A split vehicle door and pre-bending compensation method thereof

Abstract

The present application relates to the technical field of vehicle door design, and specifically to a split vehicle door and a pre-bending compensation method thereof. The pre-bending compensation method includes: dividing the vehicle door into a large deformation area and a small deformation area according to the deformation prediction result; compensating and adjusting the small deformation area of ​​the vehicle door by a fixture; driving the large deformation area of ​​the vehicle door to rotate the digital model according to a preset calculation angle with the water tangent line of the vehicle door window frame as the rotation axis; monitoring the welding fitting surface condition of the large deformation area of ​​the vehicle door, and reconstructing the digital model of the fitting surface of the large deformation area of ​​the vehicle door according to the monitoring result, so that the welding fitting surface of the large deformation area of ​​the vehicle door is restored to the initial fitting state. For the vehicle door area with a large deformation amount, the present application adopts the method of rotating the product digital model around a specific axis at a specific angle to obtain the process digital model. It avoids the large workload of CAE analysis and complete reconstruction of the door frame digital model, thereby solving the problem of long reconstruction cycle and poor accuracy of digital model.

Description

Technical Field

[0001] The present application relates to the technical field of vehicle door design, and in particular to a split vehicle door and a pre-bending compensation method thereof. Background Art

[0002] The vehicle's opening assembly consists of the door assembly, trunk lid assembly (or tailgate assembly), and hood assembly. These are relatively independent components within the vehicle. The door assembly is connected to the side panels via hinges, limiters, and latches, and has clearance and surface differences with surrounding components such as the side panels and fenders. To ensure sealing requirements for rain and dust protection, as well as sound insulation and noise reduction, one or two sealing strips are placed between the door assembly and the body to create a sealed space. However, the compression of the sealing strips creates a reaction force on the door, which can cause deformation of the door sheet metal.

[0003] To mitigate the effects of this deformation on door sealing, closing force, and gap and flushness, related technologies often employ fixture adjustment or pre-deformation. The first method, during the industrialization phase, involves adjusting the fixture's support surface to forcefully correct the door frame. Compensation is achieved by fine-tuning the relative distance between the door nut plate and the door in the Y and Z directions. Pre-deformation, on the other hand, requires CAE analysis, allowing for reverse pre-deformation during sheet metal design to mitigate door sheet metal deformation.

[0004] However, the fixture adjustment method can only be used for fine-tuning of parts with smaller deformations, and is difficult to apply to large deformation adjustments. The pre-deformation method based on CAE analysis requires the establishment of a car door model, the selection of grid units, and the application of uniformly distributed loads to obtain the deformation of the window frame. Based on this deformation, the car door sheet metal process data is then pre-bent and deformed. However, due to the limitations of structural characteristics, the area of ​​a single grid at the car door window frame and the lower part of the car door are quite different. Therefore, applying a uniformly distributed load based on the grid area results in low accuracy in the pre-bending analysis results of the door opening and closing parts of the existing technology. In addition, the digital model is reconstructed, which is equivalent to reconstructing the digital model based on the deformation of each point on the car door calculated by CAE. The workload is relatively large and the cycle is relatively long. Summary of the Invention

[0005] In the related technology, in the pre-bending deformation processing of the door sheet metal process data, the deformation differences among various parts of the door are large. The pre-deformation analysis results of the door opening and closing parts based on CAE analysis are low in accuracy and the workload is large.

[0006] In a first aspect, an embodiment of the present application provides a method for compensating for pre-bending of a split vehicle door, the method comprising:

[0007] According to the deformation prediction results, the door is divided into a large deformation area and a small deformation area;

[0008] Compensate and adjust the small deformation area of ​​the door through the fixture;

[0009] Drive the large deformation area of ​​the door to rotate digitally according to the preset calculation angle with the door window frame water tangent line as the rotation axis;

[0010] The condition of the welding joint surface in the large deformation area of ​​the car door is monitored, and the digital model of the joint surface in the large deformation area of ​​the car door is reconstructed based on the monitoring results, so that the welding joint surface in the large deformation area of ​​the car door is restored to the initial joint state.

[0011] In combination with the first aspect, in one embodiment, dividing the vehicle door into a large deformation area and a small deformation area according to the magnitude of the deformation includes:

[0012] The door frame assembly of the vehicle door is divided into a large deformation area. The door frame assembly includes a door frame portion and a door frame connecting plate. The door frame connecting plate is connected to both ends of the door frame portion.

