CN113184082A - Automobile door clearance surface difference control system and control method thereof - Google Patents
Automobile door clearance surface difference control system and control method thereof Download PDFInfo
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- 238000004088 simulation Methods 0.000 claims abstract description 21
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
- B62D65/005—Inspection and final control devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
- B62D65/02—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
- B62D65/06—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components the sub-units or components being doors, windows, openable roofs, lids, bonnets, or weather strips or seals therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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Abstract
The invention discloses an automobile door clearance surface difference control system, which comprises: the device comprises a measuring module for measuring the difference of clearance surfaces of welding assembly and general assembly, a simulation calculating module, a data processing module for obtaining the difference mean deviation and the extreme difference of the clearance surfaces of actual vehicle door welding assembly and general assembly, a control module for judging whether the output of the data processing module meets the requirements and executing action S4-1 or action S4-2, and an executing unit for executing welding assembly, coating and general assembly. The invention also provides a control method of the automobile door clearance surface difference control system, which comprises the following steps of determining a design value { H } of the automobile door welding clearance surface difference; welding the car door to achieve the standard of welding and dispatching the car; and coating and final assembly are carried out, whether the mean deviation and the range of the final assembly clearance surface difference meet the requirements or not is judged, if yes, the final design value of the vehicle door welding clearance surface difference is output, and if not, the { H } is circularly adjusted and corrected. The invention improves the clearance surface difference qualification rate after the final assembly of the vehicle door.
Description
Technical Field
The invention relates to the technical field of automobile assembly, in particular to an automobile door clearance surface difference control system and a control method thereof.
Background
In the process of analyzing the manufacturing of the whole automobile, the process variables from welding to final assembly are more, and the influence on the clearance surface difference state of the automobile door area is large. At present, the assembly and adjustment of the vehicle door are finished on an assembly and adjustment line in a welding workshop, if the vehicle door is assembled and adjusted by taking a complete vehicle DTS as a target, the vehicle door needs to be adjusted and repaired once and greatly when the vehicle door is assembled and disassembled due to large change of the state of a welded vehicle body and the state of the assembled vehicle, and the debugging period is long. The following factors are the main factors influencing the poor state of the clearance surface of the vehicle door region: (1) the vehicle door sheet metal part can cause the vehicle door to sink due to the gravity of the vehicle door sheet metal part; (2) the weight of the components on the door that are assembled in the final assembly causes the door to sag: for example, door glass, a glass lifter, a door inner protective plate, a loudspeaker and the like cannot be assembled when a door is welded and adjusted, the weight of the parts is large, and the phenomenon that the door sinks can also occur after the parts are assembled; (3) the pressing counter force of the sealing strip of the vehicle door can cause the vehicle door to be outwards expanded; (4) and baking deformation of the vehicle body metal plate in the coating process.
In addition, most of the existing welding tools, clamps and checking tools are developed according to the digital definition of the whole vehicle, and because the state change of a vehicle door area in welding and final assembly is large, the whole vehicle data is seriously deviated from the welding state, so that part of the tools, the clamps and the checking tools cannot be applied. It is therefore not appropriate to use the entire vehicle DTS to evaluate the trim state of the welded vehicle door.
Chinese patent CN204432397U discloses a method for improving the welding quality of car doors, wherein, the method discloses that the total weight of the parts assembled on each car door in the final assembly process is respectively weighed, corresponding counter weight blocks are manufactured according to the total weight of the parts on each car door, the corresponding seed matching blocks on each car door are hung on the proper position of the car door as counter weight when the car door is welded and debugged, then the car door is adjusted to meet the process requirements, the counter weight blocks are taken down, and the car door is welded and assembled. In the prior art, only the problem of sinking of the vehicle door is solved, the condition that the door frame is outwards expanded by the counter force of the sealing strip is not solved, the operation is complicated, parts need to be weighed, the gravity center needs to be calculated, the counterweight block needs to be manufactured, the adjustment can be carried out only after a real object exists, the counterweight blocks of the front door and the rear door generally have 10-15 kilograms, a vehicle door adjusting person needs to weld and take the counterweight blocks for multiple times a day, the labor intensity is high, and the positions of the gravity center and the counterweight can not be accurately calculated, so that the real working condition cannot be reproduced.
