Method for manufacturing a motor vehicle

Abstract

Method for manufacturing a motor vehicle comprising at least one vehicle door (2), wherein, within the framework of the manufacturing process, in an assembly state of the vehicle door (2) in which a base frame of the vehicle door (2) is separated from a body of the motor vehicle, at least one component is mounted on the base frame, wherein at least one section of the vehicle door (2) is excited to vibrate in the separated state and a quality parameter of the vehicle door (2) is determined in the excited state of the vehicle door (2), wherein the vehicle door (2) is released or subjected to further processing depending on the determined quality parameter.

Description

[0001] The invention relates to a method for manufacturing a motor vehicle comprising at least one vehicle door, wherein, within the manufacturing process, in an assembly state of the vehicle door in which a base frame of the vehicle door is separated from a body of the motor vehicle, at least one component is mounted on the base frame.

[0002] Such methods for manufacturing motor vehicles that have at least one vehicle door are generally known from the prior art. Typically, during the initial assembly of the motor vehicle, the at least one vehicle door is attached to the body or vehicle structure, while individual manufacturing process steps, such as surface treatment, painting, or other processes, are carried out. Subsequently, the at least one vehicle door is usually separated or disassembled from the rest of the motor vehicle and further processed on a separate production line, for example, by assembling other components such as trim, windows, window regulators, speakers, and the like. This is done in particular to ensure that the vehicle doors do not obstruct the assembly of components inside the vehicle.Subsequently, as part of the final assembly of at least one vehicle door, at least one vehicle door is reconnected to or mounted on the rest of the vehicle.

[0003] This means that, in principle, the vehicle doors and the rest of the vehicle are manufactured largely separately, only being reassembled towards the end of the production process. To ensure that at least one vehicle door meets the requirements of the manufacturing process, a worker typically opens and closes the door at the end of production, or assesses any irregularities in the vehicle's operation during a test drive. If an irregularity is detected at this very advanced stage of the manufacturing process, eliminating the cause is comparatively complex, as locating the source of the defect is usually difficult, and reassembling the vehicle door to a state that allows access to the source of the defect is time-consuming.Since the described assessment of deviations, particularly acoustic ones, also depends on the subjective evaluation of the product, and since, possibly for reasons of cost and / or time, it is not possible to assess each individual vehicle door separately, or an anomaly may not be apparent during the assessment, for example, during a test drive, it is possible that this will only be noticed later, for example, by the customer. In both cases, the effort required for troubleshooting and rectification increases compared to the previous state of the manufacturing process.

[0004] The invention is based on the objective of providing an improved method for manufacturing a motor vehicle, in which, in particular, quality assurance with regard to the vehicle doors is improved.

[0005] The problem is solved by a method according to claim 1. The dependent claims relate to possible embodiments.

[0006] As described, the invention relates to a method for manufacturing a motor vehicle comprising at least one vehicle door, wherein, within the manufacturing process, in an assembly state of the vehicle door in which a base frame of the vehicle door is separated from the body of the motor vehicle, at least one component is mounted on a base frame. As already described in the introduction, in the aforementioned assembly state, the vehicle door is separated from the rest of the body of the motor vehicle, so that at least one component can be mounted on the base frame of the vehicle door in this separated state. In other words, the vehicle doors are removed from the body of the motor vehicle and mounted separately from the body, whereby, for example, components for the interior can be installed inside the body of the motor vehicle during this process.Components mounted on the base frame of the vehicle door are ultimately arbitrary, for example, window regulators, windows, seals, trim parts, speakers, microphones, sensors, and the like. In principle, the present invention is also transferable to vehicle hatches, for example, front and rear hatches, so that the description is transferable and, within the scope of the invention, hatches are understood to be vehicle doors.

