WO2016051286A2 - Appareil et procédé pour le traitement d'une carrosserie de véhicule sur laquelle un enduit est appliqué - Google Patents

Appareil et procédé pour le traitement d'une carrosserie de véhicule sur laquelle un enduit est appliqué Download PDF

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Publication number
WO2016051286A2
WO2016051286A2 PCT/IB2015/053079 IB2015053079W WO2016051286A2 WO 2016051286 A2 WO2016051286 A2 WO 2016051286A2 IB 2015053079 W IB2015053079 W IB 2015053079W WO 2016051286 A2 WO2016051286 A2 WO 2016051286A2
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WIPO (PCT)
Prior art keywords
vyd
ved
working tool
installation
installation according
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PCT/IB2015/053079
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English (en)
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WO2016051286A3 (fr
Inventor
Algirdas NORVILAS
Original Assignee
Uab "Norvilsis"
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Application filed by Uab "Norvilsis" filed Critical Uab "Norvilsis"
Publication of WO2016051286A2 publication Critical patent/WO2016051286A2/fr
Publication of WO2016051286A3 publication Critical patent/WO2016051286A3/fr

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Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/42—Recording and playback systems, i.e. in which the programme is recorded from a cycle of operations, e.g. the cycle of operations being manually controlled, after which this record is played back on the same machine
    • G05B19/4202—Recording and playback systems, i.e. in which the programme is recorded from a cycle of operations, e.g. the cycle of operations being manually controlled, after which this record is played back on the same machine preparation of the programme medium using a drawing, a model
    • G05B19/4207—Recording and playback systems, i.e. in which the programme is recorded from a cycle of operations, e.g. the cycle of operations being manually controlled, after which this record is played back on the same machine preparation of the programme medium using a drawing, a model in which a model is traced or scanned and corresponding data recorded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
    • B24B19/26—Single-purpose machines or devices for particular grinding operations not covered by any other main group for grinding workpieces with arcuate surfaces, e.g. parts of car bodies, bumpers or magnetic recording heads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B27/00—Other grinding machines or devices
    • B24B27/0038—Other grinding machines or devices with the grinding tool mounted at the end of a set of bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/12—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation involving optical means
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/401—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/37—Measurements
    • G05B2219/37417—By linear varying electrical signal
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/39—Robotics, robotics to robotics hand
    • G05B2219/39122—Follower, slave mirrors leader, master
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/39—Robotics, robotics to robotics hand
    • G05B2219/39141—Slave program has no taught positions, receives position from master, convert from master
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/40—Robotics, robotics mapping to robotics vision
    • G05B2219/40407—Master slave, master is replica of slave
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/50—Machine tool, machine tool null till machine tool work handling
    • G05B2219/50214—Refurbish, refinish, reprofile, recondition, restore, rebuild profile

Definitions

  • the invention belongs to the field of vehicle body repair and is related to the method of the removal of excessive hardened filler composed of additional material from the defective body parts of the vehicle by using a computer controlled robotic apparatus.
  • Robotic equipment is widely used in vehicle manufacturing and repair industry, where operations are carried out by deploying various programmable equipment, for example, robots programmed by using CAD models.
  • mass production robots are effective means insignificantly reducing labor costs and increasing the volume of productivity.
  • most if not all robots of this category are pre-programmed which makes them not practical in processing a large number of individual parts of different vehicles.
  • the operations like the excessive hardened filler removal, i.e. grinding, performed after a mechanical reconstruction of the damaged vehicle body parts, would differ in case of each individual part of the vehicle body, resulting in the necessity to re-programm a robotic apparatus for processing each new part.
  • the vehicle body repair equipment has to meet certain specific requirements. It must be easily prepared for work, i.e. easily programmed and calibrated, compact and portable.
  • the US patent application No. 06/495,982 describes an automatic car body contour grinding machine for surface smoothing, comprising a robot and a computer which can be operated by an operator from a distance. The machine operation is based on the contour data and the information received from sensors. The car body part surface's interaction with a working instrument data is received from sensors which are used to determine the processed material in accordance to the feedback signal. Sensors measure material characteristics such as friction, sound, reflected light, sparking of the grinded surface.
  • the described device can be used only to grind very small areas when it is essentially impossible to considerably deviate from the initial shape of the car body part.
