JP4740463B2 - Outer shell unit and welding method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an improvement in an outer shell unit for suspending a vehicle and a welding method thereof.
[0002]
[Prior art]
The strut type shock absorber functions as a structural member for positioning the wheel as a part of the suspension member in addition to the original damping force generating function.
[0003]
FIGS. 8 and 9 show a conventional method of welding the spring guide 6 and the knuckle bracket 7 to the cylindrical outer shell 3 as the outer shell unit 10 constituting the strut type shock absorber 1.
[0004]
As shown in FIGS. 8A and 8B, when the upper end 7 e of the knuckle bracket 7 is welded to the outer shell 3, the outer shell 3 is rotated around the central axis O arranged substantially vertically. At the same time, the torch 61 of the arc welder is welded by a so-called downward welding method in which the torch 61 is directed downward to the corner between the outer peripheral surface 3a of the outer shell 3 and the upper end 7e of the knuckle bracket 7. The shape of this welded part is an overlapped shape with a part of fillet.
[0005]
As shown in FIGS. 9A and 9B, when welding the lower end 7 f of the knuckle bracket 7 and the lower cap 17 over the entire circumference of the outer shell 3, the outer shell 3 should be placed against the horizontal plane. While rotating around the central axis O inclined by 60 °, the torch 61 of the arc welder is directed downward at the corner between the lower end 3b of the outer shell 3 and the lower end 7f of the knuckle bracket 7 and the lower cap 17, so-called downward Welded by welding method. The shape of this weld is a special shape with some fillet, overlap, and flare features, requiring advanced welding techniques and long welding times.
[0006]
As shown in FIGS. 9B and 9C, the lower end 6a of the spring guide 6 is welded to the outer peripheral surface 3a of the outer shell 3 at three locations. The shape of this weld is a lap shape.
[0007]
[Problems to be solved by the invention]
However, in such a conventional outer shell unit welding method, a high level of welding technology is required to weld the knuckle bracket 7 and the spring guide 6 to the outer shell 3 in the welding line, and the welding time becomes longer. There was a problem.
[0008]
The present invention has been made in view of the above problems, and an object thereof is to provide a method for welding an outer shell unit with high productivity.
[0009]
[Means for Solving the Problems]
1st invention is applied to the welding method of an outer shell unit provided with the cylindrical outer shell which incorporates a damping force generation mechanism, and the suspension components welded to an outer shell.
[0010]
Then, the arc welder's torch is placed close to the welded part between the side of the outer shell and the suspended part, and the outer shell unit is rotated so that the welded part facing the torch rises, and the suspended part is welded to the outer shell. Whether the horizontal plane including the central axis O of the outer shell is the horizontal reference plane X, the point where the extension line of the torch intersects the outer shell unit is the welding point W, and the welding point W is placed on the horizontal reference plane X. Or offset so as to be positioned above the horizontal reference plane X by a length Lx, and a vertical plane including the center axis O of the outer shell is defined as a vertical reference plane Y, and the welding point W is set to a length Ly from the vertical reference plane Y. The welding point W is arranged so that the vertical offset amount Lx is smaller than the horizontal offset amount Ly, and the torch is tilted upward with respect to the horizontal reference plane X. The angle of the torch angle [theta] x, and characterized by arc force while suppressing the sputtering drop amount is rapidly increased by setting the torch angle [theta] x in the range of 0 to 30 ° is configured to act to push the molten metal To do.
[0014]
The second invention is applied to an outer shell unit including a cylindrical outer shell having a damping force generation mechanism and a suspension part welded to the outer shell.
[0015]
And the torch of the arc welder is disposed close to the welded part between the side part of the outer shell and the suspended part, and the outer shell unit is rotated so that the welded part facing the torch rises, so that the suspended part is attached to the outer shell. The horizontal plane including the center axis O of the outer shell is the horizontal reference plane X, the point where the extension line of the torch intersects the outer shell unit is the welding point W, and the welding point W is placed on the horizontal reference plane X Or offset so as to be positioned above the horizontal reference plane X by a length Lx, the vertical plane including the outer shell center axis O is defined as the vertical reference plane Y, and the welding point W is longer than the vertical reference plane Y. The welding point W is arranged so that the vertical offset amount Lx is smaller than the horizontal offset amount Ly, and the torch is aligned with the horizontal reference plane. Arrangement an angle inclined upwardly and torch angle [theta] x, arc force while suppressing the sputtering drop amount is rapidly increased by setting the torch angle [theta] x in the range of 0 to 30 ° acts to press the molten metal against It was characterized by being formed by the welding method described above .