[0013] The door panel assembly of the vehicle door is divided into small deformation areas, and the door panel assembly includes a door inner panel, an inner panel reinforcement plate and a door outer panel.

[0014] In combination with the first aspect, in one embodiment, driving the large deformation area of ​​the vehicle door to perform digital-analog rotation according to a preset calculated angle with the door window frame water tangent line as the rotation axis includes:

[0015] Calculate the preset rotation angle based on the size of the door frame assembly;

[0016] The line connecting the two ends of the door frame connecting plate is used as the rotation axis to drive the door frame to rotate at a preset rotation angle.

[0017] In conjunction with the first aspect, in one embodiment, calculating the preset rotation angle according to the size of the door frame assembly includes:

[0018] Take the highest point of the door frame in the Z direction of the vehicle, and draw a perpendicular line from the first highest point to the rotation axis, which intersects the rotation axis at the zero boundary point;

[0019] Determine the second highest point of the door frame portion in the Z direction of the vehicle after the door frame portion is rotated according to the position of the door frame portion after the door frame portion is rotated;

[0020] The preset rotation angle of the door frame portion is calculated according to the positions of the first highest point and the second highest point in the vehicle Z direction before and after the door frame portion is rotated.

[0021] In combination with the first aspect, in one embodiment, calculating the door frame rotation angle based on the highest points H1 and H1' in the vehicle Z direction before and after the door frame rotates includes:

[0022] Set the distance T between the first highest point and the second highest point, and calculate the preset rotation angle θ of the door frame according to the formula:

[0023] θ=arccos((D1 2 +D1 2 -T 2 ) / 2*D1*D1)

[0024] Where D1 is the distance from the first highest point to the zero boundary point, and T is the distance between the first highest point and the second highest point.

[0025] In combination with the first aspect, in one embodiment, setting the distance T between the first highest point and the second highest point includes:

[0026] The distance T between the first highest point and the second highest point is set to 1.5 mm.

[0027] In conjunction with the first aspect, in one embodiment, monitoring the condition of the welding joint surface in the large deformation area of ​​the vehicle door includes:

[0028] After rotation, the fitting status of all fitting surfaces between the door frame, door frame connecting plate and door inner panel is tested.

[0029] In conjunction with the first aspect, in one embodiment, reconstructing the digital model of the fitting surface of the large deformation area of ​​the vehicle door according to the monitoring results includes:

[0030] When the monitoring results show that only the door frame and the door frame connecting plate are in a fitted state after rotation, and the other fitting surfaces are not in a fitted state, the fitting surface of the door frame connecting plate is digitally reconstructed;

[0031] When the monitoring results show that the three-layer bonding surfaces of the rear door frame, the door frame connecting plate and the vehicle door inner panel are bonded together, the bonding surfaces of the door frame are digitally reconstructed.

[0032] In combination with the first aspect, in one embodiment, compensating and adjusting the small deformation area of ​​the vehicle door by using a clamp includes: using the clamp to compensate and adjust the deformation of the vehicle door inner panel, the inner panel reinforcement plate and the vehicle door outer panel.

[0033] In a second aspect, an embodiment of the present application provides a split vehicle door, which is manufactured after deformation compensation processing using any of the pre-bending compensation methods described above.

[0034] The beneficial effects of the technical solutions provided in the embodiments of the present application include:

[0035] This application divides the car door into large and small deformation areas, and then uses different pre-bending compensation methods to perform pre-bending compensation on the two areas. Furthermore, for the car door area with larger deformation, this application adopts the method of rotating the product digital model around a specific axis at a specific angle to obtain the process digital model (digital model of industrial molds, inspection tools, and fixtures), matches the welding overlap area of ​​the door frame and the door frame connecting plate in the door frame assembly, and changes the digital model locally and slightly. The large workload of CAE analysis and complete reconstruction of the door frame digital model is avoided, thereby solving the problem of long reconstruction cycle and poor accuracy of the digital model. The frequency and amplitude of subsequent industrial adjustments to the fixture are significantly reduced, ensuring the requirements of the door clearance, surface difference, sealing, and opening and closing force, and ensuring quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 This is a front view of the split door in the embodiment of the present application;

