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1、汽车焊接夹具的设计1 摘要依据车体焊装线夹具设计理论，对各工位焊接夹具及其焊装总线进行规划、设计，之后进行夹具建模、装配，插入焊钳确定其数量、型号及判断其可达性，最终设计出符合要求的焊接夹具。关键词：焊接部件；基础；夹紧；位置1. 介绍装配和焊接夹具在汽车车身装配和焊接生产线与生产制造优质的汽车设备息息相关。焊装夹具，是焊接工艺的重要组成部分。装配和焊接夹具除了是完成这个过程中零部件装配的途径和定位,同时在生产线上也作为一个测试和校准程序，完成检测焊接配件和焊接质量的任务。因此焊装夹具的设计和制造，直接影响焊接过程中汽车的生产能力和产品质量。汽车焊装夹具是保证其制造质量、缩短其制造周期的重要手
2、段。因此，正确理解焊装夹具设计要点，改善和提高焊装夹具的设计手段和设计水平，并提高夹具的调整和验证水平等三方面都是必不可少的，也是汽车制造公司在激烈的竞争中得以生存所必须解决的问题。汽车的风格不同,焊接夹具的形状,因而有着很大的不同,但在设计、制造和调整都是共同的,可以借鉴采用。2. 焊接夹具的结构设计焊接夹具的结构设计,确保该夹具有良好的操作方便性、装夹定位的可靠性。焊装夹具的制造商也很容易集成的调整,以保证结构各部分的表面应该允许足够的空间用于调整，以确保立体可调。当然，在确保焊接夹具质量准确性的前提下,焊接夹具的结构应尽可能简单。夹具设计通常是夹具上全部元件的位置都是直接根据设计基准确定
3、的，最终保证制造出合格的焊接工装结构。根据作业高度可初步决定夹具底板的高度，即夹具固定位置的高度。焊接夹具设计首先要考虑夹紧方式，一般有手动和气动两种，手动夹紧一般适合于小件、外协件、小批量工件焊装，对于大型车体部件、规划于生产线内、自动化程度要求高的焊接夹具宜选用气动夹紧，汽车生产的一般采用气动夹紧,然后手工大批量夹紧可作为辅助夹紧。这样可以相应的降低成本。部分手动夹紧产品已拥有标准的型号和数量，需要时可以到市场购买即可。对于某些装置,规定采用气动夹紧，但如果直接使用气动夹紧，可能损坏的工件,所以,可以由人工先按地方,来提供一种气动夹紧力夹紧工件,这是手动-气动。该夹具夹紧系统是安装在一个大
4、平台,所有固定在此保证焊接位置的焊接条件应符合设计尺寸的工件坐标系定位夹具,这牵涉到的基准。3. 装配和焊接夹具的基准和他们所选择的支撑面3.1 设计基准的确定每个夹具必须具有固定坐标系统,在这个坐标系统, 它的支撑基础坐标尺寸应该支持工件以及坐标对应于同样的大小。所以在整个的焊装夹具系统中,为了确保自动焊件系统的三维空间坐标一致, 所有的焊装夹具在该系统中必须有一个共同的基准。该基准是夹具安装平台,这是X,Y坐标、每一个具体部件都固定在平台相应位置,要具有相应的高度,所以,应协调Z坐标，由此建立了三维XYZ坐标系统。为了方便夹具的安装及测量、安装平台必须有坐标的参考,通常有三种类型。结构如下
5、：3.1.1 基准孔的方法安装平台设计时有四个基准孔,其中每一个孔圆心坐标的两个方向、四个孔的坐标构成两条相互垂直的线。这就是,XY平面坐标系统上集合。这个基准的建立相对简单,易加工,但同时使用的测量与基准精确。任何形状都是由空间点组成的，所有的几何量测量都可以归结为空间点的测量，因此精确进行空间点坐标的采集，是评定任何几何形状的基础。参考一侧靠近两个基准形成的一个协调的方向。3.1.2 v型检测法这种方法是在这一过程中安装平台分为每两个90度范围的,这两条轴线的线组成一平面垂直安装的平台,这样平面垂直于平台,这两个轴线沟槽的表面形式XY平面坐标系统。3.1.3 参考试块法参考使用侧块垂直于三
6、维XYZ坐标系统,通常是一个检具的底座与3到4块可直接安装在平台上，也可以添加一个轴承固定夹具平台,但需要参考块的最后一个平面来控制高度，必须保证方向一致。制造时，调整块在前面的两种方法是较为困难的,但这种测量极为方便,尤其是使用CMM测量。该方法要求用的基准块平面加工安装平台相对较低,所以大一点的尺寸的安装平台应该使用这种方法。3.2 轴承表面的选择 轴承表面选择时，使用焊接试件的固定表面上的切平面和安装平台的角度不大于15度。检测表面应尽可能的和焊接管件的相同、尽可能为了方便平面处理和调整。轴承表面结构设计上应可以很容易地处理模块,而这一数字为产品的可用于轴承数控表面加工上。当然设计车身坐
7、标点不一定就是适合轴承表面,特别是数控夹具,这就需要以支持夹具堵住存取点S为基础,建立了数字表面,这个表面应该是和被支承面一致的。所以此时是制造基地点S数控加工、精密加工及装配调试比较容易容易。4. 定位工件一般位置的工件表面特征是相对于孔或明显的定位参考表面确定的。常用是定位销组件。分为夹紧定位和固定定位两部分。考虑焊接位置和所有焊接设备，既不能影响最终焊接件的取出，也可以让焊钳或者焊枪到达焊接位置。对于确实有影响的定位销等要考虑采用可以活动的定位销。为了方便工件进出,可选用伸缩定位销，具体的结构可查找手册。焊装夹具的设置应便于施工，有足够的装配、焊接空间，不能影响焊接操作和焊工观察，不妨碍
8、焊件的装卸。所有的定位元件和夹紧机构应与焊点保持适当距离，或布置在焊件的下方或面。夹紧机构的执行元件应能够伸缩或转位。根据形成原理,将工件放进夹紧、定位。之后打开夹具将工件取出。确保夹具的打开和关闭没有干涉。为减少装卸工件的辅助时间，夹紧装置应采用高效快速装置和多点联动机构。对于薄板冲压件，夹紧力作用点应作用在支承面上，只有对刚性很好的工件才允许作用在几个支承点所组成的平面内，以免夹紧力使工件弯曲或脱离定位基准。另外设计时要防止在夹紧机构由夹紧到打开时夹住手。5. 焊接件的工位调动大多数汽车焊接配件的焊装过着在几个工艺完成。因此它需要传动装置,通常工件在传输之前应避开焊接夹具的干扰,第一步将工
9、件升起,这需要使用电梯、起重机构，齿轮齿条,等等,此时的齿条和齿轮结构，它们的结构加工、连接并不像完成通常连接结构站间传输的机构那样简单,有几种形式,如齿轮、齿条传动机构、传动机构、摇臂机构,由于是往复运动形式,摇臂机构的转移制造到调试比另一种更好,所以一般选用普通摇臂转移机构。6. 结论最近几年，汽车焊接夹具如何正确、合理的设置辅助定位支承，是一项极为复杂的系统问题，虽然我们已在这方面积累了一定经验，但在该领域还有大量的知识有待去进一步地学习和研究，以便为焊装夹具设计领域的不断发展创新，提供新的理论支持。随着中国汽车工业的发展，需要越来越多的焊接夹具。夹具虽然原理很简单,但是真正的设计和制造
10、出高质量焊接夹具系统是一项极其复杂的工程。The Design of the Welding Junetion Clamp of MotorcarAbstractThe text introduces the design method and construction of the welding junction clamp of motorcar. KeyWords: Weldingassembly Base Clamp Loeation 1. Introduction Assembly and welding fixture in the automotive body assembl