[0016]
Operation and effect of the invention
According to the first and second inventions, by balancing the welding speed and the dripping speed of the molten metal, a welding speed exceeding the capability of a welding machine obtained by a conventional downward welding method can be obtained, and the outer shell unit. Increase productivity.
[0017]
And by arrange | positioning the welding point W on the horizontal reference plane X or above the horizontal reference plane X, since a gravity works in the direction which adheres a molten metal to an outer shell, a favorable bead shape is obtained.
[0018]
And by making the offset amount Lx small, the speed at which the molten metal drips is increased, the welding speed can be increased, and the width of the bead can be increased.
[0019]
And by setting torch angle (theta) x in the range of 0-30 degrees, while suppressing spatter fall amount, insufficient penetration and poor fusion can be suppressed effectively.
[0020]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.
[0021]
As shown in FIG. 1, a strut type shock absorber 1 includes a rod 2 connected to the vehicle body side, an outer shell 3 connected to a knuckle (not shown) that supports an axle, and a rod 2 attached to the outer shell 3. A rod guide 9 that is slidably supported, an inner tube 4 that defines an oil reservoir chamber 18 partially filled with gas inside the outer shell 3, and an inner tube 4 connected to the tip of the rod 2 The piston 5 is partitioned into an upper oil chamber 16 and a lower oil chamber 19, a piston valve 11 that generates a damping force in the expansion stroke, and a base valve 12 that generates a damping force in the contraction stroke. It constitutes a damping force generation mechanism that attenuates the vibration of the.
[0022]
In the extension stroke in which the rod 2 moves upward, the upper oil chamber 16 is pressurized, the hydraulic oil flows into the lower oil chamber 19 through the piston valve 11, and a damping force is generated. At this time, hydraulic oil corresponding to the retraction of the rod 2 opens the base valve 12 from the oil reservoir chamber 18 and flows into the lower oil chamber 19 with almost no resistance.
[0023]
In the contraction stroke in which the rod 2 moves downward, the hydraulic oil in the lower oil chamber 19 opens the piston valve 11 and flows into the upper oil chamber 16 with almost no resistance. At this time, hydraulic oil corresponding to the amount of penetration of the rod 2 flows from the lower oil chamber 19 through the base valve 12 into the oil reservoir chamber 18 and a damping force is generated.
[0024]
The strut-type shock absorber 1 includes a spring guide 6 that receives a lower end of a suspension spring as a suspension part, and a knuckle bracket 7 to which a knuckle is connected, and performs a function of positioning a wheel as a part of a suspension member.
[0025]
An annular stepped portion 35 is formed in the middle of the outer shell 3 by bulging. The spring guide 6 is pressed into and fixed to the stepped portion 35. Thereby, it is not necessary to weld the spring guide 6 to the outer peripheral surface 3 a of the outer shell 3.
[0026]
The spring guide 6 has a fitting portion 6a that fits into the outer shell 3, and a seat portion 6b that receives the lower end of the suspension spring, and is integrally formed by pressing.
[0027]
The outer shell 3 has a cylindrical main body 30 and a bottom 31 that closes the lower end of the main body 30. The bottom 31 of the outer shell 3 is integrally formed with the main body 30 of the outer shell 3 by plastic processing called closing processing.
[0028]
Since the bottom 31 of the outer shell 3 is sealed by the closing process, there is no need to seal the bottom 31 by welding, and high-speed welding can be performed by a vertical downward welding method as will be described later.
[0029]
The bottom 31 is inclined at an angle α with respect to a plane orthogonal to the central axis O, and the angle α is set to 30 ° (π / 6 rad), for example. A convex portion 34 that protrudes from the bottom 31 to the inside of the outer periphery of the outer shell 3 is formed by a closing process, and the bottom 31 is reliably closed.