[0037] Figure 2 This is a front view of the door frame assembly in the embodiment of the present application;

[0038] Figure 3 A side view of a split vehicle door according to an embodiment of the present application;

[0039] Figure 4 This is a partial schematic diagram of a door inner panel in an embodiment of the present application;

[0040] Figure 5 A partial cross-sectional view of a split vehicle door in an embodiment of the present application;

[0041] Figure 6 Schematic diagram of the split vehicle door before and after the door frame rotates in an embodiment of the present application;

[0042] Figure 7 This is a schematic diagram showing the principle of the split vehicle door before and after the door frame rotates in an embodiment of the present application;

[0043] Figure 8 This is a partial cross-sectional view of the door frame after rotation in the embodiment of the present application;

[0044] Figure 9 This is a partial cross-sectional view of the second situation after the door frame part is rotated in the embodiment of the present application.

[0045] Description of the drawings: 1. Door frame assembly; 11. Door frame part; 111. First side door frame; 112. Second side door frame; 12. Door frame connecting plate; 121. Door frame front connecting plate; 122. Door frame middle connecting plate; 123. Door frame rear connecting plate; 2. Door inner panel; 3. Inner panel reinforcement plate; 4. Door outer panel; 5. Hinge nut plate assembly; 6. Vehicle body. DETAILED DESCRIPTION

[0046] In order to enable those skilled in the art to better understand the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0047] In the related technology, in the pre-bending deformation processing of the door sheet metal process data, the deformation differences among various parts of the door are large. The pre-deformation analysis results of the door opening and closing parts based on CAE analysis are low in accuracy and the workload is large.

[0048] In order to make the objectives, technical solutions and advantages of this application clearer, the implementation methods of this application will be further described in detail below with reference to the accompanying drawings.

[0049] In a first aspect, an embodiment of the present application provides a method for compensating for pre-bending of a split vehicle door, the method comprising:

[0050] Step S1: Divide the vehicle door into a large deformation area and a small deformation area according to the deformation prediction result.

[0051] In the first optional implementation provided by this application, the door is divided into three regions according to the size of the deformation: a large deformation region Y1, a very small deformation region Y2 and a micro deformation region Y3. Figure 1 As shown, the area above the door projected along the vehicle Y direction by the straight line L1 is the deformation area Y1, wherein: the front and rear end points of the door frame connecting plate 12 of the door frame assembly 1 are point M and point N respectively. Figure 2 As shown, L1 is a straight line passing through points M and N, i.e., the window frame water tangent line. The door frame connecting plate 12 includes: a door frame front connecting plate 121, a door frame middle connecting plate 122, and a door frame rear connecting plate 123, which are welded together with the vehicle door inner panel 2 of the door panel assembly; the area between the straight line L1 and the straight line AC projected onto the vehicle door along the Y direction is the micro-deformation area Y3; the area between the straight line AC and the straight line BC projected onto the vehicle door along the Y direction is the extremely small deformation area Y2, which is simply the triangular area surrounded by the upper and lower hinges and the lock; the area below the vehicle door projected along the Y direction by the straight line BC is the micro-deformation area Y3.

[0052] It should be noted that if Figure 3 As shown, point A is the center of the upper screw hole of the upper hinge on the door inner panel 2, point B is the center of the lower screw hole of the lower hinge on the door inner panel 2, and points P1 and P2 are points on the cutting edge line of the lock hole on the door inner panel 2 (see Figure 4 ), point C is the center point of line segment P1P2.

[0053] In the second optional implementation provided by the present application, the door frame assembly 1 of the vehicle door is divided into a large deformation area, and the door frame assembly 1 includes a door frame portion 11 and a door frame connecting plate 12, and the door frame connecting plate 12 is connected to both ends of the door frame portion 11; the door panel assembly of the vehicle door is divided into a small deformation area, and the door panel assembly includes a vehicle door inner panel 2, an inner panel reinforcement plate 3 and a vehicle door outer panel 4.

[0054] Furthermore, the door panel assembly includes two micro-deformation regions Y3 and one extremely small deformation region Y2. The door inner panel 2 region, due to the large cross-sectional area created by the hemming of the door outer and inner panels, provides a certain degree of strength for the entire door. Regarding the door frame assembly 1, the door frame assembly 1 serves as deformation region Y1. Due to its small cross-sectional area, its strength is lower than that of the door inner panel 2 region.