[0007] The invention is based on the finding that at least one section of the vehicle door is excited to vibrate in the separated state, and a quality parameter of the vehicle door is determined in this excited state. Depending on the determined quality parameter, the vehicle door is then either released or subjected to further processing. In other words, the invention proposes that the inspection of the vehicle doors is not carried out only after the vehicle door has been reattached to the vehicle body following final assembly, but rather that the determination of the quality parameter is specifically performed in the separated state, in which the vehicle door is detached from the body.This makes it possible to determine the quality parameter at different stages of the vehicle door's production, for example, determining a first quality parameter after the first component has been mounted on the base frame of the vehicle door, determining a second quality parameter after the second component has been mounted on the base frame of the vehicle door, and so on. It is also possible to determine the quality parameter separately for each processing station, for example, after passing through each or at least two downstream processing stations in the manufacturing process.

[0008] This allows deviations of the vehicle door from a defined requirement to be detected during the door assembly process. This significantly reduces the effort required for rework and troubleshooting compared to determining the quality parameter during a test drive after the vehicle's production is complete. In particular, it is possible to detect a manufacturing deviation directly in the door's state of manufacture, ensuring that access within the door or its frame is still possible and not obstructed by trim panels or subsequently installed components. Furthermore, the door can be released for final assembly on the vehicle body, eliminating the need for further testing.

[0009] The process can be further developed such that the separation state in the manufacturing process lies between the initial assembly of the vehicle door to the body and the final assembly of the vehicle door to the body. As described, a vehicle door initially mounted to the body is separated from the body after completion of at least one process step in the manufacturing process, for example, painting, for the assembly of components on the vehicle door and components within the body. The assembly state, or the separation state, therefore lies temporally and process-wise between the initial assembly, in which the vehicle door is mounted to the body for the first time, and the final assembly of the vehicle door to the body, which describes the final fastening of the vehicle door to the body.

[0010] By arranging the separation of components in a separate state prior to final assembly, the vehicle door can be inspected as an individual assembly. This simplifies troubleshooting, as, for example, an acoustic issue cannot be caused by another vehicle door or a different component on the body. Furthermore, the improved accessibility makes it easier to rectify any identified fault. This reduces costs, as the fault can be addressed closer to its source.

[0011] As previously described, a quality parameter is determined for at least one vehicle door. In the simplest case, the quality parameter indicates whether the vehicle door is "OK" or "not OK." Based on this quality parameter, the vehicle door can then be controlled within the production line, for example, by being sent for rework or to a subsequent assembly step. In one embodiment of the process, the quality parameter can describe a foreign object located in or on the vehicle door and / or an assembly defect, particularly a loose component. In other words, the quality parameter does not describe vibration excitation of correctly assembled components or parts of the vehicle door, but rather indicates whether an assembly defect exists or whether a foreign object is located in or on the vehicle door.Such a foreign object could be, for example, a part of a component or the vehicle door itself, or a tool part that gets into or onto the vehicle door during the assembly of a component on the vehicle door or generally during the manufacture of the vehicle door or the motor vehicle, for example, falling into a cavity.

[0012] Such a foreign object can be detected by determining the quality parameter and removed from the vehicle door immediately after detection. The same applies to identified assembly errors, such as incorrectly installed components, loose parts, incorrectly routed wiring harnesses, and the like. If these exhibit anomalies, particularly acoustic ones, during the determination of the quality parameter, they are immediately sent for rework to correct the error. It has been shown that anomalies, especially acoustic ones, are particularly critical in the vehicle doors because they are located close to the driver or other vehicle occupant, making acoustic anomalies in this area especially easy to perceive.

[0013] As described at the outset, in the separated state, at least one section of the vehicle door is set into vibration. This can be a mechanical vibration, in particular structure-borne sound. According to one embodiment of the method, an actuator can be used to excite the vibration of at least one section of the vehicle door, transmitting a vibration to that section, and / or at least one actuator can open and / or close the vehicle door to excite the vibration. The actuator can, for example, comprise a vibration motor or a shaker.

