CN113441907A - Diesel engine exhaust manifold welding process - Google Patents

Diesel engine exhaust manifold welding process Download PDF

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Publication number
CN113441907A
CN113441907A CN202110126993.7A CN202110126993A CN113441907A CN 113441907 A CN113441907 A CN 113441907A CN 202110126993 A CN202110126993 A CN 202110126993A CN 113441907 A CN113441907 A CN 113441907A
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CN
China
Prior art keywords
welding
exhaust manifold
welding process
detecting
namely
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Granted
Application number
CN202110126993.7A
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Chinese (zh)
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CN113441907B (en
Inventor
吴亚君
任广昶
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Suzhou Huanyu Auto Parts Co ltd
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Suzhou Huanyu Auto Parts Co ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20Bonding
    • B23K26/21Bonding by welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/60Preliminary treatment

Abstract

The invention relates to a welding process of an exhaust manifold of a diesel engine, which mainly comprises the following steps: polishing, surface tension treatment, press fitting, shaping, laser welding, various detection, packaging and warehousing and the like, most of exhaust manifolds for the existing diesel engine are multi-section exhaust manifolds, welding positions of a plurality of corrugated pipes and castings exist, the problems of low sealing performance and easy leakage are easily caused by using the traditional corrugated pipe and casting welding mode, and during welding, due to the fact that the thicknesses of the castings and the corrugated pipes are different, the welding surface is easily uneven, and the welding is wrong, so that the invention provides a novel welding process, the exhaust manifolds are welded smoothly, the air tightness is good, the automation degree is good, and batch processing production can be carried out.