[0055] It should be noted that the door frame assembly 1 experiences significant deformation, with the topmost point (located on the side of the lock catch, point C) deforming approximately 1.5 mm. This deformation increases linearly from point C upward. The door frame connecting plates 12 comprise a front connecting plate 121, a middle connecting plate 122, and a rear connecting plate 123. Line L1 connects the two endpoints of connecting plate 122. Deformation compensation for the door frame assembly 1 is achieved by rotating the door frame digital model by a certain angle, rather than using data reconstruction.

[0056] Step S2: Compensating and adjusting the small deformation area of ​​the door using a fixture.

[0057] In some embodiments, a clamp is used to compensate and adjust the deformation of the door inner panel 2 , the inner panel reinforcement plate 3 , and the door outer panel 4 .

[0058] It should be noted that the deformation of the door panel area is small (usually less than 0.5mm) and the difference in deformation between the upper and lower parts is small (less than 0.3mm). This deformation compensation can be achieved by adjusting the fixture rather than using data reconstruction.

[0059] Specifically, if Figure 5 As shown, the door inner panel 2 and the door inner panel reinforcement plate 3 are first welded together to form a subassembly, which is then welded to the hinge nut plate assembly 5 (with nuts welded to it). Finally, the door outer panel 4 and the door inner panel 2 are hemmed together using a rolling hemming process. The relative position of the hinge nut plate assembly 5 and the inner panel reinforcement plate 3 is adjusted using a fixture, thereby changing the position of the door outer panel 4 relative to the vehicle body 6, thereby compensating for the door panel area.

[0060] Step S3: driving the large deformation area of ​​the door to perform digital-analog rotation according to a preset calculation angle with the door window frame water tangent line as the rotation axis.

[0061] The above step S3 includes:

[0062] Step S3a: Calculate a preset rotation angle according to the size of the door frame assembly 1.

[0063] Specifically, if Figure 6 As shown, take the first highest point H1 of the door frame part 11 in the Z direction of the vehicle, draw a perpendicular line through the first highest point H1 to the rotation axis L1, and intersect the rotation axis L1 at the zero boundary point 0; determine the second highest point H1' of the door frame part 11 in the Z direction of the vehicle after rotation according to the position of the door frame part 11 after rotation; calculate the preset rotation angle of the door frame part 11 according to the positions of the first highest point H1 and the second highest point H1' in the Z direction of the vehicle before and after rotation of the door frame part 11.

[0064] Further, if Figure 6 and Figure 7 As shown, the door frame 11 rotates a certain angle toward the interior of the vehicle with the rotation axis L1 as the rotation axis to reach point H1', ​​so that the distance from point H1 to point H1' is T, which is generally set to 1.5 mm. According to the cosine theorem:

[0065] T 2 =D1 2 +D1 2 -2*D1*D1*cosθ

[0066] The distance T between the first highest point and the second highest point is set, and the preset rotation angle θ of the door frame portion 11 is calculated according to the above formula:

[0067] θ=arccos((D1 2 +D1 2 -T 2 ) / 2*D1*D1)

[0068] Wherein, D1 is the distance from the first highest point to the zero boundary point 0, and T is the distance between the first highest point H1 and the second highest point H1'. Preferably, the distance T between the first highest point and the second highest point is set to 1.5 mm.

[0069] Step S3b: Using the line connecting the two ends of the door frame connecting plate 12 as the rotation axis, drive the door frame portion 11 to rotate at a preset rotation angle.

[0070] It is understandable that the deformation compensation is achieved by rotating the door frame digital model by a certain angle, and the data reconstruction method is not used for compensation.

[0071] Step S4: monitor the condition of the welding joint surface in the large deformation area of ​​the vehicle door, and reconstruct the digital model of the joint surface in the large deformation area of ​​the vehicle door based on the monitoring results, so that the welding joint surface in the large deformation area of ​​the vehicle door is restored to the initial joint state.

[0072] The above step S4 includes:

[0073] Step S4a: After the rotation, the fitting status of all fitting surfaces between the door frame portion 11, the door frame connecting plate 12, and the vehicle door inner panel 2 is detected.

