CN114720149A - Vehicle door matching size deviation analysis method taking test bed as carrier - Google Patents
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Abstract
The invention relates to a vehicle door matching size deviation analysis method taking a test bed as a carrier, which is characterized in that a motion simulation system simulates the change of a vehicle door hinge in three directions of XYZ and simulates the change of the posture of a vehicle door on a vehicle body; the data scanning system scans three-dimensional size data of the front and rear vehicle door assemblies by using a high-resolution optical scanner and outputs a required vehicle door function size value according to user selection; scanning the clearance surface difference value of each measuring point under different postures of the vehicle door, inputting the analog value obtained by scanning the measuring points into a reverse iteration system, and calculating the deviation between the analog value of the measuring points under different postures and the measured value of the real vehicle; the invention has convenient and labor-saving operation, can completely realize automatic problem analysis, obtains detailed problem cause through system analysis, provides a correction scheme for quickly correcting problems, and improves the resolution efficiency of size problems.
Description
Technical Field
The invention relates to the technical field of analysis of problems of matching sizes of vehicle doors, in particular to a method for analyzing deviation of matching sizes of vehicle doors by taking a test bed as a carrier.
Background
Along with the market competition is fierce, the product updating iteration period is shorter and shorter, the aesthetic requirement of the market on the appearance of the automobile is continuously improved, the requirement of a host factory on the tolerance of the appearance dimension of the whole automobile is more and more strict, the tolerance of the appearance dimension of the automobile is required to be +/-1.0 mm from the original requirement of the clearance surface difference of the appearance dimension to be +/-0.7 mm at present, even +/-0.5 mm, and the dimension appearance tolerance of the side area is usually +/-0.5 mm and +/-0.7 mm.
The dimensional appearance qualification rate in the field of the side part is always the field which is most difficult to analyze and solve in all host factories, and the side part comprises two opening and closing parts (a front door and a rear door), so that the size chain ring is very long as the size requirement for matching the two opening and closing parts is met, thereby not only bringing great difficulty to problem analysis, but also bringing great difficulty to rectification and solution.
Taking the difference of the clearance surfaces of the bright stripes of the front and rear door and window frames as an example, the measured values of the problem points include the deviation caused by the assembling influence, the deviation caused by the hinge surface influence, the deviation caused by the position influence of the door on the vehicle body, the deviation caused by the door function size influence and the deviation caused by the vehicle body function size influence, wherein the assembling influence and the hinge installation surface size influence are the most unstable factors in the analysis process, so that the problem analysis of the door is very complicated, and the problem elimination time is very long.
Therefore, in the face of such small tolerance requirements, such fast update rhythm, how to quickly analyze the cause of the problem, and give direction and opinion of rectification, becomes an especially urgent problem to be solved.
Compared with the existing analysis method for the size problems, under the conditions of cost control in the trial-manufacturing process and less personnel in the trial-manufacturing stage, the problems that the data samples are insufficient, factors such as long verification period of a carrying vehicle body are restricted, and the gap surface difference of a window frame area is required to be produced in quantity and can be solved under the condition of a large quantity of real vehicle sample quantities, meanwhile, the influence caused by unknown values in the analysis process and unstable installation and debugging processes cannot be continuously analyzed under the condition of insufficient sample quantities. In the analysis process of the actual problems, the whole vehicle evaluation questions of a certain real vehicle are usually used as a source to carry out analysis, if accidental phenomena are analyzed, the real vehicle needs to be disassembled, the disassembled vehicle body and the disassembled vehicle door are sent to three coordinates to be measured, the parts of the well disassembled vehicle door are sent to Cubin to be measured, if the process is disassembled, the parts of the same batch need to be used for measurement, and the whole problem analysis period is very long; if the problem is high in frequency, the data of the vehicle bodies and the vehicle doors in the same batch are analyzed, if unknown values exist, the stability of the parts and the stability of the installation and adjustment of the parts need to be verified, but the stability is difficult to judge due to the limited number of samples.
