车身溶组概要教育训练课件.pptx

1、1 目目 次次壹、钣件组立与夹治具间定位关系壹、钣件组立与夹治具间定位关系 1、前言 （Introduction）2、前柱组立钣件、名称 （The parts composition of the front pillar assembly.）3、前柱组立夹治具概要 （The front pillar assembling jig.）4、前柱上内板定位状态 （Positioning a front pillar inner upper.）5、前柱下外板件定位状态 （Positioning a front pillar outer lower.）6、前柱组立状态 （The positioned

2、parts of front pillar assembly.）7、钣件投入治夹具压持板压持状态 （Clamping must be done so that the parts are secure.）8、钣件投料定位方式 （How to set the part.）9、钣件投料前外观确认事项 （The parts must be checked before setting them.）10、钣件放置物料架场所 （The parts must be placed in the specified position.）11、定位座上尘积及点焊飞溅物有否 （The locator must b

3、e kept clean.）12、钣件定位状态是否良好 （If a part is wrongly positioned,it can not be clamped correctly）13、钣件和钣件间搭接不良造成压持板压持钣件变形 （If a part is wrongly positioned,it can not be clamped correctly.）(Contents)2 1、前、前 言言n汽车车体是由许多冲压钣金单品经过溶接组焊而成。（A body of vehicle is composed of many stamped steel plate parts which a

4、re assembled by spot welding.）n车体精度良否与单品间相互搭间（合）状态有绝对应关系。（It is important to spot weld keeping the exact position among the parts.）n溶组夹治具系能将钣金部品正确地定位进行溶接组立作业。（The function of jigs is to set upset up the parts to the right position.）n钣金单品正确地投入夹治具之作业方法之教育就更显重要了。（This textbook is useful to know how to

5、set the parts to jigs correctly.）(Introduction)32、前柱组立钣件名称、前柱组立钣件名称前档开口部雨水槽(Front wind shield channel)前柱组立(Front pillar assembly)前柱下外板(Front pillar outer lower)前柱上外板 (Front pillar outer upper)顶蓬雨水槽(Roof drip channel)(The parts composition of the front pillar assembly)43、前柱组立夹治具概要、前柱组立夹治具概要(The front

6、 pillar assembling jig)气 压 缸 Air cylinder 定位座 Locator 压持板起动钮 Clamp button 位置安全销 Locating pin 气 压 阀 Air operated valve 压 持 板 Clamp54、前柱上内板件定位状态、前柱上内板件定位状态(Positioning a front pillar inner upper)前柱上外板件 Front pillar outer upperAA 定位座 Locator 定位座 LocatorA-A断面图断面图NGOK与定位座 搭接无间隙 No gap与定位座搭 接间隙不良 gap65、前柱

7、下外板件定位状态、前柱下外板件定位状态(Positioning a front pillar outer lower)AA前柱下外板件Front pillar outer lower前柱上外板件Front pillar outer upper定位座LocatorA-A断面图断面图NGOK与定位座 搭接无间隙 No gap与定位座搭 接间隙不良 gap76、前柱组立状态、前柱组立状态(The positioned parts of front pillar assembly)87、钣件投入治夹具压持板压持状态、钣件投入治夹具压持板压持状态(Clamping must be done so tha

8、t the parts are secure)压持板起动钮 Clamp button 压持板 Clamp 定位座 Locator搭接无间隙No gap压持板 Clamp钣件 PartOKNG搭接产生间隙 gap 搭接产生间隙 Gap 位置定位销Locating pin 搭接无间隙 No gap98、钣件投料定位方法、钣件投料定位方法(How to set the part)钣件 Part 凹 Dent 定位 Locator 定位座 LocatorOK 钣件与定位座碰撞造成凹陷不良（The dent happens if the part is struck to the locator）NG1

9、09、钣件投料前外观确认、钣件投料前外观确认 (The parts must be checked before setting them)钣件 Part OKNG 凹凸 Dent and hump 折曲变形 Bent 生锈 Rust1110、钣件放置物料架场所、钣件放置物料架场所 (The parts must be placed in the specified position)OKNG 物料架 Palette 钣件 Part 物料放置区域 Line 倾斜 Leaning 放置位置偏离 Do not place over the line 1211、定位座上尘积及点焊飞溅物有否、定位座上

10、尘积及点焊飞溅物有否 (The locator must be kept clean)定位座 Locator 尘积 Dirt 点焊飞贱物 Spatter良好状态（Good state）搭接不良 造成间隙 GapNGNG钣件搭接 良好无间隙 Gap搭接不良 造成间隙 Gap钣件 partOK1312、钣件定位状态是否良好、钣件定位状态是否良好 (If a part is wrongly positioned,it can not be clamped correctly.)搭接无间隙 No gap 钣件定位状态良好 Well positioned 压持板 Clamp OKNG 钣件变形（投料未定