[0014] Furthermore, a robot can be used as an actuator to swing, vibrate, or shake the vehicle door or at least one section of it. The excitation of the section can be direct or indirect, for example, by the actuator directly engaging the section or by transmitting the vibration, such as contactlessly via sound or pressure waves. Another possibility is that the actuator can open and close the vehicle door, for example, by slamming it shut with a defined acceleration to generate vibrations and thus determine the quality parameter of the vehicle door. The slamming of the vehicle door can, for example, take place on a test bench that provides a counterpart to the vehicle door. If there is an assembly error or a foreign object in or on the vehicle door, this can be determined by the deviation from the standard behavior for the vehicle door that occurs in the excited state.

[0015] Alternatively or additionally, at least one vehicle door can be transported by means of at least one transport device, in particular an overhead conveyor, wherein at least one section of the conveyor is designed to generate vibrations. This at least one section of the conveyor can have defined irregularities, for example, steps or depressions, that protrude from or are embedded in an otherwise smooth surface of the conveyor. When the transport device passes over this section of the conveyor, vibrations are generated due to the irregularities and transmitted to the vehicle door coupled to the transport device.

[0016] For example, the transport system can be designed as an overhead conveyor, which is attached to the conveyor track via at least one roller element. When the roller element passes over the section of the conveyor track with the unevenness, a mechanical vibration is generated, which is transmitted to the vehicle door, which is attached to the overhead conveyor. Alternatively or additionally, it is also possible for the transport system to provide a device for vibration excitation, which enables active excitation of the vehicle door in at least one or different transport states. Furthermore, active vibration excitation can be achieved, for example, by means of an actuator, such as a vibrating plate, which the transport system passes over.

[0017] To determine the quality parameter, at least one vibration signal can be detected according to one embodiment of the method, in particular by means of a microphone, especially one integrated into the vehicle door, and / or a directional microphone and / or a structure-borne sound sensor. In other words, the vehicle door is excited to vibrate as described, and a vibration signal, for example a spectrum emitted by the vehicle door in the excited state, is detected. For example, the characteristic noise or vibration of the vehicle door can be detected via a microphone or a structure-borne sound sensor. The vibration signal can, in particular, be composed of different individual amplitudes that oscillate at different frequencies.Specifically, a vibration signal can be predefined that describes a vehicle door in the corresponding manufacturing state or is emitted by it when the excited state is executed. The quality parameter can then be determined based on this.

[0018] In principle, the vibration signal can be captured in any way. As described, a microphone can be used for this purpose. This could be, for example, a separate, external microphone or a microphone integrated into the vehicle door. Such an integrated microphone can be provided as part of the product for use in the finished vehicle, for example, for voice input, telephony, noise cancellation, configuration of the vehicle's audio environment, especially the infotainment system, and the like. The microphone integrated into the vehicle door can therefore constitute a functional component of the vehicle.

[0019] The integrated microphone can, for example, be energized during a functional test of vehicle door components, such as the window regulator, and used in this state to detect the vibration signal. Alternatively, a separate microphone, particularly a directional microphone, can be used to detect the vibration signal without contact. Furthermore, a structure-borne sound sensor can be used, which is connected to the section of the vehicle door, at least for the duration of the excited state or for determining the quality parameter.

[0020] Furthermore, the procedure can include comparing the recorded vibration signal with a reference signal and determining the quality parameter based on the comparison result. As previously described, a reference signal can be predefined or obtained by recording the vibration signal of a vehicle door deemed satisfactory. The recorded vibration signal of a vehicle door under test is then compared with the provided reference signal, for example, by comparing the spectra or the individual amplitudes of different frequencies. In general, it may be sufficient to check whether there is a deviation between the recorded vibration signal and the reference signal.

[0021] If this is the case, a deviation can be inferred that requires or triggers rework or at least an inspection. If the vibration signal matches the reference signal, the vehicle door can be released and fed into the next assembly or manufacturing process. In other words, the reference signal describes a target state of the vehicle door, and the vibration signal describes the actual state of the vehicle door under inspection. If these deviate from each other, apart from noise or normal fluctuations, especially by more than a defined limit, a negative quality parameter can be output; otherwise, a positive quality parameter is output.