  • the US patent application No. 09/731 ,979 discloses an automated aircraft surface finishing method and apparatus comprising a central controller, a versatile transportation apparatus for aircraft panels, a scanning instrument and a panel surface processing device, which can be moved in multiple axes. Multiple surface finishing tools are used for surface finishing of the panel wherein the scanning means are adapted to generate the output control signal for actuating and operating the surface processing device, wherein the processing device is activated in order to remove surface deviations.
  • the method and apparatus are used only in conjunction with programmed geometry of the panel, which is confirmed by the scanning device.
  • a vehicle body in most cases is made of thin (about 1 mm) metal sheets, i.e. steel, aluminum. If it is touched during machining operation it becomes thinner, loses anticorrosion material layer, mechanical properties deteriorate and overall stiffness of a vehicle body is reduced. Therefore vehicle body repair requires special devices, special equipment and processing techniques that would impart minimal damage to a steel sheet. Disadvantages and shortcomings of the above-cited patents and patent applications are eliminated with the proposed installation and method.
  • the apparatus with its installation and method have clear industrial application in the field of restoration of surfaces of vehicle body parts.
  • the present invention is intended to provide an innovative vehicle body surface treatment method using specially adapted surface treatment devices. Short description of the invention
  • the invention concerns installation and method for removal of hardened filler material from defective vehicle body parts by using real-time computer controlled robotic device.
  • the proposed installation for removal of excessive hardened filler material from a surface of a vehicle body part consists of a computer control unit, a master and a slave unit (respectively denoted by VeD and VyD).
  • VeD and VyD are two independent units, which may be mobile, disposed relatively one to another at a distance having no influence to the performed work, or stationary and adaptable to a vehicle body shape.
  • Both, the master and the slave unit comprise a series of identical members: a stand with stand holders, holders of robots with robots, guidance members and impact sensors. Both of the units differ only in that the VeD has a profilometer with a profilometer holder and VyD has an end effector with a working tool. Said master and slave units may be interchanged by interchanging the differing members of each unit.
  • the proposed installation is also different in that the end effector of VyD has a rotary unit equipped with a brush element electrically connecting a conductive shaft of the rotary unit, a tool chuck and a working tool.
  • a computer control unit is connected to the electrical terminals of the brush.
  • the brush fixed in a brush holder is used to establish an electrical contact between the electrically conductive working tool and the brush terminals used to connect to the computer control unit.
  • Electrical connection between the computer control unit and the working tool is effected through a conductive shaft bearing, the shaft, the housing and the tool chuck of the rotary unit.
  • the computer control unit is connected to the conductive part of the processed surface.
  • the proposed installation has a marker in a shape of a machining tool, according to its form and fixing method.
  • the proposed installation may be used to manufacture a template of a working tool head according to the used working tool.
  • Proposed methods and installation for carrying out the methods enable the use of robots which have less than 3 degrees of freedom or 3 or more degrees of freedom and in particular 6 degrees of freedom.
  • Another aspect of the invention is method for processing a vehicle body surface having excessive amount of filler material thereon by using a computerized, half automated installation comprising at least a computer control unit, VeD and VyD.
  • the method comprises the following steps: setting up VeD and VyD with respect to one another and a reference and a processed surfaces, determinates contour of the area to be processed of the damaged surface, defines the area of the contour of the reference surface on the opposite side of a vehicle body, i.e.
  • mirroring method scanning the contour area of the reference surface, performing quality check of the straightened surface of a damaged vehicle body part by determining areas of electrical and/or mechanical contact, after performing further straightening if required, performing the surface processing in real-time while simultaneously scanning the reference surface or performing the surface processing according to coordinates of a pre-scanned reference surface after the filling of depressions with filler.
  • the proposed method further comprises using contact, half-contact or contactless profilometers for scanning areas of a processed surface and reference surface.
  • Fig.1 - shows a general view of the first example of the installation
  • Fig.2 - shows a general view of the second example of the installation
  • Fig.3 - shows the end effector with the guidance unit, the impact sensor and the working tool
  • Fig.4a - shows the rotary unit having an electrical contact in a rotary unit
  • Fig.4b - shows the rotary unit having an electrical contact with the working tool
  • Fig.5a - shows the rotation apparatus having a contactless profilometer (25);
  • Fig.5b - shows the rotation apparatus (17) that is fitted with the tool chuck with a blank;
  • Fig.6 - shows a general view of the marker
  • Fig.7 - shows a structural scheme of the installation with a robot having 3 degrees of freedom or less
  • Fig.8 structural scheme of the installation with a robot having more than 3 degrees of freedom.
