System for mounting an insulating element on a structural element

Abstract

The present invention relates to a system for mounting insulating elements (16) onto structural elements (12, 14) of a motor vehicle, the system comprising: a plurality of provided insulating elements (16), a transfer element (30), an intermediate station (29), a robot (8), and at least one structural element (12, 14). The transfer element (30) is configured to place the provided insulating elements (16) in the intermediate station (29), and the insulating elements (16) are positioned in a predefined spatial location and orientation within the intermediate station (29) for removal by the robot (8). The robot (8) is configured to remove each individual insulating element (16) from the intermediate station (29) and place it onto the structural element (12, 14).

Description

Technical Field

[0001] This invention relates to a system for mounting an insulating element onto a structural element in a motor vehicle. Furthermore, this invention relates to a method for mounting such an insulating element onto a structural element. Background Technology

[0002] In many cases, components (such as the body and / or frame of vehicles, especially water, land, or air vehicles) have cavitary structures to enable lightweight construction. However, these cavities cause various problems. Depending on the type of cavity, it must be sealed to prevent the ingress of moisture and contaminants that can lead to corrosion of the component. It is also often desirable to significantly reinforce the cavity and therefore the component while maintaining a low weight. It is also often necessary to stabilize the cavity and therefore the component to reduce noise that would otherwise be transmitted along or through the cavity. Many of these cavities have irregular shapes or narrow dimensions, making them difficult to properly seal, reinforce, and dampen.

[0003] Therefore, baffles are used, especially in automobile manufacturing and aircraft and shipbuilding, to seal and / or acoustically isolate cavities, or reinforcers are used to strengthen cavities.

[0004] exist Figure 1 The diagram schematically shows the body of a car. The body 10 here has several different structures with cavities, such as pillars 14 and beams or supports 12. These cavity structural elements 12, 14 are typically sealed or reinforced with insulating elements 16.

[0005] Typically, this insulating element 16 is manually installed on the structural elements 12, 14. However, the disadvantage of this known manual method is that it requires a great deal of work and carries the risk of installing the insulating element in an unintended position or in the wrong position on the structural element. Summary of the Invention

[0006] Therefore, the objective of this invention is to provide an improved system for mounting insulating elements onto structural components in motor vehicles, a system that avoids the disadvantages of the prior art. In particular, the system should have improved economic efficiency and minimize the risk of incorrect installation.

[0007] The task is first addressed by a system for mounting insulating elements onto structural elements of a motor vehicle, the system comprising: a plurality of provided insulating elements, a transfer element, an intermediate station, a robot, and at least one structural element; the transfer element is configured to place the provided insulating elements in the intermediate station; the insulating elements are positioned in the intermediate station at predefined spatial locations and orientations for removal by the robot; and the robot is configured to remove each individual insulating element from the intermediate station and place it onto the structural element.

[0008] The advantage of the system proposed here is that it significantly reduces workload by automatically installing insulating elements onto structural components. By placing the insulating elements in intermediate stations, particularly enabling the loading and preparation of the system or process, the system or process can operate autonomously for extended periods. Since many such insulating elements are typically installed on each vehicle, this translates to substantial savings in manual labor.

[0009] Furthermore, the advantage of automating the installation of insulating elements onto structural components is that it reduces the risk of operational errors. For example, insulating elements of similar shapes may sometimes be installed in different locations on a vehicle body. In particular, there are cases where mirrored insulating elements are used on the left and right sides of the vehicle body. In such and similar situations, there is a risk of using the wrong insulating element in a particular location or confusing the left and right insulating elements when installing them manually. Automating this process can largely eliminate such incorrect operations.

[0010] Furthermore, the system proposed here has the particular advantage of enabling more efficient and cost-effective automation by pre-defining the insulating elements in the intermediate station. The process of the robot gripping the insulating elements is simplified and made more efficient by pre-defining the insulating elements in terms of spatial location and orientation in the intermediate station.

[0011] The term "insulating element" within the scope of this invention includes elements used for isolating and / or sealing and / or enclosing and / or reinforcing and / or insulating structural elements. These different characteristics of such insulating elements can appear individually or in combination with each other.

[0012] The terms "upper side" and "lower side" refer, within the scope of this invention, to the two main surfaces or the two largest sides of an insulating element. Since the insulating element is designed to enclose the cross-section of a structural element, this means that, in use, the upper and lower sides are substantially located in the plane of a cross-section to be insulated. The upper or lower side can also have a stepped shape; that is, the upper or lower side does not necessarily have to be constructed to be completely flat.

[0013] Within the scope of this invention, the term "parallel" in relation to the arrangement of insulating elements in a stack of multiple identical insulating elements means that the corresponding identical surfaces and / or edges of the same insulating elements are arranged substantially parallel to each other.

[0014] In one exemplary embodiment, the insulating element includes: a carrier; and an expandable material disposed on the carrier, the insulating element having an upper side and a lower side that are oriented substantially in the plane of the cross-section of the structural element to be insulated in the use state.

[0015] In one exemplary embodiment, the plurality of provided insulating elements are stacked on top of each other.

[0016] This has the primary advantage of providing insulating elements in a stacked form. Therefore, these insulating elements can be stacked on top of each other for transport and packaged and transported in a stacked state. This results in savings in transportation costs because it allows for more space-efficient packaging of the insulating elements, enabling the transport of more insulating elements within a given volume than with conventional insulating elements. Furthermore, this stacking or piling of insulating elements has the advantage of making it easier to identify confusion between different insulating elements. For example, if a first insulating element is packaged in a container with multiple second insulating elements, this will be immediately noticeable because the first insulating element typically cannot be stacked with the second insulating elements. This significantly reduces confusion.