11、位）Bent 位置定位偏移 Gap 搭接间隙 Gap 1413、钣件间搭接不良造成压持板压持不良、钣件间搭接不良造成压持板压持不良 (If a part is wrongly positioned，it can not be clamped correctly)OKNG 钣件搭接良好 Well positioned 压持板 Clamp 搭接无间隙 No gap 钣件压持变形 Bent 钣件间搭接不良 Wrongly positioned 搭接间隙 Gap 15 目目 次次贰、焊接组立方法及焊接设备介绍贰、焊接组立方法及焊接设备介绍1、前言 （Introduction）2、汽车由点焊组立而成 （

12、A car is spot welded.）3、车体点焊部位概要图 （The outline of spot welding of a car body.）4、什么是焊接组立 （What is welding and assembling?）5、点焊组立作业实例 （The examples of welding and assembling work.）6、点焊作业是将一个钣件与另一钣件连接起来的一项作业 （The spot welding is the work to connect one part to another.）7、固定式点焊机 （The mechanism of a stat

13、ionary spot welder.）8、活动式点焊机 （The mechanism of a portable spot welder.）9、如何吊装活动式点焊枪 （How to hang a portable spot welding gun?）10、管路必须用橡胶带绑扎 （The hoses must be bound by rubber binders.）11、平衡器须选用适合活动式电焊枪重量的平衡器 （The spring balancer must be selected to fit the weight of the portable spot welding gun.）12

14、、平衡器拉力可调整 （Lifting force of a spring balancer can be adjusted.）13、平衡器钢索坏了就不能使用 （The spring balancer with a broken wire with must not be used.）(Contents)1614、活动式点焊枪的种类 （The kind of portable spot welding guns.）15、活动式点焊机的机构 （The mechanism of the portable spot welding gun.）16、活动式点焊枪的冷却系统 （The cooling sy

15、stem of a portable spot welding gun.）17、电极头的种类 （The kind of electrode tips.）18、焊接螺帽用的电极头 （The electrodes for welding nuts.）19、焊接焊帽用的电极机构 （The mechanism of the electrode for a welding nut.）20、电极杆的种类 （The kind of shanks.）21、电极接头的种类 （The kind of adaptors.）22、上下电极头的中心须压在同一个点上 （The centers of the upper e

16、lectrode and the lower electrode must press the same point.）23、旧的电极头必须研磨 （The worn electrode tip must be dressed.）24、研磨电极头要使用的特殊工具 （The specified tool must be used for tip dressing.）25、旧&短的电极头必须更换 （The worn and shortened electrode tip must be changed.）26、更换电极头需使用的取出工具 （The taking out tool must be us

17、ed to change the electrode tip.）27、钣金件是如何连接在一起的 （How are the steel plates joined together?）上 的 小 凸，步 骤-B,-B(Too short)（Leather gloves.(The examples of welding and assembling work.顶蓬外板膜厚18-20m 研磨范围在70mm以内导线 Cable检查方法：用裸露的手检查（触摸它们一会儿，不要被烫伤）（The hoist moves as the indication of the push button switch.(

18、Causes of dent and hump on the finished surface.（The limit of a sanding discs.level difference.9 pushing tool.（The check point for overheat.吊挂口死点不能正常工作8、如何使用涂密封胶和粘着剂的工具67、电极头中心不一致确认（The tools for finishing.(The causes of the sheet separation.如果步骤还很难判断凹凸，就用油石来判断1728、按下握把时会发生什么 （What is it happened wh

19、en the trigger is pulled?）29、点焊条件是什么 （What is spot welding conditions?）30、点焊有哪些缺陷 （What kind of the defects are there by spot welding?）31、为何会发生脱焊 （Why does the disjunction happens?）32、电流过低会造成脱焊 （The disjunction happens in case the welding current is too small.）33、焊接时间过短会造成脱焊 （The disjunction happens

20、 in case the weld time is too short.)34、加压力过大或过小会造成脱焊 （The disjunction happens in case the welding force is too large or too small.）35、电极头末端直径过大会引起脱焊 （The disjunction happens in case the diameter of the electrode tip end is too large.）36、焊枪置入角度不良会导致脱焊 （The disjunction happens in case the gun setting

