WO2009095262A2

WO2009095262A2 - Method for producing a break in a chassis section of a motor vehicle as necessary

Info

Publication number: WO2009095262A2
Application number: PCT/EP2009/000630
Authority: WO
Inventors: Klaus Sammer; Stefan Kosch
Original assignee: Bayerische Motoren Werke Aktiengesellschaft
Priority date: 2008-02-02
Filing date: 2009-01-30
Publication date: 2009-08-06
Also published as: EP2240288B1; ATE512735T1; EP2240288A2; WO2009095262A3; DE102008007284A1

Abstract

In a method according to the invention to produce breaks in a chassis section (1) of a motor vehicle as necessary, at least two guide holes (5) are provided which correspond to the necessary breaks (3) in the chassis section (1) as the case requires. Depending on what break (3) is actually required in the affected vehicle chassis, one or the other guide hole (5) is used for introduction of a tool (10). The tool (10) comprises a tension stamp (12) with a stamp plate (14) and a tension rod (16). The tension rod (16) is passed through the respective guide hole (5) from the back side (R) of the chassis section (1) and is introduced into a drive unit (30) placed at the front side of the chassis section (1). The drive unit (30) is designed as a hydraulic piston-cylinder unit, for example, and has a matrix-like free end section (36) at the side facing the chassis section (1), said end section forming a stamping apparatus together with the stamping plate (14). The drive unit (30) moves the stamping plate (14) and the end section (36) together in such a way that the panel section (6) lying therebetween is cut away, thus resulting in the necessary break (3). With the method according to the invention, preparation areas can be provided with comparatively very small guide holes (5) into which the tool (10) is inserted at an already painted chassis as necessary and subsequently the necessary breaks (3) are produced depending on the vehicle configuration. The un-necessary guide holes (5) can be sealed with small plugs.

Description

A method for generating a break-through in a body portion of a vehicle as needed

The invention relates to a method for generating on demand a breakthrough in a body portion of a vehicle according to the preamble of claim 1

Automotive bodywork requires breakthroughs for the passage of cables, rods or more complex components in the mass production of motor vehicles in large numbers with the possibility of customization according to the customer's wishes and / or taking into account different market requirements depends on the type and number of such breakthroughs Many factors from, for example, the respective Landerausfuhrung, engine, drive, special equipment etc A particularly vivid building game differently required breakthroughs in a motor vehicle, the arrangement of the steering column in the right or in the left half body, depending on whether the motor vehicle for a market with Right or left traffic is determined

One way to provide breakthroughs for all benotigten variants of a motor vehicle is to provide a variety of breakthroughs already in the shell of the body, so that all variants can be operated Not required breakthroughs are closed, for example, with lids, which, however, a lot of effort for Sealing measures and the fixed attachment of these covers (gluing, riveting, screwing etc) results in overlapping flanges, these lids also lead to an additional weight numerous breakthroughs The acoustic properties and corrosion resistance also deteriorate

In order to avoid some of the disadvantages mentioned, it is known, instead of breakthroughs that are actually kept at all relevant points of the body to perforate the body at all relevant points, for example with a laser and then depending on the variant of the motor vehicle only However, the prophylactic perforation also results in a comparatively high outlay, with an unclean separation point of the knocked out sheet metal part. In addition, perforation already takes place A weakening of the motor vehicle body If necessary, the unused perforated preparation site must be sealed

The object of the invention is to provide a method with which in variants of a motor vehicle on the already painted body in a simple manner, if necessary, breakthroughs can be generated

This object is achieved by a method having the features of claim 1

The key idea here is to produce the breakthrough through a punching process on the already painted body section only when and if it is really needed. Thus, there is no unnecessary weakening of the body structure by "held" and actually unneeded breakthroughs, so that there are advantages in terms With the restriction to the actually necessary number of breakthroughs, there are no unnecessary leak points on the body. In addition, there are no additional material costs for lids for closing the breakthroughs, nor are there any additional costs for the lid how manufacturing costs for the assembly and the sealing of the cover emerge also result weight advantages, because cover can be avoided with an overlapping flange The punching tool can be applied almost anywhere on a vehicle body and in principle at any time after completion of the painting on a motor vehicle body

