JP4466347B2 - Vehicle door shape inspection device - Google Patents

Description

  The present invention relates to a vehicle door shape inspection apparatus for inspecting the shape of a vehicle door by reproducing a state where a door is actually attached to a vehicle such as an automobile.

  Since the door for an automobile is greatly affected by the action of gravity when it is assembled to a vehicle body, it is necessary to perform an operation assuming an actual vehicle state in which the door is assembled to the vehicle body in an assembly / inspection process (for example, Patent Document 1).

  Conventionally, inspection of the door shape has been performed by actually attaching the door to be inspected to an inspection gauge simulating the ideal structure (hinge, fender, body, etc.) around the door of the vehicle body, and reproducing the actual vehicle state. An inspector measures the level | step difference and clearance gap formed between the inspection door and the inspection gauge using a caliper or the like.

However, inspection gauges such as those described above require the manufacture of dedicated gauges for each of the left, right, left and right doors, as well as the manufacture of dedicated gauges for each type of vehicle. Need. Further, since the door to be inspected is attached to the inspection gauge by bolt fastening or the like as in the case of attaching to the normal vehicle body, a huge man-hour is required.
JP-A-6-64573 (paragraph number 0007)

An object of the present invention is to provide a vehicle door shape inspection device that is low in cost and excellent in work efficiency.
In order to achieve the above object, according to the present invention, there is provided a vehicle door shape inspection device for inspecting the shape of a vehicle door, wherein a lower portion of the door to be inspected is connected to the inspection door. A first support mechanism for supporting movement along the front-rear direction, and a second support mechanism for supporting at least one main surface of the door to be inspected movably along the front-rear direction of the door to be inspected There is provided a vehicle door shape inspection apparatus comprising: a gauge including: an inspection unit that inspects a shape of the door to be inspected supported in an upright state by the gauge based on a relative position with respect to the gauge. .

  In the present invention, the lower part of the door to be inspected is supported by the first support mechanism of the gauge so as to be movable along the front-rear direction, and at least one main surface of the door to be inspected is supported by the second support mechanism of the gauge. It supports so that it can move along the front-back direction, and the shape of the to-be-inspected door is inspected by the inspection means. The front-rear direction of the door to be inspected here is a direction corresponding to the traveling direction of the vehicle to which the door is attached.

  As a result, when the door shape is inspected, the inspector can easily set the door to be inspected by simply sliding the door to be inspected in the gauge, so that the work efficiency of the inspection process can be improved. .

  Further, when inspecting the door shape, the first and second support mechanisms of the gauge only support the lower part of the door to be inspected and at least one main surface, so the doors of the vehicle before and after the vehicle and the doors of different varieties are different. However, it is possible to use the same apparatus and to reduce the cost.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a diagram showing an overall configuration of a vehicle door shape inspection apparatus according to a first embodiment of the present invention, FIG. 2 is a rear view of the gauge shown in FIG. 1, and FIG. FIGS. 4A to 4C are top plan views of the gauge shown in FIG. 1, and FIG. 4A is a diagram showing a state in which the door to be inspected is sliding. 4B is a view showing a state in which the door to be inspected is regulated by the stopper, and FIG. 4C is a view showing a state in which the stopper is retracted from the moving path of the door to be inspected.

  The vehicle door shape inspection device 1 according to the first embodiment of the present invention is a device for inspecting the shape of the door D by reproducing the state in which the door D is attached to the automobile.

  As shown in FIG. 1, the vehicle door shape inspection apparatus 1 includes a gauge 10 that supports a door D to be inspected in a shape inspection, and a reference for measuring a predetermined reference position of the door D to be inspected. Based on various data generated by the position measurement sensor 20, the shape measurement sensor 30 that measures the shape of the predetermined measurement point of the door D to be inspected, the reference position measurement sensor 20, the shape measurement sensor 30, and the like, the gauge 10 And a computer 40 for inspecting the shape of the door D to be inspected supported in an upright state.

