Alignment of frame members in welded assemblies

A system for improving alignment in welded assemblies is provided. The system includes a support member having a surface and a projection extending from the surface. The projection may include one of a convex or a concave geometry. The system includes a positioning member provided over the support member for receiving a frame member. The positioning member may be movable over the support member, and the positioning member may include a geometry configured to engage the one of the convex or the concave geometry. The frame member may be movable from a first position relative to a center of the projection to a second position relative to the center of the projection during movement of the positioning member over the support member.

TECHNICAL FIELD

The present disclosure relates generally to improving alignment in welded assemblies and, more particularly, to improving alignment of frame members in welded assemblies.

BACKGROUND

Frame members may be welded to form assemblies for use in various structures, such as vehicle frames, machine frames, building frames, and/or the like. Multiple frame members may be welded to a same support member, which forms a node or a hub of a welded assembly. In general, a tubular frame member is inserted into a counterbored section of a support member and welded in place. However, angular repositioning of the tubular frame member, prior to welding, may be desired based on tolerance differences existing between the tubular frame member and the counterbored section of the support member. Additionally, when one end of a tubular frame member is rigidly welded to one support member, repositioning of an opposite end of the tubular frame member, relative to a counterbored section of an opposite support member, may be desired based on an angle at which the tubular frame member extends from the one support member. The inability to angularly position tubular frame members relative to a support member may, upon welding of the tubular frame members, result in a welded assembly having improper alignment and/or imbalances.

One attempt at improving a frame work assembly is disclosed in U.S. Pat. No. 3,211,481, (hereinafter, “the '481 patent”). Per the '481 patent, a frame work comprising tubular elements and devices having at least one spigot, pin, or the like over which a tubular element can be slid in a spigot and socket fashion is disclosed.

While the method disclosed by the '481 utility model addresses one method of improving a frame work assembly by way of sliding tubular elements in a spigot and socket fashion, a need exists for more precise and/or effective control over the angular positioning of tubular frame members prior to forming a welded assembly and/or overcoming other problems in the art.

SUMMARY

According to some implementations, the present disclosure is related to a system for improving alignment in welded assemblies. The system may include a support member having a surface and a projection extending from the surface, the projection may include one of a convex or a concave geometry. The system may include a positioning member positioned over the support member configured to receive a frame member, the positioning member may be movable over the support member, and the positioning member may include a geometry configured to engage the one of the convex or the concave geometry. In some implementations, the frame member may be movable from a first position relative to a center of the projection to a second position relative to the center of the projection during movement of the positioning member over the support member.

According to some implementations, the present disclosure is related to an additional system for improving alignment in welded assemblies. The system may include a support member having a surface and a projection extending from the surface, the projection may include one of a convex or a concave geometry. The system may include a positioning member positioned over the support member, the positioning member may be movable over the support member, and the positioning member may include a geometry configured to engage the one of the convex or the concave geometry. The system may include a frame member attached to the positioning member, the frame member may extend along an elongate axis. In some implementations, the frame member may be movable from a first position relative to the surface of the support member to a second position relative to the surface of the support member during movement of the positioning member over the support member. In some implementations, when the frame member is in the first position, the elongate axis is disposed at a first angle relative to the surface and, when the frame member is in the second position, the frame member is disposed at a second angle relative to the surface, the second angle may be different than the first angle.

According to some implementations, the present disclosure is related to an assembly. The assembly may include a support member having a first projection and a second projection, a first positioning member may be disposed over the first projection, and the first positioning member may be movable relative to the first projection. The assembly may include a second positioning member disposed over the second projection, and the second positioning member may be movable relative to the second projection. The assembly may include a first frame member attached to the first positioning member and a second frame member attached to the second positioning member. In some implementations, the first frame member may be movable in a first plurality of positions relative to a center of the support member when the first positioning member moves relative to the first projection, and the second frame member may be movable in a second plurality of positions relative to the center of the support member when the second positioning member moves relative to the second projection.

DETAILED DESCRIPTION

The instant disclosure relates to improving alignment in welded assemblies, in some implementations, by way of allowing for the angular displacement of one or more frame members relative to a support member, prior to the frame members being welded respective to the support member. In this way, the positioning and alignment of the frame members may be optimized prior to welding the frame members in a fixed position.

Turning now toFIG. 1, a diagram of an exploded view of an example system, generally designated100, and a device for improving alignment in a welded assembly is provided. In some implementations, the device for improving alignment in the welded assembly may include a positioning member102as described herein. System100may include positioning member102disposed between a support member104and a frame member106. In some implementations, positioning member102may include an annular positioning ring by which frame member106may be spaced apart from and/or moved relative to support member104, so that frame member106may be provided in a desired position and/or angle θ relative to support member104, prior to welding, as described herein.