Chinese patent CN106218752A discloses a car body size control technology, which mainly comprises the following steps: 1) collecting the project body-in-white related geometric dimension file and product definition; 2) collecting and verifying inspection and acceptance records of a stamping die, a welding clamp and a checking fixture, and preliminarily judging the size deviation condition of the body-in-white and possible geometric size problems by analyzing the files; 3) welding a first tool sample car: 4) analyzing the geometric dimension of the first tooling sample car; 5) and carrying out problem analysis and adjustment in different areas. In the second prior art, a vehicle body geometric dimension file and product definition, a checking record of a die, a checking tool and a clamp and the like are used for analyzing and judging the condition of white vehicle body dimension deviation and possible problems, a primary version geometric dimension change scheme is determined, problem analysis and adjustment are carried out in different regions by loading, and correction is continued until the clearance surface difference meets the design requirement, so that the method relies on actual experience to identify the dimensions which may have the problems to a great extent.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provide a control system and a control method for the clearance surface difference of the automobile door.
In order to achieve the above object, the present invention provides an automobile door clearance surface difference control system, comprising:
the measuring module is used for outputting actual vehicle door welding clearance surface difference and actual vehicle door final assembly clearance surface difference;
the simulation calculation module is used for outputting a simulation value { C } of the clearance surface difference of the vehicle door assembly;
the data processing module is used for outputting the initial design value { H } of the door welding clearance surface difference according to the design value { Z } of the door assembly clearance surface difference and the simulated value { C } of the door assembly clearance surface difference0And outputting the mean deviation of the difference of the actual welding clearance surfaces of the vehicle door according to the difference of the actual welding clearance surfaces of the vehicle door and the design value of the difference of the welding clearance surfaces of the vehicle door { H }
Extremely poor { H ] with the welding clearance surface difference of the actual car doorROutputting the mean deviation of the difference of the actual vehicle door assembly clearance surfaces according to the difference of the actual vehicle door assembly clearance surfaces and the design value of the difference of the vehicle door assembly clearance surfaces (Z)
Range of clearance surface difference from actual vehicle door assembly { ZR}；
A control module for determining whether the output of the data processing module meets the requirements, respectively, and for performing action S4-1 or action S4-2;
s4-1: when the difference mean deviation of the actual vehicle door assembly clearance surface
Range of clearance surface difference from actual vehicle door assembly { ZRWhen all the requirements are met, outputting an initial design value of the welding clearance surface difference of the vehicle door (H)0Taking the difference as a design value of the welding clearance surface difference of the vehicle door;
s4-2: when the difference mean deviation of the actual vehicle door assembly clearance surface
When the requirement is not met, controlling and adjusting the design value { H } of the welding clearance surface difference of the vehicle door, and when the actual vehicle door is assembled, the extreme difference of the clearance surface difference { Z } is adjustedRWhen the requirements are not met, the stability of the process from welding to final assembly is improved;
and the execution unit is used for welding, coating and assembling the vehicle door.
Further, the data processing module is used for processing the data according to a formula { H }0Obtaining an initial design value { H } of the welding clearance surface difference of the vehicle door { Z } - { C }0And Z is a design value of the vehicle door assembly clearance surface difference, and C is a simulated value of the vehicle door assembly clearance surface difference.
Furthermore, the technical process of welding the vehicle door by the execution unit further comprises the steps of pre-lifting the vehicle door metal plate assembly during assembling, and pre-bending the vehicle door metal plate assembly in the vehicle door welding process.
Furthermore, the control module is also used for controlling the execution unit to weld the vehicle door and adjusting the technological parameters of the vehicle door welding until the actual vehicle door welding clearance surface difference mean deviation
Extremely poor { H ] with the welding clearance surface difference of the actual car doorRAll satisfy the requirements.