The inventive method is suitable for a wide range of use cases An important application here Landerausfuhrungen for right or left traffic, the different breakthroughs for the steering column, the windscreen wiper axles, the brake device, the pedal mechanism etc condition Furthermore, depending on Landerausfuhrung, motorization, drive ( Shift or automatic transmission, front or rear wheel drive, four-wheel drive, Hybridantπeb etc), optional equipment etc. different breakthroughs for a variety of components are required, for example, individual electrical lines and complete wiring harnesses, hydraulic lines, compressed air lines, fuel lines, lines for heating and / or air conditioning, Cables, linkages, levers, shafts, heating / air-conditioning devices, switch blocks, shift rods, reversing cameras, roof antennas, roof rails, camera systems, sensor systems, if applicable components for hybrid vehicles, etc

The stamping burr, which generally results from the production of the breakthrough on the already painted body, must be aftertreated to prevent corrosion

In an embodiment of the method, a punching tool is used with a punching plate and a counter-holder The punching plate corresponds in shape and size to the breakthrough to be generated and is positioned at the relevant point of the vehicle body On the opposite side of the body portion of the corresponding counter-holder is arranged so that a Abstutzung the applied punching force takes place This accessibility of the body is required from two sides

Such a punching tool is designed, for example, pliers-like, with a fixed position assignment of punching plate and anvil at the end portions of the "Pincers" and with a device for applying the punching force between the punching plate and counter-holder, comparable to a welding tongs in the body construction.The disadvantage here are the comparatively high weight and the size of such a punching tool, whereby the accessibility is limited and the handling is difficult.

In a preferred embodiment of the method according to the invention, a small guide hole is introduced at the location of the vehicle body or the body section at which a breakthrough is required. This guide hole serves to position the punching tool. The punching tool has a punching plate whose punching device is designed in size and contour so that the punching plate can produce the required breakthrough. From the punching plate is approximately perpendicular to a pull rod, which is intended to be passed through the guide hole. First, the punching plate is arranged on one side of the bodywork section of the vehicle to be machined. Subsequently, a tensile force is applied to the pull rod on the other side of the body portion, which presses the punch plate against the body portion, whereby the breakthrough is punched out. Here, the punching plate (male) is supported against a counter-mold (die) (or vice versa). A certain limitation exists only in the geometry of the apertures, which can deviate only to a limited extent from a two-dimensional shape.

With the above-described embodiment of the method, it is possible in a simple manner, with a very small guide hole by applying a correspondingly larger punching tool, which is positioned by the guide hole in position to produce a large breakthrough exactly at the predetermined location and exclusively for those vehicles where the need for each breakthrough actually exists.

The tool required for the method according to the invention can be designed to be very simple and cost-effective, in contrast to the expensive tools with a punch insert used in the stamping shop during bodyworking. Due to its compact design, the tool can be used almost anywhere Vehicle body and are used in principle at any time during the manufacture of a motor vehicle body

In the one-piece version, the pull rod is fixedly connected to the punching plate and approximately perpendicular to it. In the two-part execution, the pull rod is separated from the punching plate and can be screwed, for example, into an internal thread on the punching plate Also a reversible latching connection or the like is conceivable

In a one-piece pull stamp, the pull rod is inserted from the side into the Fuhrungsloch at which the punch plate is to come to rest on the body portion of the two-part punch the tie rod can alternatively be introduced from that side in the Fuhrungsloch at the following the Traction is applied

The punching plate is preferably formed as a substantially flat plate, wherein the peripheral edge of the plate in cooperation with a arranged on the other side of the body portion die forms the "cutting edge" for the punching operation

The punching plate may have a different thickness along its peripheral edge, so that on the side facing the body portion of the punching plate, for example, a wave-shaped "cutting edge" arises, which attaches to the beginning of the punching process only on a partial extent of the opening to be created and only in the further course of The cutting force reduction achieved hereby achieves an improved punching process, comparable to a scarfing operation. This is particularly advantageous in the case of thicker sheet metal materials, in order to ensure a uniform and not too high cutting force over the course of the punching process

In addition to plate-shaped punch plates also "pot-shaped" variants are conceivable, with a protruding in the direction of the die circumferential "punching ring" Anlog to the flat punching plate can in this case the cutting edge of the punching ring a constant Have height opposite the bottom of the cup-shaped punching plate or analogously to the unevenly thick punching plate along the circumference of the punching ring varying height, for example, in turn wavy.