Referring toFIG. 1, and in some implementations, support member104may include a body108of material. In some implementations, body108may include a solid body of material being formed from a metal or a metal alloy. Body108may be formed by way of casting, forging, extruding, machining, and/or the like, and may be formed in any shape configured to support one or more positioning members102and/or one or more frame members106attached to the one or more positioning members102. Support members104formed from non-solid bodies of material and/or non-metallic bodies of material are also contemplated herein. In some implementations, support member104may be devoid of one or more counterbores for receiving frame members106directly. In this way, frame members106may be movably displaced relative to support member104to optimize alignment and/or placement of the frame members106prior to being welded in a welded assembly. In some implementations, frame members106may include tubular frame members (e.g., tubes), such as tubular vehicle frame members, tubular building frame members, and/or the like.

In some implementations, support member104may include a surface110(e.g., an outer surface, an exterior surface, and/or the like) and at least one projection112extending from surface110. In some implementations, projection112may include a geometry114or profile over which positioning member102may move by way of swiveling, gliding, sliding, rotating, tilting, pivoting, and/or the like. In some implementations, geometry114of projection112may include one of a concave or a convex geometry, having a rounded and/or partially spherical surface or wall. In some implementations, the rounded surface or wall of geometry114may terminate proximate an upper surface116. In some implementations, upper surface116may include a substantially flat or planar surface, which may be configured to limit an amount by which positioning member102may swivel, slide, or otherwise move, relative to projection112.

In some implementations, positioning member102may include at least a first body portion118A and a second body portion118B to which frame member106may couple via welding, brazing, swaging, crimping, and/or the like. As an example, frame member106may be welded to positioning member102and positioning member102may, in turn, be welded to support member104for forming a welded assembly as described herein. As a specific example, frame member106may be welded to positioning member102by way of a fillet welding method, and positioning member102may be welded to support member104by way of a final, robotic welding method. Positioning member102and/or frame member106may each be formed from a metal or metallic material, a metal alloy material, a non-metal material, and/or the like. Positioning member102, support member104, and frame member106may be formed from a same material (e.g., a same metal material, a same metal alloy, and/or the like) or different materials, where desired.

In some implementations, positioning member102may be configured to position (e.g., angle, angularly position, and/or the like) frame member106relative to support member104, and may be welded to support member104when frame member106is provided in a desired position relative to support member104. In some implementations, the respective first and second body portions118A and118B of positioning member102may collectively form a geometry120that may be one of a convex or a concave geometry configured to engage geometry114of projection112. As an example, geometry120may include a rounded, concave geometry121configured to engage convex geometry115. In this way, positioning member102may move on, over, against, and/or otherwise relative to projection112, for positioning frame member106at a desired angle θ relative to a center C of projection112. In some implementations, center C of projection112may be disposed along a central axis X, which may correspond to a center of support member104, such that projection112may be centered relative to support member104. In some implementations, center C of projection112may be non-centered relative to support member104. In some implementations, frame member106may be provided at any one of a plurality of different angles θ relative to center C and/or central axis X of projection112, support member104, and/or the like.

Still referring toFIG. 1, and in some implementations, positioning member102may include a seat or ledge122formed by or between first body portion118A and second body portion118B, over which frame member106may be disposed. In some implementations, positioning member102may additionally include an outer wall124, around which an inner wall126of frame member106may be disposed. In this way, tedious tolerance matching between frame members and counterbores may be obviated.

In some implementations, concave geometry121may be configured in a shape that substantially conforms to convex geometry115, so that positioning member102may swivel over portions of convex geometry115to assume a desired position relative to convex geometry115. In this way, positioning member102may position frame member106at a desired angle θ relative to center C and/or central axis X of projection112and/or support member104. In some implementations, concave geometry121substantially matches a geometry of convex geometry115, so that concave geometry121may fittingly engage, oppose (e.g., face), and/or abut portions of convex geometry115during movement of concave geometry121relative to convex geometry115. In some implementations, convex geometry115may be partially nested within concave geometry121for improving movement of positioning member102relative to support member104. In some implementations, positioning member102may be welded to support member104when frame member106is provided in a desired position, for example, when frame member106is provided at a desired angle θ relative to projection112and/or support member104.

FIG. 1is provided as an example. Other examples may differ from what was described in connection withFIG. 1. In other words, system100, the components shown as being included in system100, and/or the arrangement of the components, are provided for illustrative purposes only.

FIGS. 2 and 3are diagrams of an assembled system100and device (e.g., positioning member102) for improving alignment in a welded assembly according toFIG. 1.FIG. 2illustrates positioning member102and frame member106being provided in a first position P1relative to center C (e.g., and central axis X) of projection112and/or surface110of support member104.FIG. 3illustrates positioning member102and frame member106being provided in a second position P2relative to center C (e.g., and central axis X) of projection112and/or surface110of support member104. Positioning member102and frame member106may be provided in any number of positions relative to projection112and/or support member104, as described herein. As described above, frame member106may be movable and, thus, positionable with respect to center C of projection112and/or surface110of support member104, by way of moving positioning member102on, over, and/or against projection112.