[0074] It should be noted that the door frame front connecting plate 121 and the door frame rear connecting plate 123 in the door frame assembly 1 have several welded joint surfaces with the first side door frame 111 and the second side door frame 112 of the door frame portion 11 before the compensatory rotation. After the compensatory rotation toward the vehicle, the welded joint surfaces have gaps (or interferences) and are not in good alignment. It is necessary to reconstruct the digital model of the joint surfaces to make them fit again (see Figure 4 ).

[0075] Step S4b: reconstructing the digital model of the joint surface of the large deformation area of ​​the vehicle door according to the monitoring result, so that the welding joint surface of the large deformation area of ​​the vehicle door is restored to the initial joint state.

[0076] Specifically, due to the different conditions of the fitting surface, it is necessary to formulate a digital model reconstruction strategy based on the change state of the original fitting surface after rotation. The specific steps include:

[0077] Case 1: When the monitoring results show that only the door frame portion 11 and the door frame connecting plate 12 are in contact with each other after rotation, and the other contact surfaces are not in contact with each other, the contact surface of the door frame connecting plate 12 is digitally reconstructed;

[0078] Specifically, if Figure 8 As shown in the figure, the dotted line frame part is the fitting surface area. When only the first side door frame 111 is fitted with the door frame rear connecting plate 123, the digital model of the fitting surface of the door frame rear connecting plate 123 is reconstructed.

[0079] Case 2: When the monitoring result shows that the three bonding surfaces of the rear door frame portion 11 , the door frame connecting plate 12 and the vehicle door inner panel 2 are bonded together, the bonding surface of the door frame portion 11 is digitally reconstructed.

[0080] Specifically, if Figure 9 As shown in the figure, the dotted-line area represents the bonding surface area. When the door inner panel 2, the door frame front connecting plate 121, and the second side door frame 112 are welded together, the digital model of the door inner panel 2 cannot be changed. The digital model of the door frame front connecting plate 121 cannot be changed because it must be bonded to the door inner panel 2. Only the digital model of the door frame welded to the outside can be modified to match the connecting plate, thereby reconstructing the digital model of the second side door frame 112.

[0081] In a second aspect, the present application provides a method for manufacturing a split vehicle door, wherein the manufacturing steps include: a method for compensating for pre-bending of a split vehicle door, the method comprising:

[0082] Step S1: Divide the vehicle door into a large deformation area and a small deformation area according to the deformation prediction result.

[0083] In the first optional implementation provided by this application, the door is divided into three regions according to the size of the deformation: a large deformation region Y1, a very small deformation region Y2 and a micro deformation region Y3. Figure 1 As shown, the area above the door projected along the vehicle Y direction by the straight line L1 is the deformation area Y1, wherein: the front and rear end points of the door frame connecting plate 12 of the door frame assembly 1 are point M and point N respectively. Figure 2 As shown, L1 is a straight line passing through points M and N, i.e., the window frame water tangent line. The door frame connecting plate 12 includes: a door frame front connecting plate 121, a door frame middle connecting plate 122, and a door frame rear connecting plate 123, which are welded together with the vehicle door inner panel 2 of the door panel assembly; the area between the straight line L1 and the straight line AC projected onto the vehicle door along the Y direction is the micro-deformation area Y3; the area between the straight line AC and the straight line BC projected onto the vehicle door along the Y direction is the extremely small deformation area Y2, which is simply the triangular area surrounded by the upper and lower hinges and the lock; the area below the vehicle door projected along the Y direction by the straight line BC is the micro-deformation area Y3.

[0084] It should be noted that if Figure 3 As shown, point A is the center of the upper screw hole of the upper hinge on the door inner panel 2, point B is the center of the lower screw hole of the lower hinge on the door inner panel 2, and points P1 and P2 are points on the cutting edge line of the lock hole on the door inner panel 2 (see Figure 4 ), point C is the center point of line segment P1P2.

[0085] In the second optional implementation provided by the present application, the door frame assembly 1 of the vehicle door is divided into a large deformation area, and the door frame assembly 1 includes a door frame portion 11 and a door frame connecting plate 12, and the door frame connecting plate 12 is connected to both ends of the door frame portion 11; the door panel assembly of the vehicle door is divided into a small deformation area, and the door panel assembly includes a vehicle door inner panel 2, an inner panel reinforcement plate 3 and a vehicle door outer panel 4.