Further, the control module is further configured to determine when the actual door final assembly clearance surface difference mean deviation occurs when performing act S4-2
When the requirements are not met, the control data processing unit adjusts the design value { H } of the welding clearance surface difference of the vehicle door to be
The invention also provides a control method of the automobile door clearance surface difference control system, which is characterized by comprising the following steps:
s1: determining an initial design value { H } of the gap surface difference of the welding machine door according to the design value { Z } of the gap surface difference of the general assembly of the vehicle door and the simulated value { C } of the gap surface difference of the general assembly of the vehicle door0Giving an initial value to a welding clearance surface difference design value { H }, and making { H } ═ H }, a welding clearance surface difference design value { H } be a welding clearance surface difference design value, and a welding clearance surface difference design value is obtained by adding the initial value to the welding clearance surface difference design value { H }, and then giving a welding clearance surface difference design value to the welding clearance surface difference design value { H }, and giving a welding clearance surface difference design value to the welding clearance surface difference design value { H }, wherein the welding clearance surface difference design value is obtained by adding the initial value to the welding clearance surface difference design value { H } and the welding clearance surface difference design value { H } to the welding clearance surface difference design value to the welding clearance surface difference0}；
S2: welding the car door to make the actual car door welding clearance surface difference mean deviation
Does not exceed the welding clearance face difference tolerance (D) of the vehicle doorHThe range limited, and the actual welding clearance surface difference of the vehicle door { H }RNo greater than the tolerance of the welding clearance face difference of the vehicle door (R)HA limit value of };
s3: coating and final assembly are carried out to obtain the difference mean deviation of the clearance surface of the actual vehicle door final assembly
And the extreme difference of the actual vehicle door assembly clearance surface difference { Z }RJudging whether the two meet the requirements;
s4-1: when the difference mean deviation of the actual vehicle door assembly clearance surface
Range of clearance surface difference from actual vehicle door assembly { ZROutputting a design value of the vehicle door welding clearance surface difference { H } as a final design value of the vehicle door welding clearance surface difference when all the requirements are met;
s4-2: when the difference mean deviation of the actual vehicle door assembly clearance surface
When the requirements are not met, adjusting the design value { H } of the welding clearance surface difference of the vehicle door; when the final assembly clearance surface of the actual vehicle door is poor, the polar difference ZRWhen the requirements are not met, the stability of the process from welding to final assembly is improved, and the steps S2-S3 are repeated until the mean deviation of the gap surface difference of the actual vehicle door final assembly
And the extreme difference of the actual vehicle door assembly clearance surface difference { Z }RAll satisfy the requirements.
Further, the welding process of the vehicle door further comprises the steps of pre-lifting the vehicle door metal plate assembly during assembling, and pre-bending the vehicle door metal plate assembly in the vehicle door welding process.
Further, when the actual vehicle door is assembled, the clearance surface difference mean deviation
When the requirements are not met, adjusting the design value { H } of the welding clearance surface difference of the vehicle door to be
Further, the method for determining the pre-lifting amount T of the vehicle door sheet metal assembly comprises the step of obtaining the difference between the gap of the highest measurement point of the vehicle door in the design value { Z } of the total assembly clearance surface difference and the gap in the design value { H } of the welding clearance surface difference, and the method for determining the pre-bending amount { N } of the vehicle door sheet metal assembly comprises the step of obtaining the difference between the surface difference in the design value { Z } of the total assembly clearance surface difference and the surface difference in the design value { H } of the welding clearance surface difference.
Further, when the actual vehicle door is assembled, the clearance surface difference mean deviation
Tolerance of mean deviation of gap surface difference of vehicle door final assembly is not exceeded { DZThe limited range is the satisfying requirement, when the actual vehicle door is assembled with the extreme difference of clearance surface difference { Z }RTolerance of range not greater than the difference of the clearance surface of the vehicle door assembly (R)ZAnd meeting the requirement.
Further, the door welds clearance face difference tolerance { DHAnd the extreme value tolerance of the welding clearance face difference of the vehicle door (R)HAnd the tolerance (IT) of the design value of the vehicle door assembly clearance surface difference is one third.
Further, the tolerance { D of the difference mean deviation of the door assembly clearance surfaceZTolerance of difference between { R } and the clearance face of the door assemblyZAnd the tolerance (IT) of the design value of the vehicle door assembly clearance surface difference is one third.
Further, after the final design value of the welding clearance surface difference of the vehicle door is determined, a welding design digital model of the vehicle door assembly is determined according to the pre-lifting amount T of the vehicle door metal plate assembly and the pre-inward bending amount { N } of the vehicle door metal plate assembly, wherein the unilateral through hole amount delta D of the lower hinge hole of the vehicle door is T X H/L, H is the Z-direction distance of the upper hinge hole and the lower hinge hole of the vehicle door, and L is the X-direction total length of the vehicle door assembly.
The invention has the beneficial effects that:
1. and accurately determining the design value of the welding clearance surface difference of the vehicle door. The method determines the initial design value of the welding clearance surface difference of the vehicle door through the design value of the total assembly clearance surface difference of the vehicle door and the simulated value of the total assembly clearance surface difference of the vehicle door, considers the variation of the clearance surface difference of the vehicle door from welding to the total assembly process in advance, then verifies through a real vehicle, if the actual total assembly clearance surface difference of the vehicle door does not meet the requirement, adjusts the design value of the welding clearance surface difference of the vehicle door and/or improves the stability of the process from welding to the total assembly until the requirement is met and the final design value of the welding clearance surface difference of the vehicle door is obtained, and provides accurate guidance for the control of the clearance surface difference in the welding, assembly and adjustment process.
Drawings
FIG. 1 is a schematic structural diagram of an automobile door clearance and surface difference control system.
Fig. 2 is a schematic view of a measurement point of the door clearance surface difference in the present embodiment.
FIG. 3 is a flow chart of a control method of the present invention.