Referring toFIG. 2, and in some implementations, positioning member102and frame member106may be provided in first position P1, which may be coaxial, or substantially coaxial, with respect to projection112and/or support member104. For example, in first position P1, positioning member102and frame member106may be centered with respect to central axis X, so that central axis X may correspond to a central axis of positioning member102, support member104, frame member106, and/or projection112. In some implementations, positioning member102may be welded to support member104, so that frame member106may be maintained in first position P1to form a welded assembly. As described herein, a welded assembly may include one or more support members104, and each support member104may be connected (e.g., via welding, and/or the like) to one or more positioning members102and/or one or more frame members106. Frame members106may be disposed in a plurality of different angles and/or positions relative to projection112, support member104, and/or portions thereof, as described herein.

Still referring toFIG. 2, and in some implementations, positioning member102and frame member106may be provided in first position P1, which may be disposed at a first angle α1 relative to surface110of support member104. In some implementations, first angle α1 may include an angle between a center and/or a central axis (e.g., a central, elongate axis X2,FIG. 3) of frame member106and surface110. First angle α1 may include an acute angle, a right angle, or an obtuse angle. In some implementations, first angle α1 may range from about 45° to about 135°, or any angle or subrange of angles therebetween. First angles α1 that are less than about 45° and/or greater than about 135° are also contemplated herein.

Turning now toFIG. 3, and in some implementations, positioning member102and frame member106may be provided in second position P2, which may be non-coaxial, non-centered, offset, and/or otherwise angled relative to center C of projection112and/or support member104. For example, in second position P2, positioning member102and/or frame member106may be offset, by angle θ, from center C and central axis X of projection112and/or support member104. In some implementations, frame member106includes a central, elongate axis X2that may be offset by angle θ with respect to center C and/or central axis X of projection112and/or support member104. In some implementations, angle θ may include an angle ranging from between about 1° and about 60°, or any angle or subrange of angles therebetween. Angles θ of greater than about 60° are also contemplated herein. In some implementations, positioning member102may be welded to support member104so that frame member106may be maintained in second position P2upon formation of a welded assembly.

Still referring toFIG. 3, and in some implementations, positioning member102and frame member106may be provided in second position P2, which may be disposed at a second angle α2 relative to surface110of support member104. In some implementations, second angle α2 may correspond to an angle between elongate axis X2of frame member106and surface110of support member104. Elongate axis X2of frame member106can, but does not have to, correspond to a center of positioning member102. In some implementations, second angle α2 may include an acute angle, a right angle, or an obtuse angle. In some implementations, second angle α2 may range from about 45° to about 135°, or any angle or subrange of angles therebetween. Second angles α2 that are less than about 45° and/or greater than about 135° are also contemplated herein. In some implementations, second angle α2 may be greater than first angle α1, or less than first angle α1.

FIGS. 2 and 3are provided as examples. Other examples may differ from what was described in connection withFIGS. 2 and 3. In other words, the positioning of components shown inFIGS. 2 and 3and/or the arrangement of the components shown inFIGS. 2 and 3are provided for illustrative purposes only. Other positioning and/or arrangements of the components shown inFIGS. 2 and 3are contemplated herein.

FIG. 4is a sectional view of an assembly, generally designated200, a portion of which may include the system and device according toFIG. 1. Assembly200may include a support member202and a plurality of projections (e.g.,204A-204D) extending from support member202. Support member202may include a metallic body of material or a non-metallic body of material, which may be cast, extruded, machined, and/or the like. Support member202may include a symmetric body of material, which may be symmetric respective to a center C1of support member202, or a non-symmetric body of material, which may be devoid of a center C1. In some implementations, support member202may form a node or hub of a welded assembly, to which one or more positioning members (e.g.,206A-206D) may be attached (e.g., via welding and/or the like). One or more frame members (e.g.,208A-208D) may, in turn, be welded to the one or more positioning members (e.g.,206A-206D), in some cases, in advance of positioning the one or more positioning members (e.g.,206A-206D) relative to support member202. In some implementations, center C1of support member202can, but does not have to, correspond to centers C2of the one or more projections. In this way, frame members (e.g.,208A-208D) may be angled respective to center C1of support member and/or centers C2of projections by way of moving the one or more positioning members (e.g.,206A-206D) relative to support member202and/or projections.

