DE102020004027A1 - Method for aligning and assembling an add-on part on a body of a motor vehicle - Google Patents

Abstract

The invention relates to a method for aligning and assembling an attachment (10) on a body (12) of a motor vehicle with the following steps: - positioning the attachment (10) in a test position (P) - measuring at least one first measuring point (24) of the attachment (10), whereby first measurement data are obtained; - Measurement of at least one second measurement point (34), whereby second measurement data are obtained; - Carrying out a simulation by means of an electronic computing device, with the simulation: o the first measurement data and the second measurement data in a common coordinate system are transformed; o on the basis of the transformation, a simulation model of the attachment (10) is moved from the test position (P) into a further position; undo correction data are determined; - depending on the correction data, the attachment (10) is moved from the test position (P) to an assembly position (M); and - the add-on part (10) located in the assembly position (M) is connected to the body (12) and is thereby mounted on the body (12).

Description

The invention relates to a method for aligning and assembling an add-on part on a body of a motor vehicle according to the preamble of patent claim 1.

Nowadays, a simulation process, in particular a simulated alignment process, for example according to the so-called best-fit alignment principle, is used for the assembly of add-on parts such as doors, fenders, trunk lids, engine hoods, rear wall doors and others in the bodyshell or assembly of motor vehicle bodies. This requires many vehicle-type-specific and contour-bound assembly tools which, for example, require a large number of cost-intensive 2D laser triangulation sensors based on the double-head principle. Thus, only a small number of different derivatives of the motor vehicle body of a vehicle series can be manufactured in one station. The low level of flexibility available today is usually solved by expensive and cycle-time intensive tool changes or second stations or lines. Furthermore, devices are used in assembly, for example, which control various robots and tools in complex processes.

• - Selbststätiges Ausrichten des Roboters und/oder dessen Funktionseinheit anhand von Orientierungsdaten; und
• - Reproduzierbares Durchführen von Einzelkontrollen mittels der Prüfvorrichtung, wobei die Schritte selbststätiges Ausrichten und reproduzierbares Durchführen wiederholt werden, bis ein Abbruchskriterium erfüllt und/oder die Endkotrolle komplett durchgeführt ist.

Aufgabe der vorliegenden Erfindung ist es, ein Verfahren zur Ausrichtung und zur Montage eines Anbauteils an einer Karosserie eines Kraftwagens derart zu gestalten, dass eine höhere Taktung bei der Ausrichtung und der Montage des jeweiligen Montageteils erzielt werden kann.From the DE 10 2006 006 246 A1 a system and a method for the fully automatic final inspection of components are known. Here, a robot comprises a test device for performing a final inspection. The following steps are carried out:

• - Automatic alignment of the robot and / or its functional unit on the basis of orientation data; and
• - Reproducible performance of individual checks by means of the test device, the steps of automatic alignment and reproducible performance being repeated until a termination criterion has been met and / or the final inspection has been carried out completely.

The object of the present invention is to design a method for aligning and assembling an add-on part on a body of a motor vehicle in such a way that a higher cycle rate can be achieved during the alignment and assembly of the respective assembly part.

According to the invention, this object is achieved by a method for aligning and assembling an add-on part according to the features of patent claim 1. Advantageous refinements with expedient developments of the invention are specified in the remaining patent claims.

According to the present invention, a method for aligning and assembling an attachment on a body of a motor vehicle, in particular a passenger car, is provided, in which in a first step the attachment is positioned in a test position relative to the body by means of a first robot. Here, the first robot grips the attachment, for example by means of a gripping device and / or suction device arranged on the first robot, and positions it in the test position. In particular, the attachment is positioned in the test position in the immediate vicinity of the body.

Furthermore, in a second step of the method, at least one first measuring point of the add-on part is measured by means of a laser radar, also referred to as a lidar or lidar sensor, arranged on a second robot. The attachment is in the test position. The first measurement data characterizing the first measurement point are obtained through the measurement. Depending on the measured variable, further laser triangulation sensors can be used for recording transitional dimensions. On the other hand, simple distance information can be recorded, for example, by means of further triangulation methods and / or further camera sensors.

This is followed by a third step of the method, in which at least one second measuring point is measured by means of the laser radar while the attachment is in the test position. Second measurement data characterizing the second measurement point are obtained through the measurement. This measurement can be carried out analogously to the measurement of the first measurement point, for example by means of the further laser triangulation sensors. Simple distance information, on the other hand, can also be acquired by means of, for example, the further triangulation methods and / or the further camera sensors.

