DE102016002767A1 - Tooling device and method for roll folding with ultrasonic superposition - Google Patents

Abstract

The invention relates to a tool device (100) for roll folding, comprising a roll folding head (110) which can be fastened to a robot arm and has at least one rotatably mounted folding roller (120), wherein at least one folding roller (120) and / or the folding roller bearing (130) Ultrasonic transducer (150) is arranged, which can act on the seaming roller (120) with ultrasonic vibrations (U). The invention further relates to a method for roll-folding with such a tool device (100), wherein the folding roller (120) is subjected during folding with ultrasonic vibrations (U).

Description

The invention relates to a tool device and a method for roll-folding.

The joining of sheet metal components by producing a rabbet joint is known from the prior art. To produce a rabbet joint, a folded edge provided on the first sheet metal component (outer part) is folded over or bent over with the aid of a suitable folding tool and pressed onto the seaming flange of at least one second sheet metal component (inner part) to form a folding pocket or folding loop. The second component can also be formed from a non-metallic material (eg CFRP or GFRP). In automotive engineering, folding, for example, is widely used in the manufacture of bodywork components (eg doors, flaps, mudguards, etc.).

Various folding methods and devices are known from the prior art. Common methods are folding using at least one folding jaw, such as in the DE 10 2014 213 063 A1 described, and the Rollfalzen using at least one folding roller, such as in the DE 10 2012 004 054 A1 described.

When folding results in a so-called fold loss (folding edge shift and concomitant outline change between the setting or pre-folding and Fertigfalzen), which is subject to fluctuations. In addition, it comes between the folding tool and the fold edge to be folded to a sliding movement. Both are related and has u. a. Influence on the quality and dimensional accuracy of the rabbet joint and subsequently, for example, effect on gap dimensions on a motor vehicle body.

From the DE 10 2014 213 063 A1 is a tool device with a folding tool and the folding tool moving tool kinematics known. The tool kinematics is designed in such a way that the folding tool can execute a pivoting movement and at the same time can be successively tracked by linear displacement of the folded seam edge in order to avoid a sliding movement between the seaming tool and the seaming edge.

In the JP H05 185159 (A) a device for producing a rabbet joint is described by Rollfalzen, in which the folding tool or the folding roller is acted upon in the pressing direction with vibrations, thereby to achieve an advantageous hammer effect during folding.

The object of the invention is to specify a tool device and a method for roll-folding, which do not have at least one disadvantage associated with the prior art or at least only to a reduced extent.

This object is achieved by a tool device according to the invention with the features of patent claim 1 and by an inventive method with the features of the independent claim. Preferred developments and refinements of the invention are analogous to both subject matters of the dependent claims, the following description and the drawings.

The tool device according to the invention has a Rollfalzkopf, which is fastened to a robot arm of an industrial robot or the like and which is equipped with at least one rotatably mounted seaming roller.

According to the invention, at least one ultrasonic transducer is arranged in the folding roller and / or on or in its folding roller bearing, which can apply ultrasonic vibrations to the folding roller or through which the folding roller can be acted upon by ultrasonic vibrations, so that folding with ultrasound overlay is made possible.

An ultrasound transducer is understood in particular to mean a transducer which converts electrical energy into ultrasound or ultrasound vibrations. It is preferably a piezoelectric ultrasonic transducer. In the context of the invention, ultrasonic vibrations are oscillations in the kilohertz range with a frequency of at least 16 kHz, preferably at least 18 kHz and in particular at least 20 kHz. The ultrasonic transducer is provided for an ultrasonic application of the seaming roller and designed and arranged accordingly. The ultrasound application allows folding with ultrasound overlay. On the one hand, the ultrasound vibrations generated by the ultrasonic transducer during folding through the folding roller body passed through to the operating point (point of contact between effective surface and seam edge) and cause z. B. a reduction in friction. On the other hand, the folding roller or the folding roller body is excited during folding to vibrate. Investigations by the Applicant have shown that during folding with ultrasound superimposition (ie by the ultrasonic application of the seaming roller according to the invention), the friction between the seaming roller and the seam edge of the relevant component is influenced and thereby the folding quality and the dimensional stability (both of the seaming seam to be produced and of the component composite to be produced). can be significantly improved. By changing the travel speed, the pressing force and in particular the oscillation amplitude and / or the oscillation frequency (the ultrasonic vibrations), the folding process can be specifically influenced.