The components in the figures are numbered as follows: the system comprises a measurement module 100, a simulation calculation module 200, a data processing module 300, a control module 400 and an execution unit 500.
Detailed Description
The following detailed description is provided to further explain the claimed embodiments of the present invention in order to make it clear for those skilled in the art to understand the claims. The scope of the invention is not limited to the following specific examples. It is intended that the scope of the invention be determined by those skilled in the art from the following detailed description, which includes claims that are directed to this invention.
As shown in fig. 1, an automobile door clearance and surface difference control system includes: a measurement module 100, a simulation calculation module 200, a data processing module 300, a control module 400 and an execution unit 500.
The measuring module 100 is used for measuring and outputting the actual door welding clearance surface difference and the actual door final assembly clearance surface difference to the data processing module 300. In this embodiment, the door assembly clearance surface difference refers to a clearance surface difference after the assembly of the DTS of the whole vehicle in the door area is completed, and the door welding clearance surface difference refers to a clearance surface difference after the welding of the DTS in the door area is completed.
The simulation calculation module 200 is configured to output a simulated value { C } of the clearance surface difference of the vehicle door assembly to the data processing module 300 according to the CAE simulation method.
The data processing module 300 is used for obtaining the mean deviation of the difference of the actual welding gap and the actual welding gap of the vehicle door according to the output of the measuring module 100
Poor range of actual door welding clearance surface { H }RMean deviation of difference between clearance surfaces in actual vehicle door assembly
Range of clearance surface difference from actual vehicle door assembly { ZROutput to the control module 400 for judgment; the data processing module 300 is further configured to process the data according to the formula H0Obtaining an initial design value { H } of the welding clearance surface difference of the vehicle door { Z } - { C }0}。
In this embodiment, the control module 400 is used to control the execution unit 500 to weld the vehicle door and adjust the process parameters of the vehicle door welding until the mean deviation of the gap surface difference of the actual vehicle door welding
Extremely poor { H ] with the welding clearance surface difference of the actual car doorRAll satisfy the requirements.
The control module 400 is further configured to determine whether the output of the data processing module 300 meets the requirements, and to perform act S4-1 or act S4-2, respectively;
s4-1: when the difference mean deviation of the actual vehicle door assembly clearance surface
Range of clearance surface difference from actual vehicle door assembly { ZRWhen the requirements are met, outputting a design value of the vehicle door welding clearance surface difference { H } as a final design value of the vehicle door welding clearance surface difference;
s4-2: when the difference mean deviation of the actual vehicle door assembly clearance surface is judged
When the requirements are not met, the control data processing unit adjusts the design value { H } of the welding clearance surface difference of the vehicle door to be
When judging the range of gap surface difference when the actual car door is assembledRWhen the requirements are not met, controlling an execution unit to improve the stability of the process from welding to final assembly; repeating the steps S2-S3 until the average deviation of the difference of the actual door assembly clearance surface
And the extreme difference of the actual vehicle door assembly clearance surface difference { Z }RAll satisfy the requirements. The execution unit 500 is used for welding, coating and final assembly of the vehicle door, and comprises the steps of adjusting the total technological parameters of welding and coating and adjusting the stability of the process from welding to final assembly, so that the mean deviation of the gap surface difference of the actual vehicle door final assembly is reduced
Extremely different from the actual vehicle door assembly clearance surface { H }R}。
In this embodiment, the welding process performed by the execution unit 500 for the vehicle door further includes pre-lifting the vehicle door metal plate assembly during assembling, and pre-bending the vehicle door metal plate assembly in the vehicle door welding process, so that the difference mean deviation of the actual vehicle door welding gap surface
Extremely poor { H ] with the welding clearance surface difference of the actual car doorRAll satisfy the requirements.
In this embodiment, the control system processes the measurement result of the measurement module 100 and the output result of the simulation calculation module 200 to the data processing module 300 to obtain the initial design value of the gap surface difference between the measurement module 100 and the simulation calculation module 200 and outputs the initial design value to the door welding clearance surface difference, and then the control module controls the execution unit to weld the door, so that the actual door welding clearance surface difference average value deviation is obtained
Extremely poor { H ] with the welding clearance surface difference of the actual car doorRThe welding and dispatching requirements are met, then the control module controls the execution unit to perform final assembly to judge whether the design value { H } of the door welding clearance surface difference meets the requirements, if the actual door final assembly clearance surface difference does not meet the requirements, the control data processing module adjusts the design value { H } of the door welding clearance surface difference or controls the execution unit to improve the stability of the procedure from welding to final assembly until the requirements are met and the final design value { H } of the door welding clearance surface difference is obtainedendAnd therefore, the poor qualification rate of the clearance surface after the vehicle door is assembled is improved.