[0022] The described method can be further developed to locate a fault source based on the recorded vibration signal and / or the determined comparison result. For example, specific fault signals, i.e., characteristic vibration signals, can be defined for different fault conditions. If the vibration signal corresponds to a previously defined fault signal, the fault can be determined, and the fault source can be located. Similarly, the location of the fault source can be determined by triangulation, so that a worker performing rework can be shown the location of the fault within the vehicle door or its extent can be narrowed down.

[0023] Furthermore, the process can include the use of artificial intelligence to perform anomaly detection based on the vibration signal. The artificial intelligence can be trained using training data relating to inspected vehicle doors. In other words, the vibration signal can be determined for a specific number of vehicle doors that have been inspected manually, visually, or otherwise and found to be "OK." The training data can therefore be provided to the artificial intelligence labeled as "OK." This large number of vibration signals can be used as training data to train the artificial intelligence.

[0024] This allows artificial intelligence to subsequently determine whether a detected vibration signal from a vehicle door exhibits an anomaly. If so, a corresponding quality parameter can be determined. Furthermore, the artificial intelligence can also be trained to recognize fault conditions, for example, by feeding it vibration signals from faulty vehicle doors with appropriate labels. In this case, it is particularly possible to differentiate between various fault conditions, enabling the artificial intelligence to output, for example, the precise fault for a specific vehicle door as a quality parameter.

[0025] In addition to the method, the invention relates to a system for manufacturing a motor vehicle, comprising at least one vehicle door, wherein the system is configured to mount at least one component on the base frame in an assembly state of the vehicle door in which a base frame of the vehicle door is separated from a body of the motor vehicle, wherein a determining device is configured to excite at least one section of the vehicle door to vibration in the separated state and to determine a quality parameter of the vehicle door in the excited state of the vehicle door, wherein the system is configured to release the vehicle door or to subject it to further processing depending on the determined quality parameter.

[0026] The system is designed in all its details to carry out the previously described process. Specifically, the system includes a control device that can control the relevant units of the system and on which the process can be executed. The control device can, in particular, be connected to or integrated into the determining device, or vice versa.

[0027] All advantages, details, designs and / or features described in relation to the process are fully transferable to the plant.

[0028] The invention is explained with reference to exemplary embodiments and the figures. The figures are schematic representations and show: Fig. 1. A schematic representation of a section of a plant for the manufacture of a motor vehicle according to an exemplary embodiment; and Fig. 2 a schematic representation of a flowchart of a process for the manufacture of a motor vehicle according to an exemplary embodiment.

[0029] Fig. Figure 1 schematically shows a section of Plant 1 for the manufacture of a motor vehicle not shown in detail. The in Fig. Figure 1 shows a section of the plant 1 where a vehicle door 2 is assembled, for example, where various components can be attached to a base frame 3 of the vehicle door 2. Such components can be, for example, trim parts, wiring harnesses, control devices, microphones, loudspeakers, windows, window regulators, actuators, locks, seals, and the like.

[0030] In the Fig. In the state of the manufacturing process shown in Figure 1, the vehicle door 2 is clearly separated from the body of the rest of the vehicle. In this separated state, the vehicle door 2 can, for example, be fully assembled and then mounted onto the vehicle body as part of final assembly. Annex 1 includes a determining device 4, which is fundamentally designed to determine a quality parameter of the vehicle door 2. The determining device 4 communicates, for example, with other devices in Annex 1, which are designed to detect a vibration signal from the vehicle door 2. The individual devices of Annex 1 can be configured as shown in Figure 1. Fig. 1 shown, may be intended to be implemented together, or these can be understood as possible options, with each of the individual facilities also being able to be implemented separately.