  • a vehicle body part surface processing installation comprises a master unit (VeD) and a slave unit (VyD), and a computer control unit (1 ) with display (1 a) and data entry equipment (1 b).
  • VeD and VyD comprises a stand (2, 2 ') with a stand holder (2a, 2'a), a robot holder (3, 3'), a distance meter (3a, 3'a) for the robot holder, a robot (4, 4 '), a guidance unit (5, 5') and impact sensor (6, 6 ').
  • VeD is additionally equipped with a profilometer holder (7) and a profilometer (8) and VyD is further equipped with end effector (9) and a working tool (10).
  • the profilometer holder (7) is used to mount and/or replace the mechanical or automatic profilometer (8) which is controlled by a computer control unit (1 ).
  • An electrically conductive working tool (10) is used for processing a processed surface (13) and where necessary establishing an electrical connection with the electrically conductive part of the processed surface (13).
  • Robot holders (3, 3 ') are equipped with distance meters (3a, 3'a).
  • Vehicle body surface processing apparatus also includes one or more video recorders (1 1 ).
  • VyD units are mechanically interconnected: a stand holder (2a), a stand (2), a robot holder (3), a distance meter (3a) of the robot holder, a robot (4), a guiding unit (5), an impact sensor (6) and a profilometer holder (7) with a profilometer (8).
  • VyD units are mechanically interconnected: a stand holder (2'a), a stand (2 '), a robot holder (3'), a distance meter (3'a) of the robot holder, a robot (4 '), a guiding unit (5 '), an impact sensor (6') and the end effector (9) with a working tool (10).
  • Robots (4,4 ') can be coordinate measuring machines controlled by a computer control unit (1 ) to operate a working tool (10) and a profilometer (8) in Cartesian coordinate space. According to the level of difficulty, robots (4, 4 ') can have 2 or more degrees of freedom, weight compensation of the free end with a mounted device thereat, force feedback, sense of touch, vibration absorption or another function, their components must be protected against water and dust.
  • Computer control unit (1 ) is equipped with necessary data acquisition, processing, and outputting devices to control hardware and software and can transmit and receive information from all units connected to it by data transmission/reception means, i.e. wires, wirelessly or other data transmission/reception means.
  • Profilometer (8) can be a contact, semi-contact or contactless device, for example a laser scanner.
  • Figure 1 also shows the reference (12) and the processed (13) surfaces.
  • the reference surface (12) has a desired shape to be replicated on the processed surface (13).
  • the processed surface (13) has a damaged area (13a) of a vehicle body surface to be processed and a damage-free surface area around the damaged area for calibration with a reference surface (12).
  • the electrically conductive area of the processed surface (13) has an electrical contact with the computer control unit (1 ).
  • the damaged area (13a) is filled with an excessive amount of usually non-conductive filler material.
  • the reference (12) surface and processed surface (13) may be on one and the same object (14), for example symmetrical parts of a vehicle body. Electrical connections of the computer control unit (1 ) with relevant units of the installation are not shown in Figure 1 as it is self-evident.
  • the stand holder (2a, 2'a) are equipped with guidance, securing, tilting, tilt angle detection relatively to the surface, locking and relocating means.
  • the robot holders (3, 3') are provided with orientation, tilt angle detection, securing to the holder (2, 2 ') and the robot (4, 4') units.
  • the robot holders (3, 3 ') are fitted with a distance meters (3a, 3a') at a known angle used to measure distance to the reference (12) surface and the processed surface (13) points and the tilt angle detection of the holders (2, 2 ') with respect to the reference (12) surface and the processed surface (13) planes.
  • Units for orientation of robot holders (3, 3 '), tilt angle detection and the distance meters (3a, 3a') are used for calibration of the robot holders (3, 3 ') with reference (12) surface and the processed surface (13) planes.
  • stand holders (2a, 2'a) and the robot holders (3, 3 ') can be operated manually or can be controlled with electromechanical means by computer control unit (1 ).
  • Guiding units (5, 5 ') are used to position and secure the profilometer (8) and the working tool (10) with respect to the reference (12) surface and the processed surface (13).
  • VeD and VyD units in particular robots (4, 4 ') and computer control unit (1 ) are chosen such that would ensure desired productivity and quality and compatibility of VeD and VyD hardware.