The patent document with the publication number of CN106218752A relates to a vehicle body size control technology, and belongs to the field of electric vehicle production processes. The method mainly comprises the steps of 1) collecting relevant geometric dimension files and product definitions of the project white body; 2) collecting and verifying a stamping die acceptance record, a welding fixture acceptance record and a checking tool acceptance record, preliminarily judging the body-in-white size deviation condition and possible geometric dimension problems by analyzing the files, and confirming an original plate geometric dimension change scheme; 3) welding a first tooling sample car; 4) analyzing the geometric dimension of the first tooling sample car; 5) and carrying out problem analysis and adjustment in different areas. The method effectively solves the problem of the geometric dimension of the vehicle body, quickly and efficiently completes the comprehensive dimension matching of the white vehicle body and parts of the whole vehicle, and simultaneously provides an analysis method and a prevention measure of related problems. Thereby shortening the industrial development period of the product and reducing the industrial cost.
The above patents are different from the present application, and no related patent is found through searching, and no reference scheme is found in the present application.
Disclosure of Invention
The invention aims to solve the technical problems that in the prior art, when the vehicle door matching problem is analyzed, the source of an unknown value is unclear, clear and effective data support is unavailable, the analysis time is long and the like, and provides a vehicle door matching size deviation analysis method taking a test bed as a carrier.
With the test bench, as shown in fig. 8, the test bench comprises four parts, including a bottom plate platform 1, a control vehicle door Z-direction movement part 2, a control vehicle door X-direction movement part 3 and a detection part 4, the method has great advantages in the aspects of analyzing single problems and problems with high frequency of problem analysis, only needs to put the door assembly on a test bed, utilizes a simulation system to simulate the change of the door hinge in three directions of XYZ, simulates the change of various postures (camber, inclination, forerake, retroversion and position) of the door on the vehicle body, obtains the deviation influence caused by installation and adjustment, the size deviation influence of the hinge surface and the specific influence value of the position deviation of the door in the Z direction of the vehicle body on a problem point, meanwhile, the data scanning system is used for obtaining the functional size deviation of the vehicle door, and finally, the specific deviation number of the functional size of the vehicle body is obtained through operation processing. Through the analysis, the complete disassembly of the side dimension problems is obtained.
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
In order to solve the technical problems, the invention is realized by adopting the following technical scheme:
a vehicle door matching size deviation analysis method taking a test bed as a carrier is characterized in that:
the motion simulation system simulates the change of the door hinge in three directions of XYZ and simulates the change of the posture of the door on the vehicle body;
the data scanning system scans three-dimensional size data of the front and rear vehicle door assemblies by using a high-resolution optical scanner and outputs a required vehicle door function size value according to user selection; and scanning the clearance surface difference value of each measuring point under different postures of the vehicle door, and inputting the analog value obtained by scanning into a reverse iteration system for calculating the deviation between the analog value under different postures and the measured value of the real vehicle.
Further, the motion simulation system comprises six servo electric cylinders for controlling the motion of the hinge XYZ in three directions through controlling displacement and one servo electric cylinder for simulating the sinking amount of the vehicle door through controlling force.
Further, the motion simulation system simulates changes in the attitude of the vehicle door on the vehicle body, wherein the attitude on the vehicle body comprises camber, forward lean, backward lean, and position.
Furthermore, the motion simulation system comprises a metal frame, seven servo electric cylinders and controllers thereof, a speed reducer and a hinge connection module, wherein the rear door assembly to be tested is arranged on the test bed through the hinge connection module; seven servo electric cylinders are controlled to move by simulating control signals and controlling the force and displacement.
Furthermore, the data scanning system comprises a high-resolution optical scanner, and based on a blue light technology, the measuring head uses thin-strip blue light, so that in the image acquisition process, ambient light interference is filtered, and accurate three-dimensional measurement data of the functional size of the vehicle door is calculated.
