WO2020239640A1

WO2020239640A1 - Method for producing a custom component for a vehicle

Info

Publication number: WO2020239640A1
Application number: PCT/EP2020/064332
Authority: WO
Inventors: Ralf Welp; Silvan Horovitz; Simone Wilsdorf; Sylvain Fischer
Original assignee: Volkswagen Aktiengesellschaft
Priority date: 2019-05-27
Filing date: 2020-05-22
Publication date: 2020-12-03
Also published as: DE102019207694A1

Abstract

The method according to the invention for producing a custom component for a vehicle is characterised by the following method steps: In one step, data regarding the shape of the component desired by the user is captured. The manner in which the shape data are captured is substantially dependent on the component. The data capture may result in data in a wide range of different forms, for example digital models, photographs, drawings or completed questionnaires. It is of minor importance whether the desired shape is based on the aesthetical perception or physiological characteristics of the user. In a further method step, data for 3D printing are generated on the basis of the desired shape captured. In this step the various data obtained is converted into a dataset that can be processed by a 3D printer. For example, data generation for the 3D printing may consist of the conversion of a geometry model from the data capture. In a further step, the component is produced by means of a 3D printing method. Individual components may advantageously be integrated into a series production in a digital process chain by means of the method according to the invention. The digital process chain allows a high degree of automation cost-efficiently. A further advantage lies in the applicability for a multitude of components of a vehicle.

Description

description

Method for producing an individualized component for a vehicle

The invention relates to a method for producing an individualized component for a vehicle, in particular vehicle seats.

There is a need for individualization of a wide variety of components

Vehicle. This need is partly based on the desire to have an individually designed vehicle that has features that distinguish it from the otherwise identical vehicles from series production. The need can also be based on physiological deviations of the user from the average person for whom a series vehicle was designed. Examples of this are: adapting a vehicle seat to an individual body shape, adapting a steering wheel to the user's hands and arms, adapting the pedals, etc. According to the prior art, this need for customization is met by the aftermarket, but this is disadvantageous in terms of costs and Environmental aspects, as new parts from series production are replaced.

In the case of vehicle seats, the need for customization is particularly high, since the body shape of the users can sometimes differ considerably from one another and the consequences of an unsuitable shape of the seat are significant for the driving experience and also for driving safety. For example, a poorly adapted shape of the vehicle seat can lead to back pain accompanied by premature fatigue of the driver or even to a

Lead to a restricted view, which represents a potential hazard. Vehicle seats are designed according to the state of the art for men of average build. For people with a body structure that differs from the average, in particular with regard to body size, corpulence, body shape or for people with other individual, for example medical or physiological characteristics, this design is disadvantageous and leads to problems. In normal vehicle seats, these problems are countered by various adjustment options for the vehicle seats, which can be adjusted to a comfortable sitting position for most body shapes.

In vehicles that are set up for a sporty driving style, shell or full shell seats are often used. These are intended to give the occupant a high level of Provide lateral support and containment to absorb the forces acting on the body during dynamic driving. A deviation from the normal body structure is particularly important in these seats, as there are hardly any adjustment options due to the design. Bucket seats usually consist of a seat shell to which upholstery elements such as cushions are attached on the inside. The seat shell is often made of fiber composite materials, as this allows a low weight with high mechanical stability.

Studies have shown that there are also a number of individual preferences for the

Design of a vehicle seat exist, for example for the shoulder area, the calf rest, the seat cheeks, the backrest cheeks, the backrest inclination or for asymmetries. These preferences can currently only be met by means of the adjustment options of a standard vehicle seat, which is often not sufficient.

For series vehicles, no method for customizing the shape of a vehicle seat is known from the prior art.

Two methods are known from motorsport to adapt the shape of the seats to the driver. In a first method, an expanding foam is injected into a bag arranged between the driver and the seat shell. The driver sits in the driving position on the seat shell. As a result of the expansion of the foam, the cavities between the driver and the seat shell are filled with the expanded foam and thus a very good one

The driver is enclosed in the bucket seat. Disadvantageously, a vehicle seat produced in this way only offers extremely low seating comfort, since the construction foam is very hard. In addition, the surface quality and visual appearance are inferior. Last but not least, the durability is far from sufficient for series vehicles.