Description

Diesel engine exhaust manifold welding process
Technical Field
The invention relates to the field of exhaust manifold welding mechanisms, in particular to a welding process for an exhaust manifold of a diesel engine.
Background
The exhaust manifold is a pipeline for collecting exhaust of each cylinder of the engine and discharging the exhaust, and the existing conventional diesel engine exhaust manifold is of a plug-in type, but has certain problems, on one hand, sealing rings in the inserted multi-section exhaust manifold are easy to age and leak air; on the other hand, the existing exhaust manifold is mostly in hard connection, deformation is easy to generate at high temperature, and air leakage is easy to occur at the joint of the flange surface and the cylinder cover; the existing exhaust manifold is formed by independently arranging each cylinder and sealing and welding the metal corrugated pipes, so that the two problems are solved, but because the metal corrugated pipes are thin-walled parts and the castings are thick-walled parts, the corrugated pipes are melted in the traditional welding process, the castings are not melted, and the corrugated pipes are welded together difficultly and are easy to pull out.
The invention provides a method for welding the two parts together by laser welding after special process treatment, and meets the sealing requirement and the durability requirement of customers.
Disclosure of Invention
The invention aims to provide a welding process for an exhaust manifold of a diesel engine, which solves the problems of a corrugated pipe and a casting in the existing welding process.
In order to achieve the purpose, the invention adopts the technical scheme that:
a welding process of an exhaust manifold of a diesel engine is used for welding a combined exhaust manifold containing a casting and a corrugated pipe and mainly comprises the following steps:
s1, polishing, namely polishing the welding end faces of a plurality of pipe fittings to be welded;
s2, processing the welding surface material to ensure that the wetting tension of the surface of the material is not less than 36 mN/m;
s3, press fitting, namely arranging the plurality of pipe bodies in sequence and fixing the pipe bodies to ensure that the corrugated pipe and the casting do not fall off and no inward turning and gaps exist in the corrugated pipe;
s4, shaping, namely shaping the tube bodies after crimping is completed, aligning the adjacent tube bodies, and adjusting the flatness to a proper position;
s5, welding, namely, welding by using a laser welding machine to ensure that the welding surface is continuous and complete;
s6, detecting air tightness, namely detecting the air tightness of the welded exhaust manifold;
s7, detecting flatness to ensure that the integral flatness of the welded exhaust manifold is proper;
s8, detecting hole positions, namely detecting the hole positions on the surface of the exhaust manifold after welding;
s9, detecting the appearance, and detecting whether the paint is scratched or not and whether the paint is complete or not;
and S10, packaging and warehousing, spraying antirust oil, and correctly pasting the mark.
Preferably, in S2, the material surface wetting tension is tested using a dyne pen.
Preferably, in S3, the plurality of pipe bodies are press-fitted and fixed using an air cylinder having an air pressure of 0.6MPA ± 0.1 MPA.
Preferably, the power of the laser welding machine is 500-800W, and the rotating speed is 20-40 r/min.
Preferably, the surface of the welding seam in S5 is silvery white, the fusion width of the welding surface is less than 1.5mm, and the fusion depth is more than 1 mm.
Preferably, in S6, the exhaust manifold is made to be at the air pressure of 0.5MPA ± 0.05MPA for a certain period of time, and after the air outlet is blocked, there is no minute leakage inside.
Preferably, in S7, the range of flatness is less than 0.1.
Due to the application of the technical scheme, compared with the prior art, the invention has the following advantages:
the welding process is different from the traditional electric heating welding, the area influenced by the traditional electric heating welding is large, a casting is not melted when a corrugated pipe is melted, and the casting and the corrugated pipe are difficult to combine together. And then carrying out a series of tests such as air tightness test, flatness test, hole site test, appearance test and the like on the welded exhaust manifold, and finally coating rust preventive oil, then labeling, warehousing and storing. The whole operation is simple and quick, and the requirement on operators is low.
Drawings
Some specific embodiments of the invention will be described in detail hereinafter, by way of illustration and not limitation, with reference to the accompanying drawings. The same reference numbers in the drawings identify the same or similar elements or components. Those skilled in the art will appreciate that the drawings are not necessarily drawn to scale. In the drawings:
FIG. 1 is a block diagram of the steps of the present invention;
FIG. 2 is a schematic structural view of a laser welder;
FIG. 3 is a schematic structural view of a crimping tool;
fig. 4 is a schematic structural view of the airtightness detection tool.
Wherein the reference numerals are as follows:
11. a support frame; 12. a cylinder; 13. laser welding machine; 14. a rotating shaft; 15. a disc; 16. a motor; 17. a universal drive assembly;
21. a base; 22. a slide rail; 23. a bellows support frame; 24. a casting support frame; 25. a cylinder;
31. a fixing member; 32. a plugging block; 33. and (7) an air tightness detector.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the accompanying drawings, and it should be understood that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In addition, the technical features involved in the different embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
Referring to fig. 1, the present invention is primarily directed to welding an exhaust manifold having a combination of a casting and a bellows, comprising the steps of:
s1, polishing the end surfaces of the casting and the corrugated pipe to be welded, and preventing the end surfaces from being uneven during welding;
and S2, processing the polished end face to ensure that the wetting tension of the surface of the material is not less than 36mN/m, and continuously using a dyne pen to test in the process until the tension of the surface of the material reaches 36mN/m and then stopping the processing.
At the step of S3, the method comprises the steps of, the pressure equipment, a plurality of bodys are arranged according to the order and are fixed with the body, guarantee bellows and foundry goods and do not drop, do not have enstrophe and clearance in the bellows, use the crimping frock to carry out the crimping, the crimping frock includes base 21, be provided with slide rail 22 on the base 21, be provided with bellows seat and foundry goods seat on the slide rail 22, bellows seat and foundry goods seat can slide on the slide rail, be provided with bellows support frame 23 on the bellows seat, be provided with foundry goods support frame 24 on the foundry goods seat, be connected with the cylinder on bellows support frame 23 and the foundry goods support frame 24 respectively, the atmospheric pressure when opening and shutting of bellows support frame 23 and foundry goods support frame 24 can be controlled respectively to different cylinders 25, the atmospheric pressure control of bellows support frame 23 and foundry goods support frame 24 is between 0.6MPA 0.01MPA, can fasten bellows and foundry goods under this atmospheric pressure and can not make the pipe fitting crush simultaneously. The distance between the corrugated pipe seat and the casting seat can be adjusted by moving the corrugated pipe seat and the casting seat back and forth on the slide rail 22, the corrugated pipe seat and the casting seat are aligned with each other, and the two ends of the base are also provided with cylinders 25 for tightly abutting against the corrugated pipe seat and the casting seat to realize preliminary positioning and fastening.
S4, shaping; shaping the preliminarily positioned pipe body by using a shaping tool, wherein the shaping range comprises a hole position and a planeness position, so that the planeness range is smaller than 0.1;
s5, welding, wherein a laser welding machine is used for welding, and the laser welding machine comprises a support frame 11, a driving mechanism, a welding mechanism and a cylinder 12; the support frame 11 is provided with a plurality of rotating shafts 14, the rotating shafts 14 define a space for placing an exhaust manifold to be welded, the rotating shafts 14 are provided with a plurality of discs 15, the discs 15 are used for supporting pipe fittings, the discs 15 are provided with protrusions used for driving the corrugated pipes to rotate, the driving mechanism comprises a motor 16 used for driving the rotating shafts to rotate, the driving assembly further comprises a universal transmission set 17, and the universal rotating assembly 17 is arranged to aim at not changing the position of the motor when the position of part or all of the rotating shafts 14 is changed up and down; the both ends of pivot 14 all can slide from top to bottom, and the effect that sets up cylinder 12 can promote pivot 14 and adjust the position of pivot 14 to adapt to not the pipe fitting of equidimension and weld, welding mechanism is laser welding machine 13, can be at support frame 11 upper level and vertical removal, and vertical removal can adapt to the body of different diameters, and horizontal migration can weld the bellows and the foundry goods at different positions. The whole welding process is simple and convenient, the operation is automatic, the laser welding device is used for processing products with different sizes, the applicability is strong, and the problems of unstable welding, uneven welding seam surface and the like caused by the traditional welding can be avoided by the laser welding. The power of a laser welding machine is required to be 500-800W in the welding process, the rotating speed is 20-40 r/min, the surface of a welding line is required to be silvery white, the color shows that the protection effect is good, no other impurities exist, the fusion width of the welding surface is smaller than 1.5mm, the fusion depth is larger than 1mm, and the data can not damage the structures of the corrugated pipe and the casting under the condition of ensuring welding fastening.
S6, detecting airtightness, namely detecting the welded exhaust manifold, detecting by using an airtightness detection tool, wherein after the pore diameter is required to be blocked, the exhaust manifold lasts for no more than one minute within the air pressure range of 0.5MPA +/-0.05 MPA, and after an air outlet is blocked, the gas in the whole pipe does not leak; the air tightness detection tool comprises a fixing piece 31 and an air tightness detector 33, the fixing piece 31 fixes the exhaust manifold, then the blocking blocks 32 are used for sealing the air inlets, and then the air tightness detector 33 is started to reach a certain air pressure range to observe whether the air inlets are air-leaked.
And S7, carrying out flatness detection on the exhaust manifold after the tightness detection is finished, wherein the flatness range of the whole exhaust manifold is less than 0.1.
And S8, detecting the hole positions and observing whether the air outlet holes on the surface are reasonable or not. Whether the deviation is within a certain range.
And S9, appearance detection, wherein whether the surface of the exhaust manifold is scratched or knocked and whether the painted surface is complete or not is detected in the press fitting and welding processes.
And S10, performing rust prevention treatment on the exhaust manifold which is qualified by detection, coating rust prevention oil on the outer leakage coated surface for rust prevention, wherein the type of the rust prevention oil is generally WD40, pasting a correct identifier on the treated exhaust manifold, and then warehousing and storing.
During specific operation, can carry out the fine setting of part step according to the circumstances of reality, but holistic step is unchangeable, uses laser welding exhaust manifold to compare traditional electrothermal welding airtight effect on the one hand better, can reach the durable requirement of high temperature, and on the other hand has realized mechanical automation, and welding efficiency is high, and the cost of labor is lower.
The above embodiments are merely illustrative of the technical concept and features of the present invention, and the purpose thereof is to enable those skilled in the art to understand the content of the present invention and implement the invention, and not to limit the scope of the invention, and all equivalent changes or modifications made according to the spirit of the present invention should be covered by the scope of the present invention.