Furthermore, the reverse iteration system takes all the subsystems as a system, and the control signal of each servo electric cylinder is input, namely the control signal matrix [ x ] of the servo electric cylinder]Obtaining the simulation value matrix [ y ] of each measuring point under different postures after the system response]Control signal matrix [ x ] with servo electric cylinder]Correspondingly, a response function matrix [ H ] of the reverse iterative system is obtained through calculation]While passing through the inversion matrixTo obtain the size response function [ H ] of the reverse iterative system-1]Finally, through an iterative algorithm, a matrix [ y ] of the simulation values of all the measuring points under different postures is obtained]Through iteration, the real measurement values of the infinite approaching measurement points in the real vehicle state are recorded, and the control signal matrix [ x ] of the seven servo electric cylinders when the real measurement values of the nearest measurement points are recorded]Namely, the influence factor value which influences the matching size deviation of the vehicle door in the real vehicle state.
Further, the control signal matrix [ x ] of the input servo electric cylinder]Mainly from X-direction deviation X of hinge surface on vehicle door1X-direction deviation X of lower hinge surface of car door2Y-direction deviation x of hinge surface on vehicle body3Y-direction deviation x of lower hinge surface of vehicle body4Z-direction position deviation x of upper hinge and lower hinge of vehicle body5、x6And a door weight x7And (4) forming.
Further, the response function matrix [ H ]]Size response function [ H ]-1]The following were used:
referring to FIG. 2, two paths of displacement signals are inputted (X direction deviation X of hinge surface on vehicle door)1X-direction deviation X of lower hinge surface of car door2) Its response function matrix [ H ]]Size response function [ H ]-1]The following were used:
[y]＝[H][x] [x]＝[H-1][y]
in the formula: [ x ]: a control signal matrix of a servo electric cylinder in the motion simulation system;
x1: deviation of the hinge surface on the vehicle door in the X direction;
x2: deviation of the lower hinge surface of the vehicle door in the X direction;
[ y ]: analog value matrixes of various measuring points under different postures;
y1、y2：[y]simulated values of 2 stations in (1)The positions of the measuring points can be set at will, as shown in the example of FIG. 3;
[H] the method comprises the following steps A matrix of response functions;
[H-1]: a size response function;
according to the response of the whole system, obtaining a control signal matrix [ x ] of the input servo electric cylinder]Matrix of simulated values [ y ] from respective measurement points at different attitudes]The size response function [ H ] is obtained by matrix inversion operation-1]。
Further, a size response function [ H ] is obtained-1]Then, the measured value of the real vehicle measuring point is input into a reverse iteration system, and the reverse iteration system controls a control signal matrix [ x ] of a servo electric cylinder in the motion simulation system through an iteration algorithm]The control command is sent out by the controller to control seven servo electric cylinders to move, and a signal matrix [ x ] is controlled every time]After the input of the system is responded by the whole set of system, the analog value matrix [ y ] of each measuring point under different postures is obtained]Then, the analog value matrix [ y ] of the measuring point is measured]Comparing with the corresponding measured point to obtain an analog value matrix [ y]And continuously iterating and approaching the deviation amount between the measured values of the corresponding measuring points, continuously reducing the deviation amount between the measured values and the measured values of the corresponding measuring points, and setting an error rate to achieve a final iteration result.
