摘    要

課題的目的是通過對長安之星II汽車中門焊接生產(chǎn)線現(xiàn)行的工藝及工裝夾具進(jìn)行分析和研究。分析在整個(gè)中門生產(chǎn)的工藝流程中，保證車門焊接質(zhì)量、效率的焊接設(shè)備、工裝夾具和工藝參數(shù)。當(dāng)這些工藝參數(shù)偏離工廠現(xiàn)行工藝的規(guī)定值時(shí)車門的焊接質(zhì)量會出現(xiàn)何種缺陷，并提出解決這些缺陷的方案、措施。最終使焊接工藝得到優(yōu)化，中門的焊接質(zhì)量得到保證。
在長安之星二代汽車中門的焊接生產(chǎn)過程中，由于電阻焊在薄板焊接方面有著其它焊接工藝難以比擬的優(yōu)勢，并且它易操作，有良好的經(jīng)濟(jì)性，焊接工藝成熟可靠，所以電阻焊承擔(dān)了長安之星II汽車車門的整個(gè)焊接過程。所以電阻焊的工藝參數(shù)是保證焊接質(zhì)量的關(guān)鍵。工藝參數(shù)包括：焊接時(shí)間、焊接電流、預(yù)壓時(shí)間、電極壓力、維持時(shí)間、休息時(shí)間。只有在這些參數(shù)在規(guī)定的范圍內(nèi)，中門最后的焊接質(zhì)量的檢測中才能合格，減少廢品率。文中對規(guī)定范圍內(nèi)的焊接參數(shù)分析、優(yōu)化，在保證中門的焊接精度的基礎(chǔ)上，提高了電阻焊焊接的可靠性，使得車門的焊接質(zhì)量得到改善，進(jìn)而提高生產(chǎn)效率，降低生產(chǎn)成本，使企業(yè)具備更強(qiáng)的競爭力。
在車門焊接流水線上，真正用于焊接操作的工作量僅占30%-40%，剩下的60%-70%為輔助和裝夾工作。因此夾具在車門焊接過程中起著重要的作用，文中先對中門焊接生產(chǎn)線的工藝布局進(jìn)行分析，重點(diǎn)對中門內(nèi)蒙皮在車門焊接過程中的定位夾緊，車門零件之間正確的裝配關(guān)系進(jìn)行了分析、研究。選取中門內(nèi)蒙皮焊接總成16個(gè)電阻焊夾具中的7號夾具，分析它的組成結(jié)構(gòu)、夾緊原理及設(shè)計(jì)過程。包括是如何保證中門在焊接總成的位置，怎樣縮短輔助裝夾工序的時(shí)間和如何確定和計(jì)算夾緊力，目的是保證組成中門各焊接零部件的裝配位置、焊接精度，平衡工位，降低非生產(chǎn)用時(shí)，最終使中門焊接質(zhì)量得到保證，使企業(yè)生產(chǎn)出優(yōu)異的產(chǎn)品。
 

關(guān)鍵詞： 電阻焊，焊接夾具，汽車車門，電阻焊機(jī)，點(diǎn)焊

ABSTRACT

The purpose is to subject the Chang'an Star II car door welding production lines in existing technology and fixture for analysis and research. Analysis of the entire production process in the door, ensure that the doors welding quality and efficiency of welding equipment, fixture and technical parameters. When these technical parameters deviate from the provisions of the existing factory at the door of the welding quality of what will appear defects, shortcomings and propose solutions to these programmes and measures. The end, the welding process has been optimized, the welding quality of the door is assured.
  Chang'an Star in the second-generation car door in the welding production process, because of resistance in the welding area plates with other welding process difficult to compare the advantages, and it easy to operate, a good economy, welding technology mature and reliable, so resistance welding Commitment to the Star II Changan Automobile door of the welding process. Therefore, the resistance welding process parameters is the key to guarantee the quality of welding. Technical parameters, including: welding, welding current, time-pressure, the electrode pressure to maintain the time, rest time. Only in these parameters in the scope of the provision, the doors of the welding quality of the final test in order to pass the waste reduction rate. Text of the provisions of the welding parameters analysis, optimization, to ensure accuracy in the door of the welding on the basis of improving the reliability of the resistance welding, making the doors of the welding quality has improved, thus increasing production efficiency, reduce production costs, Enterprises have stronger competitiveness.
  Welding on the door in the pipeline, the real welding operation for the workload of only 30 percent to 40 percent, while the remaining 60 percent supporting and 70 percent for clamping work. Therefore fixture in the process of welding the doors play an important role in the first text on the door in the process of welding production line layout analysis, the focus on the doors of the building skin in the process of welding the positioning clamp, the door between the right of assembly parts relations An analysis of research. Select the skin of the building welding assembly 16 fixture in the resistance welding fixture on the 7th, the composition of its structure, clamping principle and the design process. Including how to ensure that the doors are welded assembly in the location and how to reduce the fixture supporting processes and how to determine the time and calculated clamping force, the purpose is to ensure that all doors in the composition of welding parts of the assembly position, welding precision, the balance - To reduce non-production, in the end, the welding quality be assured that the door to enable enterprises to produce superior products.