[0031] As examples of the devices included, Annex 1 features a directional microphone 5, a structure-borne sound sensor 6, and a microphone 7. In other words, Annex 1 can also include only one of these devices or any combination thereof, with the others being optional. Furthermore, the microphone 7 can also be integrated into the vehicle door 2, i.e., provided as part of the product and remaining in the vehicle door 2 to perform a function during the subsequent operation of the vehicle. In other words, the microphone 7 in the vehicle door 2 can also constitute a functional component of the vehicle door 2.

[0032] The vehicle door 2, in its detached state (i.e., not mounted on the vehicle body), is set into vibration, for example, by means of the control device 4. For this purpose, the control device 4 can include or be coupled to an actuator 8 to control the actuator 8. The actuator 8 is, for example, designed as a vibration motor or incorporates one. Alternatively, the actuator 8 can be a robot to set the vehicle door 2 into vibration, for example, to operate it in a controlled manner.

[0033] Alternatively, a transport device 9 is shown, which can be considered a component of the determining device 4 or can be coupled to the determining device 4 in order to generate a vibration excitation of the vehicle door 2. For example, the transport device 9 has an actuator 10 that can excite the vehicle door 2 coupled to the transport device 9 to vibrate. Likewise, the transport device 9 can have deliberately introduced irregularities 11 into a transport track section 12, so that when the transport device 9 passes over the irregularities 11, these vibrations are transmitted to the vehicle door 2. The irregularities 11 are, for example, designed as ridges and / or depressions in an otherwise flat transport track.

[0034] As a further option, an actuator 13 is shown, which is designed, for example, as a vibrating device or "shaker" to set a section of the transport track of the transport device 9 into vibration, which is then transmitted to the vehicle door 2 due to the coupling. Each of the individual devices that trigger a vibration of the transport device 9 or the vehicle door 2 can be implemented as a single option or in any combination with other options. In other words, the system 1 can also be implemented with only a single device or any number of the devices shown, in particular the actuators 8, 10, 13 and the irregularities 11.

[0035] As described, the vehicle door 2 is thereby excited to vibrate, whereby a vibration signal is detected by the detection device 4, for example by means of a directional microphone 5, structure-borne sound sensor 6 or microphone 7. The vibration signal can, for example, describe the noise or vibrations that the vehicle door 2 emits or produces as a result of the excitation. The vibration signal can be understood, for example, as individual amplitudes of different frequencies, i.e. as a spectrum.

[0036] The detection device 4 can then compare the detected vibration signal with a previously provided reference signal, for example, the vibration signal of a vehicle door deemed satisfactory, and determine any deviations. If no (significant) deviations are present, the vehicle door 2 can be moved to the next process step or finally mounted on the vehicle body. If deviations are present, particularly above a limit value, the vehicle door 2 can be specifically directed to rework by appropriately controlling the production line. This is particularly advantageous because any deviations that occur can be identified and subsequently eliminated directly at the point of origin during production, thus reducing the effort required for troubleshooting and error correction.

[0037] Fig. Figure 2 schematically shows a flowchart of a process for manufacturing a motor vehicle, which is fundamentally already related to Fig. 1 was described. All relating to Fig. 1 and Fig. The advantages, details, and features described in section 2 can be combined, interchanged, and transferred to one another as desired. Annex 1 from Fig. 1. The procedure can be carried out in Fig. 2. Explain in detail.

[0038] The procedure schematically starts in Fig. 2 in a block 14, in which the vehicle door 2 is provided in a separated state. In block 15, the vehicle door 2, or at least a section of the vehicle door 2, is deliberately excited to vibrate, for example by transmitting a mechanical vibration, as previously described in relation to Fig.As described in section 1. In block 16, the vibration signal is acquired, which describes the vibration of vehicle door 2 in the excited state generated in block 15. Subsequently, in block 17, the acquired vibration signal is evaluated, in particular compared with a reference signal. Depending on the comparison result, for example, whether it deviates from the reference signal by more than a permissible limit, a decision is then made as to whether vehicle door 2 can be released or sent for further processing, and accordingly, the process branches from block 17 to block 18 or block 19.