  • a robot with more than three degrees of freedom may not have a robot holder (3, 3 '), the robot holder distance meters (3'a, 3a), a stand holder (2a, 2'a) and orientation unit (5, 5').
  • the impact sensors (6, 6 ') are necessary for additional protection of the robots (4, 4'), the end effector (9), the working tool (10), the profilometer holder (7), the profilometer (8), the reference (12) surface and the processed surface (13) against accidental mechanical damage.
  • Impact sensors (6, 6 ') can have a lock with the option to activate it when working mechanically.
  • Fig. 2 shows an apparatus for processing surface of a vehicle body part covered with filler material when the reference surface is not a symmetrical part of a vehicle body but a pre-manufactured part with a desired surface, or other similar surface of another vehicle placed in a separate room, where the distance does not affect the opearation of the installation.
  • VeD and VyD construction differs from construction in Figure 1 by further comprising extension members (2b, 2'b) and their positioning units (2c, 2'c). They are adjustable by positioning units (2c, 2'c) of the extension elements of the stand and stand extension units (2b, 2'b).
  • Fig. 3 shows an end effector (9) with the impact sensor (6 '), guiding unit (5') and the working tool (10).
  • the end effector (9) comprises a tool chuck (15) and a sensor unit (16), a rotation apparatus (17) and its holder (18).
  • the tool chuck (15) can be operated manually or automatically, i.e. controlled by a computer control unit (1 ).
  • a mobile control unit (19) can be fixed to the holder (18) and have indicators, control buttons and a display which is a touch display or non-touch display. At least one mobile control unit (19) can be separate from the holder (18).
  • the sensor unit (16) is attached to the rotation apparatus (17) through the sensor unit holder (20).
  • the sensor unit holder (20) is chosen such that the sensor would have sufficient stability and could be positioned at different angles, positions and distances.
  • the sensor unit (16) comprises at least a profilometer, a temperature sensor, an ultrasonic sensor, light sensor, an inductive sensor, a laser distance meter, a humidity sensor.
  • Fig. 4a shows the rotation apparatus (17), the working tool (10) and the processed surface (13).
  • the rotation apparatus (17) comprises the housing (21 ), a turning device (22) and a tool chuck (15). Electrical connection between the working tool (10) and the computer control unit (1 ) is formed by pressing the brush (23) against the shaft of the turning device (22). Said brush has terminals (23a) for connection with the computer control unit (1 ).
  • Fig. 4b shows a brush (24) within a brush holder (24a) being pressed to the shaft of the outer surface of the working tool (10), where said brush has terminals (24b) for connection to the computer control unit (1 ). Terminals (13b) are used for electrical contact between electrically-conductive area of the processed surface (13) and the computer control unit (1 ).
  • the brush holder (24a) holds terminals (24b) and the brush (24), acts as a shock absorber and presses it to the external surface of the working tool (10).
  • the brush holder (24a) is further designed to retract the brush (24) from the working tool (10) when tool is changed and may form electrical connection between the working tool (10) and the computer control unit (1 ).
  • the rotation apparatus (17) has at least one electrical contact terminal (23a, 24b) for connection to the computer control unit (1 ) coupled via the brush (23, 24) connecting the working tool (10). If the electrical contact is present between the working tool (10), the tool chuck (15), the turning device (22) shaft, the bearing of the shaft of the turning device (22) and the housing (21 ), the brush may be omitted and the electrical connection between the computer control unit (1 ) and the working tool (10) is made through the bearing of the shaft of the turning device (22) or the housing (21 ).
  • Processed surface (13) is shown compromising surface area (13a) with a filler material.
  • Fig. 5a shows a rotation apparatus (17) that is fitted with the tool chuck (15) with working tool (10) and contactless profilometer (25).
  • Contactless profilometer (25) may be a separate component or one of the sensor units (16) may be used for measuring working tool (10).
  • Fig. 5b shows the rotation apparatus (17) that is fitted with the tool chuck (15) with a blank (26) for the profilometer head part template and the machining tool or a processing device (27).
  • Fig. 6 shows general view of the marker (28).
  • the marker (28) comprises a securing element (29), a controller (30), an extension element (31 ) and a head (32).
  • the marker (28) accurately reproduces the working tool (10).