[0017] Providing insulation elements in a stacked configuration also offers the following advantages: the individual insulation elements are less susceptible to damage due to the stacked arrangement for transport and storage. If individual insulation elements are transported loosely in a container as has been the case so far, numerous contacts occur between the insulation elements, which can sometimes lead to damage. However, if the insulation elements are transported in a stacked manner, the number of mechanical contacts between the insulation elements is greatly reduced. Furthermore, the insulation elements can be constructed such that the intended contact areas are robust or resistant to damage, and / or the vulnerable areas of the insulation elements are placed in protected locations, such as those covered by adjacent insulation elements when stacked.

[0018] In one exemplary embodiment, the plurality of provided insulating elements are disposed within the container.

[0019] In one exemplary embodiment, the insulating element has at least one, at least two, or at least three contact positions on its upper and lower sides, respectively, such that when multiple identical insulating elements are stacked, adjacent insulating elements are positioned vertically abutting each other through these contact positions and thus arranged parallel to each other.

[0020] In one exemplary embodiment, the insulating element has exactly three contact positions on its upper and lower sides, which are positioned vertically when adjacent insulating elements are stacked.

[0021] In an alternative extension, the insulating element has exactly four or at least four such contact positions on the upper and lower sides.

[0022] In another alternative embodiment, the insulating element has exactly five or at least five such contact points on the upper and lower sides.

[0023] In one exemplary embodiment, at least one contact position on the upper side and a contact position on the lower side assigned to the contact position are configured such that adjacent insulating elements are fixed in place when stacked in a vertical direction to prevent horizontal movement.

[0024] In one exemplary extension, at least one contact position on the upper side and a contact position on the lower side assigned to the contact position are configured such that a mechanical lock is formed between the respective contact positions during stacking.

[0025] In one exemplary embodiment, the contact position on the upper side is configured as a first coupling element and the contact position on the lower side assigned to the first coupling element is configured as a second coupling element. When stacked, the first coupling element and the second coupling element are interlocked with each other such that temporary fixation of adjacent insulating elements is achieved.

[0026] In one exemplary embodiment, at least one contact location is located in the area of ​​the fixing element.

[0027] Within the scope of this invention, "region of the fixing element" is understood to include the fixing element itself, the base of the fixing element, and the expandable material at the base of the fixing element, the expandable material being used to insulate the opening in the structural element into which the fixing element is inserted.

[0028] In one exemplary embodiment, the fixing element is constructed as a clip.

[0029] In an alternative embodiment, the fixing element is constructed as a tab, a welded tab, a clamp, a hook, or a rivet.

[0030] In one exemplary embodiment, the fixing element is made of plastic, especially polyamide, or metal.

[0031] In one exemplary embodiment, the height of the fixing element along the stacking direction is less than 8 mm, preferably less than 7 mm, and particularly preferably less than 6 mm.

[0032] In one exemplary embodiment, the height of the fixing element substrate along the stacking direction (which includes both the substrate of the fixing element and the expandable material at the fixing element substrate, the expandable material being used to insulate the opening in the structural element into which the fixing element is inserted) is at most 130%, at most 120%, or at most 110% of the height of the fixing element along the stacking direction.

[0033] The advantage of this relatively tall design is that it allows for more space-efficient packaging of insulating components.

[0034] In one exemplary embodiment, at least one contact location is configured as a spacer element, which is used to support and / or position the insulating element on the structural element in the state of use of the insulating element in the structural element.

[0035] In one exemplary extension, the spacer elements are configured to be stackable, and the total height of two nested spacer elements along the stacking direction is at most 170%, 160%, 150%, 140%, or 130% of the height of a single spacer element.

[0036] In one exemplary embodiment, the steps of the carrier form an angle of at least 35° or at least 40° or at least 45° or at least 50° or at least 55° with the stacking direction.

[0037] The advantage of this stepped design is that insulating elements with flatter steps can be stacked better than those with steeper steps. A particular problem exists with steeper steps, where adjacent insulating elements cannot be vertically overlapped without horizontal offset.

[0038] In one exemplary embodiment, at least one contact location is configured as a support element that protrudes from the general surface of the upper or lower side of the insulating element along the stacking direction.

[0039] In one exemplary embodiment, all or some of the contact locations are formed by a carrier.

[0040] In an alternative implementation, all or some of the contact points are formed of an expandable material.

[0041] In another embodiment, at least one contact site is formed by a carrier, and at least one contact site is formed by an expandable material.

[0042] Since carriers can typically be manufactured with smaller tolerances than expandable materials, it is advantageous to form contact points through carriers whenever possible.

[0043] In one exemplary embodiment, the insulating element has at least one limiting element configured such that when the insulating elements are stacked on top of each other, the insulating element is fixed by the limiting element of the adjacent insulating element to prevent it from moving laterally in the stacking direction and / or to prevent the insulating element from rotating about the stacking direction.

[0044] In one exemplary embodiment, the limiting elements are configured such that when the insulating elements are stacked on top of each other, the limiting elements of two adjacent insulating elements overlap in the stacking direction.

[0045] In one exemplary extension scheme, the limiting elements overlap by at least 3 mm, at least 5 mm, or at least 7 mm in the stacking direction.

[0046] In one exemplary embodiment, the limiting element has at least one guide surface configured such that, during stacking, the guide surface guides the insulating elements to be stacked, such that the newly stacked insulating elements are disposed substantially coincidentally on the insulating elements along the stacking direction.

[0047] In one exemplary embodiment, at least one spacer element is configured as a motion-limiting element.

[0048] In one exemplary extension, the spacer element is configured to be substantially Y-shaped. For example, the faces of the legs of this Y-shaped spacer element can be configured as guide faces.