[0086] Furthermore, the door panel assembly includes two micro-deformation regions Y3 and one extremely small deformation region Y2. The door inner panel 2 region, due to the large cross-sectional area created by the hemming of the door outer and inner panels, provides a certain degree of strength for the entire door. Regarding the door frame assembly 1, the door frame assembly 1 serves as deformation region Y1. Due to its small cross-sectional area, its strength is lower than that of the door inner panel 2 region.

[0087] It should be noted that the door frame assembly 1 experiences significant deformation, with the topmost point (located on the side of the lock catch, point C) deforming approximately 1.5 mm. This deformation increases linearly from point C upward. The door frame connecting plates 12 comprise a front connecting plate 121, a middle connecting plate 122, and a rear connecting plate 123. Line L1 connects the two endpoints of connecting plate 122. Deformation compensation for the door frame assembly 1 is achieved by rotating the door frame digital model by a certain angle, rather than using data reconstruction.

[0088] Step S2: Compensating and adjusting the small deformation area of ​​the door using a fixture.

[0089] In some embodiments, a clamp is used to compensate and adjust the deformation of the door inner panel 2 , the inner panel reinforcement plate 3 , and the door outer panel 4 .

[0090] It should be noted that the deformation of the door panel area is small (usually less than 0.5mm) and the difference in deformation between the upper and lower parts is small (less than 0.3mm). This deformation compensation can be achieved by adjusting the fixture rather than using data reconstruction.

[0091] Specifically, if Figure 5 As shown, the door inner panel 2 and the door inner panel reinforcement plate 3 are first welded together to form a subassembly, which is then welded to the hinge nut plate assembly 5 (with nuts welded to it). Finally, the door outer panel 4 and the door inner panel 2 are hemmed together using a rolling hemming process. The relative position of the hinge nut plate assembly 5 and the inner panel reinforcement plate 3 is adjusted using a fixture, thereby changing the position of the door outer panel 4 relative to the vehicle body 6, thereby compensating for the door panel area.

[0092] Step S3: driving the large deformation area of ​​the door to perform digital-analog rotation according to a preset calculation angle with the door window frame water tangent line as the rotation axis.

[0093] The above step S3 includes:

[0094] Step S3a: Calculate a preset rotation angle according to the size of the door frame assembly 1.

[0095] Specifically, if Figure 6 As shown, take the first highest point H1 of the door frame part 11 in the Z direction of the vehicle, draw a perpendicular line through the first highest point H1 to the rotation axis L1, and intersect the rotation axis L1 at the zero boundary point 0; determine the second highest point H1' of the door frame part 11 in the Z direction of the vehicle after rotation according to the position of the door frame part 11 after rotation; calculate the preset rotation angle of the door frame part 11 according to the positions of the first highest point H1 and the second highest point H1' in the Z direction of the vehicle before and after rotation of the door frame part 11.

[0096] Further, if Figure 6 and Figure 7 As shown, the door frame 11 rotates a certain angle toward the interior of the vehicle with the rotation axis L1 as the rotation axis to reach point H1', ​​so that the distance from point H1 to point H1' is T, which is generally set to 1.5 mm. According to the cosine theorem:

[0097] T 2 =D1 2 +D1 2 -2*D1*D1*cosθ

[0098] The distance T between the first highest point and the second highest point is set, and the preset rotation angle θ of the door frame portion 11 is calculated according to the above formula:

[0099] θ=arccos((D1 2 +D1 2 -T 2 ) / 2*D1*D1)

[0100] Wherein, D1 is the distance from the first highest point to the zero boundary point 0, and T is the distance between the first highest point H1 and the second highest point H1'. Preferably, the distance T between the first highest point and the second highest point is set to 1.5 mm.

[0101] Step S3b: Using the line connecting the two ends of the door frame connecting plate 12 as the rotation axis, drive the door frame portion 11 to rotate at a preset rotation angle.

[0102] It is understandable that the deformation compensation is achieved by rotating the door frame digital model by a certain angle, and the data reconstruction method is not used for compensation.

[0103] Step S4: monitor the condition of the welding joint surface in the large deformation area of ​​the vehicle door, and reconstruct the digital model of the joint surface in the large deformation area of ​​the vehicle door based on the monitoring results, so that the welding joint surface in the large deformation area of ​​the vehicle door is restored to the initial joint state.