  • Surface of the head (32) is divided into different electrically conductive areas (32a) made of electrically conductive material, for example from metal, and are isolated one from another. Each area has ink supply channels (32b) which are connected to said controller (30) via the extension element (31 ).
  • Each one of said electrically conductive areas (32a) of the head (32) is separately connected to the controller (30).
  • the controller (30) has a connector (not shown) for connection to a computer control unit (1 ) directly or through circuits of the end effector (9) and securing element (29).
  • the controller (30) is provided with an ink cartridge with ink (not shown) which is connected to the ink supply channels (32b) via ink nozzles (not shown) in the controller (30) for controlling the ink supply.
  • the ink cartridge is pressurized or compressed air is supplied into the ink cartridge by a separate element (not shown), for spraying ink.
  • ink nozzle of said area is activated for delivering ink from the ink cartridge provided in the controller (30).
  • Ink is sprayed on to the processed target surface (13) by at least one nozzle of the electrically conductive area (32a), while the electrical signal goes to the computer control unit (1 ).
  • the marker (28) head (32) may be made of a soft material, such as foam, sponge, rubber, silicone, where surface can be coated with a colouring liquid or powder for marking a contact point with the processed surface. Any colouring liquid may be used instead of ink.
  • Fig. 7 shows a flow diagram of the functional connections of VeD and VyD units, as well as other units, with the computer control unit (1 ), when robots (4, 4 ') with 3 or fewer degrees of freedom are used.
  • Fig. 8 shows a flow diagram of the functional connections of VeD and VyD units, as well as the other units, with the computer control unit (1 ), when robots (4, 4 ') with 3 or more degrees of freedom are used.
  • Stands (2, 2 ') are calibrated one with respect to another and to their respective seat surfaces; holders (3, 3') of robots are calibrated with respect to reference (12) and processed (13) surfaces e.g. inclination angle, setting of distances and defining of position.
  • Positioning units (5, 5') are configured.
  • VeD and VyD are calibrated by positioning holders (3, 3') of robots along the extension members (2b, 2b') and configuring the extension members (2b, 2b') by using positioning units (2c, 2'c) along the stands (2, 2'), afterwards continuing with VeD and VyD setting up calibration.
  • This step of set-up calibration can be omitted when using robots with three or more than three degrees of freedom.
  • the calibration of the installation can be carried out manually or electro-mechanically by using the distance meters (3a, 3'a), measuring inclination angles of stand holders (2a, 2a') and holders (3, 3') of robots, calibration units provided in stand holders (2a, 2a') and holders (3, 3') of robots as well as the computer control unit (1 ).
  • Determining distances between the holders (3, 3') of robots and the reference (12) surface and the processed surface (13) comprises verification of travel path of the robots (4, 4 '), the working tool (10) and the profilometer (8) in planned working Cartesian coordinate system during operation time and leaving a safety reserve for free of interference movement of VeD and VyD. During calibration all data is recorded to the computer control unit (1 ).
  • Adjustment calibration of the working tool (10) and the profilometer (8) is performed by: determining distances of the working tool (10) and the profilometer (8) to the planes of the processed surface (13) and the reference (12) surface; by parallelization; and by determining positions in Cartesian coordinate system.
  • the profilometer is used instead of the working tool (10) during the calibration.
  • VeD and VyD calibration proceeds by measuring distance between the working tool (10) and the processed surface (13), the profilometer (8) and the reference surface (12), which measurements are sent to the computer control unit (1 ).
  • For calibration at least three points are selected on the undamaged area out of the processed surface (13) boundaries and at least three identical three points on the reference surface (12).
  • Adjustment calibration can be performed mechanically by regulating units for set-up calibration and VeD and Vy Dprofilometers, where the working tool (10) of VyD is replaced by profilometer while calibrating, by hand or automatically under control of the computer control unit (1 ).
  • Working area of the working tool (10) and the profilometer (8) is defined by a contour comprising identical points of undamaged zones out of the boundaries of processed surface (13) and the reference (12) surface which points are registered by the computer control unit (1 ).
  • the computer control unit (1 ) is supplied with data of points of undamaged part of the processed surface (13) and the undamaged reference (12) surface areas, generated planes, and the coordinates of the robots (4, 4 ') positions in space, spatial relation between planes and the working tool (10) and the profilometer (8) and the processed surface (13) and reference (12) surface.