[0049] In an alternative extension, the spacer element is constructed in a substantially U-shaped or V-shaped configuration. The faces of the legs of this U-shaped or V-shaped spacer element can then be configured as guide surfaces.

[0050] In one exemplary embodiment, at least one stepped structure serves as a motion-limiting element.

[0051] In one exemplary embodiment, at least one region of the fixing element is configured as a motion-limiting element.

[0052] In one exemplary extension, the base of the fixing element is configured as a limiting element. This base can be configured, for example, as substantially U-shaped. The faces of the legs of the U-shaped base of the fixing element can also be configured as guide surfaces.

[0053] In one exemplary embodiment, all or some of the motion-limiting elements are formed by a carrier.

[0054] In an alternative implementation, all or some of the motion-limiting elements are formed of an expandable material.

[0055] In another embodiment, at least one limiting element is formed of a carrier, and at least one limiting element is formed of an expandable material.

[0056] Since carriers can typically be manufactured with smaller tolerances than expandable materials, it is advantageous to form the limiting element from the carrier as much as possible.

[0057] In principle, expandable materials can be made from various materials that can be foamed. These materials may or may not have reinforcing properties. Typically, expandable materials expand due to heat, humidity, or electromagnetic radiation.

[0058] Such expandable materials typically employ chemical or physical blowing agents. Chemical blowing agents are organic or inorganic compounds that decompose under the influence of temperature, humidity, or electromagnetic radiation, with at least one decomposition product being a gas. Physical blowing agents, for example, can be compounds that transform into a gaseous aggregate state upon increasing temperature. Thus, both chemical and physical blowing agents can create foam structures within polymers.

[0059] The preferred expandable material is thermally foamed, using a chemical blowing agent. Suitable chemical blowing agents include, for example, azodicarbonamide, sulfonyl hydrazine, bicarbonate, or carbonate. Suitable blowing agents are also commercially available, for example, from AkzoNobel (Netherlands) under the trade name Expancel® or from Chemtura (USA) under the trade name Celogen®. The heat required for foaming can be introduced by an external or internal heat source, such as an exothermic chemical reaction. The expandable material is preferably foamed at a temperature ≤250°C, particularly 100°C to 250°C, preferably 120°C to 240°C, and most preferably 130°C to 230°C.

[0060] Suitable expandable materials are, for example, single-component epoxy resin systems that do not flow at room temperature, particularly those with increased impact toughness and containing thixotropic agents such as aerosols or nanoclays. Such epoxy resin systems, for example, comprise 20 to 50 wt% liquid epoxy resin, 0 to 30 wt% solid epoxy resin, 5 to 30 wt% toughening modifier, 1 to 5 wt% physical or chemical foaming agent, 10 to 40 wt% filler, 1 to 10 wt% thixotropic agent, and 2 to 10 wt% heat-activated curing agent. Suitable toughening modifiers are reactive liquid rubbers based on nitrile rubber or polyether polyol polyurethane derivatives, core-shell polymers, and similar systems known to those skilled in the art.

[0061] Equally suitable expandable materials are one-component polyurethane compositions containing a foaming agent, which are composed of a crystalline polyester containing OH groups, a polyol, preferably a polyether polyol, and a polyisocyanate with end-capped isocyanate groups. The melting point of the crystalline polyester should be ≥50°C. The isocyanate groups of the polyisocyanate can be end-capped, for example, with nucleophiles such as caprolactam, phenol, or benzoxazolone. Furthermore, end-capped polyisocyanates, for example, those used in powder coating technology and commercially available from Degussa GmbH, Germany, for example under the trade names Vestagon® BF 1350 and Vestagon® BF 1540, are also suitable. So-called encapsulated or surface-deactivated polyisocyanates, known to those skilled in the art and described, for example, in EP 0 204 970, are also used as isocyanates.

[0062] In addition, two-component epoxy / polyurethane compositions containing a foaming agent, such as those described in WO 2005 / 080524 A1, are also suitable as expandable materials.

[0063] In addition, ethylene vinyl acetate compositions containing foaming agents are also suitable as expandable materials.

[0064] Equally suitable expandable materials, such as those sold under the trade names SikaBaffle® 240, SikaBaffle® 250, or SikaBaffle® 255 by Sika Corporation of the United States, are described in US 5,266,133 and US 5,373,027. Such expandable materials are particularly preferred for the present invention.

[0065] Preferred expandable materials with reinforcing properties include, for example, those sold by Sika Corporation under the trade name SikaReinforcer® 941. Such materials are described in US 6,387,470.

[0066] In one exemplary embodiment, the expandable material has an expansion rate of 800% to 5000%, preferably 1000% to 4000%, and more preferably 1500% to 3000%. The advantage of an expandable material with such an expansion rate is that it enables reliable sealing or insulation of structural elements relative to liquids and sound.

[0067] In one exemplary embodiment, the expandable material is configured as a temperature-inducing material.

[0068] This has the following advantages: a furnace can be used to bake the impregnation liquid, causing the expandable material to expand and thereby insulate the cavity. Therefore, no additional working steps are required.

[0069] The carrier can be made of any material. Preferred materials are plastics, especially polyurethane, polyamide, polyester, and polyolefin; preferably high-temperature resistant polymers such as polyphenylene ether, polysulfone, or polyethersulfone, which are also foamed; metals, especially aluminum and steel; or grown organic materials, especially wood or other (pressed) fibrous materials or glassy or ceramic materials; especially such foamed materials; or any combination of these materials. Polyamides, especially polyamide 6, polyamide 6,6, polyamide 11, polyamide 12, or mixtures thereof, are particularly preferred.