21、 angle is wrong.）37、电极头冷却不良 （The electrode tip is not cooled enough.）38、焊接电流分流会造成脱焊 （The disjunction happens in case the welding current is diverged.）39、无感电缆断线会造成脱焊 （The disjunction happens in case the secondary cable is broken.）40、两片钣件间有间隙 （There is a gap between two steel plates.）41、飞溅表面飞溅、夹渣的危害 （

22、The burrs surface splattering,expulsionare harmful.）1842、表面飞溅和夹渣 （Surface splattering and expulsion.）43、表面飞溅和夹渣产生的原因 （Why does the surface splattering and the expulsion occur.）44、焊枪置入角度不良会产生表面飞溅 （The surface splattering occurs in case the gun setting angle is wrong.）45、两片钣金件间有间隙 （There is a gap betw

23、een two steel plates.）46、钣件表面有脏物会产生表面飞溅和夹渣 （The surface splattering and the expulsion occur in case the surfaces of the parts are dirty.)47、电极头表面有脏物会产生表面飞溅 （The surface splattering occurs in case the electrode tip is dirty.）48、焊接加压力过小会产生表面飞溅 （The expulsion occurs in case the welding force is too sma

24、ll.）49、初期加压时间过短易产生表面飞溅 （The surface splattering occurs in case the squeeze time is too short.）50、焊接电流过小时易产生表面飞溅 （The surface splattering occurs in case the welding current is too large.）51、为什么必须设定适当的点焊条件 （Why must the suitable spot welding conditions be set?）52、如何设定点焊条件 （How to set the spot welding

25、conditions.）53、如何设定点焊条件 （How to set the spot welding conditions.）54、必须由专业人员设定点焊条件 （The specified person must set the spot welding conditions.）55、如何检查焊点品质 （How to check the spot weld.）1956、如何检查焊点品质 （How to check the spot weld.）57、如何确认焊点的熔接 （How to check the weld of welding nut.）58、熔池是什么 （What is nugg

26、et?）59、活动式点焊枪的检查清单 （The check list for portable spot welding gun.)60、压缩空气泄漏确认 （The check point for air leak.）61、冷却水泄漏确认 （The check point for water leak.）62、螺丝松动检查 （The check point for a screw loose.）63、外观破洞检查 （The check point for a broken hose.）64、电路接头松动检查 （The check point for a terminal loose.）65、过

27、热检查 （The check point for overheat.）66、外观毛刺检查 （The check point for stuck spatter.）67、电极头中心不一致确认 （The check point for a disagreement of electrode tip centers.）68、焊枪吊具磨损检查 （The check point for a worn hanger.）69、无感电缆断线检查 （Checking the breaking of a secondary cable.）20 1、前、前 言言(Introduction)n点焊是将一片钣件与另一片

28、钣件连接起来的一种生产方法。（The spot welding is the manufacturing method to connect one steel plate to another.）n车厢、车体和车子的结构都是钣金件制成的。（A cabin,a body and a frame of a car is made of steel plates.）n因此为了制造汽车必须研究点焊方法。（Therefore it is necessary to study the method of spot welding for manufacturing cars.）n这本教材对研究在制造汽车

29、必须应用到的点焊是很有帮助的。（This textbook is useful to study about spot welding that is necessary to manufacture a car.）21 2、汽车由点焊组立而成、汽车由点焊组立而成(A car is spot welding.)轿 车 Passenger car 公共汽车 Bus 小公共汽车 Mini bus 商 务 车 Commercial car 22 3、车体点焊部位概要图、车体点焊部位概要图(The outline of spot welding of a car body.)标示符号表示焊点 Mark

30、,shot weld 23 4、什么是焊接组立？、什么是焊接组立？(What is welding and assembling?)冲压冲压（Stamping）点焊组立点焊组立 （Welding assembling）喷喷 涂涂 （Painting）装装 配配 （Trimming）24 5、焊接组立作业实例、焊接组立作业实例(The examples of welding and assembling work.)项次项次（NO.）作业内容作业内容（Operation）零部件名称零部件名称（Parts name）1放置钣件（Part set）前柱上外板（Front pillar outer u

31、pper assembling）2放置钣件（Part set）前柱加强板（Plate front pillar）3点焊（Spot weld）（1&2）4放置钣件（Part set）大灯框托架（Break H/L bezel side）5放置钣件（Part set）前角托架（Break front corner side）6放置钣件（Part set）前踏板（Panel step front）7放置钣件（Part set）前柱加强板（Plate front pillar）8涂胶（Gelatinizing）（4&5&6&7）9放置钣件（Part set）限位器托架（Break check）10放置