  The gauge 10 in this embodiment includes a first support mechanism 11 that supports a lower portion of the door D to be inspected so as to be movable along the front-rear direction of the door D, and an inner main surface of the door D to be inspected. A second support mechanism 12 that is movably supported along the front-rear direction of D, and a stopper member 13 that restricts the movement of the door D to be inspected supported by the first and second support mechanisms 11, 12. Have.

  As shown in FIGS. 1 to 3, the first support mechanism 11 constituting the gauge 10 includes four sets of rotating rollers 11 a arranged in a line along the movement path L of the door D to be inspected. The support member 11b attached to the base plate 15 is rotatably held. In the inspection, when the inspector pushes the door D to be inspected into the gauge 10 from the insertion port side (right side in FIG. 1), each rotating roller 11a rotates, and the door D to be inspected can be easily slid. It is possible.

  As shown in FIG. 1, the rotating roller 11 a of the first support mechanism 11 is disposed along the movement path L so as to be inclined at an angle α. By providing such an inclination, the rotating roller 11a rotates due to the dead weight of the door D to be inspected, so that the door D to be inspected can be automatically and completely abutted against the stopper 13, and high-precision inspection is performed. I can do it.

  As shown in FIGS. 1 to 4C, the second support mechanism 12 constituting the gauge 10 has four rotating rollers 12a arranged in a line along the movement path L inside the door D to be inspected. And four rubber members 12f arranged in a line along the movement path L on the outside of the door D. In addition, in this embodiment, the inner side or inner main surface of the door D to be inspected means the vehicle interior side or the vehicle interior side main surface when the door D is attached to the automobile. The outer side and the outer main surface of the door D mean the outer side and the outer main surface of the vehicle when the door D is attached to the automobile.

  As shown in FIG. 3, the door D to be inspected thrown into the gauge 10 of the present embodiment is inclined toward the rotating roller 12 a side (inside), and the rotating rollers arranged inside the door D to be inspected. While 12a contacts the inner main surface of the door D to be inspected and supports the door D, the rubber member 12f disposed outside the door D to be inspected is the outer main surface of the door D to be inspected. It is located a predetermined distance away without touching. In particular, as described above, by supporting the door D to be inspected only by the inner main surface, it is possible to ensure the quality of the outer main surface that requires high quality in appearance.

  As shown in FIGS. 4A to 4C, the rotating roller 12a of the second support mechanism 12 is rotatably supported at one end of the rotating member 12b. The rotating member 12b is supported by an inner support member 12e stretched between the columns 16 of the gauge 10 so as to be rotatable about a fulcrum 12c. A coil spring 12d is attached to the other end of the rotating member 12b, and the rotating roller 12a is suitable for the inner main surface of the door D to be inspected by the elastic force of the coil spring 12d. The door D can be supported while applying a pressing force. The other end of the coil spring 12d is attached to a beam member or the like stretched between the columns 16 so as not to rotate together with the rotating member 12b, although not particularly illustrated.

  The rubber member 12 f of the second support mechanism 12 has a substantially semicircular shape and is directly fixed to the outer support member 12 g stretched between the columns 16 of the gauge 10. As shown in FIG. 3, the gauge 10 is inserted in a state in which the door D to be inspected is inclined toward the rotating roller 12 a, but even if the door D to be inspected falls to the outside, By supporting the rubber member 12a, damage to the outer main surface of the door D due to overturning can be suppressed.

  The stopper member 13 of the gauge 10 is provided on the movement path L of the door D to be inspected supported by the first and second moving mechanisms 11 and 12, and abuts against the tip of the door D to be inspected. The sliding movement of the inspection door D in the forward direction is restricted, and the door D can be positioned at the time of inspection. Examples of the front end portion of the door D to be in contact with the stopper member 13 include a door hinge mounting portion. Since this door hinge mounting portion is generally a relatively rigid portion in the door D, there is no possibility of deformation even if it is brought into contact with the stopper member 13.

  As described above, in the present embodiment, the door D to be inspected is positioned simply by contacting the stopper member 13 in the inspection, and therefore, the operation such as bolt fastening that requires the same effort as the mounting operation to the normal vehicle body is performed. This eliminates the need for inspection of the door shape in a very short time. When an extremely short time inspection is possible, it is possible to inspect all door shapes.