Further, through comparison and iterative approximation, after a target error rate is reached, the displacement deviation amount of different servo cylinders under the control state relative to the theoretical position 0 is recorded, and meanwhile, the size deviation y of the vehicle door obtained through scanning in a data scanning system is outputDeviation value of vehicle door sizeFinally, the measured value y of the measuring point is measuredMeasured value of measuring pointSubtracting the final analog value y after the iteration of the corresponding measuring pointAnalog value of measuring pointThen subtracting the size deviation value y of the vehicle doorDeviation value of vehicle door sizeAnd finally obtaining a result, namely the deviation value of the vehicle body size, wherein the calculation formula is as follows:
ydeviation value of vehicle body dimension at measuring point position＝yMeasured value of measuring point-yAnalog value of measuring point-yDeviation value of vehicle door size
Finally, by the method, canA control signal matrix [ x ] of the servo cylinder when the actual measurement value of the actual vehicle is obtained](i.e., dimensional deviation of the door upper and lower hinge surfaces in the X-direction, dimensional deviation of the body upper and lower hinge surfaces in the Y-direction, and positional deviation of the door in the Z-direction) and scanning the same to obtain the dimensional deviation Y of the doorDifference in door dimensionsCalculating to obtain the size deviation y of the vehicle bodyDeviation value of vehicle body dimension at measuring point positionThe above information is summarized as the influence factor for generating the deviation of the measured value of the measuring point.
Compared with the prior art, the invention has the beneficial effects that:
the method is convenient and labor-saving to operate, can completely realize automatic analysis of problems, systematically analyzes the true cause of the problems of size matching of the real vehicle door, provides data support for unknown values generated in the analysis process, provides a correction scheme for quickly correcting the problems, and improves the analysis efficiency for analyzing the problems of the size of the vehicle door.
Drawings
The invention is further described with reference to the accompanying drawings in which:
FIG. 1 is a schematic representation of accurate three-dimensional measurement data for calculating functional dimensions of a vehicle door using a high resolution optical scanner;
FIG. 2 is a schematic diagram of two signals, which are X-direction deviation X of hinge surface on the door1X-direction deviation X of lower hinge surface of car door2A schematic diagram;
FIG. 3 is an exemplary diagram of output positions of a measured point simulation value matrix [ y ];
FIG. 4 is a system diagram of a method for analyzing the deviation of the matching dimension of a vehicle door using a test bed as a carrier according to the present invention;
FIG. 5 is a control flow diagram of the motion simulation system of the present invention;
FIG. 6 is a control flow diagram of the data scanning system of the present invention;
FIG. 7 is a control flow diagram of a reverse iteration system of the present invention;
FIG. 8 is an isometric view of a test stand used in the present invention;
FIG. 9 is a view showing the effect of the back door being mounted to the test stand according to the present invention;
in the figure: 1. a base plate platform; 2. controlling a Z-direction moving part of the vehicle door; 3. controlling the X-direction moving part of the vehicle door; 4. a detection section.
Detailed Description
In order to make the implementation objects, technical solutions and advantages of the present invention clearer, the technical solutions in the embodiments of the present invention will be described in more detail below with reference to the accompanying drawings in the embodiments of the present invention. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The described embodiments are illustrative of some, but not all embodiments of the invention. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention. Embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
In the description of the present invention, it is to be understood that the terms "central," "longitudinal," "lateral," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like are used in the orientations and positional relationships indicated in the drawings, which are based on the orientation or positional relationship shown in the drawings, and are used for convenience of description and simplicity of description, but do not indicate or imply that the device or element so referred to must have a particular orientation, be constructed in a particular orientation, and be operated, and therefore should not be construed as limiting the scope of the invention.
The invention is described in detail below with reference to the attached drawing figures:
a car door matching size deviation analysis method with a test bed as a carrier comprises the following three parts:
the first part is a motion simulation system which simulates the change of XYZ three directions of a door hinge so as to simulate the change (camber, dip, forward tilt, backward tilt and position) of various postures of a door on a vehicle body, the system mainly comprises six servo electric cylinders which control the movement of the hinge in three directions through controlling displacement and one servo electric cylinder which simulates the sinking amount of the door through controlling force, and a test bed consists of four parts in total and comprises a bottom plate platform 1, a door Z-direction control movement part 2, a door X-direction control movement part 3 and a detection part 4; the bottom plate platform 1 is placed on a horizontal ground; the Z-direction moving part 2 of the control vehicle door is fixed at one end of the bottom plate platform 1; the control vehicle door X-direction moving part 3 is fixed with the control vehicle door Z-direction moving part 2; the detection part 4 is fixed at the other end of the bottom plate platform 1; the control vehicle door Z-direction moving part 2 and the control vehicle door X-direction moving part 3 control the Z-direction displacement and the X-direction displacement of the vehicle door; after the detection part 4 is adjusted to the theoretical position, the vehicle door assembly is hung on the X-direction movement part 3 of the control vehicle door, the C column of the vehicle door and a door lock detection block in the detection part 4 are sucked to be flat by a magnet, the Y-direction rotation of the vehicle door is limited, and a structural diagram refers to fig. 8.