[0104] The above step S4 includes:

[0105] Step S4a: After the rotation, the fitting status of all fitting surfaces between the door frame portion 11, the door frame connecting plate 12, and the vehicle door inner panel 2 is detected.

[0106] It should be noted that the door frame front connecting plate 121 and the door frame rear connecting plate 123 in the door frame assembly 1 have several welded joint surfaces with the first side door frame 111 and the second side door frame 112 of the door frame portion 11 before the compensatory rotation. After the compensatory rotation toward the vehicle, the welded joint surfaces have gaps (or interferences) and are not in good alignment. It is necessary to reconstruct the digital model of the joint surfaces to make them fit again (see Figure 4 ).

[0107] Step S4b: reconstructing the digital model of the joint surface of the large deformation area of ​​the vehicle door according to the monitoring result, so that the welding joint surface of the large deformation area of ​​the vehicle door is restored to the initial joint state.

[0108] Specifically, due to the different conditions of the fitting surface, it is necessary to formulate a digital model reconstruction strategy based on the change state of the original fitting surface after rotation. The specific steps include:

[0109] Case 1: When the monitoring results show that only the door frame portion 11 and the door frame connecting plate 12 are in a fitted state after rotation, and other fitting surfaces are not in a fitted state, the fitting surface of the door frame connecting plate 12 is digitally reconstructed.

[0110] Specifically, if Figure 8 As shown, the dotted box portion in the figure is the fitting surface area. When only the first side door frame 111 is fitted with the door frame rear connecting plate 123, the digital model of the fitting surface of the door frame rear connecting plate 123 is reconstructed.

[0111] Case 2: When the monitoring result shows that the three bonding surfaces of the rear door frame portion 11 , the door frame connecting plate 12 and the vehicle door inner panel 2 are bonded together, the bonding surface of the door frame portion 11 is digitally reconstructed.

[0112] Specifically, if Figure 9 As shown in the figure, the dotted-line area represents the bonding surface area. When the door inner panel 2, the door frame front connecting plate 121, and the second side door frame 112 are welded together, the digital model of the door inner panel 2 cannot be changed. The digital model of the door frame front connecting plate 121 cannot be changed because it must be bonded to the door inner panel 2. Only the digital model of the door frame welded to the outside can be modified to match the connecting plate, thereby reconstructing the digital model of the second side door frame 112.

[0113] In a third aspect, the present application provides a split vehicle door, which is manufactured by performing deformation compensation processing using the pre-bending compensation method as described in any one of the above items.

[0114] In summary, the present application divides the vehicle door into large and small deformation areas, and then adopts different pre-bending compensation methods to perform pre-bending compensation on the two areas. Furthermore, for the vehicle door area with larger deformation, the present application adopts the method of rotating the product digital model around a specific axis at a specific angle to obtain the process digital model (digital model of industrial molds, inspection tools, and fixtures), matches the welding overlap area of ​​the door frame and the door frame connecting plate in the door frame assembly, and changes the digital model locally and slightly. The large workload of CAE analysis and complete reconstruction of the door frame digital model is avoided, thereby solving the problem of long reconstruction cycle and poor accuracy of the digital model. The frequency and amplitude of subsequent industrial adjustments to the fixture are significantly reduced, ensuring the requirements of the door clearance, surface difference, sealing, and opening and closing force, and ensuring quality.

[0115] In the description of this application, it should be noted that the terms "upper" and "lower" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application. Unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be internal communication between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to the specific circumstances.

[0116] It should be noted that, in this application, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, an element defined by the sentence "comprising a ..." does not exclude the presence of other identical elements in the process, method, article or device comprising the element.

[0117] The foregoing is merely a list of specific embodiments of the present application, intended to enable those skilled in the art to understand or implement the present application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to the embodiments shown herein, but is intended to conform to the broadest scope consistent with the principles and novel features of the present application.

Claims

1. A method for compensating for pre-bending of a split vehicle door, characterized in that: The pre-bending compensation method comprises: According to the deformation prediction results, the door is divided into a large deformation area and a small deformation area; Compensate and adjust the small deformation area of ​​the door through the fixture; Drive the large deformation area of ​​the door to rotate digitally according to the preset calculation angle with the door window frame water tangent line as the rotation axis; The condition of the welding joint surface in the large deformation area of ​​the car door is monitored, and the digital model of the joint surface in the large deformation area of ​​the car door is reconstructed based on the monitoring results, so that the welding joint surface in the large deformation area of ​​the car door is restored to the initial joint state.