[0030]
On the other hand, the knuckle bracket 7 includes a fitting portion 7a that fits into the outer shell 3, a pair of flange portions 7b that sandwich the knuckle, and a cut and raised hose bracket 7g. Bolt holes 7c and 7d are formed in each flange portion 7b, and the knuckle is fastened to the knuckle bracket 7 via two bolts that pass through the bolt holes 7c and 7d. Each bolt hole 7c, 7d is drilled after the knuckle bracket 7 is fixed to the outer shell 3 by welding to ensure dimensional accuracy. The knuckle bracket 7 is a single plate type in which no reinforcing member is provided between the flange portions 7b.
[0031]
The knuckle bracket 7 is pressed into the outer shell 3 and then fixed by welding. The outer shell 3 has a lower end that is narrowed by a closing process so that the outer shell 3 can be smoothly press-fitted.
[0032]
The single plate type knuckle bracket 7 has upper and lower ends 7e and 7f fixed to the outer shell 3 by welds 21 and 22, respectively.
[0033]
As shown in FIGS. 2A, 2 </ b> B, and 2 </ b> C, when forming the upper bracket welded portion 21, the torch 61 of the arc welder has an outer peripheral surface 3 a of the outer shell 3 and a knuckle bracket 7. It is directed to the corner between the upper end 7e, that is, the welding site of the present invention, and is welded by the vertical downward welding method. In the vertical downward welding method, the outer shell 3 is rotated around the central axis O arranged substantially horizontally, and the torch 61 of the arc welder is directed to the side portion of the outer shell 3. The direction of rotation of the outer shell 3 is set so that the portion of the outer shell 3 facing the torch 61 rises as shown by the arrow in FIG.
[0034]
A horizontal plane including the central axis O of the outer shell 3 is defined as a horizontal reference plane X. A vertical plane including the central axis O of the outer shell 3 is defined as a vertical reference plane Y. A point where the extension line of the torch 61 of the arc welder intersects the outer peripheral surface 3a of the outer shell 3 is defined as a welding point W.
[0035]
The welding point W is arranged on the horizontal reference plane X or offset so as to be positioned above the horizontal reference plane X by a predetermined length Lx. In the present embodiment, the outer diameter of the outer shell 3 is about 45 mm, and the offset amount Lx is set in the range of 0 to 10 mm.
[0036]
The welding point W is offset from the vertical reference plane Y by a predetermined length Ly. As a condition of the vertical downward welding method, the welding point W is arranged so that the vertical offset amount Lx is smaller than the horizontal offset amount Ly.
[0037]
The torch angle θx at which the torch 61 is inclined upward with respect to the horizontal reference plane X is set to be smaller than the torch angle θy with respect to the vertical reference plane Y. In the present embodiment, the torch angle θx is set in a range of 0 to 30 ° (0 to π / 6 rad).
[0038]
As shown in FIGS. 3A and 3B, when forming the lower bracket weld 21, the torch 61 of the arc welder is located between the lower end 3 b of the outer shell 3 and the lower end 7 f of the knuckle bracket 7. It is directed to the corner and welded by vertical down welding. In the vertical downward welding method, the outer shell 3 is rotated around the central axis O arranged substantially horizontally. The rotation direction of the outer shell 3 is set so that the part facing the torch 61 of the outer shell 3 rises as indicated by an arrow in FIG.
[0039]
The welding point W is arranged on the horizontal reference plane X or offset so as to be positioned above the horizontal reference plane X by a predetermined length Lx. In the present embodiment, the outer diameter of the outer shell 3 is about 45 mm, and the offset amount Lx is set in the range of 0 to 10 mm.
[0040]
The torch angle θx at which the torch 61 is inclined upward with respect to the horizontal reference plane X is set in the range of 0 to 15 ° (0 to π / 12 rad).
[0041]
In the vertical downward welding method, the torch angle θx and the offset amount Lx are arbitrarily set together with the current and voltage of the torch 61 and the rotational speed of the outer shell 3 according to the outer diameter of the outer shell 3, and the welding speed and molten metal By balancing the sagging speed, a welding speed higher than the capability of the welding machine obtained by the conventionally used downward welding method can be obtained.