  As shown in FIG. 4C, the stopper member 13 is provided so as to be rotatable with respect to the first and second support mechanisms 11 and 12 of the gauge 10, and from the movement path L of the door D to be inspected. It is possible to evacuate. Thereby, the flow of the door shape inspection can be limited to one direction along the moving path L from the inlet to the outlet, so that the vehicle door shape inspection apparatus 1 is installed in the automobile production line. Is also possible.

  FIG. 5 is a top plan view of a gauge according to the second embodiment of the present invention. As shown in FIG. 5, the rotating roller 12 h may be arranged not only inside but outside the door D to be inspected. Thereby, the to-be-inspected door D can be supported more stably.

  In this case, as shown in the figure, the four rotating rollers 12h are rotatably supported at one end of the rotating member 12i, respectively, along the moving path L outside the door D to be inspected. Arranged in a row. The rotating member 12i is supported by an outer support member 12g stretched between the columns 16 of the gauge 10 so as to be rotatable about a fulcrum 12j. A coil spring 12k is attached to the other end of the rotating member 12i, and the rotating roller 12h is pressed against the outer main surface of the door D to be inspected by the elastic force of the coil spring 12k. It is possible to support the door D while applying pressure. Although not particularly shown, the other end of the coil spring 12k is attached to a beam member or the like stretched between the columns 16 so as not to rotate together with the rotating member 12i.

  The reference position measurement sensor 20 in the present embodiment is an image processing apparatus that measures a predetermined reference position of the door D to be inspected and generates relative position data of the door D to the gauge 10 based on the measurement result. . The reference position measuring sensor 20 images a predetermined reference position of the door D to be inspected by a CCD camera, performs image processing on the image information, measures a two-dimensional coordinate value of the predetermined reference position, and detects the door to be inspected. The relative position of D with respect to the gauge 10 can be calculated. As the predetermined reference position, as shown in FIGS. 1 and 2, for example, a total of three positions including two upper and lower positions of the door hinge mounting portion of the door D to be inspected and an inner reference hole of the door D can be cited. However, the present invention is not particularly limited to this, and any number and position can be set as long as it is at least three or more. Each CCD camera of the reference position measurement sensor 20 is fixed to a beam member or the like extending between the columns 16 so that a predetermined reference position can be imaged, as shown in FIG. In the present embodiment, the image processing apparatus is described as being used as the reference position measurement sensor 20, but the present invention is not particularly limited thereto, and for example, a laser displacement meter or the like may be used.

  The shape measurement sensor 30 according to the present embodiment measures the shape of a predetermined measurement point of the door D to be inspected and generates shape data at the predetermined measurement point of the door D to be inspected based on the measurement result. It is a shape sensor. This shape measuring sensor 30 has a laser oscillator and a CCD camera, and images the band-shaped laser light irradiated from the laser oscillator to the object to be measured by a CCD camera from a predetermined angle such as 45 °, for example. The shape of the predetermined measurement point of the door D to be inspected in two dimensions can be measured by the optical cutting method for measuring the shape of the door. As the predetermined measurement positions measured by the shape measuring sensor 30, there are a total of two locations, that is, a vehicle outer front upper portion and a vehicle outer rear lower portion of the door D to be inspected, as shown in FIGS. However, the present invention is not particularly limited to this, and an arbitrary number and position can be set.

  The reference position measurement sensor 20 and the shape measurement sensor 30 described above are connected to a computer 40 so that each data can be sent out as shown in FIG. The computer 40 determines the step value and the gap value generated by the door D to be inspected with respect to the structure around the door of the vehicle based on data stored in advance (described later) and data sent from the sensors 20 and 30. Can be calculated for each measurement point, and the step and gap data of the door D to be inspected can be generated.

  Furthermore, the computer 40 can determine the quality of the shape of the door D to be inspected based on the generated level difference and gap data. As a specific method for determining pass / fail in the computer 40, for example, step and gap data are respectively compared with predetermined threshold values, and if all data is smaller than the threshold values, the shape of the door D to be inspected is good. On the other hand, when any data is larger than the threshold value, a method of determining that the shape of the door D to be inspected is defective can be cited. The computer 40 can display the determination result on, for example, a monitor.