[0070] Furthermore, the carrier can be, for example, solid, hollow, foamed, or have a grid-like structure. The surface of the carrier can typically be smooth, rough, or structured.

[0071] In the case of an insulating element where the expandable material is located on a carrier, the manufacturing method varies depending on whether the carrier is made of a material that can be injection molded. If so, a two-component injection molding method is typically used. First, the first component, in this case, the carrier, is injected. After the first component has cured, the cavity in the mold is enlarged or adjusted, or the manufactured injection preform is placed into a new mold, and the second component, in this case, the expandable material, is injected onto the first component using a second injection unit.

[0072] If the carrier is made of a material that cannot be manufactured by injection molding, such as metal, then the carrier is placed in a suitable mold and the expandable material is injected onto the carrier. Of course, there is also the possibility of fixing the expandable material onto the carrier using special fixing devices or methods.

[0073] In addition, carriers can also be manufactured by other methods, such as extrusion.

[0074] In one exemplary embodiment, the transfer element is configured as a robot or a collaborative robot.

[0075] In an alternative implementation, the transfer element is the operator.

[0076] In one exemplary embodiment, the intermediate station includes at least one base element, which includes positioning elements for positioning insulating elements on the base element, such that the insulating elements or stacks can be positioned on the base element in a predefined manner.

[0077] In an alternative embodiment, the intermediate station includes at least one conveying system configured to sequentially transport insulating elements or stacks to predefined take-out locations.

[0078] In one exemplary extension, the conveying system is implemented as a bucket elevator.

[0079] In another alternative embodiment, the intermediate station includes at least one support capable of accommodating multiple insulating elements and of preparing the insulating elements in a predefined take-out position.

[0080] In one exemplary extension, the support has at least one guide element that at least partially conforms to the outline of the insulating element.

[0081] In one exemplary extension, the at least one or more guiding elements are configured such that the insulating element can only be accommodated in one spatial location.

[0082] In one exemplary embodiment, the intermediate station includes its own support for each different type of insulating element provided by the system for processing. Each support here specifically has a guide element designed such that only insulating elements of a predetermined type can be placed therein.

[0083] The advantage of setting up individual and type-specific supports is that it can prevent erroneous operation.

[0084] The insulating elements have a stacking height that corresponds to the additional height of the stack of insulating elements along the stacking direction, which is increased when another insulating element is stacked on top of the stack.

[0085] In one exemplary embodiment, the stacking height of the insulating elements is at most 80%, preferably at most 70%, preferably at most 60%, preferably at most 50%, preferably at most 40%, and preferably at most 30% of the total height of the individual insulating elements along the stacking direction.

[0086] This has the following advantages: it allows for more space-efficient placement of insulating elements within the stack. Furthermore, the increased stability of the entire stack is achieved through stronger vertical nesting of adjacent insulating elements within the stack.

[0087] In one exemplary embodiment, the stack includes at least 10, at least 15, at least 20, at least 25, or at least 30 stacked insulating elements.

[0088] In another exemplary embodiment, the stack comprises up to 150, up to 120, up to 100, up to 80, or up to 60 stacked insulating elements.

[0089] In one exemplary embodiment, the bottom insulating element of the stack rests flat on the base element.

[0090] The advantage of setting up this basic component is that it allows the stack of insulating components to be placed on a flat surface, and more importantly, the stack will not tip over.

[0091] In one exemplary extension scheme, the base element is configured such that the stack is positioned such that the stacking direction extends substantially vertically.

[0092] In one exemplary extension scheme, the base element includes at least one positioning element for positioning the bottommost insulating element of the stack on the base element.

[0093] The advantage of having at least one such positioning element is that it can improve the support or orientation of the stack on the one hand, and predefine the positioning of the stack on the base element on the other hand.

[0094] For automation processes, it is often important to precisely define the spatial position of the components manipulated by the robot. By appropriately selecting such positioning elements on the base components, this predefined positioning of stacking can be achieved.

[0095] In one exemplary extension scheme, the base element includes multiple positioning elements.

[0096] In one exemplary extension, a first positioning element is configured to accommodate a stack of insulating elements of a first type, and at least one additional positioning element on the same base element is configured to accommodate a stack of insulating elements of the same type.

[0097] In an alternative extension, the base element further includes multiple positioning elements, wherein a first positioning element is configured to accommodate a stack of insulating elements of a first type, and at least one additional positioning element on the same base element is configured to accommodate a stack of insulating elements of a different type.

[0098] Thus, multiple stacks of the same type of insulating elements or different types of insulating elements can be predefined and set on the same base element.

[0099] In one exemplary embodiment, the base element is configured to be concave and convex, wherein each stack has a correspondingly shaped recess formed on the surface of the base element.

[0100] However, this basic component can also be constructed in different ways, for example, by setting a planar substrate on which different support elements, such as pillars or the like, can be set, which will be positioned, oriented and supported in a predefined location.

[0101] In one exemplary embodiment, the base element is made of cardboard.

[0102] In an alternative exemplary embodiment, the base element is configured in the form of a plastic blister pack.

[0103] In an alternative implementation, the base element is made of plastic, particularly constructed as an injection-molded or printed element.

[0104] In addition, other different implementation possibilities for the basic components can be conceived.

[0105] In one exemplary embodiment, the provided insulating member is disposed within the container. In an exemplary extended embodiment, the insulating elements are disposed within the container in a stacked manner.

[0106] The advantage of using such a container is, for example, that the insulating elements can be provided precisely in a container that is also used to transport the insulating elements. This avoids the need for reassembly or rearrangement of the insulating elements.

[0107] In one exemplary embodiment, the container is constructed as a box, crate, or tray.

[0108] In one exemplary embodiment, at least one basic element is disposed within the container.

