What is the bus welding line?
The welding of the large bus body is a crucial step in the production process, and the quality of body welding plays a significant role in determining the overall quality of large buses. The large bus body consists of various components such as the bottom skeleton, left/right peripheral skeleton, front/back peripheral skeleton, and top peripheral skeleton. These six major skeletal pieces are welded together to form a sturdy framework for the bus body.
The process flow is as follows: prefabrication of six-piece skeleton → group welding of body hexahedron → supplementary welding → welding of all kinds of small parts → grinding of weld seams, skeleton correction → skeleton pre-treatment as a whole → (welding of the inner skin → pre-treatment of the inner skin →) welding of the left/right side of the skin → welding of the front/rear perimeter of the skin → researching and installing all kinds of door parts → sent to the painting workshop for the body top coating.
An automotive welding line is a crucial part of the automotive manufacturing process and is mainly used to join the various metal parts of an automobile together by welding to form the body structure.
Workpiece Preparation: Including material preparation, cleaning, cutting, etc., to ensure that the welding surface is clean and free of grease.
Assembly and Positioning: Use fixtures to position the workpiece accurately to ensure the accuracy of the welding position.
Welding process: Welding according to preset process parameters, including current, voltage, time, pressure, and other parameters.
Welding Inspection: Welding quality is inspected by means of visual inspection, ultrasonic inspection, and X-ray inspection.
Post-processing: including removal of welding slag, grinding, painting, etc. to enhance the surface quality and corrosion resistance of the welded parts.
The passenger car welding process flow includes a series of steps to ensure the body structure's strength, stability, and safety. The following is the detailed passenger car welding process flow:
1. Workpiece pre-treatment
Cleaning: Remove oil, oxidized layer, etc. on the surface of the workpiece to ensure that the welding surface is clean.
Grinding: Grind the welding parts to improve the welding quality.
2. Assembly and Positioning
Preliminary assembly: according to the design drawings of the components for the initial assembly.
Positioning and fixing: Use special jigs and fixtures to fix the workpiece in the correct position to ensure the precision of welding.
3. Welding process
Spot Welding: For body frames, doors, and other parts, spot welding is usually used, using electrodes to press the metal plate and energize, it so that the contact surface melts and cools to form a welded joint.
Arc welding: For thick plates or load-bearing parts, arc welding is adopted, in which the metal is melted and cooled to form a welded seam by arc heating.
Laser welding: For high precision and complex shape parts, laser welding is adopted, which has the advantages of high speed and high precision.
4. Welding process control
Parameter Setting: Set the welding parameters according to the process requirements, such as current, voltage, welding speed, and so on.
Online monitoring: Use sensors and monitoring systems to monitor the parameter changes in the welding process in real-time to ensure stable welding quality.
5. Welding Inspection
Visual inspection: Conduct a preliminary visual inspection of the weld to find obvious welding defects, such as uneven welds, cracks, etc.
Non-destructive testing: Adopt non-destructive testing techniques such as ultrasonic testing, X-ray testing, etc., to carry out in-depth inspection of the weld seam to ensure the welding quality.
6. Post-welding treatment
Welding slag removal: Remove the welding slag on the surface of the weld seam to ensure that the surface of the weld seam is smooth.
Grinding: Grind the weld to eliminate welding spatter and burrs.
Painting: Anti-rust treatment and painting of the welded parts to improve corrosion resistance.
7. Assembly and commissioning
General assembly: general assembly of the welded parts to form a complete bus body structure.
Debugging and checking: Carry out debugging and checking on the assembled body to ensure that all parts are well coordinated and function properly.
8. Quality Control
Process control: Strict process control is implemented throughout the welding process to ensure that each step meets the process requirements.
Finished product inspection: carry out comprehensive finished product inspection on the finished welded body to ensure the quality of the final product.
9. Record and Improvement
Process Record: Record the parameters and test results of the welding process to form a complete process file.
Process Improvement: According to the test results and feedback information, continuously improve the welding process, improve the welding quality and production efficiency.