Typically, the roll-folding takes place in several stages or running through. The Rollfalzkopf may have a plurality of folding rollers, namely at least one folding roller for pre-folding (prefolding) and at least one folding roller for Fertigfalzen (Fertigfalzrolle), then preferably only the folding roller for pre-folding can be acted upon by ultrasonic vibrations and this in the respective folding roller and / or at the Falzrollenlager at least one ultrasonic transducer is arranged. It has been shown that, in particular, pre-folding has a decisive influence on the quality and dimensional accuracy of the seam connection, so that ultrasound application during pre-folding may be sufficient.

The method according to the invention for roll-folding, d. H. for the production of a rabbet joint by roll-folding, provides for the use of a tool device according to the invention, wherein the folding roll during folding, d. H. during the folding process, is subjected to ultrasonic vibrations.

• – Anordnen, Ausrichten und Fixieren der durch Falzen bzw. durch Herstellen einer Falzverbindung zu fügenden Blechbauteile (Werkstücke) auf einem Falztisch bzw. Falzbett, wobei das erste (äußere) Blechbauteil wenigstens einen, insbesondere bereits aufgestellten, Falzrand und das wenigstens eine zweite (innere) Blechbauteil wenigstens einen Falzflansch aufweist;
• – Falzen bzw. Ausführen eines Falzvorgangs, bei dem der Falzrand des ersten Blechbauteils (Außenteil) mit Hilfe einer erfindungsgemäßen Werkzeugvorrichtung umgebogen und unter Ausbildung einer Falzschlaufe auf den Falzflansch des zweiten Blechbauteils (Innenteil) gedrückt wird und dabei die Falzrolle der Werkzeugvorrichtung zumindest zeitweise mit Ultraschallschwingungen beaufschlagt wird.

The process according to the invention preferably has at least the following steps:

• Arranging, aligning and fixing the sheet-metal components (workpieces) to be joined by folding or by producing a seam connection on a folding table or rebate bed, wherein the first (outer) sheet metal component has at least one rebate edge, in particular already set up, and the at least one second (inner ) Sheet metal component has at least one folding flange;
• - Folding or performing a folding operation in which the seaming edge of the first sheet metal component (outer part) is bent by means of a tool device according to the invention and pressed to form a folding loop on the seaming flange of the second sheet metal component (inner part) while the folding roller of the tooling device at least temporarily with ultrasonic vibrations is charged.

Preferably, the seaming roll is deliberately set into a resonant oscillation by the application of ultrasound. As a result, particularly good folding results can be achieved, in particular even at high folding speed or travel speed. The oscillation of the folding roller can be detected, for example, by sensors and changed by means of a control circuit so that a resonance oscillation occurs or is generated.

For the production of a rabbet joint several passes can be provided for pre-folding and Fertigfalzen, in which case preferably only during pre-folding the respective folding roller or the respective folding rollers is subjected to ultrasonic vibrations / are.

As already explained above, during folding, i. H. during a folding pass, the vibration amplitude and / or the vibration frequency of the ultrasonic vibrations are varied, thereby adjusting or adjusting the folding process.

When folding, d. H. During a folding pass, the actual geometry and / or actual position (or the actual course) of the generated folded edge can be detected, for example by means of a camera. The recorded actual data can be used for documentation. However, the actual data can also be used for a process control, such that the actual geometry and / or actual position automatically adapted to a desired geometry and / or desired position by changing the oscillation amplitude and / or the oscillation frequency of the ultrasonic vibrations becomes (control loop). In addition, it is also possible to change the travel speed and / or pressure force. The fold path on which the seaming roll is moved along the fold to be folded using the robot remains unchanged (i.e., no path correction or the like). The component position and orientation remain unchanged.

A process control can also be done by detecting the actual friction between the seaming roller and the seaming edge and automatic adjustment to a desired friction by changing the oscillation amplitude and / or the oscillation frequency of the ultrasonic vibrations, the travel speed and / or the pressing force.

In series production (series production) of seam connections, the control can also be carried out in such a way that each produced seam connection is checked and if necessary the process parameters (travel speed, pressure force, oscillation amplitude and / or oscillation frequency) are adjusted for the next seam connection to be produced. This can also be done manually.