[0109] In an alternative implementation, only one basic element is disposed within the container.

[0110] The advantage of using at least one base element with a container is that the stack can be oriented and positioned for transport, which is often space-saving and material-protecting for insulating elements.

[0111] In one exemplary embodiment, the base element substantially covers the bottom of the container.

[0112] In another alternative implementation, multiple basic components are arranged in the container.

[0113] In one exemplary expansion scheme, the plurality of basic elements substantially cover the bottom of the container.

[0114] In an alternative expansion scheme, the plurality of basic elements are arranged to overlap at least partially.

[0115] In one exemplary extension, the plurality of base elements form a partition, such that insulating elements or stacks are arranged in the container in multiple layers separated from each other by the base elements.

[0116] In one exemplary embodiment, the stack is arranged in the container such that when the container is in its predetermined orientation, the stacking direction extends vertically.

[0117] In an alternative implementation, the stack is oriented such that the stacking direction extends substantially horizontally when the container is in its predetermined orientation.

[0118] In one exemplary embodiment, multiple stacks are arranged within a container. In an exemplary extended embodiment, the stacks within the container are oriented substantially parallel to each other.

[0119] In one exemplary embodiment, multiple stacks of the same type of insulating elements are arranged in a container.

[0120] In one example implementation, multiple stacks of the same type of insulating elements are arranged on a base element.

[0121] In an alternative implementation, multiple stacks of different types of insulating elements are arranged in a container.

[0122] In an alternative implementation, multiple stacks of different types of insulating elements are arranged on a base element.

[0123] In one exemplary embodiment, the container also includes a non-slip intermediate layer.

[0124] This anti-slip interlayer can be used, for example, to separate multiple stacked layers in a container from each other, without the risk of the layers sliding relative to each other.

[0125] In one exemplary embodiment, the robot includes a multi-jointed robotic arm and a gripper disposed on the robotic arm.

[0126] In one exemplary extension, the robot includes multiple grippers. The robot is configured such that it can individually remove a single insulating element from an intermediate station and place it onto a structural element using each gripper.

[0127] This clamp can be formed in different ways.

[0128] For example, the clamp can include a suction clamp and / or a parallel clamp and / or an expansion clamp.

[0129] In one exemplary embodiment, the clamp is configured to hold a variety of different types of insulating elements.

[0130] In one exemplary embodiment, the clamp has at least two interlocking elements configured such that they can engage with corresponding interlocking elements on an insulating element.

[0131] These interlocking elements on insulating components and on robot grippers can be implemented in different ways.

[0132] For example, the insert element on the insulating element can exist in the form of a cap or recess, and the corresponding insert element on the holder can be constructed to complement it. Alternatively, the insert element on the holder can be constructed with holes or elongated holes of, for example, different sizes, and the insert element on the insulating element can, for example, have a tapered design. Furthermore, the insert element on the insulating element can, for example, be constructed as a step, edge, or rib.

[0133] In one exemplary extension scheme, the at least two interlocking elements of the clamp are shaped differently.

[0134] The advantage of different shapes for the interlocking elements is that they allow for precise determination of the orientation of the insulating element on the gripper, preventing the insulating element from being gripped upside down by 180°. This helps avoid erroneous operation by the robot.

[0135] In one exemplary embodiment, the structural element is a single metal plate or multiple interconnected metal plates, particularly a column or beam or support, or the structural element is a component of the vehicle body, or the structural element is the vehicle body itself.

[0136] In one exemplary embodiment, the structural element has at least one opening, and the insulating element has at least one fixing element, both elements being configured such that the fixing element can snap into the opening.

[0137] In the case of stacked insulating elements, in one exemplary embodiment, each additional insulating element will increase the stack height by up to 20 mm, particularly preferably up to 18 mm, particularly preferably up to 16 mm, particularly preferably up to 14 mm, particularly preferably up to 12 mm, and particularly preferably up to 10 mm.

[0138] The close stacking of insulating elements has the advantage of enabling more efficient packaging and transportation of insulating elements.

[0139] Furthermore, the task mentioned at the beginning is solved by a method for installing insulating elements on structural components of a motor vehicle, the method comprising the following steps: providing multiple insulating elements; transferring the insulating elements to an intermediate station; providing the insulating elements in the intermediate station at predefined spatial locations and orientations for removal by a robot; removing each individual insulating element from the intermediate station by the robot; and installing the insulating elements on the structural components by the robot.

[0140] In one exemplary embodiment, the method is implemented using the system described above.

[0141] In one exemplary embodiment, the provided insulating element exists in the form of a stack of multiple insulating elements stacked on top of each other, and these stacks are transported during transfer.

[0142] In one advantageous implementation, the robot has multiple grippers, allowing multiple insulating elements to be individually removed from the intermediate station.

[0143] In an alternative implementation, the robot has only one gripper and can only remove one insulating element at a time from the intermediate station.

[0144] In one exemplary embodiment, the method further includes the steps of: transporting an insulating element in a container and / or on a base element; the insulating element in the same container and / or on the same base element is provided for removal by a robot.

[0145] The advantage of using containers and / or base components to both transport and provide insulating elements for removal by robots is that it can greatly simplify the entire logistics process and make it more efficient.

[0146] In one exemplary embodiment, during installation, a robot grasps the insulating element in a gripping direction and mounts the insulating element onto the structural element in an application direction, the gripping direction and the application direction forming an angle of approximately 90° or 180°.

[0147] In an alternative embodiment, the clamping direction and the application direction form an angle in the range of 90° to 180°.

[0148] The advantage of using this orientation when mounting insulating elements onto structural elements is that it allows for the selection of a smaller clamping force along the clamping direction, since the force applied when mounting the insulating element onto the structural element does not react with the clamping force.