AsFIG. 4illustrates, and in some implementations, assembly200may include at least a first projection204A, a second projection204B, a third projection204C, and a fourth projection204D formed therein. More than four, or less than four, projections are contemplated. In some implementations, each projection may include a rounded, convex geometry over which at least one positioning member may be provided. The at least one positioning member may be attached to a respective frame member for positioning the respective frame member by way of moving on, over, and/or against a respective projection. In some implementations, the at least one positioning member may move the respective frame member by an angle (e.g., β1, β2, and/or the like), relative to center C1of support member and/or center C2of an underlying projection.

In some implementations, assembly200may additionally include at least a first positioning member206A provided over first projection204A, a second positioning member206B provided over second projection204B, a third positioning member206C provided over third projection204C, and a fourth positioning member206D provided over fourth projection204D. Similarly, assembly200may additionally include at least a first frame member208A coupled (e.g., welded, tacked, swaged, and/or the like) to first positioning member206A, a second frame member208B coupled to second positioning member206B, a third frame member208C coupled to third positioning member206C, and a fourth frame member208D coupled to fourth positioning member206D. More than four, or less than four, positioning members and/or frame members may be provided on or over support member202. In some implementations, each positioning member (e.g.,206A-206D) may include a concave geometry or profile, configured to fittingly engage and/or move (e.g., slide, swivel, tilt, and/or the like) relative to an underlying projection (e.g.,204A-204D), as described herein.

Still referring toFIG. 4, and in some implementations, the frame members (e.g.,208A-208B) may be configured to move in one or more directions D during movement of a positioning member to which a frame member is attached. In this way, the frame members may be located at various angular positions respective to center C1of support member202and/or center C2of an underlying projection. For example, first frame member208A may be movable in a first plurality of positions relative to center C1of support member202and/or center C2of first projection204A, during movement of first positioning member206A relative to first projection204A. As a specific example, first frame member may be located at a first angle β1 relative to center C1of support member202and/or center C2of first projection204A during movement of first positioning member206A relative to first projection204A.

Similarly, second frame member208B may be movable in a second plurality of positions relative to center C1of support member202and/or center C2of second projection204B during movement of second positioning member206B relative to second projection204B. As an example, second frame member may be located at a second angle β2 relative to center C1of support member202and/or center C2of second projection204B during movement of second positioning member206B relative to second projection204B. Third frame member208C and fourth frame member208D may likewise be locatable relative to center C1of support member202and/or centers of underlying projections as described herein. In this way, locations of the various frame members (e.g.,208A-208D) may be optimized prior to welding.

In some implementations, assembly200includes a plurality of adjacent projections (e.g.,204A-204D), a plurality of coaxial projections (e.g., first projection204A is coaxial to third projection204C, and/or the like), and/or a plurality of non-coaxial projections.

In some implementations, a method of providing assembly200may be provided. The method may include assembling one or more frame members, of a plurality of frame members (e.g.,204A-204D), to one or more positioning members, of a plurality of frame members (e.g.,206A-206D), and welding (e.g., fillet welding, tack welding, and/or the like) the one or more frame members to the one or more positioning members. As an example, and in some cases, individual frame members may be assembled and/or attached to a respective individual positioning member. The method of providing assembly200may additionally include moving the one or more frame members to a desired position relative to a center or surface of support member202by way of the one or more positioning members, and welding (e.g., fillet welding, tack welding, and/or the like) the respective positioning members to support member202. A robotic welding machine may be used to weld the components (e.g., frame members, positioning rings, support member, etc.) of assembly200in a final position for forming a welded assembly. Multiple welded assemblies may likewise be welded together, where desired, to form a desired structure (e.g., a vehicle frame, and/or the like), as described herein.

FIG. 4is provided as an example. Other examples may differ from what was described in connection withFIG. 4. In other words, assembly200, the components shown as being included in assembly200, and/or the location and/or arrangement of the components of assembly200, are provided for illustrative purposes only.

INDUSTRIAL APPLICABILITY

The disclosed example system100and example assembly200, which may include example system100, may incorporate a plurality of frame members106that may be movable to any one of several different angular positions over a support member104in advance of welding the frame members106in an assembly. In this way, providing counterbores in support member104may be obviated. In this way, waste attributed to frame members106failing to satisfy specific tolerances may be prevented. Moreover, customizing the positions of frame members106by way of moving positioning members102over support member104may improve alignment in a welded assembly, and reduce distortions.

The foregoing disclosure provides illustration and description, but is not intended to be exhaustive or to limit the implementations to the precise form disclosed. Modifications and variations are possible in light of the above disclosure or may be acquired from practice of the implementations. It is intended that the specification be considered as an example only, with a true scope of the disclosure being indicated by the following claims and their equivalents. Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the disclosure of possible implementations. Although each dependent claim listed below may directly depend on only one claim, the disclosure of possible implementations includes each dependent claim in combination with every other claim in the claim set.