  • the working tool (10) is returned (inserted) back into the tool chuck (15). Calibration of the working tool (10) and the profilometer (8) is repeated along the axes in z direction. This is performed by touching the working tool (10) and the profilometer (8) to identical points on the undamaged part of the processed surface (13) and reference (12) surface areas which points coordinates are entered into the computer control unit (1 ) by using a mobile control unit (19) or a data input device (1 b).
  • the working tool (10) and the profilometer (8) travel along identical points in Cartesian coordinate system with respect to the processed surface (13) and the reference (12) surface.
  • Synchronicity of the VeD and VyD can be mechanically tested by manually bringing the profilometer (8) to any one of points to be machined and monitoring movement of the working tool (10) along the processed surface (13). The travel of the working tool (10) and the profilometer (8) can be adjusted.
  • Profilometer head template is produced by scanning the working tool (10), being mounted into the turning device (22), with a contactless profilometer (25) and recording the collected data on a computer control unit (1 ). Instead of the working tool (10) a profilometer head template blank (26) is inserted. VyD processes the blank with a cutting knife or a processing device (27) according to the scanned data of the working tool (10). When straightening of the damaged surface is performed it is recommended to leave at least 1 -2 mm distance to the target surface level, where possible, for the filler material. A profilometer or a marker (28) is inserted into VyD tool chuck (15), the VeD and VyD with a new tools once again are set at the reference points.
  • VeD and VyD are run to inspect straightening quality of the processed surface (13), i.e. electrical contact between the processed surface (13) and the marker (28) is tested when scanning reference (12) surface preset area points. If electrical contact between the processed surface (13) and the marker (28) is established, the marker (28) sprays ink or marks in another way the area on the processed surface (13). Upon completion of the inspection of the processed surface (13), all mechanical contact areas are marked and the operator has to decide the need for supplementary straightening of the surface and/or VeD and VyD are recalibrated. Inspection of straightening quality of the processed surface (13) is once more performed on the processed surface (13) after supplementary straightening if required and the processed surface (13) can be covered with filler material (13a).
  • the working tool (10) is inserted into VyD tool chuck (15) and, if necessary, VeD and VyD are recalibrated again. Afterwards the machine is started for operation. There are two operating modes - the reference surface (12) is scanned by VeD, and the VyD processes the processed surface (13) in real time, or when the computer control unit (1 ) operates VyD according to a previously recorded and possibly corrected data of the reference surface (12). If an electrical contact between the electrically conductive part of the processed surface (13) and the working tool (10) is detected during the operation, the computer control unit (1 ) receives a signal from the program to adjust the processing.
  • Corrective action may include the following: machining process is stopped, and further steps are performed by the operator; the working tool (10) is retracted from the processed surface (13) to a certain predetermined value and direction; the program execution process is moved back by a number of steps; the program execution process is moved forward by a number of steps; when the machining process takes place in real-time the processing program passes in to a calibration mode in a small electrical contact area and after it is completed it returns back to the processing mode.
  • VyD installation position has to be taken into account to eliminate risk of damaging equipment or the processed surface (13). Operator can always interfere, correct or stop the operation of the VeD and VyD units. Possibility to detect the contact with a metal enables safer work of the equipment protects its components and the processed surface (13) against unforeseen damage. Not always vehicle body part areas have the mirror image on the right place, or both vehicle body parts may be damaged. In this case it is necessary to find a second intact and identical or similar part from a vehicle of the same model, serial number or shape, for example a hood, quarter panels, wheel arches, rocker panels or any other undamaged part.
  • Minor damage on the reference surface (12) intended area can be filled with substance which can be easily removed after repair of the processed surface (13) is completed. Minor damage on the reference surface (12) can be left untreated. Minor deviations of the processed surface (13) can be repaired by using standard vehicle body repair methods.
  • VeD and VyD are mobile and can adapt (by moving) to a vehicle body processing location as shown in Fig. 1 and Fig. 2 and described above; VeD and VyD are stationary, and a vehicle body processing location is adapted to the location of the VeD and VyD.
  • Identical nodes of VeD and VyD can be interchanged, when processing mirror parts of vehicle body (if VeD and VyD are stationary), i.e. the end effector (9) with the working tool (10) and the profilometer holder (7) with the profilometer (8).
  • VeD and VyD may have different configurations, including robots (4, 4 ') with different degrees of freedom. In such a case the calibration is performed according to calibration specifics of robots having less degree of freedom.