In a fourth step of the method, a simulation is then carried out by means of an electronic computing device, with the first measurement data and the data based on a reference of the first measurement data to at least one test body assigned to the attachment and a reference of the second measurement data to a reference point on the body during the simulation second measurement data are transformed into a common coordinate system. For example, using a control algorithm, correction movements can be processed and transformed into Cartesian correction vectors, which can be adapted to the vehicle coordinate system. Using the transformation, a simulation model of the attachment is converted from the test position relative to a simulation model of the body into a another position different from the test position. Furthermore, correction data, in particular all six degrees of freedom, are determined as a function of the movement of the first simulation model relative to the second simulation model from the test position into the further position.

For the simulation model, for example, a simulation model or a simulation method is already known in which a joint pattern, which represents an important quality feature of a vehicle body, is largely determined by the alignment of the add-on parts with the surrounding body assemblies. Sensor-guided industrial robots are used for the automated assembly of add-on parts, as geometry parameters such as gap and transition dimensions are sensed and used to calculate the position correction of the add-on part. In addition to optimizing the product quality, the use of this best-fit technology can reduce the manual adjustment effort required to correct the joint pattern. The typical sensor arrangement of a best-fit assembly application requires overdetermined sensor information, which leads to complex corrective movements of the robot. In particular, further simulation methods and / or programs which are designed to meet the necessary requirements for the method can also be used here.

In a fifth step, depending on the correction data, the attachment is moved by means of the first robot from the test position relative to the body into an assembly position different from the test position, whereby the attachment is aligned relative to the body. The assembly position is adapted in particular by the correction data so that the subsequent assembly of the attachment takes place in a tolerance range specified by the OEM, with a gap contour of the attachment in particular being adapted to a further attachment and / or the body in the tolerance range. It is thus possible to achieve a high-quality attachment part alignment before assembly and to avoid subsequent corrections, which are costly and time-consuming.

Finally, in a sixth step, the add-on part located in the assembly position is connected to the body by means of a third robot and is thereby mounted on the body. Here, the third robot comprises at least one tool that can be used for assembly and is aligned using the correction data, as a result of which the attachment is assembled in the assembly position. In particular, gripping accuracy and also robot inaccuracies are regulated by means of the correction data.

In a further advantageous embodiment, it is provided that the first measuring point comprises at least a partial area of a wall area, in particular an edge or edge area of the attachment, the wall area of which after the attachment of the attachment to the body has a gap between the attachment and the body at least partially limited. In particular, both add-on part tolerances and dimensional deviations of the add-on part and further inaccuracies at the first measuring point are to be assumed. Thus, a previously predetermined width of the gap can be set with a predetermined tolerance range after the method has been carried out by the attachment. In particular, it is possible to measure a joint area of joining partners outside of an installation position of the joining partners.

A further advantageous embodiment provides that the second measuring point comprises at least a second partial area of a second wall area, in particular an edge or edge area of the body, the second wall area of which at least partially closes the gap between the attachment and the body after the attachment has been mounted on the body limited. In particular, body tolerances as well as dimensional deviations of the body and further inaccuracies at the second measuring point are to be assumed. The width of the gap specified by the original equipment manufacturer can thus be set with a specified tolerance range after the method has been carried out. In particular, it is possible to measure a gap contour of the joining partner by means of a laser radar. Furthermore, referencing of the measuring points, in particular the measured data, is also possible on the basis of further geometric features on the body, whereby the transformation can be carried out using the simulation model.

In a further advantageous embodiment, it is provided that the at least one test body is held on the first robot or on the attachment part, bypassing the first robot. In particular, the test body is designed as a zero point of a coordinate system of the attachment for determining Cartesian correction vectors, which is used as a first reference point for the first measuring point. Furthermore, the test body is used in the simulation model as a reference point for the test position of the attachment and for the simulated alignment of the attachment. Here, the test body serves as one of at least two reference points for the simulation model, the second reference point being attached to the body, for example a lozenge hole, and being used as a reference point to determine the second measuring point. During the subsequent movement of the attachment from the test position to the In the assembly position and in the alignment of the attachment relative to the body, the test body with the correction data is used as a reference point. In particular, it is possible to set the reference points for the alignment and assembly of further add-on parts on the body, the simulation model determining all correction data of the add-on parts and forwards them to the robots. Furthermore, several test bodies are also possible, which can be used for several geometric features of the body.