11、y and welding production line of critical process equipment related to manufacturing quality of the car. In welding production. Assembly and welding fixtures in addition to the completion of this process the parts assembly, positioning, the also served as a test and calibration procedures on the Roa
12、d, welding parts welding quality of the task, so its design and manufacture of the welding process affects the level of automobile production capacity and product quality.Automotive style vary, welding fixture shape and thus vary widely, but in the design, manufacture, adjustments have in common, yo
13、u can learn from each other. 2. the structural design of welding fixture Fixture structural design, to ensure that the folder has a good convenience of operation, clamping positioning reliability. Fixture manufacturers also adjusted to ensure easy integration of various parts of the structure surfac
14、e should allow sufficient room for adjustment to ensure the three-dimensional adjustable. Ensuring the accuracy of the welding quality and welding under the premise of the structure of fixture should be as simple as possible. Fixture design is usually the general use of welded structures, the basic
15、component is divided into three parts, namely base, support the positioning part, clamping parts, for each specific fixture positioning support base and some of the general use of 10 to 20 mm thick steel plate welded structure A3.Clamping part of the normal 10 mm with a thickness of about 45 combina
16、tion of welded steel plate. Pneumatic and manual clamping part of the two, according to the size of car production clamping method to determine the general high-volume pneumatic clamping, then manually clamping can be used as auxiliary clamping; small quantities in order to reduce the cost of manual
17、ly clamp mode. Manual clamping is usually manually fast clip, manual quick clip of their products has become the standard, type and quantity needed can be purchased in the market. For some fixtures require apneumatic clamping, but direct use of pneumatic clamping. May damage the workpiece, then, can
18、 be manually pressed first place, to give a pneumatic clamping force to clamp the workpiece, which is manual - Pneumatic J the fixture clamping system is installed on a large platform, all guaranteed fixture in the welding position of welding conditions should be consistent with the design of the wo
19、rkpiece coordinate dimensions, which involves the positioning fixture benchmarks. 3 assembly and welding fixtures benchmarks and their choice of support surface 3.1 t flip-chip benchmark test fixture Each fixture must be a fixture coordinate system, in this coordinate system, the coordinates of its
20、base of support size should be supporting the workpiece and the coordinates corresponding to the same size. Fixture coordinate system is established based on fixture side of the child base. Because the whole fixture system to guarantee a space auto welding pieces of three-dimensional coordinate syst
21、em, so this system in all of the fixture must have a common benchmark, this benchmark is the fixture to install platform that is the X, Y Zuo Biao, each specific fixture in platform location, the corresponding height shall coordinate Z, so that three-dimensional XYZcoordinate system is established.