  As described above, in the vehicle door shape inspection apparatus 1 according to the present embodiment, the gauge 10 supports only the lower part and the inner main surface of the door D to be moved along the front-rear direction, and in this state the object to be inspected. The shape of the door 1 is inspected. As a result, when the door shape is inspected, the inspector can easily set the door D to be inspected simply by sliding the door D to be inspected within the gauge 10, thereby improving the work efficiency of the inspection process. It becomes possible.

  Further, when the door shape is inspected, the first and second support mechanisms 11 and 12 of the gauge 10 only support the lower portion and the inner main surface of the door D to be inspected. The same device can be used for the door of the vehicle, and the cost can be reduced.

  Furthermore, in the present embodiment, since the measurement work that the inspector has conventionally spent enormous man-hours using calipers or the like is performed using the sensors 20 and 30 and the computer 40, the inspection can be performed in a short time. Become. Conventionally, there are variations in the inspection results due to individual differences among the inspectors, but by performing the measurement work using the sensors 20 and 30 and the computer 40, it is possible to perform a highly accurate inspection without variations.

  6 is a DFD (Data Flow Diagram) showing a reference door registration process in the embodiment of the present invention, FIG. 7 is a flowchart showing the reference door registration process in the embodiment of the present invention, and FIG. 8 is an inspection target in the embodiment of the present invention. DFD showing the door measurement process, FIG. 9 is a flowchart showing the measurement process of the door to be inspected in the embodiment of the present invention, and FIG. 10 is a diagram for explaining the logic for calculating the step value and the gap value in the embodiment of the present invention. It is a graph.

  Hereinafter, a method of calculating the step value and the gap value generated for the structure around the door of the vehicle door of the door D to be inspected by the vehicle door shape inspection apparatus 1 according to the present embodiment will be described with reference to FIGS. .

  First, a master door registration process (calibration operation) for preregistering various data related to a reference door as a reference in using the vehicle door shape inspection apparatus 1 will be described with reference to FIGS. 6 and 7. In addition, the reference door in this embodiment is not a door that is ideal in design (no step and no gap when attached to an automobile), but a single door extracted from an actually manufactured door. Yes, it is a door that also creates a step and a gap in the quality assurance when it is attached to an automobile.

  In this calibration operation, first, as shown in step S10 of FIG. 7, the three-dimensional coordinate values of predetermined measurement points on the reference door are respectively measured. This measurement is performed using, for example, a three-dimensional measuring machine without using the apparatus 1 according to the present embodiment. Next, by comparing this measured value with CAD data of the structure around the door of the vehicle (hinge, fender, body, etc.), the step value and the gap value at each predetermined measurement point are calculated, respectively. Data is input to the computer 40 as a master door value and stored.

  Next, as shown in step S20 of FIG. 7, a CAD reference shape value composed of a theoretical three-dimensional coordinate value of each predetermined reference position and each predetermined measurement point, a step, a gap direction vector, and the like is calculated from the CAD or the like. Input to 40 and store.

  Next, as shown in step S30 in FIG. 7, the inspector puts the reference door into the vehicle door shape inspection apparatus 1 according to the present embodiment. Then, the reference position measurement sensor 20 measures each predetermined reference position of the reference door in two dimensions, generates two-dimensional relative position data of the reference door with respect to the gauge 10 based on the measurement result, and this relative position data. Is stored in the computer 40 as a reference door position measurement value (step S40 in FIG. 7). In addition, the shape measurement sensor 30 measures the shape of the predetermined measurement point of the reference door in two dimensions, and generates two-dimensional shape data at the predetermined measurement point of the reference door based on the measurement result. The reference door shape measurement value is stored in the computer 40 (step S50 in FIG. 7), and the calibration operation is completed.

  The calibration work described above does not have to be performed every time the apparatus 1 is used. In principle, the calibration work only needs to be performed once when the apparatus 1 is introduced. If the measurement accuracy of the apparatus 1 deteriorates, You may carry out at the time of replacement | exchange of 20,30.