As shown in fig. 2 to 3, taking a certain SUV model as an example, the control method of the vehicle door clearance surface difference control system is as follows:
s1: determining an initial design value { H } of the gap surface difference of the welding machine door according to the design value { Z } of the gap surface difference of the general assembly of the vehicle door and the simulated value { C } of the gap surface difference of the general assembly of the vehicle door0Giving an initial value to a welding clearance surface difference design value { H }, and making { H } ═ H }, a welding clearance surface difference design value { H } be a welding clearance surface difference design value, and a welding clearance surface difference design value is obtained by adding the initial value to the welding clearance surface difference design value { H }, and then giving a welding clearance surface difference design value to the welding clearance surface difference design value { H }, and giving a welding clearance surface difference design value to the welding clearance surface difference design value { H }, wherein the welding clearance surface difference design value is obtained by adding the initial value to the welding clearance surface difference design value { H } and the welding clearance surface difference design value { H } to the welding clearance surface difference design value to the welding clearance surface difference0}。
First, a complete vehicle DTS is set, where the design value of the clearance surface difference of the door assembly is set { Z }, which includes the clearance surface differences of 14 measurement points, and the tolerance of the clearance surface difference of the door assembly is set { IT }, which includes the tolerances of the clearance surface differences corresponding to 14 measurement points, and both { Z } and { IT } include clearance components and surface difference components, as shown in table 1.
TABLE 1 design values and tolerances for door assembly clearance face difference
Then, using CAE simulation method, calculating to obtain design digital model, and obtaining the simulation value of the clearance surface difference of the vehicle door assembly as a set { C } after applying process boundary conditions. The boundary conditions imposed by the simulation include: the weight of the door assembly and the compression reaction of the door weatherstrip, wherein the front door applies a compression reaction 240N and the rear door applies a compression reaction 220N.
TABLE 2 simulation value of clearance surface difference of vehicle door assembly
In this embodiment, the initial design value of the door weld clearance surface difference { H }0Is according to the formula { H }02{ Z } - { C }. The arrangement is that { Z } - { H } is the variable quantity from welding to assembly during actual loading, a CAE simulation calculation model is established according to { Z }, the actual working condition is simulated, and simulation is carried out by taking { Z } as a target to obtain a simulated value { C } of the clearance surface difference of the vehicle door assembly, so that { C } - { Z } is the variable quantity obtained in the simulation process from welding to assembly; the simulation variation is theoretically equal to the actual loading variation, namely { Z } - { H } - { C } - { Z }, so that the initial design value { H } of the welding clearance surface difference of the vehicle door is obtained by a CAE simulation method02{ Z } - { C }. Giving an initial value to a welding clearance surface difference design value { H }, and enabling { H } -, namely { H }, to be H0}。
TABLE 3 initial design values of door weld clearance surface difference
S2: welding the car door to make the actual car door welding clearance surface difference mean deviation
Does not exceed the welding clearance face difference tolerance (D) of the vehicle doorHThe range limited, and the actual welding clearance surface difference of the vehicle door { H }RNo greater than the tolerance of the welding clearance face difference of the vehicle door (R)HA limit value of.
In this embodiment, with { H } as a target value, door assembly and adjustment are performed on 4 trial vehicles, the door sheet metal assembly is assembled and pre-lifted, the door sheet metal assembly is pre-bent in the door welding process, and a set { H } of actual door welding clearance surface differences of the 4 trial vehicles is measured to obtainsiH (i ═ 1,2,3,4), 4 sets H are computedsiMean of the values is set
Range is set { H }RMean deviation as set
The measurement and calculation structures are shown in table 4.
Adjusting the pre-lifting amount T and the pre-inward bending amount N, wherein in the embodiment, the pre-lifting amount T of the vehicle door sheet metal assembly is the difference between the gap of the highest measurement point of the vehicle door in the total assembly clearance surface difference design value { Z } and the gap in the welding clearance surface difference initial value { H }, and the pre-inward bending amount { N } of the vehicle door sheet metal assembly is the difference between the total assembly clearance surface difference design value { Z } and the welding clearance surface difference initial value { H }. Make the collection
Does not exceed the vehicle door welding clearance face difference tolerance (D)HThe tolerance range defined by the corresponding element in { H }, and the set { HREvery element in the element is not more than the limit value tolerance of the welding clearance surface difference of the vehicle door (R)HThe limit value of the corresponding element in the above embodiment, the gap face difference tolerance of the welded vehicle door (D)HPoor tolerance of welding clearance surface of vehicle door { R }HAnd the tolerance (IT) of the design value of the welding clearance surface difference of the vehicle door is one third. And sending the trial-manufactured vehicle to the next process.