Through these steps, the bus welding process ensures the strength and safety of the body structure and meets the design and use requirements.
Bus Skin Roller Press Equipment
Skin roll forming equipment is divided into : top and middle skin roll forming equipment, top and bus side skin roll forming equipment, and side enclosure skin roll forming equipment.
Passenger bus body skin roll forming process is the use of roll forming equipment will skin roll forming, through the roll pressure to make the skin reach the cross-section requirements of the drawings of the special equipment, and then after the roll forming of the skin welded to the body skeleton.
The main advantage is that the welded parts of the skin and the skeleton are not exposed, and the deformation of the welded parts does not affect the flatness of the outer skin. The width direction can be adjusted numerically. The skin roll forming process effectively improves the surface quality of the body and reduces the amount of scraping, reducing production costs, while the body can be achieved at the same time the lower edge of the skin of the body of the large curvature of the modeling needs, the process is one of the current domestic and foreign passenger bus technology and process development trend.
Bus Six-side Body Skeleton CNC Assembly Equipment
The six-piece skeleton group welding is the key process in the production of bus body welding, where multiple structural components are welded together to form a sturdy and functional framework for the bus body. This equipment consists of a body frame positioning mechanism, left/right side frame clamping mechanism, front/rear periphery positioning mechanism, top periphery lifting device, and power system. The body welding assembly generally has a side enclosure production line, frame production line, main line, etc. The production line is equipped with welding equipment as well as tools, fixtures for positioning and clamping, a quality inspection and control system, safety protection devices, and a transport system. Bus body skeleton assembly is a common production process used by bus manufacturers in mass production, and it is also the main way to improve the efficiency of the production line. The six-piece skeleton group welding equipment meets the two production processes of chassis and shell body and can be used for on-line production (when using the on-line production process with chassis, it needs to be equipped with additional chassis lifting and positioning devices). This process requires precision, adherence to welding standards, and rigorous quality control to achieve optimal results.
Bus Skin Tensioning Equipment
Bus skinning equipment is specialized equipment used in the bus manufacturing process. In bus manufacturing, the skin usually refers to the outer covering plate or shell of the vehicle, which is used to cover and protect the internal structure and components of the vehicle. Bus skin is an important platform to show the quality, appearance, and modeling of the outer surface of the body, its surface flatness determines the quality of the bus and the effect of body modeling, high-quality skin can effectively improve the performance of the body sealing, noise reduction, and strength, and can ensure that the welded area is flat and wrinkle-free to enhance the quality of welding. Skin production is a key production process in bus manufacturing.
Skin-pulling process production mainly has a cold-pulling method and a hot-pulling method. Cold tensioning refers to the bus skin at room temperature through the role of mechanical force, so that the bus skin achieves the process parameters, and then through riveting, welding, or resistance spot welding will be fixed with the skin and the skeleton of the operation; hot tensioning the use of the skin of the principle of thermal expansion and contraction, the skin is heated to elongate the skin, the heat will be fixed at both ends of the skin of the bus, the natural cooling of the skin contraction and tensioning to achieve the bus skin of the flatness. Flatness.
Automatic Spot Welding of Bus Skins
In the bus manufacturing process, after the skeleton and skin are positioned on the equipment and the skin is tightened by the hydraulic tensioner, the skeleton is transferred to the spot welding station by the skeleton transfer vehicle, and the roof skin and the skeleton need to be welded together by means of resistance pre-spot welding.
Prior to automatic pre-spot welding of the skins, it is first necessary to ensure that the positioning of the skins is accurate and stable. This involves the use of special fixtures or positioning devices to secure the skin to the welding fixture to prevent shifting or distortion during the welding process. By automatically welding the top skin in the processes of tensioning, spot-fixing, automatic spot-welding, supplementary welding support, opening, flanging, grinding, etc., the method effectively improves the firmness and reliability of the weld quality of the top skin of the bus, reduces the risk of de-welding of the skin, and improves the production efficiency and reduces the labor intensity.
