A general-purpose door opening and closing tool clamp suitable for automobile front door, rear door and tail door

Abstract

The application relates to the technical field of automobile part detection, and discloses a universal door opening and closing tool clamp suitable for automobile front doors, rear doors and tailgates, which comprises a fixed base, a turnover frame, a hinge shaft assembly, an adjustable product mounting assembly and a locking mechanism; the fixed base is a whole machine bearing reference, the bottom is matched with an adjustable foot stand, and a standardized mounting groove is formed in the base plate surface; the hinge shaft assembly is arranged in pairs at the left and right ends of the fixed base and comprises a bearing seat and a through-type rotating shaft; the rotating shaft center line serves as a simulated door hinge reference axis and reproduces the real swing center of the whole vehicle door; the turnover frame is rigidly connected with the rotating shaft through a connecting support and can reciprocatingly swing in the 0-90 degree interval along the rotating shaft axis to simulate the complete opening and closing movement stroke of the door; when different door types are switched, only the position and angle of the adjustable product mounting assembly need to be adjusted, the tool main body does not need to be disassembled and assembled, the single-time changing type time is shortened, the efficiency is remarkably improved, and the production and detection rhythm is effectively guaranteed.

Description

Technical Field

[0001] This invention belongs to the field of automotive parts testing technology, specifically a universal door opening and closing tooling fixture applicable to the front door, rear door and tailgate of automobiles. Background Technology

[0002] In the processes of automobile manufacturing, component performance testing (such as hinge durability), and assembly debugging, tooling fixtures are required to accurately simulate the actual installation state and opening / closing trajectory of the door to ensure assembly accuracy and the reliability of test results. Currently, automobile models are iterating rapidly, and the structural dimensions and installation points of different models and door types (front doors, rear doors, tailgates) vary significantly. Existing tooling fixtures have the following core technical deficiencies, making it difficult to meet the demands of mass production and high-precision testing: Poor versatility and high equipment investment costs: Traditional tooling fixtures are designed specifically for a single door type. One set of tooling can only be adapted to a specific door of a certain car model (such as only the front door of a certain model), and cannot accommodate the structural differences, installation point offsets, and posture differences of the front, rear, and tail doors. To meet the production and testing needs of multiple door types, companies need to invest in multiple sets of dedicated tooling, which not only significantly increases equipment procurement costs but also occupies a large amount of production space, resulting in high production and operating costs.

[0003] Low changeover efficiency affects production cycle time: When it is necessary to switch between different door types (such as from front door to rear door or tailgate), the tooling fixtures need to be completely disassembled, repositioned, and repeatedly adjusted. A single changeover can take up to several hours, which seriously slows down the production and testing cycle time and cannot meet the needs of the automotive industry for efficient and large-scale production.

[0004] Insufficient motion simulation accuracy leads to unreliable test results: Some simple general-purpose tooling does not accurately match the actual hinge axis of the car door. The rotation axis of the hinge axis assembly deviates significantly from the actual door hinge axis, resulting in a distorted door opening and closing motion trajectory. This affects the accuracy of test results for key performance indicators such as door sealing and hinge durability, potentially causing substandard products to enter the market and increasing the quality risk for enterprises.

[0005] Poor scalability and limited adaptability: Existing tooling is mostly a fixed structure, which cannot be equipped with sensors, automated drive components, etc. according to the testing requirements. It is difficult to adapt to the upgrade requirements of automated testing lines, and it cannot be flexibly adjusted to adapt to the changes in the gate structure of new vehicle models. Summary of the Invention

[0006] The purpose of this invention is to provide a universal door opening and closing tooling fixture applicable to the front door, rear door and tailgate of automobiles, thus solving the problems of the prior art.

[0007] The present invention adopts the following technical solution: A universal door opening and closing fixture suitable for automobile front doors, rear doors and tailgates, including a fixed base, a flip frame, a hinge shaft assembly, an adjustable product mounting assembly and a locking mechanism; The fixed base serves as the load-bearing benchmark for the entire machine, and is equipped with adjustable feet at the bottom. Standardized mounting slots are provided on the base plate surface. The hinge shaft assembly is arranged in pairs at the left and right ends of the fixed base, including a bearing seat and a through-type rotating shaft. The center line of the rotating shaft serves as the reference axis for simulating the door hinge, replicating the real swing center of the entire vehicle door. The flipping frame is rigidly connected to the rotating shaft via a connecting bracket, and can swing back and forth along the axis of the rotating shaft in the range of 0°-90° to simulate the complete opening and closing motion of a car door. The adjustable product mounting assembly has at least three independent mounting modules. Each module has multi-directional displacement and multi-angle posture adjustment capabilities to adapt to the different mounting hole positions and tilted assembly postures of front doors, side rear doors, and hatchback tailgates of different car models. Each mounting module includes a base, a linear slide, an angle adjustment plate, and locking bolts. One of the mounting modules is rigidly fixed on the fixed base, and the mounting reference does not rotate synchronously with the flip frame. The locking mechanism is mounted on the end of the rotating shaft and can lock the rotating shaft at any swing angle of the flipping frame; the locking mechanism integrates an angle acquisition element and establishes an electrical interlock control logic with the adjustable product mounting components.