The second part is a data scanning system that is based on blue light technology using a high resolution optical scanner. Because the measuring head uses the thin-strip blue light, the interference of ambient light can be effectively filtered in the image acquisition process. The light source with abundant energy is helpful to shorten the measuring time. By utilizing the high-resolution optical scanner, the accurate three-dimensional measurement data of the functional size of the car door can be rapidly calculated. See fig. 1.
The third part is a reverse iterative system which utilizes a set of iterative algorithms to realize the reproduction of the problem. The main working principle is that all subsystems are used as a system, and control signal matrixes x of different servo electric cylinders]Obtaining the simulation value matrix [ y ] of each measuring point under different postures after the system response]Control signal matrix [ x ] with servo electric cylinder]Correspondingly, inputting a control signal matrix [ x ] of the servo electric cylinder]Mainly from X-direction deviation X of hinge surface on vehicle door1X-direction deviation X of lower hinge surface of car door2Y-direction deviation x of hinge surface on vehicle body3Y-direction deviation x of lower hinge surface of vehicle body4Z-direction position deviation x of upper hinge and lower hinge of vehicle body5、x6And a door weight x7Composition, through inputting seven variable values in a large quantity, a response function matrix [ H ] of the system can be obtained through calculation]At the same timeObtaining the size response function [ H ] of the whole system by matrix inversion-1]。
Obtaining a size response function [ H-1]Then, the measured value of the real vehicle measuring point is input into the system, and the system outputs a control signal [ x ] for controlling the servo electric cylinder through an iterative algorithm]Controlling seven servo electric cylinders to move, wherein each time the control signal [ x ] is converted]Obtaining the analog value matrix [ y ] of the corresponding measuring point after the system response]Then the analog value matrix [ y]And comparing with a measured value of the measured point, and achieving a final iteration result by continuously comparing, iteratively approaching and setting an error rate. For example, 30 measured points are input, and each iteration generates a matrix of simulated values [ y ] of 30 corresponding measured point positions]Setting error rate to 80%, i.e. after 30 points are close to input measured value, through comparison and iterative approximation, and when the target error rate is reached, recording control signal matrix [ x ] of servo electric cylinder at this moment](i.e., dimensional deviation of door upper and lower hinge surfaces in X-direction, dimensional deviation of body upper and lower hinge surfaces in Y-direction, positional deviation of door in Z-direction) and scanningDeviation value of vehicle door sizeAnd then calculating to obtain the size deviation y of the vehicle bodyVehicle body ruler deviation value of measuring point positionThe above information is summarized as the influence factor for generating the deviation of the measured value of the measuring point.
A vehicle door matching size deviation analysis method with a test bed as a carrier comprises three parts, namely a motion simulation system, a data scanning system and a reverse iteration system, and is shown in figure 4.