[0042]
FIG. 4 shows the relationship between the torch angle θx and the amount of spatter drop, and an arc force acts on the molten metal as indicated by an arrow in the figure, and the molten metal is pushed forward. For this reason, if the torch angle θx is set larger than 30 °, the amount of spatter drop increases rapidly.
[0043]
When the torch angle θx is increased, the bead width is increased and the appearance is improved. However, insufficient melting and poor fusion are likely to occur, and a concave bead shape is likely to cause insufficient strength. This lack of penetration occurs because the molten metal precedes and an arc is generated on the molten metal.
[0044]
Therefore, by setting the torch angle θx in the range of 0 to 30 °, it is possible to suppress the spatter drop amount and to effectively suppress the insufficient melting and poor fusion.
[0045]
When the welding point W is disposed below the horizontal reference plane X and the offset amount Lx is set to a negative value, the bead shape is deteriorated because gravity acts in the direction of separating the molten metal from the outer shell 3. By arranging the welding point W above the horizontal reference plane X, a good bead shape can be obtained.
[0046]
FIG. 5 shows a general relationship between the offset amounts Lx and Ly of the welding point W and the bead shape. The smaller the offset amount Lx, the higher the speed at which the molten metal droops, and the bead width increases. Conversely, as the offset amount Lx increases, the speed at which the molten metal droops decreases, and the bead width decreases. At this time, if the rotational speed of the outer shell 3 is increased, the balance with the speed at which the molten metal drips is lost, resulting in poor welding.
[0047]
When the knuckle bracket 7 is welded to the outer shell 3, the larger the outer diameter of the outer shell 3, the larger the offset amount Lx of the welding point W with respect to the horizontal reference plane X is set. In the present embodiment, the outer diameter of the outer shell 3 is about 45 mm, and by setting the offset amount Lx in the range of 0 to 10 mm, the molten metal drooping speed becomes appropriate and a good bead shape is obtained. It is done.
[0048]
As another embodiment, as shown in FIGS. 6A and 6B, the knuckle bracket 7 is a two-plate type in which a reinforcing member 15 is provided between the flange portions 7b and has a cylindrical shape. A thing may be used. The reinforcing member 15 is fixed between the flange portions 7 b and increases the rigidity of the knuckle bracket 7.
[0049]
After the knuckle bracket 7 is press-fitted into the outer shell 3, only the lower end 7f is fixed to the outer shell 3 by welding. It is not necessary to fix the upper end 7e of the knuckle bracket 7 to the outer shell 3 by welding.
[0050]
As shown in FIGS. 6 (a) and 6 (b), the torch 61 of the arc welder is provided at the corner between the lower end 3b of the outer shell 3 and the lower end 7f of the knuckle bracket 7, that is, at the welding site of the present invention. Directed and welded by vertical down welding. In the vertical downward welding method, the outer shell 3 is rotated around the central axis O arranged substantially horizontally. The direction of rotation of the outer shell 3 is set so that the portion of the outer shell 3 facing the torch 61 rises as shown by the arrow in FIG.
[0051]
The welding point W is arranged on the horizontal reference plane X or offset so as to be positioned above the horizontal reference plane X by a predetermined length Lx. In the present embodiment, the outer diameter of the outer shell 3 is about 45 mm, and the offset amount Lx is set in the range of 0 to 10 mm.
[0052]
The torch angle θx at which the torch 61 is inclined upward with respect to the horizontal reference plane X is set in the range of 0 to 30 ° (0 to π / 6 rad).
[0053]
In this case, by using the cylindrical two-plate knuckle bracket 7, it is not necessary to fix the upper end 7e of the knuckle bracket 7 to the outer shell 3 by welding, and the working time required for welding can be shortened.
[0054]
As another embodiment, as shown in FIGS. 7A, 7B, and 7C, the stepped portion 35 formed by bulging on the outer shell 3 is abolished, and the spring guide 6 is You may adhere to the outer peripheral surface 3a of the shell 3 by welding.
[0055]
After the spring guide 6 is press-fitted into the outer shell 3, its lower end 6c is fixed to the outer peripheral surface 3a of the outer shell 3 by welding.