A further advantageous embodiment provides that the attachment is used as a door, in particular a side door, of the motor vehicle. The attachment, designed as a side door, is aligned using the method and mounted on the body, which accelerates the assembly process. Furthermore, it is possible to align and assemble further side doors by means of the method, the simulation model determining correction data for all side doors of the motor vehicle in one pass and forwarding them to the robots. It is thus possible to mount the side doors on the body in one pass by the robots, which increases the cost-effectiveness of the add-on part assembly on production lines. Other add-on parts such as fenders, trunk lids, engine hoods and rear wall doors can also be aligned and installed using the method.

In a further advantageous embodiment it is provided that the add-on part located in the assembly position is connected to the body by means of a third robot. In particular, by means of a tool, the attachment is connected to the body in a non-destructive detachable manner and fastened or mounted. In this case, the third robot is designed in particular to carry out the connection without changing tools. In particular, this significantly increases type flexibility within a production line. In particular, it is possible to connect the add-on part by means of a starting point designed as a TCP tool center point for aligning the tool of the third robot with the body. The correction data is also forwarded to the third robot by means of the simulation model, as a result of which the starting point is adapted according to the correction data.

Finally, it is provided in a further embodiment of the invention that the electronic computing device is coupled in a contactless manner to a data cloud from the original equipment manufacturer. In this case, by means of the electronic computing device, designed in particular as a central electronic computing device, with a high computing capacity, it is possible to carry out several simulations for several add-on parts in a shorter computing time. Then, for example, a data transmission device can transmit the measurement data to a data cloud which is coupled contactlessly to the central electronic computing device. The correction data are then transmitted from the central electronic computing device to the data cloud and transmitted from there to the respective robots by means of a data receiver device. It is thus possible, in particular, to centralize the computing power and, for example, to carry out simulations for several production lines by means of the central electronic computing device. In particular, this enables time to be saved, no need for several different electronic computing devices and centralized control of the robots for the product lines.

• - Vermessung der Spaltkontur der Fügepartner mit einem Laserradar;
• - Vermessung des Fugenbereichs der Fügepartner außerhalb einer Montageposition beziehungsweise einer Einbauposition;
• - Referenzieren der Messstellen beziehungsweise der Messung anhand weiterer geometrischer Merkmale an der der Karosserie;
• - Zusammenbringen von Fugenscans der Fügepartner in einer Software, insbesondere eines Simulationsmodells, mit Hilfe der Messstellen beziehungsweise von Referenzmessungen und somit der relativen Messungen;
• - Virtuelle Best-Fit Ausrichtung innerhalb des Simulationsmodells beziehungsweise der Software;
• - Ermittlung von Korrekturdaten beziehungsweise Berechnung einer Basekorrektur für die Roboter, wobei Korrekturdaten beziehungsweise Baskorrektur die Greifgenauigkeit, die Bauteiltoleranzen beziehungsweise die Maßabweichungen und einen Teil der Robotergenauigkeiten regelt.

In summary, the invention represents a method which, for example, by means of a simulation model, in particular a best-fit alignment simulation, enables add-on part assembly to a body without a contour-bound sensor system for many different derivatives within a station without a tool change. Furthermore, in the final assembly, a new technology, in particular the method, can be used for aligning and assembling, for example, an attachment, a front module and / or a bumper. In particular, the following steps must be used:

• - Measurement of the gap contour of the joint partners with a laser radar;
• - Measurement of the joint area of the joint partners outside of an assembly position or an installation position;
• - Referencing the measuring points or the measurement based on further geometric features on the body;
• Bringing together of joint scans of the joining partners in software, in particular a simulation model, with the aid of the measuring points or of reference measurements and thus the relative measurements;
• - Virtual best-fit alignment within the simulation model or the software;
• - Determination of correction data or calculation of a base correction for the robots, with correction data or base correction regulating the gripping accuracy, the component tolerances or the dimensional deviations and part of the robot accuracy.

An economical attachment part assembly on production lines with the high Type variance tracked. Furthermore, there is no need to change tools in the add-on assembly lines, which enables significantly more type flexibility within the production line. The best-fit alignment quality is used with much simpler robotic tools without gap-bound double-head sensors. Ultimately, a higher component alignment quality is made possible for vehicles for which no conventional best-fit line is economically viable. In this way, the steadily growing quality expectations with regard to gap or body joints and the gap dimensions as a design and quality feature are met, whereby the external appearance of the motor vehicle can be influenced.

Further advantages, features and details of the invention emerge from the following description of an exemplary embodiment and with reference to the drawing. The features and combinations of features mentioned above in the description as well as the features and combinations of features mentioned below in the description of the figures and / or shown alone in the figure can be used not only in the respectively specified combination, but also in other combinations or alone, without the scope of the Invention to leave.