In addition, the side surface of the punching plate or the punching ring can be parallel to the pulling direction or be beveled at a small angle thereto.

The tensile force can be applied for example via a hydraulic, a pneumatic or an electric drive unit to the pull rod of the punching tool. The advantage here is that on the pull rod, a flexible and simple drive unit can be placed, which can be positioned at a small size in comparatively difficult to reach places. Preferably, hydraulic drive units are used due to the high forces that can be achieved. Of course, however, electric motors can be used, the z. B. exercise the traction over a spindle drive. Also conceivable is the manual application of a tensile force, for example via a threaded spindle driven by a hand tool.

The punching plate is attached to one side of the body section, where the breakthrough is to be generated. Subsequently, the drive unit is placed on the other side of the body section. This requires that both sides of the body section are accessible. Restrictions on accessibility on both sides may result from already installed adjacent components or an inaccessible cavity.

Preferably (with the drive unit plugged onto the drawbar), the end section of the drive unit facing the body section forms an abutment for the punching table. Thus, this end portion of the drive unit acts as a die for the patrizenartigen punching plate (or vice versa). For this purpose, the drive unit is already plugged as far as possible in the direction of the body section on the pull rod when applied to the pull rod.

When inserting a one-piece Zugstempels or already assembled two-part Zugstempels in the guide hole of the "Punching" of the body section is the pull rod on the "drive side" of the body section preferred here, the pull rod is already inserted during the pushing through the Fuhrungsloch directly into the standby drive unit For facilitated imports of the drawbar in the drive unit is the Entrance opening on the drive unit For example, the connection between tie rod and drive unit is preferably carried out by formschlussiges locking For this purpose, the tie rod, for example, a circumferential groove or the like The connection can also be made by a bayonet lock, by means of magnets, by a screw etc When using electromagnets, these can be used, for example, during imports of Pull rod are activated in the drive unit and produce in this way a positive or positive connection between the tie rod and drive unit

The extension of the pull rod from the drive unit after punching the opening is done either via the drive unit itself or a separate device, such as springs that bias during the punching process In an electromagnetic coupling are after punching and possibly the extension of the Zugstempels the electromagnets disabled again to allow the tool separation and a removal of the cut sheet metal part

In this case, an impression mechanism which operates, for example, via a piston or a lever, facilitate the detachment of the cut sheet metal part from the punching plate and / or the drive unit

In order to prevent the punching plate from falling out again, for example after insertion into the guide hole, prefixing of the punching plate to the body section is advantageous (not necessary with a pliers-type punching tool), especially if the pull rod is not coupled to the drive unit at once For this purpose, a Vorfixierungseinrichtung provided which is activated when applying the punching plate, for example via electromagnets or via a vacuum generating device This makes it possible to first set several punching plates to subsequently with a single drive unit in order to punch the breakthroughs. After punching, the prefixing device is deactivated again in order to achieve easy separation of the punching tool and removal of the stamped sheet metal part.

The prefixing device is arranged, for example, on the side of the punching plate facing the bodywork section (cutting side of the punching plate) and configured such that it pushes through to the rear side of the punching plate during the punching process. In pot-like punch plates a rigid arrangement of Vorfixierungseinrichtung within the pot is conceivable. The prefixing device can also be arranged laterally of the punching plate, that is to say outside the punching region.

In an embodiment of the Vorfixierungseinrichtung with magnets, the magnets are, for example, cylindrical and guided longitudinally displaceable in the punching plate against spring force parallel to the pulling direction, whereby they push with the application to the body section and the application of a tensile force on the draw punch through the punching plate.

The displaceability of the prefixing device is also advantageous, since this adaptation to a curved body portion is achieved and / or the deformation of the punched sheet can be followed.

In order to prevent a twisting of the drawbar in the guide hole, the guide hole may deviate from the circular shape. In this case, for example, oval, slot-like, quadrangular or polygonal geometries come into consideration.