32、钣件（Part set）前柱下外板（Pillar front center lower assembling）11压紧（Clamp）-12点焊（Spot weld）（10&2）13点焊（Spot weld）（10&4）14点焊（Spot weld）（10&4）15点焊（Spot weld）（10&6）16点焊（Spot weld）（10&2）17点焊（Spot weld）（10&9）18点焊（Spot weld）（10&5）19点焊（Spot weld）（10&4）20点焊（Spot weld）（10&4）21打开（Unclamp）-22顶升机上升（Lift up）-前柱外板组立（Front

33、pillar outer assembling）:256、点焊作业是将一个钣件与、点焊作业是将一个钣件与 另 一 钣 件 连 接 起 来 的 一 项 作 业另 一 钣 件 连 接 起 来 的 一 项 作 业(The spot welding is the work to connect one part to another.)26 8、活动式点焊机、活动式点焊机(The mechanism of a portable spot welder.)滑轨 Overhead rail 梁 Beam 变压器 Transformer 电源 Power supply 无熔丝 空气开关 Trip mecha

34、nism NFB 吊具 Hanger 平衡器 Spring balancer X型枪 X-gun 枪吊具 Hanger电极头 Electrode tip 辅助电缆 CableC型枪 C-gun 无感电缆 Kickless cable控制器 Timer conductor7、外观毛刺检查。4、置前门建付治具于车体上不要在同一部位磨太长时间，长时间研磨会造成过热变形（D class：On the part of ignore appearance,permissive deep dimple but impermissive a pit or flash.14、钢索存在的缺陷问题Dirty sur

35、face12、怎样调整氩气流量.6型平衡器 Spring balancer No.（Increasing pressure)凹凸 Dent and hump焊接时间 (Weld time)Jaw of vernier挂钩 Hook34、完成表面凹凸的原因2、密封胶和粘着剂的功能(Introduction)Air impact wrench不能过度敲击（Dont tap too much.(How to use an air orbital sander in the27 9、如何吊装活动式点焊枪、如何吊装活动式点焊枪(How to hang a portable spot welding gu

36、n.)平衡吊具 Spring balancer 平衡吊具 Spring balancer 平衡吊具 Spring balancer OKNG 缓冲胶绳 Rubber rope 钣件 Part 落下 Droop 28 10、水气电管线必须用橡胶扣带整理绑扎、水气电管线必须用橡胶扣带整理绑扎(The hoses must be found by rubber binders.)OKNG 管线下垂(落)Droop 橡胶扣带 Rubber binder 无感电缆 Kickless cable 橡胶扣带 Rubber binder 气 管 Air hose 冷却水管 Water hose 29 11、平

37、衡器须选用适合活动式、平衡器须选用适合活动式 点点 焊焊 枪枪 重重 量量 的的 平平 衡衡 器器(The spring balancer must be selected to fit the weight of the portable spot welding gun.)型 号(Balancer NO)容 量（Capacity）NO.11kg3kgNO.22.5kg5kgNO.34.5kg9kgNO.49kg15kgNO.515kg22kgNO.622kg30kgNO.730kg40kgNO.1型平衡器 Spring balancer No.1 NO.6型平衡器 Spring balan

38、cer No.6 NO.6型平衡器 Spring balancer No.6 拉力调整螺旋钮 Adjusting screw 钢 索 Wire 钢索锁紧扣环 Clasp 吊焊枪挂钩 Hook 30 12、平衡器拉力可调整、平衡器拉力可调整(Lifting force of a spring balancer can be adjusted.)钢索 Wire 开口扳手 Wrench NO.6型平衡器 Spring balancer No.6 NO.1型平衡器 Spring balancer No.1 钢索 Wire 平衡器拉力可调整 Hexagonbar spanner 往右调整可增大拉力往右调

39、整可增大拉力 （Turn to the right to stronger the force.）往左调整可减小拉力往左调整可减小拉力 （Turn to the left to reduce the force.）31 13、平衡器的钢索坏了就不能使用、平衡器的钢索坏了就不能使用(The spring balancer with a broken wire must not be used.)NGOK平衡器 Spring balancer 钢 索 Wire 32 14、活动式点焊枪的种类、活动式点焊枪的种类(The kind of portable spot welding gun.)枪本体与

40、电极臂是不可拆的（The body and the arm are undivided.）电极臂能从枪本体上拆下（The arms can be removed from the body.）适合型X枪 Proper type X gun 型X枪 Delta type X gun 适合型C枪 Proper type C gun 型C枪 Delta type C gun 枪本体与电极臂是不可拆的（The body and the arm are undivided.）电极臂能从枪本体上拆下（The arms can be removed from the body.）33 15、活动式点焊枪的机