TABLE 4 actual door weld clearance face difference
S3: coating and final assembly are carried out to obtain the difference mean deviation of the clearance surface of the actual vehicle door final assembly
And difference in clearance surface of actual door assemblyRange { ZRAnd judging whether the two meet the requirements.
Coating and final assembly are carried out on the same batch of 4 test vehicles which finish the assembly and the adjustment of the welded vehicle door metal plate assembly, parts such as vehicle door glass, a glass lifter, a door inner protective plate, a loudspeaker and the like are arranged on the vehicle door metal plate assembly, and after the final assembly is finished, the difference of actual vehicle door final assembly clearance surfaces of the 4 test vehicles is measured to be a set { Z }siAnd (i) 1,2,3,4), which are in one-to-one correspondence with the trial run numbers of the previous step, and 4 sets { Z } are calculatedsiMean of the values is set
Range is set { ZRMean deviation as set
The results of the measurements and calculations are shown in Table 5.
In this embodiment, the difference mean deviation of the clearance surface during the final assembly of the actual vehicle door
Tolerance (D) not greater than mean deviation of gap surface difference of vehicle door assemblyZThe requirements are met, and when the actual car door is assembled, the clearance surface difference is very poor { Z }RTolerance of range not greater than the difference of the clearance surface of the vehicle door assembly (R)ZAnd meeting the requirement. Wherein, the tolerance of the door assembly clearance surface difference mean deviation { DZTolerance of difference between the clearance face of the door assembly and the clearance face of the door assembly (R)ZAnd the tolerance (IT) of the design value of the vehicle door assembly clearance surface difference is one third.
TABLE 5 actual door assembly clearance face difference
As is found by analyzing table 5, it is,
in the gap component, the values of No. 4, No. 6, No. 9 and No. 10 measuring points exceed the tolerance range defined by the corresponding position elements in the { Dz } gap component;
in the surface difference component, the values of No. 5, No. 6, No. 8 and No. 11 measuring points exceed the tolerance range defined by corresponding position elements in the { Dz } gap component, and the design value { H } of the vehicle door welding gap surface difference needs to be determined again and verified; { ZRIn the component of the difference between the surfaces, the values of the measuring points No. 5, No. 8 and No. 11 exceed the value of the RZAnd f, adjusting the working procedure stability between the welding assembly and the assembly line after the welding assembly and the adjustment according to the tolerance value limited by the corresponding element.
S4-2: when the difference mean deviation of the actual vehicle door assembly clearance surface
When the requirements are not met, adjusting the design value { H } of the welding clearance surface difference of the vehicle door; when the final assembly clearance surface of the actual vehicle door is poor, the polar difference ZRWhen the requirements are not met, the stability of the process from welding to final assembly is improved; repeating the steps S2-S3 until the average deviation of the difference of the actual door assembly clearance surface
And the extreme difference of the actual vehicle door assembly clearance surface difference { Z }RAll satisfy the requirements.
According to investigation and analysis, the phenomenon that part of the sealing strip is not assembled in place in the sealing strip assembling process is found, so that the final offline surface difference of the vehicle door is unstable, and the sealing strip assembling process is subjected to stability correction.
Due to the difference mean value of the clearance surface of the actual vehicle door assembly after assembly
Difference mean value of welding clearance surface with actual welded vehicle door
The difference is equal to the mean value of the variation of the clearance surface difference brought by the process from the welding and the adjustment of the vehicle door to the final assembly and the production line of the trial-manufacture vehicle, and when the design value { H } of the clearance surface difference of the vehicle door welding and installation is re-determined, the mean value of the variation of the clearance surface difference is used
Equivalent to the clearance surface difference variation theoretical value brought by the process from the assembly and the adjustment of the welded vehicle door to the assembly offline, the clearance surface difference design value { H } of the welded vehicle door plus the clearance surface difference variation theoretical value should be equal to the clearance surface difference design value { Z } of the assembled vehicle door, that is to say
Then there is
Thus making
And alternatively 4 dollies are again verified by performing steps S2-S3. And finally, the measurement and calculation results of the actual vehicle door final assembly clearance surface difference after the final assembly is finished are obtained, and are shown in the table 6.
Table 6 measurement and calculation results of actual door assembly clearance surface difference upon re-verification
S4-1: through analysis of Table 6, the collection
All elements in set { D }ZWithin the tolerance defined by the corresponding element in (Z) } set of (Z)RNone of the elements in the set exceeds the set RZThe extreme difference defined by the corresponding position element in the verification is output, so that the set (H) in the re-verification is output as a set (H) of the final design values of the welding clearance surface difference of the vehicle doorend}。
S5: and determining a welding design digital-to-analog of the vehicle door assembly according to the pre-lifting amount T and the pre-inward bending amount { N } of the vehicle door sheet metal assembly.