Alternatively, it is possible to provide a second opening adjacent to a circular guide hole. While the guide hole in this case the introduction of the drawbar and the centering of the punching plate to the die, the second opening is the task of anti-rotation and angular positioning to. All in the context of the present invention made statements for the production of Fuhrungsloches apply mutatis mutandis to the production of the second opening

In the embodiments of the method according to the invention, which use a guide hole, a distinction is made with regard to the point in time at which the guide hole is introduced

In a first embodiment of the method, the Fuhrungslocher are already introduced in the shell at the unpainted body section Here are preferably already at all points that come later in the different vehicle variants in question, set the small Fuhrungslocher, for example by punching, drilling, milling, etc .. After Passage of the body through the painting is positioned only at those Fuhrungslochern where an actual breakthrough is needed, the punch The advantage lies in the simple and inexpensive integration of small punching units for the production of Fuhrungslocher in the press tools in the shell

The non-required Fuhrungslocher be closed, which is well possible due to the small size of Fuhrungslocher The Fuhrungslocher represent no appreciable weakening of the rigidity of the body The seal can be easily realized by appropriately designed small plug Also results in the seal by plug one adequate acoustic insulation

In a second embodiment of the method Fuhrungslocher be introduced only in case of need at the points on the already painted body where an opening is needed The introduction of Fuhrungsloches or Fuhrungslocher is preferably carried out immediately before punching the breakthrough For the production of Fuhrungslocher are suitable special method all machining methods, such as drilling The introduction of a deviating from the circular guide hole, for example, by milling or by a combined operation of drilling and milling The material obtained during machining material is removed by suction A great advantage of the method according to the invention lies in the universal applicability after the carcass of the body in order to be able to introduce subsequent breakthroughs on the completely painted body

Corresponding to the process variants shown above, all variants of the vehicle body can be produced in a uniform manner with "held" Fuhrungslochem Alternatively punching done without the aid of a Fuhrungslochs or on a previously set on the painted body Fuhrungsloch

The inventions generating the breakthroughs can be done very late in the assembly process of the vehicle body, on the assembly line of the final assembly Thus, for example, only immediately before the installation of the steering column required for this breakthrough in the front wall can be made

However, since at this time other parts have been installed in the vehicle body, the accessibility for both the punch and the drive unit may no longer be free or no longer unhindered. Therefore, in such cases, the required breakthroughs may already be generated at the beginning of the assembly line

The breakthroughs can alternatively also after the exit of the bodies from the Lackierlinie or at the output of an intermediate buffer for the painted bodies, such as a high-bay warehouse, are introduced, because there is a particularly good accessibility However, in this alternative, an additional workstation outside the actual assembly line be set up the final assembly

In individual cases, it may be useful for ease of accessibility to attach the breakthroughs before attaching the doors and flaps to the vehicle

The correct installation of the components and according to the correct introduction of the breakthroughs in a known manner by a running along with the vehicle configuration file (in paper or electronic) ensured A possible exemplary embodiment of the invention is illustrated in the drawing and is explained in more detail below It shows

Figure 1 is a plan view of a body portion of a

Motor vehicle and Figures 2 to 5 are sectional views of the individual phases of the erfmdungsgemaßen method

Figure 1 shows a body portion 1 of a motor vehicle, in this case the lower part of an end wall of a passenger car on the body portion 1 is a plurality of breakthroughs 2 recognize for carrying different lines, linkages, levers, shafts, devices, etc. Exemplary to illustrate the erfmdungsgemaßen method here two Lenksaulendurchbruche 3 highlighted that are needed depending on the execution of the vehicle as right or left-hand drive in the right or left half of the body section 1. The two Lenksaulendurchbruche 3 are located on both sides of a recess 4 for a transmission tunnel In a known manner prepared body sections 1 the two Lenksaulendurchbruche 3 already made in the shell, with each not required Lenksaulurchbruch 3 is closed by a lid

In the following, on the other hand, with reference to FIGS. 2 to 5, the need-based production of a steering-side breakthrough 3 on the body cut-out 1 will be explained