Claims (7)

1. A welding process of an exhaust manifold of a diesel engine is used for welding a combined exhaust manifold containing a casting and a corrugated pipe, and is characterized by mainly comprising the following steps of:
s1, polishing, namely polishing the welding end faces of a plurality of pipe fittings to be welded;
s2, processing the welding surface material to ensure that the wetting tension of the surface of the material is not less than 36 mN/m;
s3, press fitting, namely arranging the plurality of pipe bodies in sequence and fixing the pipe bodies to ensure that the corrugated pipe and the casting do not fall off and no inward turning and gaps exist in the corrugated pipe;
s4, shaping, namely shaping the tube bodies after crimping is completed, aligning the adjacent tube bodies, and adjusting the flatness to a proper position;
s5, welding, namely, welding by using a laser welding machine to ensure that the welding surface is continuous and complete;
s6, detecting air tightness, namely detecting the air tightness of the welded exhaust manifold;
s7, detecting flatness to ensure that the integral flatness of the welded exhaust manifold is proper;
s8, detecting hole positions, namely detecting the hole positions on the surface of the exhaust manifold after welding;
s9, detecting the appearance, and detecting whether the paint is scratched or not and whether the paint is complete or not;
and S10, packaging and warehousing, performing rust prevention treatment, and correctly pasting a mark.
2. The diesel exhaust manifold welding process according to claim 1, wherein: in S2, the material surface wetting tension was tested using a dyne pen.
3. The diesel exhaust manifold welding process according to claim 1, wherein: at S3, the plurality of pipe bodies are press-fitted and fixed using an air cylinder having an air pressure of 0.6MPA ± 0.1 MPA.
4. The diesel exhaust manifold welding process according to claim 1, wherein: the power of the laser welding machine is 500-800W, and the rotating speed is 20-40 r/min.
5. The diesel exhaust manifold welding process according to claim 1, wherein: and the surface of the welding seam in the S5 is silvery white, the fusion width of the welding surface is less than 1.5mm, and the fusion depth is more than 1 mm.
6. The diesel exhaust manifold welding process according to claim 1, wherein: in S6, the exhaust manifold is maintained at an air pressure of 0.5MPA ± 0.05MPA for a certain period of time, and after the air outlet is blocked, no small leakage occurs inside.
7. The diesel exhaust manifold welding process according to claim 1, wherein: in S7, the range of flatness is less than 0.1.
CN202110126993.7A 2021-01-29 2021-01-29 Diesel engine exhaust manifold welding process Active CN113441907B (en)