[0008] Preferably, the bearing housing is equipped with a wedge-shaped fine-adjustment positioning block at the bottom, the bearing housing adopts a fully sealed dustproof integrated shell, and a double-row self-aligning roller bearing is installed inside; the shaft and the connecting bracket adopt a key fit interference sleeve to achieve backlash-free transmission, and the surface of the shaft is nitrided for wear resistance and hardening.

[0009] Preferably, each set of installation modules includes a linear slide table comprising a transverse translation slide table and a longitudinal lifting slide table, with the transverse slide table having an adjustment stroke of 0-200mm and the longitudinal lifting slide table having an adjustment stroke of 0-80mm; the angle adjustment plate integrates a pitch pivot and a 360° horizontal rotary table, with a pitch adjustment range of ±90°; the locking bolt is equipped with a disc spring pre-tightening locking structure, with a constant locking torque of 15N・m.

[0010] Preferably, the three sets of installation modules are an upper hinge installation module, a lower hinge installation module, and a base-fixed lock block bracket module; the base-fixed lock block bracket module is used to clamp the door lock block, wiring harness fixing bracket, rubber buffer pad, and door controller, keeping the installation reference stationary throughout the process.

[0011] Preferably, the locking mechanism is a multi-plate electromagnetic brake assembly, and the angle acquisition element is a high-precision absolute angle encoder; the electromagnetic brake adopts a power-off self-locking structure, with a static holding torque ≥80N・m, an unlocking response time ≤0.1s, and a locking response time ≤0.05s; the electrical interlock logic is as follows: the shaft is forcibly unlocked when any installed module is in the loose adjustable state, and the electromagnetic brake is allowed to lock the shaft only after all modules have locked signals in place.

[0012] Preferably, a modular optional drive component is also configured; the drive component includes a servo motor, a precision planetary reducer, a real-time torque acquisition sensor, and a quick-release buckle flange; the drive component is detachably connected to the rotating shaft via the quick-release flange; the servo motor has a built-in three-segment adaptive torque and speed control program adapted to light load on the front door, medium load on the rear door, and heavy load on the tailgate, and the drive component is linked and synchronously controlled with the locking mechanism.

[0013] Preferably, the fixed base is formed by modular splicing of 6061 industrial aluminum profile; the adjustable foot integrates a level observation bubble meter and anti-loosening self-locking nut; the standardized installation groove is a T-shaped through groove structure, in which multiple types of sensor integrated supports can be slidably mounted; the base is pre-embedded with a closed built-in wiring groove to uniformly store all electrical control signal lines.

[0014] Preferably, the flip frame is welded from 4040 thickened aluminum profile, and the frame plate surface is uniformly reserved with standardized threaded installation interfaces for sliding assembly of each group of module bases; the standard swing angular velocity of the flip frame under no-load is 0.5 rad / s.

[0015] Preferably, the tooling-supporting control system incorporates three exclusive control methods: a gate type adaptive matching method, a coaxiality real-time compensation method, and a torque fluctuation fault discrimination method, to achieve tooling adaptive parameter adjustment, real-time accuracy compensation, and intelligent fault prediction. The coaxiality real-time compensation method dynamically corrects the servo output torque based on the real-time jump data of the angle encoder, offsetting the trajectory error caused by the slight offset of the rotating shaft; the door type adaptive matching method automatically matches the corresponding torque and speed control parameters based on the installation module position and the data collected by the angle sensor; the torque fluctuation fault discrimination method determines hinge wear and bracket loosening faults based on the torque time domain variance threshold; the torque acquisition sensor and the absolute value angle encoder synchronously collect resistance and angle data in real time and upload them to the PLC upper industrial control computer, and automatically generate the angle-resistance correlation detection curve by combining the three exclusive methods, quantitatively evaluate the door sealing performance and hinge rotation durability wear, and automatically output a test report that meets the standards of the car manufacturer.