2. The pre-bending compensation method for a split vehicle door as claimed in claim 1, characterized in that: The door is divided into a large deformation area and a small deformation area according to the size of the deformation, including: The door frame assembly (1) of the vehicle door is divided into a large deformation area, wherein the door frame assembly (1) includes a door frame portion (11) and a door frame connecting plate (12), and the door frame connecting plate (12) is connected to both ends of the door frame portion (11); The door panel assembly of a vehicle door is divided into small deformation areas. The door panel assembly includes a vehicle door inner panel (2), an inner panel reinforcement plate (3) and a vehicle door outer panel (4).

3. The pre-bending compensation method for a split vehicle door as claimed in claim 2, characterized in that: The method of driving the large deformation area of ​​the door to perform digital-analog rotation according to a preset calculation angle with the door window frame water tangent line as the rotation axis includes: Calculating a preset calculation angle based on the size of the door frame assembly (1); The door frame portion (11) is driven to rotate at a preset calculated angle using a line connecting the two ends of the door frame connecting plate (12) as a rotation axis.

4. The pre-bending compensation method for a split vehicle door as claimed in claim 3, characterized in that: The calculation of the preset rotation angle according to the size of the door frame assembly (1) includes: Take the first highest point of the door frame (11) in the vehicle Z direction, draw a perpendicular line through the first highest point to the rotation axis and intersect the rotation axis at the zero boundary point, the vehicle Z direction is the vehicle height direction; Determining the second highest point of the door frame portion (11) in the Z direction of the vehicle after the door frame portion (11) is rotated according to the position of the door frame portion (11) after the door frame portion (11) is rotated; The preset calculation angle of the door frame part (11) is calculated according to the positions of the first highest point and the second highest point in the Z direction of the vehicle before and after the door frame part (11) rotates.

5. The pre-bending compensation method for a split vehicle door as claimed in claim 4, characterized in that: The method of calculating a preset calculation angle of the door frame portion (11) based on the first highest point and the second highest point in the vehicle Z direction before and after the door frame portion (11) rotates comprises: The distance T between the first highest point and the second highest point is set, and the preset calculation angle θ of the door frame portion (11) is calculated according to the formula: θ =arccos(( D1 2 + D1 2 - T 2 ) / 2*D1*D1) Where D1 is the distance from the first highest point to the zero boundary point, and T is the distance between the first highest point and the second highest point.

6. The pre-bending compensation method for a split vehicle door as claimed in claim 5, characterized in that: The step of setting the distance T between the first highest point and the second highest point includes: The distance T between the first highest point and the second highest point is set to 1.5 mm.

7. The pre-bending compensation method for a split vehicle door as claimed in claim 2, characterized in that: The monitoring of the welding joint surface condition in the large deformation area of ​​the vehicle door includes: After the rotation, the fitting states of all fitting surfaces between the door frame portion (11), the door frame connecting plate (12), and the vehicle door inner plate (2) are inspected.

8. The pre-bending compensation method for a split vehicle door as claimed in claim 7, characterized in that: The reconstructing of the digital model of the fitting surface of the large deformation area of ​​the door according to the monitoring results includes: When the monitoring result shows that only the door frame portion (11) and the door frame connecting plate (12) are in a fitting state after the rotation, and the other fitting surfaces are not in a fitting state, the fitting surface of the door frame connecting plate (12) is digitally reconstructed; When the monitoring result shows that the three-layer bonding surfaces of the door frame portion (11), the door frame connecting plate (12) and the vehicle door inner panel (2) are bonded together after rotation, the bonding surface of the door frame portion (11) is digitally reconstructed.

9. The pre-bending compensation method for a split vehicle door as claimed in claim 2, characterized in that: The method of compensating and adjusting the small deformation area of ​​the vehicle door by using a clamp comprises: using the clamp to compensate and adjust the deformation of the vehicle door inner panel (2), the inner panel reinforcement plate (3) and the vehicle door outer panel (4).

10. A split vehicle door, characterized in that: It is manufactured by performing deformation compensation processing using the pre-bending compensation method described in any one of claims 1 to 9.

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