CZ291028B6 - Method for assembling and welding, optionally completion of exhaust systems for motor vehicles - Google Patents

Abstract

The present invention relates to a method for assembling and welding, optionally completion of exhaust systems for motor vehicles, which exhaust systems are made of a plurality of prefabricated components such as manifold pipe, main pipes, catalysts, central and end silencers, intermediate pipes and so on. The method is characterized in that automatically adjustable prefabricated carrier and handling systems are used in dependence on the implemented form of the exhaust systems being just required for supporting and fixing of the prefabricated components during their assembling and welding. The individual components are placed on the supporting and fixing system to their intended position, the component system is subjected to rightness check during which the correct selection and/or positioning of the components is checked, adjacent components are welded to partial units and subsequently at least one test of a catalyst, optionally a partial unit containing the manifold pipe is subjected to leakage test, the partial units are brought to a final correct position, whereupon the partial units are welded together and the exhaust system is removed from the supporting and fixing system.

Description

Technical field

The present invention relates to the assembly and welding, or assembly, of exhaust systems for motor vehicles consisting of several prefabricated components such as manifolds, main tubes, catalysts, middle and end silencers, middle tubes and the like.

BACKGROUND OF THE INVENTION

Recently, there has been a tendency in automotive concerns to dedicate the assembly of vehicle modules to the greatest possible extent, and to let suppliers supply already assembled vehicle assembly units so that only the final assembly is carried out at the respective assembly plant.

Automotive companies probably have the complete assembled exhaust systems delivered to assembly plants, and the preparation time is often only a few hours. This is somewhat problematic, since exhaust systems for motor vehicles generally have a uniform basic design, but may vary considerably in size depending on the type of vehicle or engine, so supply companies have to prepare numerous design variants.

In order to avoid storage costs for car manufacturers, supply companies must be flexible enough to assemble different exhaust systems within a short period of time.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an assembly method that overcomes the above-mentioned disadvantages and by means of which it is possible to assemble and assemble differently improved exhaust systems for motor vehicles in a short time from prefabricated components. The assembly method according to the invention is particularly suitable for automation.

In principle, this is because, depending on the desired form of exhaust systems, a self-adjustable support and handling system is used to support and fix the prefabricated components during assembly and welding. The individual components are placed on the support and fixation system in the appropriate position, the assembled component set is subjected to a correctness check, in which the correct selection and / or positioning is checked, neighboring components are welded to sub-units, followed by at least one catalyst test. and the sub-units containing the manifold, for leakage, the sub-units are brought to their final correct position, after which the sub-units are welded and the exhaust system is removed from the support and fixation system.

Since the individual components of the assembled exhaust system are fixed to the support and fixing system during the entire assembly, the method according to the invention is relatively simple and time-saving.

The accuracy check is preferably performed by measuring the relevant dimensions for installing the exhaust systems in the vehicle. Once the alignment is correct, the main pipe catalytic converter can be welded as one sub-unit and the rear part of the exhaust system with center and end silencers can be welded as the second sub-unit. The test for leakage of the catalytic converter and, if applicable, of the sub-unit containing the manifold may be carried out by measuring the pressure difference between

The engine-side main pipe connection flange and catalytic converter outlets. Errors are signaled at the correctness check and the check procedure is interrupted in response to the detected error.

The method is particularly suitable for automation, since on the basis of the defined positions of the components during assembly, the contact points between the individual components to be welded are precisely defined, so that the welding process can be carried out without difficulty by a welding robot. The catalysts contained in the sub-parts can be carried out automatically without problems.

Through the inspection steps during the installation method, it is determined that finished exhaust systems can be mounted on the vehicles without difficulty and can also be operated without any defects.

Advantageously, the individual components, for example by means of programmable robot systems, are automatically removed, depending on the desired exhaust system 15, from the respective warehouses and placed and fixed on the support and fixation system.

Overview of the drawings

The present invention will be further elucidated on the basis of exemplary embodiments thereof in conjunction with the accompanying drawings, in which:

Figure 1 shows the individual prefabricated components of a first embodiment of an exhaust system for motor vehicles assembled according to the present invention;

Figure 2a to 2c the relevant operating steps in performing the assembly and welding of the exhaust system shown in Figure 1 according to the present invention;

Figure 3 shows individual prefabricated components of a second embodiment of an exhaust system 30 for a motor vehicle mounted in accordance with the present invention;

Figures 4a to 4c show the individual steps of performing the assembly and welding method of the exhaust system shown in Figure 3.

DETAILED DESCRIPTION OF THE INVENTION

Figure 1 shows, by way of example, the most important components of a first embodiment of an exhaust system for motor vehicles which is mounted in accordance with the present invention.

This exhaust system includes, in a sequential flow direction, a catalytic converter 2 connectable to the engine via a leading main tube 1, a middle silencer 4 connected to a catalyst 2 via a first main tube 3, and an end silencer 6 connected by means of a second main pipe 5 with a medium sound absorber 4. Further, the exhaust system comprises a 45 bracket 7 for fixing the exhaust system to the vehicle.

The exhaust system is mounted on the assembly station. These include a fixed bed support and fixation system 8 with a fixed slide 10 opposite the fixed bed 9 in the direction of arrow A in Figure 2b.