[0149] In one exemplary embodiment, the force applied by the robot in the clamping direction for clamping the insulating element is less than the force applied by the robot in the application direction for mounting the insulating element onto the structural element.

[0150] In one exemplary extension scheme, the force along the application direction is at least two, three, or four times the force along the clamping direction.

[0151] In one exemplary embodiment, the clamp and the insulating element are mechanically engaged in the application direction.

[0152] This has the advantage of allowing for the selection of smaller clamping forces, as the insulating element is fixed to prevent movement along the application direction.

[0153] In one exemplary embodiment, during installation, the retaining element of the insulating element snaps into the opening of the structural element.

[0154] In one exemplary embodiment, when an insulating element is gripped by a robot, at least two interlocking elements of the insulating element engage with at least two corresponding interlocking elements of the gripper, the at least two interlocking elements of the insulating element being configured differently.

[0155] The advantage of using different engagement elements is that it can prevent erroneous operation, especially erroneous operation involving a 180° rotation.

[0156] These interlocking elements on insulating components and on robot grippers can be implemented in different ways.

[0157] For example, insert elements on insulating elements can exist in the form of caps or recesses, and corresponding insert elements on clamps can be constructed to complement them.

[0158] Alternatively, the insert elements on the clamp can be configured to have holes or elongated holes of different sizes, and the insert elements on the insulating element can have a tapered design, for example.

[0159] Furthermore, the insert elements on the insulating element can be configured as steps, edges, or ribs, for example.

[0160] In one exemplary embodiment, the system as described above is configured to enable the implementation of the above-described method. Attached Figure Description

[0161] The details and advantages of the present invention will now be described with reference to embodiments and illustrative accompanying drawings. The drawings are as follows:

[0162] Figure 1 An exemplary view of the vehicle body is shown;

[0163] Figures 2a to 2c A schematic diagram showing an exemplary insulating element or a stack having multiple such insulating elements is provided.

[0164] Figures 3a to 6 A schematic diagram showing the container together with the insulating elements disposed therein;

[0165] Figure 7 A schematic diagram of an exemplary basic component is shown;

[0166] Figures 8a to 8c A schematic diagram of an exemplary system is shown;

[0167] Figures 9a to 10d A schematic diagram of an exemplary robot and a matching gripper is shown;

[0168] Figures 11 to 13 A schematic diagram illustrating an exemplary coupling between the robot's gripper and insulating components;

[0169] Figure 14 Figures 15a-15b Figures 16a-16b , Figures 17a-17b , Figures 18a-18b and Figures 19a-19b A schematic diagram of an exemplary intermediate station is shown. Detailed Implementation

[0170] exist Figure 2aThe image first shows a single insulating element 16. This insulating element 16 has a carrier 11 and an expandable material 13 disposed on the carrier. The insulating element 16 is constructed in a substantially flat shape so as to effectively insulate the cross-section of the structural element in use. However, the insulating element 16 is not completely flat, but has different protrusions and stepped shoulders, especially steep steps 5.

[0171] The insulating element 16 here has an upper side 17 and a lower side 18. In addition, in this embodiment, the insulating element 16 has two fixing elements 3 respectively configured as clips and two spacer elements 4 respectively oriented on different sides.

[0172] In addition, the insulating element 16 has a support element 6, which in this embodiment is disposed on the upper side 17 of the insulating element 16.

[0173] In this embodiment, the insulating element 16 has three contact positions disposed on the upper side 17 and three corresponding contact positions disposed on the lower side 18. Here, two contact positions are respectively disposed in the region of the fixing element 3 and the other contact position is configured as a support element 6 or as a support point on the lower side 18 of the insulating element 16.

[0174] exist Figure 2b The text shows that it has the following characteristics: Figure 2a Multiple stacks 1 of insulating elements 16. These insulating elements 16 are stacked on top of each other in a stacking direction 19. The stacked insulating elements 16 are arranged parallel to each other and abut against each other at contact positions on their upper and lower sides respectively.

[0175] exist Figure 2c The image also shows a stack 1 with stacked insulating elements 16, in which the bottom insulating element 16 of the stack 1 is disposed on the base element 2.

[0176] exist Figures 3a to 6 Different exemplary containers 7 are shown, which have insulating elements 16 or stacks 1 disposed therein.

[0177] exist Figure 3a The image shows a container 7 having an insulating element 16 loosely disposed therein. Figure 3b The same container 7 with stacked insulating elements 16 is shown, the individual stacks 1 being arranged in the container such that when the container 7 is in its predetermined orientation, the stacking direction is substantially vertical.

[0178] exist Figure 4a and 4b A container 7 is schematically shown again in the diagram. Figure 4aThe insulating element 16 is disordered and loose, and... Figure 4b The insulating elements are stacked into multiple stacks 1. In this embodiment, the stacking direction is chosen such that when the container 7 is in its predetermined orientation, the stacking direction extends substantially horizontally.

[0179] exist Figure 5 Another container is schematically shown, comprising multiple stacks 1 with insulating elements. Such a container 7 is suitable, for example, both for transporting the stacks 1 of insulating elements and for providing the stacks of insulating elements for removal of individual insulating elements by a robot.

[0180] exist Figure 6 Another exemplary container 7 is schematically shown. In this embodiment, container 7 is constructed as a pallet. This pallet is particularly well-suited for transporting container 7.

[0181] Figure 7 An exemplary base element 2 is schematically shown. In this embodiment, the base element 2 has a plurality of positioning elements 27. Here, in this embodiment, the positioning elements 27 are constructed as recesses in the base element 2 in a concave-convex or embossed manner, each recess being provided for accommodating a stack 1 of insulating elements. By using such a base element 2, the position of the stack 1 can be predefined, so that the robot has fewer or no individual sensing devices to grasp each individual insulating element.