  Below, the measurement process of the to-be-inspected door D is demonstrated according to FIG.8 and FIG.9.

  In this measurement process, first, as shown in step S100 in FIG. 9, the inspector puts the door D to be inspected into the gauge 10 of the vehicle door shape inspection apparatus 1 according to the present embodiment. The door D to be inspected introduced into the gauge 10 from the insertion port comes into contact with the stopper member 13 by its own weight according to the taper of the angle α provided on the rotating roller 11 a of the first support mechanism 11.

  After confirming that the door D to be inspected is positioned by the stopper member 13, when the inspector turns on a measurement execution button (not shown), the reference position measurement sensor 20 has a predetermined reference position of the door D to be inspected in two dimensions. Are measured, and based on the measurement result, two-dimensional relative position data for the gauge 10 of the door D to be inspected is generated, and this data is stored in the computer 40 as a measured value of the door to be inspected. Further, the shape measurement sensor 30 measures the shape of the predetermined measurement point of the door D to be inspected in two dimensions, and generates two-dimensional shape data at the predetermined measurement point of the door D to be inspected based on the measurement result. This data is stored in the computer 40 as a measured door shape measurement value.

  Next, in step S120 of FIG. 9, the computer 40 creates a coordinate transformation matrix. As shown in FIG. 8, the coordinate transformation matrix includes the reference door position measurement value and the CAD reference shape value input / stored in the computer 40 in the above-described calibration operation, and the inspection object stored in the computer 40 in step S110. It is created based on the door position measurement value. This coordinate conversion matrix corrects the amount of misalignment that can occur each time the door D to be inspected is inserted into the gauge 10 as the door D to be inspected is roughly positioned with respect to the gauge 10 in this embodiment. It is a matrix for converting the reference door shape measurement value and the to-be-inspected door shape measurement value which were produced | generated as two-dimensional data by the apparatus 1 which concerns on embodiment to three-dimensional data.

Next, in step S130 of FIG. 9, the computer 40 performs coordinate transformation on the reference door shape measurement value and the door shape measurement value to be inspected using the matrix created in step S120, and further the data after the coordinate transformation. The theoretical door shape (see symbol P _{0 in} FIG. 10) is calculated based on the reference door value. Next, the theoretical door shape is compared with the shape data of the measured door shape, and a difference δF in the step direction and a difference δG in the gap direction as shown in FIG. 10 are calculated.

  The computer 40 compares these values δF and δG with predetermined threshold values to determine whether the shape of the door D to be inspected is good or bad. Furthermore, the computer 40 displays the above values δF and δG and the result of pass / fail judgment on a monitor or the like.

  As described above, the data on the level difference and gap generated by the reference door with respect to the structure around the vehicle door, the reference door shape data, the relative position data of the reference door with respect to the gauge 10, and the shape data of the door D to be inspected Based on the relative position data of the door D to be inspected with respect to the gauge 10, the inspection door D generates data on the level difference and the gap generated with respect to the structure around the vehicle door. Thus, the door D to be inspected can be roughly positioned, and the setting of the door D to be inspected to the gauge 10 can be simplified, so that the number of man-hours spent on the shape inspection of the door for the automobile can be significantly reduced. .

  The embodiment described above is described for facilitating the understanding of the present invention, and is not described for limiting the present invention. Therefore, each element disclosed in the above embodiment is intended to include all design changes and equivalents belonging to the technical scope of the present invention.