 
Key words： Resistance welding，welding fixture，car doors，resistance welding
　　　　　　machine，Spot Welding
 

目   錄
中文摘要 Ⅰ
ABSTRACT Ⅱ
1緒論 1
1.1電阻焊的特點(diǎn)及在汽車制造中的運(yùn)用情況 1
    1.1.1電阻焊的工作原理和特點(diǎn) 1
1.1.2電阻焊在汽車制造中的應(yīng)用 1
1.2電阻點(diǎn)焊工藝 2
1.2.1電阻焊功率計(jì)算 2
1.2.2影響電阻焊質(zhì)量的工藝參數(shù) 2
    1.2.3點(diǎn)焊焊接參數(shù)的選取方法 3
1.3電阻焊工裝夾具 4
1.3.1焊接夾具在汽車制造中應(yīng)用情況 4
1.3.2焊接夾具設(shè)計(jì)要求焊接夾具的組成及結(jié)構(gòu)特點(diǎn) 5
1.3.3焊接夾具設(shè)計(jì)應(yīng)該遵循的原則 6
1.3.4焊接夾具設(shè)計(jì)要求 7
1.3.5焊裝夾具的精度控制 7
1.4本課題的意義 8
1.5本課題的主要研究內(nèi)容 9
  1.6本課題的實(shí)現(xiàn)途徑 9
2長安之星II汽車中門焊接材料的焊接性分析 10
2.1長安之星II汽車焊接板材的化學(xué)成分和性能 10
2.2板材焊接性分析 11
2.3鍍鋅鋼板的特點(diǎn)及在汽車工業(yè)中的應(yīng)用 11
2.4鍍鋅鋼板的電阻點(diǎn)焊研究現(xiàn)狀 12
 3長安之星II汽車中門焊接工藝分析、研究及優(yōu)化 13
 3.1焊接設(shè)備的分析與選用 13
 3.1.1焊機(jī) 13
 3.1.2焊鉗 14
 3.2長安之星II汽車中門現(xiàn)行焊接工藝的分析、研究 15
   3.2.1長安之星II汽車中門內(nèi)蒙皮焊接零部件 16
   3.2.2長安之星II汽車中門焊接工藝分析 17
 3.3長安之星II汽車中門焊接質(zhì)量的檢測 20
 3.4影響中門焊接質(zhì)量的主要因素 21
   3.4.1焊接電流 21
   3.4.2焊接壓力 21
   3.4.3焊接時(shí)間 21
  3.4.4焊件表面情況 21
 3.4.5電極的材質(zhì)及接觸面的形狀 22
 3.5保證焊接質(zhì)量的主要方法 22
 3.6焊接工藝優(yōu)化 23
 4長安之星II汽車中門焊接夾具在工位中的具體運(yùn)用 24
 4.1長安之星II汽車車門蒙皮焊接夾具 24
   4.2內(nèi)蒙皮夾具 26
      4.2.1夾具地板 26
      4.2.2分析夾具的選取 27
      4.2.3組成7號夾具的零部件 28
      4.2.4 7號夾具的設(shè)計(jì)流程 29
5結(jié)論 34
6致謝 35
參考文獻(xiàn) 36