In another method, also known as the vacuum seat mat method, a gas-tight bag or sack is filled with styrofoam balls and placed between the seat shell and the driver in the driving position. The air is then sucked out of the bag or sack, causing it to stiffen and keep its shape. In order to fix the shape, it is then flooded with a fixing agent, for example a resin. The beanbag generated in this way is then optically measured and then a digital seat model is generated. On the basis of this seat model, a seat shell can then be produced, for example from a fiber plastic composite material (FRP). The disadvantage of this process is very complex and therefore costly. In addition, a lot of waste is generated with this process, since the beanbag flooded with resin, as well as the positive or negative forms for the Creation of the FRP shell can only be used once and must then be disposed of.

What both methods have in common is that they are unsuitable for series use, as they are laborious to manual and have little potential for automation.

The invention is now based on the object of a method for producing a

to propose individualized component for a vehicle that can be used in series production.

The method according to the invention for producing an individualized component for a vehicle is characterized by the following method steps:

In one step, data is recorded on the shape of the component desired by the user. The way in which data is recorded for the shape is essentially dependent on the component. The data acquisition can collect data in the most varied of forms, for example digital models, photographs, drawings or completed questionnaires. It plays one

subordinate role, whether the desired shape is based on aesthetic sensibility or

physiological characteristics of the user based.

In a further process step, the data for the 3D printing is generated based on the desired shape recorded. In this step, the various data collected are converted into a data set that can be processed by a 3D printer. For example, data generation for 3D printing can consist of converting a geometry model from data acquisition.

In a further step, the component is manufactured using a 3D printing process.

By means of the method according to the invention, individual components can advantageously be integrated into a series production in a digital process chain. The digital process chain enables a high degree of automation cost-effectively. Another advantage is that it can be used for a large number of components in a vehicle.

In a preferred embodiment of the method, the generation of data for 3D printing includes a data processing step. In this process step, all of the data collected as part of the collection of the form requested by the user are saved in a standardized form that can be further processed by software. This step also includes, for example, the evaluation of interviews with the user and their

Implementation in the component geometry. Furthermore, other, for example legal requirements for the component to be manufactured can also be incorporated in this process step. In the case of vehicle seats, for example, requirements for the hip point (also known as the H point) are set out in standards. These requirements are intended to ensure that the occupant in the seat has a good all-round view. The data preparation process step is particularly advantageous if the desired form contains data in a wide variety of forms and enables the process to be automated to the greatest possible extent. This is favored if standardized data is supplied to the data preparation, which can be processed automatically. For example, a standardized measurement protocol in connection with a standardized questionnaire would be accessible to automated data processing.

In a further preferred refinement of the method, the creation of a printable geometry data record includes a method step of creating geometry. As part of this process step, a geometry model is created using the recorded desired shape, preferably using the data from the data preparation. The geometry model can advantageously be easily converted into a printable geometry data set.

In a further preferred embodiment, a parametric geometry model is generated in a step of the geometry creation. Can take advantage of a parametric

Geometry model changes can be introduced particularly easily.

In a further preferred embodiment, a volume-body model is generated in a step of creating the geometry. This is preferably done using the parametric geometry model. A printable data record can advantageously be derived very easily from a volume-body model.

All materials that can be used in 3D printing can be used as materials for production. These are in particular a wide variety of plastics such as polyactides (PLA), acrylonitrile-butadiene-styrene copolymers (ABS), polystyrene, polyhydroxy fatty acid,

Polyetheretherkton, PETG (polyetheretherkton and glycerol), polyetherimide and polyamide. Examples of metals are aluminum (often as an alloy with silicon and magnesium),

Titanium, gold and silver can be used. Plaster of paris, ceramics and glass are printable materials and can be used for the production of components. The process can be used for all components of a vehicle that can be printed using 3D printing. Examples of corresponding components are seats, steering wheels, controls, such as

Turn signal levers or light switches, trim strips, vehicle keys, trim parts, that

Tire profile, headlight styling, pedals, gear knob or storage compartments.