FIG. 1 is a diagram showing an overall configuration of a vehicle door shape inspection apparatus according to a first embodiment of the present invention. FIG. 2 is a rear view of the gauge shown in FIG. FIG. 3 is a view showing the posture of the door under test put into the gauge shown in FIG. 4 (A) to 4 (C) are top plan views of the gauge shown in FIG. 1, and FIG. 4 (A) is a diagram showing a state in which the door to be inspected is slid. FIG. 4B is a diagram illustrating a state in which the door to be inspected is regulated by the stopper, and FIG. 4C is a diagram illustrating a state in which the stopper is retracted from the movement path of the door to be inspected. FIG. 5 is a top plan view of a gauge according to the second embodiment of the present invention. FIG. 6 is a DFD (Data Flow Diagram) showing reference door registration processing in the embodiment of the present invention. FIG. 7 is a flowchart showing the reference door registration process in the embodiment of the present invention. FIG. 8 is a DFD showing the measurement processing of the door to be inspected in the embodiment of the present invention. FIG. 9 is a flowchart showing a process for measuring the door to be inspected in the embodiment of the present invention. FIG. 10 is a graph for explaining logic for calculating the step value and the gap value in the embodiment of the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Vehicle door shape inspection apparatus 10 ... Gauge 11 ... 1st support mechanism 11a ... Rotary roller 11b ... Lower side support member 12 ... 2nd support mechanism 12a ... Rotary roller 12b ... Rotating member 12c ... Supporting point 12d ... Coil Spring 12e ... Inner support member 12f ... Rubber member 12g ... Outer support member 12h ... Rotating roller 12i ... Rotating member 12j ... Supporting point 12k ... Coil spring 13 ... Stopper 14 ... Opening / closing mechanism 15 ... Base 16 ... Post 20 ... Reference position measurement sensor 30 ... Shape measuring sensor 40 ... Computer D ... Door to be inspected
L: Path of movement of door to be inspected α ... Angle δF ... Difference in step direction δG ... Difference in gap direction

Claims (10)

A vehicle door shape inspection device for inspecting the shape of a vehicle door,
A first support mechanism that supports the lower part of the door to be inspected, which is an inspection target, so as to be movable along the front-rear direction of the door to be inspected, and at least one main surface of the door to be inspected, A gauge having a second support mechanism that is movably supported along the front-rear direction of
An inspection device for a vehicle door , comprising: inspection means for inspecting a shape of the door to be inspected supported by the gauge in an upright state based on a relative position with respect to the gauge .   The vehicle door shape inspection apparatus according to claim 1, wherein the second support mechanism of the gauge supports at least an inner main surface of the door to be inspected. The gauge further includes a restricting means that is positioned on a movement path of the door to be inspected supported by the first and second support mechanisms and restricts the movement of the door to be inspected in the forward direction.
3. The vehicle door shape inspection device according to claim 1, wherein the first support mechanism of the gauge is inclined so as to descend toward the restriction means. 4.   4. The vehicle door shape inspection apparatus according to claim 3, wherein the restricting means is retractable from a moving path of the door to be inspected.   The vehicle door shape inspection device according to any one of claims 1 to 4, wherein the inspection means inspects the door to be inspected in a non-contact state. The inspection means includes
Data on the level difference and gap generated by the reference door as a reference to the structure around the vehicle door,
Shape data of the reference door;
Relative position data of the reference door with respect to the gauge;
Shape data of the door to be inspected;
Relative position data of the door to be inspected with respect to the gauge;
The vehicle door shape inspection device according to any one of claims 1 to 5, wherein the door to be inspected generates data of a step and a gap generated with respect to a structure around the vehicle door based on the above.   The said inspection means has the reference position measurement means which measures the predetermined reference position of the said to-be-inspected door, and produces | generates the relative position data of the to-be-inspected door with respect to the said gauge based on the said measurement result. The vehicle door shape inspection device according to any one of the above.   The said inspection means has a shape measurement means which measures the shape in the predetermined measurement point of the said door to be inspected, and produces | generates the shape data in the predetermined measurement point of the said door to be inspected based on the said measurement result. 8. The vehicle door shape inspection apparatus according to any one of 7 above. The inspection means includes
Capture the step and gap data of the reference door from the outside,
The reference position measuring means generates relative position data of the reference door with respect to the gauge, and relative position data of the door to be inspected with respect to the gauge,
The shape measuring means generates shape data at the predetermined measurement point of the reference door and shape data at the predetermined measurement point of the door to be inspected,
9. The vehicle door shape inspection device according to claim 8, wherein the step and clearance data of the door to be inspected is generated based on each data. The vehicle door shape inspection device according to any one of claims 6 to 9, wherein the inspection means determines whether the shape of the door to be inspected is good or not based on the generated step and gap data of the door to be inspected.

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