On the fixed bed 9 and the adjustable carriage 10 there are adjustable clamping mechanisms for fastening the assembled components of the exhaust system. In addition, inductive and capacitive sensors are adjustable on the carrier and fixation system 8 to control the accuracy of the position and location of the individual components on the carrier and fixation system 8.

-2GB 291028 B6

The assembly station is provided with a robot system for removing the individual components of the exhaust system from the respective warehouses and for placing them on the support and fixation system 8. It is further equipped with automatic welding machines for the components mounted on the support and fixation system 8.

To control the assembly station, a programmable control device is envisaged by which the robot system, the sled 10 and the sensors of the support and fixation system 8, the sensors as well as the welding machines will be assigned, positioned and controlled to the desired exhaust system.

In operation, the operator enters the exhaust system to be assembled into the control unit. To simplify the task, the various exhaust systems are keyed as code numbers and can be read by a coding reader.

Depending on the exhaust system selected, the carriage 10, sensors and sensors are first set up on the support and fixation system 8. Then, the robot system removes the individual components belonging to the exhaust system from the respective warehouses and places them in the corresponding order on the support and fixation system 8 will be attached, using sensors. In this case, the main tube 1 and the catalytic converter 2 are placed and fixed on the movable carriage 10 and the other individual components of the exhaust system on a fixed bed 9.

Subsequently, the component arrangement thus formed is subjected to an inspection in which, by means of sensors, it is verified, on the basis of the critical dimensions of the components for mounting on the vehicle, that the corresponding components are used and correctly positioned.

If an error is detected, the control device issues the appropriate error signal and the procedure is interrupted.

If, however, no errors are detected, the overhang main pipe 1 with the catalyst 2 and the first main pipe 3 are welded by means of automatic welding robots or welding robots to form the first sub-unit as well as the middle sound absorber 4, second main pipe 5 and end damper 6 sound as the second subunit. In addition, a holder 7 for welding the exhaust system on the vehicle is welded onto the first main tube 3 as shown in Figure 2a.

Upon completion of this welding process, the sub-unit located on the adjustable carriage 10, consisting of the catalyst 2, the main tube 1 and the first main tube 5, is subjected to a leak check which is carried out by measuring the differential pressure between the connecting flange on the main tube side 1 The position and control of the test apparatus 11 used for this purpose, which is adjustable in relation to the support and fixing system 7 in the direction of the arrows B and C, is also controlled by the control device.

If, during the test procedure, it is found that the sub-unit containing the catalyst 2 is leaking, the control device gives an error signal and the procedure is interrupted.

The adjustable carriage 10 of the tester 11, after carrying out the test procedure, removes the sub-units located on the adjustable carriage 10 and the fixed bed 9 from the position shown in Figure 2b and adjusts them to the correct position as indicated in Figure 2c. common unit.

After additional components have been placed on the exhaust system, such as probes and other components, for example, the latter is removed, for example by means of a robot or a conveyor belt, from the assembly station. Alternatively, additional parts or other equipment of the exhaust system can also be placed on the exhaust system after leaving the assembly station.

FIG. 3 shows a second embodiment of the exhaust system, this exhaust system being distinguished from the exhaust system shown in FIG. 1 only in that the manifold 12 is disposed in front of the main tube 1, which, as shown in FIGS. 4a and 4c,

The mounting of the exhaust system with the main tube 1 and the catalytic converter 2 is mounted on the movable carriage 10, welded into one sub-unit and subjected to a leak check.

Industrial applicability

With this installation method, the various exhaust systems can be automatically mounted one after the other. The permanent positioning of the individual components on the fixed bed 9 and the adjustable carriage 10 is of importance here, thereby ensuring that the welding and inspection sites are precisely determined. The planned accuracy and leakage check reveals that the assembled exhaust systems can be easily mounted on the vehicles for which they are intended and at the same time ensure their correct function.

Claims (5)

1. Method of assembly and welding, eventually assembly of exhaust systems for motor 20 vehicles, made up of a plurality of prefabricated components such as manifold, main tubes, catalytic converters, middle and end silencers, middle tubes, based on the fact that, depending on the currently realized form of exhaust systems, automatically adjustable supporting and handling systems are used supporting and fixing the prefabricated components during assembly and welding, characterized in that they are individual The components are set to the appropriate position on the support and fixation system, the assembled component set is subjected to a correctness check to check the correct selection and / or positioning of the components, the adjacent components are welded to sub-units, followed by at least one catalyst test. and the sub-units containing the manifold for tightness, the sub-units are brought to their final correct position, the sub-units are welded, and the exhaust system is removed from the support and fixation system. Method according to claim 1, characterized in that the accuracy check is carried out by measuring the relevant dimensions for the installation of exhaust systems in the vehicle. 35 Method according to claim 1 or 2, characterized in that, after the alignment has been carried out, the main pipe catalyst is welded as one sub-unit and the rear part of the exhaust system is welded with intermediate and end silencers as the second sub-unit. Method according to one of Claims 1 to 3, characterized in that the test for The tightness of the catalyst, and possibly the sub-units containing the manifold, is performed by measuring the pressure difference between the connection side flange of the motor-side lead tube and the catalyst outlet. Method according to one of Claims 1 to 4, characterized in that 45 errors are signaled and the check procedure is interrupted in response to the error detected.