It is not necessary to individualize the entire component. For example, a basic shape of the component can also be mechanical, legal or other

Requirements must be specified and the options for customization restricted to certain areas of the component. An example of this are vehicle rims, for which a basic shape is given by the necessary mechanical stability, but still leaves room for customization.

In a preferred embodiment of the method, the component is a vehicle seat. In the case of vehicle seats, there is a particularly great need for individualization in order to accommodate a body shape or body size that deviates from the norm or other physiological peculiarities of the user. In the case of normal vehicle seats, the seat contour-giving assembly is individualized. In modern vehicles, this is often the foam assembly. The seat-contouring assembly is often divided into various individual components, such as seat or backrest surface or seat or backrest cheeks. These individual components are preferably manufactured individually using 3D printing and then assembled to form a seat.

In a particularly preferred embodiment, the vehicle seat is a shell or

Full bucket seat. The application of the method for bucket or full bucket seats is particularly attractive, since bucket and full bucket seats have hardly any adjustment options and so the physiological peculiarities of the user are particularly important. In addition, shell or full shell seats often only consist of a seat shell to which upholstery elements are to be attached, which simplifies an individualization process.

The seat shell is often made of fiber plastic composite material (FRP). By

Placing the continuous fibers and then printing the matrix material, components made of FRP can be easily produced using 3D printing. Carbon fibers are preferably used for shell or full shell seats, as these advantageously enable particularly high strength with low weight.

When customizing a vehicle seat, the desired shape of the component accordingly includes the ergonomic anthropometric data of the user, i.e. those for the seat and seat Backrest shape of the vehicle seat relevant body dimensions of the user. In addition, other data, such as the upholstery desired or necessary due to physiological characteristics, the desired cover fabric, desired rear ventilation or seat heating, etc. can be recorded.

In a further preferred embodiment of the method, the ergonomic anthropometric data is recorded by means of a contactless method. A method is referred to as contactless if the person to be detected is not physically touched during the detection. The non-contact processes can be divided into active and passive processes. Examples of active, non-contact methods are detection of the body shape by means of strip projection (also referred to as strip light optometry) or light section methods. For passive contactless methods, photogrammetry and silhouette cuts are good examples. The acquisition with

contactless processes can be carried out quickly and precisely. For the person to be detected, contactless methods are advantageously not noticeable and are therefore perceived as pleasant.

In a further preferred embodiment of the method, touching methods are used for the acquisition of the ergonomic anthropometric data. A very simple example of a contact method is manual measurement and the like. a. with protractors or tape measures. Data acquisition by means of pressure sensors in a seat or in a suit specially designed for this purpose is also possible. Last but not least, impressions of the body shape are also possible, which are then preferably scanned. For example, the methods described at the beginning with expanding foam or the vacuum seat mat method can be used for the impressions. The imprints are particularly preferably taken in the driving position. The advantages of contact measurement methods are great

Accuracy and low susceptibility to errors.

In a further preferred embodiment of the method, the data acquisition includes a customer-specific interview, in which, in particular, application scenarios and further user requests are discussed. The interview can be conducted in person or via the Internet. The interview is particularly advantageously carried out automatically using an Internet questionnaire or via speech recognition. In this way, the interview can be integrated into a series production of the individualized vehicle seats in a cost-effective and automated manner. In a particularly preferred embodiment of the method, the ergonomic anthropometric data of the user is recorded by sending materials for recording to the user. In this way, the user can conveniently carry out the recording himself at a location of his choice.

In a preferred embodiment of the method, a

Quality control. By adapting the parametric geometry model, the volume-body model or the 3D printing data set and printing again, errors can be detected early and easily eliminated. The adaptation is preferably carried out advantageously in a time-saving manner on the 3D printing data record.

In a further preferred embodiment of the method, after the assembly of the individual components or the completion of the seat, a test is carried out by the user. At

Complaints or problems can, if necessary, be adjusted again through a further, at least partial process run. The adaptation is preferably carried out by adapting the parametric geometry model. In this way, the adaptation of the seat to the wishes of the user can advantageously be further optimized.

