limiting the scope of the present invention. Any modification, equivalent replacement, and improvement made within the spirit and principle of the present invention should be included in the scope of the claims of the present invention.