As is apparent from Figure 2, the body portion 1 centered in the Lenksaulurchbruch 3 to be generated, the extension of which is symbolized by lines x, a Fuhrungsloch 5 The Fuhrungsloch 5 is executed, for example, as a slot with the dimensions 10 mm x 18 mm Both in the right as well as in the left half of the body section 1 a Fuhrungsloch 5 has already been introduced in the shell

I l According to Figure 3, the first part 12 of a stamping tool designated in its entirety by 10 in the Karosseπeabschnitt 1 introduced in the present approach, the import side is here called Ruckseite R of the body section 1, although based on the direction FR of the motor vehicle this Side represents the front of the front wall

The first part 12 of the tool 10 is designed as a punch and is composed of a punching plate 14 and a tie rod 16 The punching plate 14 consists of a substantially flat plate having a shape corresponding to the shape of the opening 3 to be produced The punching plate 14 has its The cross section of the tie rod 16 is adapted to the cross section of the Fuhrungsloches 5, in the present case approximately rechteckform ig, so this is an anti-rotation and an angular positioning of the pull rod 16 in the slot-like Fuhrungsloch 5 results

With stπchlierten lines an optional Vorfixierungseinrichtung 18 is shown having a plurality of cylindrical electromagnets The electromagnets are biased by springs, not shown in the direction of the body portion 1 and protrude from the punching plate 14 in the direction of the body section 1 The Vorfixierungseinrichtung 18 is with the attachment of the punch plate 14 at activates the body section 1 and fixes the punch plate 14 by magnetic force on the body section. 1

As can be seen from FIG. 4, after the drawbar 16 has been imported into the guide hole 5, a drive unit designated 30 in its entirety is placed on the drawbar 16. Deviating from the illustration of FIGS. 2 and 3, the drive unit 30 can pass through the drawbar 16 during the passage the guide hole 5 are attached to the front side V of the body section 1 in such a way that an insertion into the drive unit 30 takes place when the pull rod 16 is pushed through. In this case, an electromagnetically actuated fixing device for the pull rod 16 is provided on the drive unit 30 provided, which is activated with the imports of the drawbar 16, so that the drawbar 16 is positively connected to the drive unit 30

The drive unit 30 is designed as a hydraulic or pneumatic cylinder and has a housing 32 with an internal piston 34. The housing 32 has on its side facing the body portion 1 open side a free end portion 36 which is configured circumferentially this end portion 36 acts as a "die "and forms the counterpart to the" patnze "of the punching plate 14

After placing the drive unit 30, the piston 34 is moved in accordance with the direction of the arrow 40, whereby the pull rod 16 is moved along the direction of the arrow 40 Thus, on the one hand, the punch plate 14 on the rear side R of the body section 1 to the plant and on the other hand lies down In the further course, the stamping device formed from stamping plate 14 and end section 36 cuts through the body section 1 in the area of the preparation point predetermined by the guide hole 5, so that the required steering hole 3 is formed Electromagnets of Vorfixierungseinrichtung 18 displaced against the direction of the arrow 40

FIG. 5 shows the final state of the body section 1 with the generated steering jaw opening 3 The cut sheet metal part 6 (corresponding to the sheet section between the two lines x-x in FIGS. 2 and 3) is now inside the tool 10 and must subsequently be removed therefrom This can be done after the extension of the piston 34 against the direction of the arrow 40, whereby the punch plate 14 again emerges from the housing 32. The prefixing device 18 (if present) takes in this case the sheet metal part 6 The sheet metal part 6 dissolves after the deactivation of the electromagnets the Vorfixierungseinrichtung 18 and can be removed after the separation of the drawbar 16 of the drive unit 30

The invention can be summarized as follows Describe in a preferred embodiment of the inventive method on-demand Generating breakthroughs in a body section 1 of a motor vehicle, at least two guide holes 5 are provided, which correspond to occasionally required openings 3 in the body section 1. Depending on which opening 3 is actually required in the relevant vehicle body, one or the other guide hole 5 is used for the insertion of a tool 10. The tool 10 consists of a punch 12 with a punch plate 14 and a pull rod 16. The pull rod 16 is passed from the back R of the body portion 1 through the relevant guide hole 5 and inserted into an attached to the front of the body section 1 drive unit 30. The drive unit 30 is designed, for example, as a hydraulic piston-cylinder unit and has on its side facing the body portion 1 a matrizenartig designed free end portion 36 which forms a punching device together with the punch plate 14. The drive unit 30 moves the punching plate 14 and the end section 36 together in such a way that the sheet metal section 6 lying therebetween is cut out and thus the required opening 3 is created. With the method according to the invention, 5 preparation points can be provided with comparatively very small guide holes, in which the tool 10 is used on an already painted body as required and subsequently the required openings 3 are generated depending on the vehicle configuration. The unneeded pilot holes 5 can be closed with small plugs.