The pre-lifting amount of the front door assembly calculated according to the gap between the highest measuring point (the 4 th measuring point) of the front door is TFront side＝Z4gap-H4The clearance is 1.4mm, and the assembly pre-lifting amount of the rear door calculated according to the clearance of the highest measuring point (10 th measuring point) of the rear door is TRear end＝Z10gap-H10The gap is 1.1 mm. Z-direction distance H of upper and lower hinge holes of front doorFront side358mm, total length L of front door assembly in X directionFront side1090mm, and the single-side via hole amount of the front door lower hinge hole is calculated to be delta DFront side0.46 mm; z-direction distance H of upper hinge hole and lower hinge hole of rear doorRear end370mm, total length L in the X direction of the rear door assemblyRear endThe single-side via hole quantity of the hinge hole under the rear door is calculated to be delta D (1010 mm)Rear end＝0.41mm；
The amount of pre-clinching { N } - { Z } plane difference- { H } plane difference of the front and rear door assemblies in the welding process is shown in table 7, and a weld design digifax of the door assemblies can be defined from data of { N }. The design value of the unilateral through hole quantity of the hinge hole of the vehicle door and the design value of the pre-inward bending of the vehicle door metal plate are guided, a vehicle door metal plate design digital model considering the compensation quantity can be obtained, and matched design is carried out on matched clamps, checking tools, tools and the like according to the digital model, so that the design definitions of the clamps, the checking tools and the tools are more accurately in line with the actual situation.
TABLE 7 Pre-camber of front and rear doors
Claims (10)
1. An automotive door clearance face difference control system, comprising:
the measuring module (100) is used for outputting an actual vehicle door welding clearance surface difference and an actual vehicle door final assembly clearance surface difference;
the simulation calculation module (200), the simulation calculation module (200) is used for outputting a simulation value { C } of the clearance surface difference of the vehicle door assembly;
a data processing module (300), the data processing module (300) is used for outputting the initial design value of the door welding clearance surface difference { H } according to the design value of the door assembly clearance surface difference { Z } and the simulated value of the door assembly clearance surface difference { C }0And outputting the mean deviation of the difference of the actual welding clearance surfaces of the vehicle door according to the difference of the actual welding clearance surfaces of the vehicle door and the design value of the difference of the welding clearance surfaces of the vehicle door { H }
Extremely poor { H ] with the welding clearance surface difference of the actual car doorROutputting the mean deviation of the difference of the actual vehicle door assembly clearance surfaces according to the difference of the actual vehicle door assembly clearance surfaces and the design value of the difference of the vehicle door assembly clearance surfaces (Z)
Range of clearance surface difference from actual vehicle door assembly { ZR}；
A control module (400), the control module (400) being configured to determine whether the output of the data processing module (300) meets the requirements, and to perform an action S4-1 or an action S4-2, respectively;
s4-1: when the difference mean deviation of the actual vehicle door assembly clearance surface
Range of clearance surface difference from actual vehicle door assembly { ZRWhen the requirements are met, outputting a design value of the vehicle door welding clearance surface difference { H } as a final design value of the vehicle door welding clearance surface difference;
s4-2: when the difference mean deviation of the actual vehicle door assembly clearance surface
When the requirement is not met, controlling and adjusting the design value { H } of the welding clearance surface difference of the vehicle door, and when the actual vehicle door is assembled, the extreme difference of the clearance surface difference { Z } is adjustedRWhen the requirements are not met, the stability of the process from welding to final assembly is improved;
the vehicle door welding and coating device comprises an execution unit (500), wherein the execution unit (500) is used for welding, coating and assembling the vehicle door.
2. The automotive door clearance face difference control system according to claim 1, characterized in that: the data processing module (300) is configured to process the data according to the formula { H }0Obtaining an initial design value { H } of the welding clearance surface difference of the vehicle door { Z } - { C }0And Z is a design value of the vehicle door assembly clearance surface difference, and C is a simulated value of the vehicle door assembly clearance surface difference.
3. The automotive door clearance face difference control system according to claim 2, characterized in that: the technical process that the execution unit (500) welds the vehicle door further comprises the steps of pre-lifting the vehicle door metal plate assembly during assembling, and pre-bending the vehicle door metal plate assembly in the vehicle door welding process.