The first part is a motion simulation system, a flow chart refers to fig. 5, the system comprises a metal frame, a servo electric cylinder and a controller thereof, a speed reducer, a hinge connection module and the like, firstly, a tested rear door assembly passes through the hinge connection module, a vehicle door is installed on a test bench, and a structure refers to fig. 9 after installation is completed. The movement of seven servo electric cylinders is controlled by controlling a control signal matrix [ x ] of the servo electric cylinders, wherein three servo electric cylinders are responsible for controlling the movement of the hinge on the car door in three directions of XYZ, three servo electric cylinders are responsible for controlling the movement of the hinge under the car door in three directions of XYZ, and the last servo electric cylinder is responsible for controlling the sinking amount of the car door. Through the movement of the servo electric cylinder, the change (camber, inclination, forward inclination, backward inclination and Z-direction position) of various postures of the car door on the car body is simulated, and the car door is used for scanning data by a scanning system;
the second part is a data scanning system, see fig. 6, which is based on the blue light technique using a high resolution optical scanner. The high-resolution optical scanner can scan the three-dimensional size data of the front and rear door assemblies, and can output the required door size deviation value y according to the selection of a userDeviation value of vehicle door size(ii) a Simultaneously, the clearance surface difference value of each measuring point under different postures of the vehicle door can be scanned (the measuring point can freely set the position according to the requirement of a user), and the simulated value matrix [ y ] of each measuring point under different postures obtained by scanning]Comparing the measured values with the measured values of the actual vehicle measuring points, and inputting the deviation amount to the reverse iteration system;
the third part is a reverse iterative system, which uses a set of iterative algorithms to reproduce the real-world problem, see fig. 7. The main realization process is as follows: firstly, all subsystems are taken as a system, and control signal matrixes [ x ] of different servo electric cylinders]Obtaining the simulation value matrix [ y ] of each measuring point under different postures after the system response]Control signal matrix [ x ] with servo electric cylinder]Correspondingly, inputting a control signal matrix [ x ] of the servo electric cylinder]Mainly from X-direction deviation X of hinge surface on vehicle door1X-direction deviation X of lower hinge surface of car door2Y-direction deviation x of hinge surface on vehicle body3Y-direction deviation x of lower hinge surface of vehicle body4Z-direction position deviation x of upper hinge and lower hinge of vehicle body5、x6And a door weight x7The composition, through inputting seven variable values in large quantity, the response function matrix [ H ] of the system can be obtained through calculation]And simultaneously obtaining the size response function [ H ] of the whole system by matrix inversion-1]。
Obtaining a size response function [ H-1]Then, the measured value of the real vehicle measuring point is input into the system, and the system outputs a control signal [ x ] for controlling the servo electric cylinder through an iterative algorithm]Controlling seven servo electric cylinders to move, wherein each time the control signal [ x ] is converted]Obtaining the analog value matrix [ y ] of the corresponding measuring point after the system response]Then the analog value matrix [ y]And comparing with the measured value of the measured point, and achieving the final iteration result by continuously comparing, iterating and approximating and setting the error rate. For example, 30 measured points are input, and each iteration generates 30 simulation value matrixes [ y ] corresponding to the measured point positions]Setting error rate to 80%, i.e. after 30 points are close to input measured value, through comparison and iterative approximation, and when the target error rate is reached, recording control signal matrix [ x ] of servo electric cylinder at this moment](i.e., dimensional deviation of door upper and lower hinge surfaces in X-direction, dimensional deviation of body upper and lower hinge surfaces in Y-direction, positional deviation of door in Z-direction) and scanningDeviation value of vehicle door sizeAnd then calculating to obtain the size deviation y of the vehicle bodyDeviation value of vehicle body dimension at measuring point positionThe above information is summarized as the influence factor for generating the deviation of the measured value of the measuring point.
The invention has convenient and labor-saving operation, can completely realize automatic problem analysis, obtains detailed problem cause through system analysis, provides a correction scheme for quickly correcting problems, and improves the resolution efficiency of size problems.
The invention uses a simulation system to simulate various postures of the car door on the car body. And (4) through an iterative algorithm, taking the measured values of the side sizes as input, and reversely solving to obtain the deviation values of all the influencing elements. All opening and closing members can be analyzed in the manner of the present application, for example, the size analysis of the rear cover.