[0056]
For welding between the spring guide 6 and the outer shell 3, the torch 61 of the arc welder is directed to the corner between the lower end 6c of the spring guide 6 and the outer peripheral surface 3a of the outer shell 3, and the outer shell 3 is disposed substantially horizontally. Rotated around the center axis O made. The direction of rotation of the outer shell 3 is set so that the portion of the outer shell 3 facing the torch 61 rises as indicated by the arrow in FIG.
[0057]
The welding point W is arranged on the horizontal reference plane X or offset so as to be positioned above the horizontal reference plane X by a predetermined length Lx. In the present embodiment, the outer diameter of the outer shell 3 is about 45 mm, and the offset amount Lx is set in the range of 0 to 10 mm.
[0058]
The torch angle θx at which the torch 61 is inclined upward with respect to the horizontal reference plane X is set in the range of 0 to 15 ° (0 to π / 12 rad).
[0059]
The present invention is not limited to the above-described embodiment, and it is obvious that various modifications can be made within the scope of the technical idea.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a shock absorber showing an embodiment of the present invention.
FIG. 2 is a view showing a method of high-speed welding the upper end of the knuckle bracket to the outer shell.
FIG. 3 is a view showing a method for high-speed welding the lower end of the knuckle bracket to the outer shell.
FIG. 4 is also a diagram showing the relationship between the torch angle θx and the amount of spatter drop.
FIG. 5 is a view showing a relationship between offset amounts Lx and Ly of a welding point W and a bead shape.
FIG. 6 is a view showing a method of high-speed welding the lower end of the knuckle bracket to the outer shell in another embodiment.
FIG. 7 is a view showing a method for performing high-speed welding of the lower end of a knuckle bracket and a spring guide to an outer shell in still another embodiment.
FIG. 8 is a view showing a method of high-speed welding the upper end of a knuckle bracket to an outer shell in a conventional example.
FIG. 9 is a view showing a method of high-speed welding the lower end of the knuckle bracket and the spring guide to the outer shell.
[Explanation of symbols]
1 Shock absorber 3 Outer shell 6 Spring guide (suspended parts)
7 Knuckle bracket (suspension parts)
10 Outer shell unit 61 Torch

Claims (2)

In a welding method of an outer shell unit comprising a cylindrical outer shell having a damping force generation mechanism and a suspension part welded to the outer shell, a torch of an arc welder is connected to a side portion of the outer shell and the suspension part. The outer shell unit is rotated so that the welded portion facing the torch rises, the suspension part is welded to the outer shell, and a horizontal axis including the central axis O of the outer shell is disposed. A horizontal plane is a horizontal reference plane X, a point where the extension line of the torch intersects the outer shell unit is a welding point W, and the welding point W is arranged on the horizontal reference plane X or is longer than the horizontal reference plane X. The vertical plane including the central axis O of the outer shell is set as the vertical reference plane Y, and the welding point W is The welding point W is arranged so as to be offset from the straight reference plane Y by the length Ly, and the vertical offset amount Lx is smaller than the horizontal offset amount Ly, and the torch is located above the horizontal reference plane X. The inclination angle is set to the torch angle θx, and the torch angle θx is set in the range of 0 to 30 °, so that the arc force works to push the molten metal while suppressing the spatter drop amount from increasing rapidly. A method of welding an outer shell unit, which is characterized. In an outer shell unit including a cylindrical outer shell having a damping force generation mechanism and a suspension part welded to the outer shell, a torch of an arc welder is welded between a side portion of the outer shell and the suspension part. The suspension part is welded to the outer shell by rotating the outer shell unit so that the welded part facing the torch rises, and the central axis O of the outer shell is A horizontal plane including the horizontal reference plane X, a point where the extension line of the torch intersects with the outer shell unit is a welding point W, and the welding point W is disposed on the horizontal reference plane X or from the horizontal reference plane X The vertical plane including the center axis O of the outer shell is offset so as to be positioned upward by the length Lx. The welding point W is offset by a length Ly from the vertical reference plane Y, and the welding point W is arranged so that the vertical offset amount Lx is smaller than the horizontal offset amount Ly. An angle inclined upward with respect to X is a torch angle θx, and by setting the torch angle θx in a range of 0 to 30 °, an arc force pushes the molten metal while suppressing a rapid increase in spatter drop. An outer shell unit formed by a welding method having a working configuration .

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