The single FIGURE shows a flow chart with a side view of an attachment in the form of a side door, and with a side view of a corresponding door opening of a body, to illustrate the method according to the invention.

The figure shows a flow chart with a side view of an attachment 10 , in particular an external attachment, in the form of a side door, and with a side view of a corresponding door opening of a body 12 , in particular a motor vehicle body, a motor vehicle to illustrate the method according to the invention.

In the present method, the attachment part is in a first step of the method 10 by means of a first robot 14th in a test position P relative to the body 12 positioned. The first robot intervenes 14th for example by means of one on the first robot 14th arranged gripping device and / or suction device the attachment 10 and positions it in the test position P in the immediate vicinity of the body 12 . The attachment 10 In the figure, it is designed as a side door of a motor vehicle, in particular a passenger vehicle, and is operated by the first robot, not shown in the figure 14th held in the test position P. Here is the first robot 14th trained to use the attachment 10 relative to the body 12 to move and position in six degrees of freedom and to use correction data obtained from a simulation model of the method to position the attachment 10 from the test position P relative to the body 12 to move into an assembly position M different from the test position P.

Furthermore, in a second step of the method, at least one first measuring point 24 of the attachment 10 by means of one on a second robot 15th arranged laser radars, also referred to as lidar or lidar sensor. The attachment is located here 10 in the test position P. The measurement becomes the first measuring point 24 characterizing, first measurement data of the attachment 10 won.

For this purpose, the attachment includes 10 at least a first reference point 22nd , which is designed as a test body, and located outside of the attachment 10 is located. In particular, it is possible that the reference point 22nd or the test body on the first robot 14th or bypassing the first robot 14th to the attachment 10 is held. In particular is the first reference point 22nd as the zero point of a coordinate system of the attachment 10 designed to determine Cartesian correction vectors, which is the first reference point 22nd for the first measuring point 24 is applied.

The first measuring point 24 also includes at least a first sub-area 26th a first wall area 28 , in particular an edge or edge area of the attachment / the side door 10 , its first wall area 28 after mounting the attachment 10 on the body 12 a crack 30th between the attachment 10 and the body 12 or their door opening is at least partially limited. By means of the method, a width of the gap specified by the original equipment manufacturer is thus established 30th adjustable with a specified tolerance range.

This is followed by a third step of the method, in which at least one second measuring point 34 by means of the laser radar while the attachment 10 is in the test position P is measured. The measurement becomes the second measuring point 34 characterizing, second measurement data obtained. This measurement can be analogous to the measurement of the first measuring point 24 be carried out, for example, by means of further laser triangulation sensors. Simple distance information, on the other hand, can be recorded using, for example, a further triangulation method and / or further camera sensors.

For measuring the second measuring point 34 becomes a second reference point 38 on the body 12 , for example a lozenge hole, used. The use of a defined feature such as the lozenge hole as a second reference point 38 is used in particular for calibration in a vehicle coordinate system, for example in order to subsequently correct the influence of the error by means of an offset movement / compensation movement, for example. The reference points 22nd , 38 are then used to move the attachment 10 from the test position P to the assembly position M and when aligning the attachment 10 relative to the body 12 applied.

The second measuring point includes for this purpose 34 a second sub-area 36 a second wall area 32 , in particular an edge or edge area of the body 12 , the second wall area 32 after mounting the attachment 10 on the body 12 the gap 30th between the attachment 10 and the body 12 at least partially limited. In particular, body tolerances and dimensional deviations of the body are here 12 and further inaccuracies at the second measuring point 34 to accept.

Then the first robot 14th and using the measurement data from the first measurement point 24 and the second measuring point 34 the attachment 10 relative to the body 12 aligned. For this purpose, in a fourth step of the method, a simulation is carried out by means of an electronic computing device (not shown in the figure), with the add-on part in the simulation based on a reference of the first measurement data 10 assigned first reference point 22nd , in particular a test body, and based on a reference of the second measurement data to the second reference point 38 , in particular a reference point of the body 12 , the first measurement data and the second measurement data are transformed into a common coordinate system. For example, using a control algorithm, in particular a best-fit alignment algorithm, correction movements can be processed and transformed into Cartesian correction vectors, which can be adapted to the vehicle coordinate system. The transformation is used to create a simulation model of the attachment 10 from the test position P relative to a simulation model of the body 12 is moved into a different position from the test position P or into the assembly position M. Furthermore, depending on the movement of the first simulation model relative to the second simulation model, correction data, in particular all six degrees of freedom, are determined from the test position P into the further position or into the assembly position M.