Further preferred embodiments of the invention result from the other features mentioned in the subclaims.

The various embodiments of the invention mentioned in this application can be advantageously combined with one another, unless stated otherwise in the individual case.

The invention is explained below in an exemplary embodiment with reference to an associated drawing. It shows:

Figure 1 is a flow chart of the method for producing an individualized

Vehicle seat.

FIG. 1 shows a flow chart for producing an individualized vehicle seat.

By ordering a sports car, a user has the additional equipment of a

individualized full bucket seat selected. After the order is placed, an invitation is sent to data collection 1. This takes place in a car dealership. In the data acquisition 1, it is determined by means of a touching method. For this purpose, the user sits down in a measuring device similar to the vehicle seat and the contour of the contact area between the user and the seat is determined by means of mechanical actuating means and the ergonomic anthropometric data of the user is thus recorded.

As part of data acquisition 1, an interview is also conducted in which the user asks about the usage scenarios for the sports car and about his or her wishes with regard to the individual seat. Data is collected about the customer's wishes with regard to the

Seat properties, for example the suspension and damping behavior or the materials to be used. Data about physiological characteristics of the user, for example due to a sports injury, are also recorded. In addition, the user can select additional equipment for the vehicle seat during the interview.

The recorded data is then transmitted to the manufacturer of the seat. As a first method step, the latter carries out data processing 2 with the data record. As part of the data acquisition, a standardized data set is created from the available data from the data acquisition. This also includes legal framework conditions such as

For example, to ensure a good viewing position for the user by setting the H point.

The data from the data preparation 2 are now fed to a geometry creation 3, in which a parametric geometry model of the seat shell to be produced and from this a data record of the volume body is created.

This data record of the volume body is now fed to a 3D printing data generator 4, in which the printing data for the seat shell are generated. Then these

Print data is transmitted to the 3D printer and the seat shell is 3D printed 5.

After the 3D printing 5, a quality check 6 of the printed seat shell takes place. If printing errors are found at this point, the data from the 3D printing data generation 4 is adapted and a new 3D printing 5 takes place.

After passing the quality test 6, the seat shell is fed to an assembly 7 in which the seat upholstery and possible additional equipment are introduced. As part of the delivery 7 of the seat, the user is tested as part of a test drive. If the user has complaints here, another one

The process run, starting with a detection 1, is followed by a renewed adjustment based on the results of the first run.

List of reference symbols

Data acquisition

Data preparation

Geometry creation

3D printing data generation

3D printing

Quality inspection

Assembly

delivery

Claims

1. Process for the production of an individualized component for a vehicle,

characterized by the following process steps:

Data acquisition (1) of the shape of the component desired by the user, data generation for 3D printing (4) using the data from the data acquisition (1), production of the component using 3D printing (5).

2. The method according to claim 1, characterized in that in a further

Process step data preparation (2) the data record of the data acquisition (1) is prepared.

3. The method according to any one of the preceding claims, characterized in that in a further process step geometry creation (3) a geometry model is created.

4. The method according to claim 3, characterized in that the geometry creation (3) takes place from the data of the process step data preparation (2).

5. The method according to claim 3 or 4, characterized in that the geometry creation (2) comprises the creation of a parametric geometry model and / or the creation of a volume-body model.

6. The method according to any one of the preceding claims, characterized in that a quality test (6) takes place after the component has been manufactured.

7. The method according to any one of the preceding claims, characterized in that the production of the component by means of 3D printing (5) the production of

Includes individual components of the component and their assembly (7).

8. The method according to any one of the preceding claims, characterized in that the component is tested after production by the user and, if necessary, a new adjustment by re-executing the method according to one of the

Claims 1 to 7 takes place.

9. The method according to any one of the preceding claims, characterized in that the component is a vehicle seat and the data acquisition is ergonomic

Includes anthropometric data of the user.

10. The method according to claim 8, characterized in that the data acquisition (1) of the ergonomic anthropometric data includes the use of non-contact and / or touching methods and / or a customer-specific interview.