The invention will be explained in more detail with reference to the drawing. The features shown in the drawing or explained below can, even detached from concrete combinations of features, further develop the invention. In the drawing shows

1 schematically in a side / sectional view of a tool according to the invention Rollfalzen.

The tool device 100 has a Rollfalzkopf 110 up, over a flange 115 attached to a robot or robotic arm (such as eg in the JP H05 185159 shown). At the roller folding head 110 is at least one folding roller 120 arranged over a bolt 130 attached and rotatably mounted. To produce a rabbet joint between the two sheet metal components 210 and 220 becomes the seaming roller 120 guided by the robot along the outer part 210 belonging fold margin 215 unrolled, with the seam edge 215 bent over and forming a fold loop on the inner part 220 belonging folding flange 225 is pressed. The sheet metal components 210 and 220 , Which is, for example, aluminum and / or sheet steel parts, are here on a folding bed 300 on. In addition, a bond can be made along the fold connection.

According to the invention, the folding roller 120 an integrated ultrasonic transducer 150 on (as can be seen by the outbreak shown), which in the embodiment shown, for example, in the bolt 130 formed Falzrollenlager is housed, but, for example, could also be located directly in the reel body. The ultrasonic transducer 150 can fold the folding roll 120 Apply ultrasonic vibrations U. This ultrasonication allows ultrasonic seaming, as explained above.

The ultrasonic transducer 150 is from the controller 400 controlled. The control device 400 may comprise an alternating voltage generator, wherein the alternating voltages or currents generated by this generator from the ultrasonic transducer 150 be converted into ultrasonic waves or vibrations U.

The folded edge created during folding 230 Can immediately with the help of a camera 410 (Or, for example. By using styli or the like) are detected. The control device 400 can then, for example, by comparing the camera 410 detected actual data with stored target data (eg., A predetermined outline) detect deviations and an adaptation of the AC voltage for the operation of the ultrasonic transducer 150 Correctly intervene in the ongoing folding process. This is preferably done in a control loop. By varying the oscillation amplitude and / or oscillation frequency of the ultrasonic vibrations U, inter alia, the friction between the folding roller 120 and fold edge 215 affected. This has an effect on the folding loss and thus on the position or the course of the folded edge 230 and thereby also on the dimensional accuracy of the manufactured composite component.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102014213063 A1 [0003, 0005]
• DE 102012004054 A1 [0003]
• JP 185159 (A) [0006]
• JP 185159 [0023]

Claims (8)

Tool device ( 100 ) for roll-folding, with a roll-folding head which can be fastened to a robot arm ( 110 ), the at least one rotatably mounted folding roller ( 120 ), characterized in that in the seaming roller ( 120 ) and / or at the roller bearing ( 130 ) at least one ultrasonic transducer ( 150 ) is arranged, which the folding roller ( 120 ) can act on ultrasonic vibrations (U). Tool device ( 100 ) according to claim 1, characterized in that the Rollfalzkopf ( 110 ) at least one folding roller ( 120 ) for pre-folding and at least one folding roller for Fertigfalzen, wherein only the folding roller ( 120 ) for pre-folding with ultrasonic vibrations (U) can be acted upon. Tool device ( 100 ) according to claim 1 or 2, characterized in that it is in the ultrasonic transducer ( 150 ) is a piezoelectric ultrasonic transducer. Method for roll-folding with a tool device ( 100 ) according to any one of the preceding claims, wherein the seaming roller ( 120 ) is subjected during folding with ultrasonic vibrations (U). Method according to claim 4, wherein the folding roller ( 120 ) is set by the ultrasound application targeted in a resonant vibration. A method according to claim 4 or 5, wherein several passes are provided for pre-folding and Fertigfalzen and only during pre-folding the respective folding roller ( 120 ) is subjected to ultrasonic vibrations (U). Method according to one of claims 4 to 6, wherein the oscillation amplitude and / or the oscillation frequency of the ultrasonic vibrations (U) is changed during folding. Method according to one of claims 4 to 7, wherein during folding the actual geometry and / or actual position of the produced folded edge ( 230 ) is detected and adjusted by changing the oscillation amplitude and / or the oscillation frequency of the ultrasonic vibrations (U) to a desired geometry and / or desired position.

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