In a fifth step of the process, the attachment 10 depending on the correction data by means of the first robot 14th from the test position P relative to the body 12 is moved into the assembly position M, which is different from the test position P, whereby the attachment 10 relative to the body 12 is aligned. The assembly position M is adapted in particular by the correction data so that the subsequent assembly of the attachment 10 takes place in a tolerance range specified by the original equipment manufacturer, with the gap in particular 30th or a gap contour of the attachment 10 to another attachment and / or the body 12 is adjusted in the tolerance range.

The attachment that is then in the assembly position M. 10 is finally in a sixth step of the method by means of a third robot, not shown in the figure 16 with the body 12 connected and thereby to the body 12 assembled. Here, the third includes robot 16 at least one tool that can be used for assembly 18th and is aligned by means of the correction data, whereby the attachment 10 is mounted in the mounting position. In particular, gripping accuracy and also robot inaccuracies are regulated by means of the correction data. Furthermore, in particular by means of the tool 18th of the third robot 16 , the attachment 10 on the body 12 releasably attached or mounted. Here is the third robot 16 in particular designed to carry out a connection without having to change tools. The attachment 10 is here by means of a starting point designed as a TCP Tool Center Point 20th for aligning the tool 18th of the third robot 16 to the body 12 connected.

The electronic computing device can in particular be designed as a central electronic computing device and can be coupled contactlessly to a data cloud from the original equipment manufacturer. A data transmission device transmits the measurement data to the data cloud and the correction data resulting from the simulation are transmitted from the central electronic computing device to the data cloud and from there to the respective robots by means of a data receiver device 14th , 15th , 16 transmitted.

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was 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.

Patent literature cited

• DE 102006006246 A1 [0003]

Claims (7)

Method for aligning and assembling an add-on part (10) on a body (12) of a motor vehicle with the following steps: - Positioning of the attachment (10) by means of a first robot (14) in a test position (P) relative to the body; - Measuring at least one first measuring point (24) of the attachment (10) by means of a laser radar arranged on a second robot (15) while the attachment (10) is in the test position (P), whereby the first measuring point (24) is characterized first measurement data are obtained; - Measuring at least one second measuring point (34) by means of the laser radar while the attachment (10) is in the test position (P), whereby second measuring data characterizing the first measuring point (34) are obtained; - Carrying out a simulation by means of an electronic computing device, with the simulation: o The first measurement data and the second measurement data are transformed into a common coordinate system based on a reference of the first measurement data to at least one test body assigned to the attachment (10) and based on a reference of the second measurement data to a reference point of the body (12); o on the basis of the transformation, a simulation model of the attachment (10) is moved from the test position (P) relative to a simulation model of the body (12) into a further position different from the test position (P); and Correction data are determined as a function of the movement of the first simulation model relative to the second simulation model from the test position (P) into the further position; - Depending on the correction data, the attachment (10) is moved by means of the first robot (14) from the test position (P) relative to the body (12) into an assembly position (M) that is different from the test position (P), whereby the attachment (10) is oriented relative to the body (12); and - The add-on part (10) located in the assembly position (M) is connected to the body (12) by means of a third robot (16) and is thereby mounted on the body (12). Procedure according to Claim 1 , characterized in that the first measuring point (24) comprises at least a first partial area (26) of a first wall area (28), in particular an edge or edge area of the attachment (10), the first wall area (28) of which after the attachment of the attachment ( 10) at least partially delimits a gap (30) on the body (12) between the attachment (10) and the body (12). Procedure according to Claim 2 , characterized in that the second measuring point (34) comprises at least a second partial area (36) of a second wall area (32), in particular an edge or edge area of the body (12), the second wall area (32) of which after the mounting of the attachment ( 10) on the body (12) at least partially delimits the gap (30) between the attachment (10) and the body (12). Method according to one of the preceding claims, characterized in that the at least one test body is held on the first robot (14) or on the attachment (10) while bypassing the first robot (14). Method according to one of the preceding claims, characterized in that the attachment (10) is used as a door, in particular a side door, of the motor vehicle. Method according to one of the preceding claims, characterized in that the add-on part (10) located in the assembly position (M) is connected to the body (12) by means of a third robot (16). Method according to one of the preceding claims, characterized in that the electronic computing device is coupled contactlessly with a data cloud from the original equipment manufacturer.

Images