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Application Number Priority Date Filing Date Title
CN202110126993.7A CN113441907B (en) 2021-01-29 2021-01-29 Diesel engine exhaust manifold welding process

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Application Number Priority Date Filing Date Title
CN202110126993.7A CN113441907B (en) 2021-01-29 2021-01-29 Diesel engine exhaust manifold welding process

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CN113441907B CN113441907B (en) 2022-07-19

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Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1315634A (en) * 1970-07-18 1973-05-02 Daimler Benz Ag Exhaust manifolds for internal combustion engines
DE2425121A1 (en) * 1973-05-23 1974-12-12 Citroen Sa CONNECTING DEVICE FOR LINES
US5784881A (en) * 1996-01-11 1998-07-28 Hitachi Metals, Ltd. Multi-part exhaust manifold assembly with welded connections
JP2002285837A (en) * 2001-03-28 2002-10-03 Calsonic Kansei Corp End part connection structure of double pipe exhaust manifold and method therefor
CN103644793A (en) * 2013-11-13 2014-03-19 无锡麦铁精密机械制造有限公司 Automobile inlet manifold detection positioning device
CN204422142U (en) * 2014-12-24 2015-06-24 江西鑫田车业有限公司 A kind of robotization air-tightness detection tool of inlet manifold
JP2016089754A (en) * 2014-11-06 2016-05-23 ダイムラー・アクチェンゲゼルシャフトDaimler AG Exhaust manifold for internal combustion engine
CN106150648A (en) * 2016-08-30 2016-11-23 潍柴动力股份有限公司 A kind of electromotor and exhaust manifold thereof
CN205990953U (en) * 2016-08-16 2017-03-01 潍柴动力股份有限公司 A kind of exhaust manifold sealing structure
CN207180952U (en) * 2017-09-15 2018-04-03 芜湖中瑞模具有限公司 Motor intake manifold clamp for detecting air tightness
CN207960749U (en) * 2018-01-11 2018-10-12 东风商用车有限公司 A kind of multisection type diesel engine exhaust manifold connection structure
CN209551210U (en) * 2018-12-03 2019-10-29 江苏文灿压铸有限公司 A kind of clamp for machining of inlet manifold
CN112207471A (en) * 2020-09-28 2021-01-12 苏州市环宇汽车配件有限公司 Welding device for corrugated pipe of exhaust manifold of diesel engine

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1315634A (en) * 1970-07-18 1973-05-02 Daimler Benz Ag Exhaust manifolds for internal combustion engines
DE2425121A1 (en) * 1973-05-23 1974-12-12 Citroen Sa CONNECTING DEVICE FOR LINES
US5784881A (en) * 1996-01-11 1998-07-28 Hitachi Metals, Ltd. Multi-part exhaust manifold assembly with welded connections
JP2002285837A (en) * 2001-03-28 2002-10-03 Calsonic Kansei Corp End part connection structure of double pipe exhaust manifold and method therefor
CN103644793A (en) * 2013-11-13 2014-03-19 无锡麦铁精密机械制造有限公司 Automobile inlet manifold detection positioning device
JP2016089754A (en) * 2014-11-06 2016-05-23 ダイムラー・アクチェンゲゼルシャフトDaimler AG Exhaust manifold for internal combustion engine
CN204422142U (en) * 2014-12-24 2015-06-24 江西鑫田车业有限公司 A kind of robotization air-tightness detection tool of inlet manifold
CN205990953U (en) * 2016-08-16 2017-03-01 潍柴动力股份有限公司 A kind of exhaust manifold sealing structure
CN106150648A (en) * 2016-08-30 2016-11-23 潍柴动力股份有限公司 A kind of electromotor and exhaust manifold thereof
CN207180952U (en) * 2017-09-15 2018-04-03 芜湖中瑞模具有限公司 Motor intake manifold clamp for detecting air tightness
CN207960749U (en) * 2018-01-11 2018-10-12 东风商用车有限公司 A kind of multisection type diesel engine exhaust manifold connection structure
CN209551210U (en) * 2018-12-03 2019-10-29 江苏文灿压铸有限公司 A kind of clamp for machining of inlet manifold
CN112207471A (en) * 2020-09-28 2021-01-12 苏州市环宇汽车配件有限公司 Welding device for corrugated pipe of exhaust manifold of diesel engine

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