  • the operator can monitor the operation process of the installation in a display (1 a) or on a mobile control unit (19), being at safe distance from the installation, and can interfere in any of the processes, adjust it or control it. Additional reference points may be placed on the processed surface (13) and the reference (12) surface to facilitate surface alignment when semi-contact or contactless profilometer (8) is used.
  • VyD or VeD are operated manually by a hand, a program of the computer control unit (1 ) is set for gentle (no sudden movements) repetition of the process.
  • VeD and VyD have to operate synchronously.
  • the computer control unit (1 ) program has to adapt operation of VeD and VyD accordingly, or it can be done by operator.
  • VyD is provided with dust extraction means.
  • Other apparatus may be used instead of the working tool (10) and the rotation apparatus (17) to perform the machining of the processed surface (13) with abrasives according to the method described above.
  • Car body quality repair has gained high relevance as the number of cars is increasing every year together with number of minor accidents.
  • the proposed device and method have the following advantages: enables quality repair work, which in most cases cannot be achieved by hand, operated tools; reduces car body repair time; saves repair materials; car body metal parts are subjected to minimal damage; car body part machining is performed in the automatic mode, without direct involvement of the operator thus protecting the operator from harmful effects of used material.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Human Computer Interaction (AREA)
  • Manufacturing & Machinery (AREA)
  • Vehicle Cleaning, Maintenance, Repair, Refitting, And Outriggers (AREA)
  • Manipulator (AREA)

Abstract

L'invention concerne des installations de réparation d'une carrosserie de véhicule et un procédé de réalisation de travaux de réparation à l'aide de ladite installation, en particulier pour l'élimination de l'excès d'un matériau de remplissage durci (meulage) de pièces de carrosserie de véhicule défectueuses au moyen d'un dispositif robotique commandé par ordinateur. L'installation est composée de trois unités principales – les unités maître et esclave et une unité de commande par ordinateur. Le fonctionnement desdites trois unités principales est basé sur le balayage de la partie correspondante non endommagée du même véhicule ou de tout autre véhicule et l'exécution du traitement de la zone endommagée de la carrosserie du véhicule. L'objectif de l'invention est de fournir une installation et un procédé de fonctionnement de ladite installation par rapport aux configurations complexes à paroi mince d'une carrosserie de véhicule et aux spécificités de réparation sans endommager la partie en métal (étain) de la carrosserie du véhicule.
PCT/IB2015/053079 2014-09-30 2015-04-28 Appareil et procédé pour le traitement d'une carrosserie de véhicule sur laquelle un enduit est appliqué WO2016051286A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
LT2014114 2014-09-30
LT2014114A LT6304B (lt) 2014-09-30 2014-09-30 Automobilio kėbulo padengto užpildu apdirbimo įrenginys ir būdas

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IT201700116298A1 (it) * 2017-10-16 2019-04-16 Stefano Bampi Procedimento per la riparazione di carrozzerie
CN109877851A (zh) * 2019-04-04 2019-06-14 北京卫星制造厂有限公司 一种用于弱刚性壁板加工的移动式双机器人镜像加工系统
CN112845672A (zh) * 2020-12-31 2021-05-28 深圳市荣辉铜铝材料有限公司 一种金属板材自动调平方法
JP2022107524A (ja) * 2021-01-08 2022-07-21 仁一生醫股▲ふん▼有限公司 ツインスピンドル加工のモーションコントロール方法、ツインスピンドル加工機及びコンピュータプログラム製品

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US6495982B2 (en) 2000-06-23 2002-12-17 Texas Instruments Incorporated Electric motor control

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT201700116298A1 (it) * 2017-10-16 2019-04-16 Stefano Bampi Procedimento per la riparazione di carrozzerie
CN109877851A (zh) * 2019-04-04 2019-06-14 北京卫星制造厂有限公司 一种用于弱刚性壁板加工的移动式双机器人镜像加工系统
CN112845672A (zh) * 2020-12-31 2021-05-28 深圳市荣辉铜铝材料有限公司 一种金属板材自动调平方法
JP2022107524A (ja) * 2021-01-08 2022-07-21 仁一生醫股▲ふん▼有限公司 ツインスピンドル加工のモーションコントロール方法、ツインスピンドル加工機及びコンピュータプログラム製品

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WO2016051286A3 (fr) 2016-05-26
LT6304B (lt) 2016-08-25
LT2014114A (lt) 2016-04-11

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