[0182] This basic component 2 can be set at the bottom of the container 7.

[0183] exist Figures 8a to 8c Different embodiments of the system 20 for mounting the insulating element 16 on the structural elements 12 and 14 are illustrated schematically.

[0184] exist Figure 8a A stack 1 with insulating elements is provided in container 7. In this embodiment, transfer element 30 is configured as a robot. The transfer element transfers the insulating elements in stack 1 from container 7 to intermediate station 29. In addition to a robot arm and gripper, transfer element 30 also has a position identification device 28 capable of processing information about the position of each individual insulating element or stack 7. Then, robot 8 removes the insulating element 16 from intermediate station 29 and places it on structural elements 12, 14. In this embodiment, robot 8 is a multi-axis robot with a gripping head.

[0185] According to Figure 8bIn this embodiment, multiple insulating elements 16 are again provided, but this time the insulating elements are loosely located in the container 7. The transfer element 30 is again configured as a robot. The insulating elements 16 are disposed in the intermediate station 29 by the transfer element 30. In this example, the intermediate station 29 is configured as a conveyor system that sequentially transports the insulating elements 16 to predefined removal positions. In this embodiment, a conveyor belt is used as the robot 8, which has gripping devices disposed on the belt. The robot 8 removes the insulating elements 16 from the removal position of the intermediate station 29 and then installs each individual insulating element onto the structural elements 12, 14, which in this embodiment are configured as a single metal plate.

[0186] exist Figure 8c Another exemplary system 20 is schematically illustrated. In this embodiment, a container 7 is provided for providing insulating elements 16, which are present here as a stack 1. (The last sentence appears to be incomplete and possibly refers to a different system.) Figure 8a Unlike other embodiments, in this embodiment, stacks 1 of different types of insulating elements are arranged in a container 7. Therefore, with this system, multiple different insulating elements can be arranged on the vehicle body 10 from a single container 7. In this example, the transfer element 30 is the operator. The operator arranges the stacks 1 of insulating elements 16 in an intermediate station 29, in this example, in multiple supports 31. For example, a separate support 31 can be provided for each type of insulating element. The robot 8 removes the insulating elements 16 from these supports 31 in the intermediate station 29 and then installs each individual insulating element onto structural elements 12, 14, which in this embodiment is the vehicle body. The structural elements of the vehicle body (on which the insulating elements 16 are arranged) are accessible, that is, for example, the pillars and beams of the vehicle body are not yet enclosed.

[0187] exist Figure 9a and 9b The diagram schematically illustrates a robot 8 with an exemplary gripper 9. In this embodiment, the gripper 9 includes a suction gripper 23 capable of holding the insulating element 16 in the gripping direction. To better secure the insulating element 16 to the gripper 9, various interlocking elements 24, 26 are also provided, which interlock with each other and mechanically lock the insulating element 16 and the gripper 9 against lateral movement. In this embodiment, the fixing element 3 of the insulating element is oriented such that the application direction 22 forms a substantially 90° angle with the gripping direction 21.

[0188] Figure 10aAnother embodiment of a robot 8 with a gripper 9 is schematically shown. In this embodiment, the gripper 9 is shown as an expandable gripper. Here, the gripper 9 is configured such that it can pass through the through opening 25 in the insulating element in its unexpanded state, and the insulating element can be secured to the gripper 9 by the expansion of the expandable gripper, as in [the following text is missing from the original] Figure 10d As shown in the cross-section.

[0189] Now Figure 11 The illustration exemplarily and schematically shows a robot mounting an insulating element 16 onto structural elements 12 and 14. Here, the robot presses the insulating element 16 against the structural elements 12 and 14 in the application direction 22 such that the fixing element 3 is inserted into and mechanically locked into the opening 15 of the structural elements 12 and 14. In this embodiment, the clamping direction 21 and the application direction 22 also form a substantially 90° angle when the insulating element 16 is mounted onto the structural elements 12 and 14.

[0190] exist Figure 12 The insert elements 26 and 24 are shown schematically and exemplary. In this embodiment, the insulating element 16 has two cylindrical insert elements 26, and the robot's gripper has a plate-shaped insert element 24 having a circular and an elliptical opening and an elongated opening for receiving the cylindrical insert elements 26 of the insulating element 16.

[0191] exist Figure 13 The diagram schematically and exemplary illustrates another variation of the gripper 9 for the robot. In this embodiment, the gripper 9 includes at least two clamp-like, movable gripping elements capable of gripping the insulating element 16 on its edges.

[0192] exist Figure 14 An exemplary support 31 is schematically shown. The insulating elements 16 are arranged in a stacked manner in the support 31, and the foremost insulating element 16 is always prepared in a predefined take-out position.

[0193] Figures 15a and 15b show an intermediate station in which the insulating element 16 is disposed in a bracket 31. In the embodiment of Figure 15a, the bracket 31 is inclined, and in the embodiment of Figure 15b, the bracket 31 is vertically oriented. For example, the position of the bracket 31 in Figure 15a can be used as a filling position, and the position of the bracket 31 in Figure 15b can be used as a usage position.

[0194] exist Figures 16a to 19b Different exemplary supports 31 are shown in cross-sectional view, some with and some without insulating elements 16 disposed therein. These supports 31 are equipped with guide elements that conform to the contours of the insulating elements 16. Figures 16a-16b and Figures 17a-17b The guide element roughly follows the lower half of the cross-section of the insulating element 16, and... Figures 18a-18b and Figures 19a-19b The guide element only follows some short sections of the cross-section of the insulating element 16.