41、构、活动式点焊枪的机构(The mechanism of the portable spot welding gun.)冷却水接头 Nipple for water 枪本体 Body 电极臂 Arm 枪吊具 Hanger 握把 Trigger 气缸 Air cylinder 气管接头 Nipple for air 冷却水接头 Nipple for air 电极接头 Adaptor电极头 Electrode tip 电极杆 Shank 电极头 Electrode tip 电极杆 Shank电极接头 Adaptor34 16、活动式点焊枪的冷却系统、活动式点焊枪的冷却系统(The cooling

42、system of a portable spot welding gun.)给水量 Feed water pipe 排水路 Drain hole 给水 Feed water 排水 Drain 给水管 Feed water pipe 排水路 Drain hole 电极臂 ArmA-A断面图断面图（Section A-A）AA35 17、电极头的种类、电极头的种类(The kind of electrode tips.)16电极头 16 cap tip 12电极头 12 cap tip 16偏心电极头 16 offsetcap tip 弯曲电极头Curved tip 弯曲电极头Curved ti

43、p16插入式电极头 16 insert tip 12插入式电极头 12 insert tip 平电极头 Flat tip36 18、焊接螺帽用的电极头、焊接螺帽用的电极头(The electrodes for welding nuts.)上电极上电极 （Upper electrode）下电极下电极 （Lower electrode）选用合适的电极去适合不同的螺帽（Use the correct electrode to fit the nut.）（The movement of a door-sash top occur from the reaction by32、电流过低会造成脱焊（Bod

44、y construction accuracy.(The examples of welding and assembling work.将新的线圈滚筒放入轴中（Set the new wire reel to the spindle.（The part that is regarded as dent is symbol.气 压 缸8 of shade glasses must be used.Air impact wrenchHood outer panel 22-24 m砂轮机转动时振动 (The sander vibrates while rotating.6型平衡器 Spring b

45、alancer No.管子 Pipe5、气动砂轮机的构成（The mechanism of a stationary spot welder.Air impact wrench（The electrode tip is dirty.(Thickness)(Checking a wire rope.29、检测砂轮机和锉刀引起37 19、焊接螺帽用电极的机构、焊接螺帽用电极的机构(The mechanism of the electrodes for welding nut.)下电极断面图下电极断面图 （Cross section of lower electrode）下电极A （Lower el

46、ectrode A）绝缘套 （Insulating bush）导向销 （Guide pin）弹 簧 （Spring）绝缘板 （Insulator）下电极B （Lower electrode B）38 20、电极杆的种类、电极杆的种类(The Kind of shanks.)16 12 39 21、电极接头的种类、电极接头的种类(The Kind of shanks.)短短Short 16 12 长长Long 40 22、上下电极头的中心必须、上下电极头的中心必须 压压 在在 同同 一一 个个 点点 上上(The centers of the upper electrode and the lo

47、wer electrode.)NGOKNGOK41 23、旧的电极头必须研磨、旧的电极头必须研磨(The worn electrode tip must be dressed.)OKNGOKNG电极头必须被研磨（The electrode tip must be dressed.）电极头必须被研磨（The electrode tip must be dressed.）42 24、研磨电极头要使用的特殊工具、研磨电极头要使用的特殊工具(The specified tool must be used for tip dressing.)中等粒度平锉刀 Second-cut flat machini

48、sts file 电极修磨器 Tip dresser 切割机 Cutter 3003043 25、旧的并且短的电极头必须更换、旧的并且短的电极头必须更换(The worn and shortened electrode tip must be changed.)电极头必须更换电极头必须更换（The electrode tip must be changed.）电极头达到这个点时不能再使用 It must not be used after reaching this point 新新 （New）限度限度 （Limit）44 26、更换电极头需使用的取出夹具、更换电极头需使用的取出夹具(The

49、taking out tool must be used to change the electrode tip.)大力钳 Vice clip type 曲柄 Crank type 45 27、钣金件是如何连接在一起的、钣金件是如何连接在一起的(How are the steel plates joined together？)加压力 （Air pressure）加压力 （Air pressure）电流 Current 当电流达到6000A14000A 时（When the current is 6000 to 14000 A is passes through.）当钣金通电720周时（The

50、 steel plates for 7 to 20 cycles.）将产生电阻热且温度达到约1600（Resistance heat will occur,and the temperature will reach about 1600.）钣金熔接点达到1526（The melting point of the steel plate is 1526.）通过压力将熔化的钣金连接在一起（The molten steel plates are joined together by air pressure.）电压电压 =1820 V （Voltage）46 28、按下握把时会发生什么、按下握把时