Claims

claims

1. A method for generating on demand a breakthrough in a body portion of a vehicle in the course of mass production of vehicles, wherein in the context of mass production vehicle variants arise whose body sections require openings at different points, characterized in that the opening (3) on the already painted body section ( 1) is generated in case of need by a punching process.

2. The method according to claim 1, characterized in that the punching operation by a punching tool (10) with a punching plate (14) and a counter-holder (36).

3. The method according to claim 2, characterized in that the punching tool is formed like a pliers and carries at the opposite portions of the pliers the punching plate and the counter-holder. A method according to claim 1 or 2, characterized in that a) on the body portion (1) at the location of the need as needed breakthrough (3) a small Fuhrungsloch (5) is introduced, b) a punching tool (10) with a punching plate (14) and c) the pull rod (16) is passed through the guide hole (5) and the punch plate (14) connected or to be connected to the pull rod (16) is connected to the punch plate (14) connected or to be connected to the punch plate (14) one side (R) of the body portion (1) is arranged and d) subsequently to the on the other side (V) of the body portion (1) extending tie rod (16) is applied a tensile force for generating the breakthrough

A method according to claim 4, characterized in that the drawbar (16) with the punching plate (14) is connected to a one-piece draw punch (12), wherein the draw punch (12) via the tie rod (16) from the one side (R) of Body section (1) through the Fuhrungsloch (5) is performed

A method according to claim 4, characterized in that the pull rod is formed as a separate component, performed in a first step by the Fuhrungsloch (5) and in a second step with the punching plate is positively and / or non-positively connected

Method according to one of the preceding claims, characterized in that the punching plate (14) is formed by an approximately flat plate

Method according to one of claims 1 to 6, characterized in that the punching plate is pot-shaped, with a from the bottom of the punching plate approximately vertically projecting punching ring, the at in the body section (1) inserted punching tool (10) assigns to the body portion (1)

Method according to one of the preceding claims, characterized in that the tensile force via a hydraulic, pneumatic, electric or manual drive unit (30) is applied

Method according to one of the preceding claims, characterized in that the body section (1) facing end portion (36) of the drive unit (30) is designed as a counter-holder to the punching plate (14)

Method according to one of the preceding claims, characterized in that the drive unit (30) via a coupling device force or form-fitting with the tie rod (16) is connected

Method according to one of the preceding claims, characterized in that the punching plate (14) when attached to the body section (1) by a pre-fixing device (18) arranged on the punching plate (14) is held on the body section (1)

A method according to claim 12, characterized in that the prefixing device (18) during the punching operation in a direction opposite to the punching direction (40) moves

Method according to one of the preceding claims, characterized in that at the Fuhrungsloch (5) an anti-rotation device is attached

Method according to one of the preceding claims, characterized in that the Fuhrungslocher (5) already in the shell at the unpainted Karosseπeabschnitt (1) are introduced

A method according to claim 15, characterized in that at least one Fuhrungsloch (5) is closed when not needed

Method according to one of claims 1 to 14, characterized in that the Fuhrungsloch (5) is introduced only in case of need on the already painted body portion (1)

Method according to one of the preceding claims, characterized in that the breakthrough (3) is generated immediately before the installation of the relevant component to be performed on the assembly line of the vehicle manufacturer

Method according to one of claims 1 to 17, characterized in that the opening (3) is generated when the vehicle body enters the assembly line of the vehicle manufacturer

Method according to one of claims 1 to 17, characterized in that the breakthrough (3) is generated after the exit of the vehicle body from the painting of the vehicle manufacturer or after exiting from an adjoining the paint shop intermediate storage