[0195] List of reference numerals

[0196] 1 stacking

[0197] 2 basic components

[0198] 3 fixed components

[0199] 4 spacer elements

[0200] 5 steps

[0201] 6 Support elements

[0202] 7 containers

[0203] 8 robots

[0204] 9 clamps

[0205] 10 body

[0206] 11 carriers

[0207] 12 structural components

[0208] 13 Expandable materials

[0209] 14 structural components

[0210] 15 openings

[0211] 16 insulating elements

[0212] 17 Upper side

[0213] 18 Lower side

[0214] 19 Stacking direction

[0215] 20 system

[0216] 21 Clamping direction

[0217] 22 Application direction

[0218] 23 Suction-type gripper

[0219] 24 Sockets

[0220] 25 through the opening

[0221] 26 Socketing Components

[0222] 27 positioning elements

[0223] 28 Location Identification Devices

[0224] 29 Intermediate Station

[0225] 30 transfer elements

[0226] 31 stents

Claims

1. A system for mounting an insulating element (16) on a structural element (12, 14) of a motor vehicle, said system comprising: Multiple provided insulating elements (16), transfer elements (30), intermediate stations (29), robots (8) and at least one structural element (12, 14). The insulating element (16) includes a carrier (11) and an expandable material (13) disposed on the carrier (11). The insulating element (16) has multiple contact positions on its upper side (17) and lower side (18). These contact positions are configured such that when multiple insulating elements (16) are stacked, adjacent insulating elements are positioned vertically and parallel to each other through these contact positions. The transfer element (30) is configured to place the provided insulating element (16) in the intermediate station (29). The insulating element (16) is positioned in a predefined spatial location and orientation in the intermediate station (29) for removal by the robot (8), and The robot (8) is configured to remove each individual insulating element (16) from the intermediate station (29) and place the insulating element on the structural elements (12, 14).

2. The system according to claim 1, wherein, The upper side (17) and lower side (18) are oriented substantially in the plane of the cross section to be insulated of the structural elements (12, 14) in the service state.

3. The system according to claim 1 or 2, wherein, The plurality of provided insulating elements (16) are stacked on top of each other in the container (7).

4. The system according to claim 1 or 2, wherein, The transfer element (30) is constructed as a robot.

5. The system according to claim 1 or 2, wherein, The intermediate station (29) includes at least one base element (2) which includes positioning elements for positioning insulating elements (16) on the base element (2) so that the insulating elements (16) or stacks (1) of insulating elements (16) can be arranged on the base element (2) in a predefined manner.

6. The system according to claim 1 or 2, wherein, The intermediate station (29) includes at least one conveying system configured to sequentially convey insulating elements (16) or stacks (1) of insulating elements (16) to predefined take-out positions.

7. The system according to claim 1 or 2, wherein, The intermediate station (29) includes at least one support (31) capable of accommodating multiple insulating elements (16) and preparing the insulating elements (16) in a predefined take-out position.

8. The system according to claim 7, wherein, The bracket (31) has at least one guide element that at least partially conforms to the outline of the insulating element (16).

9. The system according to claim 8, wherein, The at least one guide element is configured such that the insulating element (16) can only be accommodated in the guide element in one spatial location.

10. The system according to claim 1 or 2, wherein, The robot (8) includes a multi-jointed robotic arm and a gripper (9) mounted on the robotic arm.

11. The system according to claim 1 or 2, wherein, The structural elements (12, 14) are a single metal plate or multiple interconnected metal plates.

12. The system according to claim 1 or 2, wherein, The transfer element (30) is configured as a collaborative robot.

13. The system according to claim 1 or 2, wherein, The structural elements (12, 14) are in the form of columns.

14. The system according to claim 1 or 2, wherein, The structural elements (12, 14) are components of the vehicle body.

15. The system according to claim 1 or 2, wherein, The structural elements (12, 14) are in the form of a car body.

16. The system according to claim 1 or 2, wherein, The structural elements (12, 14) are in the form of beams.

17. The system according to claim 1 or 2, wherein, The structural elements (12, 14) are in the form of supports.

18. A method for mounting an insulating element (16) on a structural element (12, 14) of a motor vehicle, the method comprising the steps of: A plurality of insulating elements (16) are provided, each of which includes a carrier (11) and an expandable material (13) disposed on the carrier (11), and the insulating elements (16) have a plurality of contact positions on an upper side (17) and a lower side (18) configured such that when the plurality of insulating elements (16) are stacked, adjacent insulating elements are positioned vertically abutting each other and parallel to each other through these contact positions; Transfer the insulating element (16) to the intermediate station (29); Insulating elements (16) are provided in the intermediate station (29) at predefined spatial locations and orientations for removal by the robot (8); The robot (8) removes each individual insulating element (16) from the intermediate station (29); and The robot (8) installs the insulating element (16) onto the structural elements (12, 14).

19. The method according to claim 18, wherein, The provided insulating element (16) exists in the form of a stack (1) having multiple insulating elements (16) stacked on top of each other, and these stacks (1) are transported during transfer.

20. The method according to claim 18 or 19, wherein, During installation, a robot (8) grips the insulating element (16) in the gripping direction (21) and installs the insulating element on the structural elements (12, 14) in the application direction (22), the gripping direction (21) and the application direction (22) forming an angle of approximately 90° or 180°.

21. The method according to claim 18 or 19, wherein, When the insulating element (16) is held by the robot (8), at least two interlocking elements (24, 26) of the insulating element (16) are engaged in at least two corresponding interlocking elements (24, 26) of the gripper (9), wherein the at least two interlocking elements (24, 26) of the insulating element (16) are constructed differently.

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