Bus Welding Power Line
The steel structure and power control system adopt columnar ground structure, the columns are welded with high-quality thick-walled square tubes to ensure support strength; the upper net frame is welded with high-quality square tubes, and the net frame is laid with secondary pipelines, illumination, fans, lamps, etc. according to the needs to satisfy the needs of compressed air, carbon dioxide, and electrical equipment in the production.
The ground column power grid adopts the structure of ground columns. The ground columns are fixed on the ground by ground-embedded plates or chemical anchor bolts. This structure is mainly for workshops where the steel structure of the factory roof does not have a preset hanging point. It will occupy a part of the ground space and have a certain impact on logistics transportation. The steel structure consists of two parts: the column and the upper grid. The column is equipped with a power box, air source point, fan, etc. The upper grid is equipped with components such as a compressed air main pipeline, cable tray, lighting fixtures, spiral electric pipe, and spiral air pipe. The power box on each column is equipped with a power switch, lighting switch, fan switch, etc., which can realize partition control and meet the production line's needs for power supply (AC380V, AC220V), air source (compressed air), lighting and working environment improvement (fan).
Bus Welding Fume Collection and Treatment Line
Fume is a very complex substance, welding smoke is very harmful to the human body, and toxic substances are seriously devouring human health. In order to protect the health of the staff and in line with the relevant occupational disease protection norms, it is necessary to collect the welding fume and dust generated in the welding area of this grinding station. The Bus Welding Fume Collection and Treatment Line is a crucial component of bus manufacturing facilities to ensure that welding fumes are effectively captured, filtered, and treated to protect worker health, comply with regulations, and minimize environmental impact.
| No. |
Item |
Parameter |
| 1 |
Dust collector model |
C-4-78 |
| 2 |
Handling air volume |
49200m³/h |
| 3 |
Quantity |
1 unit |
| 4 |
Number of filter cartridges / pcs |
4 pcs |
| 5 |
Filtering wind speed |
0.5m/min |
| 6 |
Equipment resistance Pa |
<1200 |
| 7 |
Equipment specification mm |
7000*14000*4500 |
| 8 |
Optional fan model |
Select fan model |
| 9 |
Optional fan parameters |
Fan Model: TFH-Z
Air volume: 50000 m³/h
Full pressure: 4500 Pa
Rotating speed: 1650 r/min
Motor power: 90kw |
1. High degree of automation: Bus welding line usually adopts automation equipment and robotics technology to achieve a highly automated production process. This automation not only improves production efficiency, but also reduces errors and labor intensity of human operation, and improves the stability and reliability of the production line.
2. High production efficiency: The automated production process enables the Bus welding line to complete welding work at a higher speed and shorter cycle, thereby greatly improving production efficiency. Compared with manual welding, automated production lines can complete mass production more quickly.
3. Accurate quality control: Automated equipment can accurately control welding parameters and welding quality during the welding process to ensure the stability and consistency of the quality of each welding point. This precise quality control helps to reduce the rate of defective products and improve the overall quality level of the product.
4. Cost saving: Despite the large initial investment, in the long run, the bus welding line can reduce the production cost per unit product. Through automated production, labor costs and scrap rates are reduced, and equipment loss and maintenance costs caused by human operation are also reduced.
5. Flexibility and adaptability: The design of the Bus welding line can be customized and adjusted according to production needs to meet the welding needs of products of different types and specifications. This flexibility enables the production line to adapt to market changes and new product needs quickly.
China's Vehicle Industry specializes in designing & building automotive fixtures & welding automation systems, it's skilled at all kinds of precision machining works: inspection equipment, welding, and assembly. Includes Whole Vehicle Cubing, Arc Welding Fixture, Spot Welding Fixture, Spot Welding Workstation, Door Fixture, Carling Fixture, Roof Fixture, and Bumper Fixture.
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Bus Welding lines adopt the method of combining an iron frame with an export wooden packaging box to enhance packaging protection for parts susceptible to friction. Apply phosphating electrophoresis anticorrosion treatment to all six vehicle body skeletons and steel components.
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