4. The automotive door clearance face difference control system according to claim 3, characterized in that: the control module (400) is also used for controlling the execution unit (500) to weld the vehicle door and adjusting the technological parameters of the vehicle door welding until the difference mean deviation of the actual vehicle door welding clearance surface
Extremely poor { H ] with the welding clearance surface difference of the actual car doorRAll satisfy the requirements.
5. The automotive door clearance face difference control system according to claim 4, characterized in that: the control module (400) is further configured to determine when the actual door final assembly clearance surface difference mean deviation occurs during execution of act S4-2
When the requirements are not met, the control data processing unit (300) adjusts the design value { H } of the welding clearance surface difference of the vehicle door to be
6. A control method of the automobile door clearance and surface difference control system based on claim 5 is characterized in that:
s1: determining an initial design value { H } of the gap surface difference of the welding machine door according to the design value { Z } of the gap surface difference of the general assembly of the vehicle door and the simulated value { C } of the gap surface difference of the general assembly of the vehicle door0Giving an initial value to a welding clearance surface difference design value { H }, and making { H } ═ H }, a welding clearance surface difference design value { H } be a welding clearance surface difference design value, and a welding clearance surface difference design value is obtained by adding the initial value to the welding clearance surface difference design value { H }, and then giving a welding clearance surface difference design value to the welding clearance surface difference design value { H }, and giving a welding clearance surface difference design value to the welding clearance surface difference design value { H }, wherein the welding clearance surface difference design value is obtained by adding the initial value to the welding clearance surface difference design value { H } and the welding clearance surface difference design value { H } to the welding clearance surface difference design value to the welding clearance surface difference0}；
S2: welding the car door to make the actual car door welding clearance surface difference mean deviation
Does not exceed the welding clearance face difference tolerance (D) of the vehicle doorHThe range limited, and the actual welding clearance surface difference of the vehicle door { H }RNo greater than the tolerance of the welding clearance face difference of the vehicle door (R)HA limit value of };
s3: coating and final assembly are carried out to obtain the difference mean deviation of the clearance surface of the actual vehicle door final assembly
And the extreme difference of the actual vehicle door assembly clearance surface difference { Z }RJudging whether the two meet the requirements;
s4-1: when the difference mean deviation of the actual vehicle door assembly clearance surface
Range of clearance surface difference from actual vehicle door assembly { ZROutputting a design value of the vehicle door welding clearance surface difference { H } as a final design value of the vehicle door welding clearance surface difference when all the requirements are met;
s4-2: when the difference mean deviation of the actual vehicle door assembly clearance surface
When the requirements are not met, adjusting the design value { H } of the welding clearance surface difference of the vehicle door; when the final assembly clearance surface of the actual vehicle door is poor, the polar difference ZRWhen the requirements are not metThe stability of the process from welding to final assembly is improved; repeating the steps S2-S3 until the average deviation of the difference of the actual door assembly clearance surface
And the extreme difference of the actual vehicle door assembly clearance surface difference { Z }RAll satisfy the requirements.
7. The control method of the automobile door clearance face difference control system according to claim 6, characterized in that: the welding process for the vehicle door further comprises the steps of pre-lifting the vehicle door metal plate assembly during assembling, and pre-bending the vehicle door metal plate assembly in the vehicle door welding process.
8. The control method of the automobile door clearance face difference control system according to claim 6, characterized in that: when the difference mean deviation of the actual vehicle door assembly clearance surface
When the requirements are not met, adjusting the design value { H } of the welding clearance surface difference of the vehicle door to be
9. The control method of the automobile door clearance face difference control system according to claim 6, characterized in that: the method for determining the pre-lifting amount T of the vehicle door sheet metal assembly comprises the step of obtaining the difference between the clearance of the highest measurement point of the vehicle door in the design value { Z } of the total assembly clearance surface difference and the clearance in the design value { H } of the welding clearance surface difference, and the method for determining the pre-bending amount { N } of the vehicle door sheet metal assembly comprises the step of obtaining the difference between the surface difference in the design value { Z } of the total assembly clearance surface difference and the surface difference in the design value { H } of the welding clearance surface difference.
10. The control method of the automobile door clearance face difference control system according to claim 6, characterized in that: when the difference mean deviation of the actual vehicle door assembly clearance surface
Tolerance of mean deviation of gap surface difference of vehicle door final assembly is not exceeded { DZThe limited range is the satisfying requirement, when the actual vehicle door is assembled with the extreme difference of clearance surface difference { Z }RTolerance of range not greater than the difference of the clearance surface of the vehicle door assembly (R)ZAnd meeting the requirement.
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Cited By (1)
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| CN114087944A (en) * | 2021-11-10 | 2022-02-25 | 东风悦享科技有限公司 | Two motorcycle types can change door assembly and examine utensil |
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