22、In order to facilitate the installation and measurement fixture, install the platform must have the coordinates of reference, there are generally three types of structure below: 3.1.1 The quasi-hole method Tomb Installation of platform design is the four reference holes, each hole in the center of t
23、he two connection lines form a coordinate direction, the four holes constitute the coordinates of two perpendicular lines. This, XY plane coordinate system on the set. The establishment of this benchmark is relatively simple, easy to process, but the measurements used in conjunction with the base bl
24、ock. Base block is a rectangular block size of the amount of accurate measurement, the platform is installed into the base hole in the base marketing, reference block off a side close to the two benchmarks to form a coordinate direction. 3.1.2 V-type to be law This approach is in the process to inst
25、all the platform into each of two 90-degree V-groove, which V-groove of a plane surface perpendicular to the installation of platform, such plane perpendicular to the platform, the two V-groove groove the surface of the form XY plane coordinate system. 3.13 reference block method Reference block usi
26、ng the side perpendicular to the two constitutive three-dimensional XYZ coordinate system, usually a fixture base with 3 to 4 blocks can be directly installed on theplatform can also add a bearing fixed to the fixture platform, but requires reference block The last plane to control the height must b
27、e consistent with the direction. Manufacturing base to adjust the block in front of the two methods is relatively difficult, but the measurement is convenient, especially the use of CMM measurements. Block method with a benchmark of installation platform plane processing requirements are relatively
28、low, a larger size of the installation platform should use this method. 3.2 The choice of bearing surface Bearing surface should be used when welding pieces are fixed on the surface of the cut plane to plane and install the platform angle is not greater than 15 degrees on the surface. As far as poss
29、ible the detection surface and welding pieces of the same, flat surface as far as possible in order tofacilitate processing and adjustment . Structure should be designed bearing surface can be easily processed, with the number of modules for the product can be used to process bearing NC surface, in
30、the design, the car coordinate Xi point was not necessarily suited fixture bearing surface with NC, which requires supporting the fixture block access point S as the base, the establishment of a digital surface, this surface should be consistent and be the Bearing surface, so that when it was manufa
31、ctured to S base point for NC machining, precision machining and assembly debugging easy. 4. positioning the workpiece The general location of the workpieces to holes or obvious surface features as the positioning reference surface. The positioning pins are commonly used components. Fixture position
32、ing sub-activities, and fixed positioning of two, for some jobs, in order to facilitate the workpiece into and out, positioning the form of optional activities, events or block pin positioning structure of the form sub-pneumatic and manual, in principle, put the workpiece seeded, positioning pieces
33、to open into the workpiece, the positioning pieces out, and then clamp; workpiece removed, the position to return items before and after clamp release. Activities can be used locate pieces of the movement structure of pan-type or flip-style, pan-type structure is usually given priority. 5 welding pi
34、eces of the station transfer between Most auto welding parts to be welded in several station, so it needs transmission device, usually to avoid interference welding fixture, the workpiece in the transmission before the first piece rises, which requires use elevator, lifting bodies Gear rack, four-li
35、nk, etc., rack and pinion drive structure processing and link structure are not as good. usually link structure Station transmission between the institutions, there are several forms, ie gear and rack transmission organizations, non-rod cylinders, transmission organizations, rocker transfer institut
36、ions, because form is the reciprocating motion, rocker transfer agencies are from manufacturing to commissioning better than the others, so common rocker transfer agencies. 6 Conclusion Automotive Welding Fixture many concrete structure, this is only in recent years, some of them work experience, along with the development of Chinese automobile industry on the requirements of more and more welding fixture, welding fixtures principle is simple, but real design and manufacture high-quality welding fixture system is a complicated project, I hope, serve this article.