The above description is only for the purpose of illustrating the present invention and the appended claims are not to be construed as limiting the scope of the invention, which is intended to cover all modifications, equivalents and improvements that are within the spirit and scope of the invention as defined by the appended claims. And those not described in detail in this specification are well within the skill of those in the art.
Claims (10)
1. A car door matching size deviation analysis method using a test bed as a carrier is characterized in that:
the motion simulation system simulates the change of the door hinge XYZ in three directions and simulates the change of the posture of the door on the vehicle body;
the data scanning system scans three-dimensional size data of the front and rear vehicle door assemblies by using a high-resolution optical scanner and outputs a required vehicle door function size value according to user selection; and scanning the clearance surface difference value of each measuring point under different postures of the vehicle door, and inputting the analog value obtained by scanning into a reverse iteration system for calculating the deviation between the analog value under different postures and the measured value of the real vehicle.
2. The method for analyzing the matching dimension deviation of the vehicle door with the test bed as the carrier according to claim 1, characterized in that:
the motion simulation system comprises seven servo electric cylinders, wherein six servo electric cylinders control the hinge XYZ to move in three directions through control displacement, and one servo electric cylinder simulates the sinking amount of the vehicle door in the Z direction through control force.
3. The method for analyzing the matching dimension deviation of the vehicle door with the test bed as the carrier according to claim 1, characterized in that:
the data scanning system comprises a high-resolution optical scanner, a measuring head uses thin-strip blue light on the basis of a blue light technology, ambient light interference is filtered in the image acquisition process, and accurate three-dimensional measurement data of the functional size of the car door are calculated.
4. The method for analyzing the matching dimension deviation of the vehicle door with the test bed as the carrier according to claim 1, characterized in that:
the reverse iteration system takes all subsystems as a system, and the control signal of each servo electric cylinder is input, namely a control signal matrix [ x ] of the servo electric cylinder]Obtaining the simulation value matrix [ y ] of each measuring point under different postures after the system response]Control signal matrix [ x ] with servo electric cylinder]Correspondingly, a response function matrix [ H ] of the reverse iterative system is obtained through calculation]And simultaneously obtaining a size response function [ H ] of the reverse iterative system through matrix inversion operation-1]And finally by iterative algorithmThe simulation values of all the measuring points under different postures are subjected to matrix [ y]Through iteration, the real measurement values of the infinite approaching measurement points in the real vehicle state are recorded, and the control signal matrix [ x ] of the seven servo electric cylinders when the real measurement values of the nearest measurement points are recorded]That is, under the real vehicle state, the influence factor value of the door matching size deviation is influenced, wherein the influence factor influencing the door matching mainly includes: the X-direction dimensional deviation of the upper and lower hinge surfaces of the door, the Y-direction dimensional deviation of the upper and lower hinge surfaces of the body, the Z-direction positional deviation of the door on the body, the dimensional deviation of the door, the dimensional deviation of the body and the door counterweight.
5. The method for analyzing the matching dimension deviation of the vehicle door with the test bed as the carrier according to claim 4, wherein the method comprises the following steps:
the control signal matrix [ x ] of the input servo electric cylinder]Mainly from X-direction deviation X of hinge surface on vehicle door1X-direction deviation X of lower hinge surface of car door2Y-direction deviation x of hinge surface on vehicle body3Y-direction deviation x of lower hinge surface of vehicle body4Z-direction position deviation x of upper hinge and lower hinge of vehicle body5、x6And a door weight x7And (4) forming.