[0039] Instead of or in addition to simply comparing the recorded vibration signal with the reference signal, an artificial intelligence can also be used. This AI can be trained on training data that, for example, describes the behavior of a vehicle door 2 deemed to be functioning correctly. The recorded vibration signals can then be fed to the AI ​​for verification, particularly in block 17, where the AI ​​can determine deviations as part of anomaly detection. Furthermore, in addition to the single reference signal, at least one error signal can be predefined, for example, through appropriate conditioning of the AI ​​to specific error cases. If a vibration signal is present that corresponds to such an error signal, the associated error case can be output.In addition to the basic classification in Block 17 in that post-processing or approval is carried out, the source of the error can be specifically specified in the case of post-processing.

[0040] The described procedure can be carried out at various stages of the manufacturing process, for example, when leaving a processing station or following a change of processing station. This ensures that if an assembly error or a foreign object occurs in or on vehicle door 2, the error can be detected and rectified as quickly as possible to minimize subsequent effort. In particular, this prevents a defect in vehicle door 2 from going unnoticed and being installed on the rest of the vehicle for final assembly. Reference symbol list 1 system 2 vehicle doors 3 basic frames 4 Determination device 5 directional microphone 6 Structure-borne sound sensor 7 Microphone 8 Actuator 9 Transport equipment 10 Actuator 11 unevennesses 12 Transport railway section 13 Actuator Block 14-19

Claims

[1] Method for producing a motor vehicle, comprising at least one vehicle door (2), wherein, within the scope of the manufacturing method, in an assembled state of the vehicle door (2) in which a base frame of the vehicle door (2) is separated from a body of the motor vehicle, at least one component is mounted on the base frame, characterized by that at least one section of the vehicle door (2) is excited to vibrate in the separated state and a quality parameter of the vehicle door (2) is determined in the excited state of the vehicle door (2), wherein the vehicle door (2) is released or subjected to post-processing depending on the determined quality parameter. [2] Method according to claim 1, characterized by that the separated state in the manufacturing process lies between an initial assembly of the vehicle door (2) on the body and a final assembly of the vehicle door (2) on the body. [3] Method according to claim 1 or 2, characterized bythat the quality parameter describes a foreign body arranged in or on the vehicle door (2) and / or an assembly error, in particular a loose component. [4] Method according to one of the preceding claims, characterized by that an actuator (8, 10, 13) is used to excite vibration of the at least one section of the vehicle door (2), which actuator transmits a vibration to the at least one section and / or that at least one actuator (8, 10, 13) opens and / or closes the at least one vehicle door (2) to excite vibration. [5] Method according to one of the preceding claims, characterized by that the at least one vehicle door (2) is transported by means of at least one transport device (9), in particular a suspended conveyor, wherein at least one conveyor track section (12) is designed to excite vibrations. [6] Method according to one of the preceding claims, characterized byin that at least one vibration signal is detected to determine the quality parameter, in particular by means of a microphone (7), in particular a microphone (7) integrated into the vehicle door (2), and / or a directional microphone (5) and / or a structure-borne sound sensor (6). [7] Method according to claim 6, characterized by that the recorded vibration signal is compared with a reference signal and the quality parameter is determined depending on the comparison result. [8] Method according to claim 6 or 7, characterized by that a source of error is located based on the detected vibration signal and / or the determined comparison result. [9] Method according to one of claims 6 to 8, characterized by that anomaly detection is carried out using artificial intelligence based on the vibration signal. [10] Plant (1) for the production of a motor vehicle, comprising at least one vehicle door (2), wherein the plant (1) is designed to mount at least one component on the base frame in an assembled state of the vehicle door (2) in which a base frame of the vehicle door (2) is separated from a body of the motor vehicle, characterized by a determining device (4) which is designed to excite at least a portion of the vehicle door (2) to vibrate in the separated state and to determine a quality parameter of the vehicle door (2) in the excited state of the vehicle door (2), wherein the system (1) is designed to release the vehicle door (2) or to subject it to post-processing depending on the determined quality parameter.

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