6. The method for analyzing the matching dimension deviation of the vehicle door with the test bed as the carrier according to claim 5, wherein the method comprises the following steps:
by inputting X-direction deviation X of hinge plane on vehicle door1X-direction deviation X of lower hinge surface of car door2Two-way displacement signal is taken as an example, and response function matrix [ H ] of the two-way displacement signal]Size response function [ H ]-1]The following were used:
in the formula: [ x ]: a control signal matrix of a servo electric cylinder in the motion simulation system;
x1: deviation of the hinge surface on the vehicle door in the X direction;
x2: deviation of the lower hinge surface of the vehicle door in the X direction;
[ y ]: analog value matrixes of various measuring points under different postures;
y1、y2：[y]the simulation values of 2 measuring points in the system can be set at will, and the positions of the measuring points can be set as shown in an example in FIG. 3;
[H] the method comprises the following steps A matrix of response functions;
[H-1]: a size response function;
according to the response of the whole system, obtaining a control signal matrix [ x ] of the input servo electric cylinder]Matrix of simulated values [ y ] from respective measurement points at different attitudes]The size response function [ H ] is obtained by matrix inversion operation-1]。
7. The method for analyzing the matching dimension deviation of the vehicle door with the test bed as the carrier according to claim 6, wherein the method comprises the following steps:
obtain the size response function [ H ]-1]Then, the measured value of the real vehicle measuring point is input into a reverse iteration system, and the reverse iteration system controls a control signal matrix [ x ] of a servo electric cylinder in the motion simulation system through an iteration algorithm]The control command is sent out by the controller to control seven servo electric cylinders to move, and a signal matrix [ x ] is controlled every time]After the input of the system is responded by the whole set of system, the analog value matrix [ y ] of each measuring point under different postures is obtained]Then, the analog value matrix [ y ] of the measuring point is used]Comparing with the corresponding measured point to obtain an analog value matrix [ y]And continuously iterating and approaching the deviation amount between the measured values of the corresponding measuring points, continuously reducing the deviation amount between the measured values and the measured values of the corresponding measuring points, and setting an error rate to achieve a final iteration result.
8. The method for analyzing the matching dimension deviation of the vehicle door with the test bed as the carrier according to claim 7, wherein the method comprises the following steps:
through comparison and iterative approximation, after the target error rate is reached, the displacement deviation amount of different servo electric cylinders under the control state relative to the theoretical position 0 is recorded, and meanwhile, the size deviation y of the vehicle door obtained through scanning in a data scanning system is outputDeviation value of vehicle door sizeAnd finally, measuring the pointMeasured value of (y)Measured value of measuring pointSubtracting the final analog value y after the iteration of the corresponding measuring pointAnalog value of measuring pointThen subtracting the size deviation value y of the vehicle doorDeviation value of vehicle door sizeAnd finally obtaining a result, namely the deviation value of the vehicle body size, wherein the calculation formula is as follows:
ymeasurement point position vehicle door size deviation value＝yMeasured value of measuring point-yAnalog value of measuring point-yDeviation value of vehicle door size
Can obtain a control signal matrix [ x ] of the servo cylinder when the actual measurement value of the actual vehicle is generated]That is, the dimensional deviation of the upper and lower hinge surfaces of the door in the X direction, the dimensional deviation of the upper and lower hinge surfaces of the vehicle body in the Y direction, and the positional deviation of the door in the Z direction on the vehicle body, and the dimensional deviation Y of the door can be obtained by scanningDeviation value of vehicle door sizeCalculating the size deviation y of the vehicle body by the formulaDeviation value of vehicle body dimension at measuring point positionThe above information is summarized as the influence factor for generating the deviation of the measured value of the measuring point.
9. The method for analyzing the matching dimension deviation of the vehicle door with the test bed as the carrier according to claim 1, characterized in that:
the motion simulation system simulates the change of the posture of the vehicle door on the vehicle body and comprises the outward inclination, inward inclination, forward inclination, backward inclination of the vehicle door and the Z-direction position change of the vehicle door on the vehicle body.
10. The method for analyzing the matching dimension deviation of the vehicle door with the test bed as the carrier according to claim 1, characterized in that:
the motion simulation system comprises a metal frame, seven servo electric cylinders and controllers thereof, a speed reducer and a hinge connection module, wherein a tested rear door assembly passes through the hinge connection module, and a rear door is arranged on a test bench; and the seven servo jacking electric cylinders are controlled to move by simulating control signals and controlling the force and displacement.
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