[0016] Preferably, the tooling also includes an intelligent detection and control method for the durability of automotive door switches; it includes three interlocking operation modes, and the specific steps are as follows: S1, Type Change Debugging Mode: The PLC calls the gate type adaptive matching method to collect data from the displacement and angle sensors of each group of slide table, automatically identifies the gate type to be tested, and synchronously preloads the corresponding torque parameters; at the same time, it cuts off the electromagnetic brake self-locking power supply, locks the servo output, and only opens the installation module adjustment permission; after all modules are locked, it automatically switches to the detection mode. S2, Automated Durability Testing Mode: The system runs in parallel using a real-time coaxiality compensation method and a torque fluctuation fault detection method; the controller dynamically corrects the servo output torque based on the output value to offset the slight coaxial offset of the rotating shaft in real time; when the torque time domain variance exceeds the preset threshold, the bracket / hinge fault is immediately determined, the servo stops, the electromagnetic instantaneous lock is activated, and an audible and visual alarm is triggered; the controller matches the torque program corresponding to the door type, and the servo drives the frame to reciprocate opening and closing. S3, Static Assembly Inspection Mode: After the flip frame swings to the target angle, the electromagnetic brake is continuously de-energized and self-locked, storing the current angle reference value for subsequent horizontal comparison of sealing data of multiple samples, completing the static detection of sealing gap and rubber buffer compression.

[0017] The beneficial effects of this invention are as follows: the tooling is compatible with the front door, rear door and tailgate of automobiles, eliminating the need to configure multiple sets of special tooling for different door types, which can significantly reduce the equipment procurement costs of enterprises, while saving tooling storage space and reducing production and operation costs; according to calculations, after this tooling is put into use, it is expected to save tens of thousands of yuan in experimental costs for each door assembly, with significant economic benefits.

[0018] When switching between different door types, only the position and angle of the adjustable product mounting components need to be adjusted, without disassembling the main tooling body. This shortens the time for a single changeover, significantly improves efficiency, and effectively ensures production and testing cycles.

[0019] The hinge axis assembly's rotation axis is completely aligned with the actual hinge axis of the car door, achieving a 1:1 accurate simulation of the door opening and closing trajectory. This completely solves the problem of trajectory distortion in existing technologies, ensuring the accuracy and reliability of test results for door sealing, hinge durability, etc., and reducing the company's quality risks.

[0020] The high-strength aluminum profile splicing structure provides ample rigidity. Combined with an electromagnetic locking mechanism, the flipping frame can be locked at any angle to prevent shaking during operation, thus improving operational safety and stability. The sealed bearing seat design extends the service life of the tooling.

[0021] It supports both manual and automated operation modes, and can be equipped with drive components as needed to adapt to upgrades to automated inspection lines; the base has a reserved standardized mounting slot, which can be used to install expansion components such as force sensors and angle sensors to meet the needs of different inspection scenarios; the modular design can be adapted to the changes in the gate structure of new vehicle models, extending the service life of the tooling.

[0022] It can reliably connect brackets, rubber products to hinges and controllers (with the controller position remaining unchanged), enabling products such as wiring harness brackets to better adapt to the increasingly stringent assembly and performance requirements of automotive parts, and improving the product qualification rate. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is the front view of the present invention; Figure 3 This is a side view of the present invention; Figure 4 yes Figure 1 A magnified schematic diagram of part A in the middle; Figure 5 yes Figure 2 A magnified schematic diagram of the partial structure of B in the middle section; Figure 6 This is a schematic diagram of the detection method of the present invention; Figure 7 This is a schematic diagram of the gate type adaptive matching method of the present invention; Figure 8 This is a schematic diagram of the coaxiality real-time compensation method of the present invention; Figure 9 This is a schematic diagram of the torque fluctuation time-domain variance fault detection process of the present invention. Detailed Implementation

[0024] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0025] Example: refer to Figure 1-5A universal door opening and closing fixture suitable for automobile front doors, rear doors, and tailgates, characterized in that it includes a fixed base 1, a flipping frame 5, a hinge shaft assembly, an adjustable product mounting assembly 7, and a locking mechanism 8; the fixed base 1 serves as the load-bearing reference for the entire machine, with adjustable feet 2 at the bottom, and standardized mounting grooves 9 formed on the base plate surface; the hinge shaft assemblies are arranged in pairs at the left and right ends of the fixed base 1, including bearing seats 3 and through-type rotating shafts 4, with the center line of the rotating shaft 4 serving as a reference axis for simulating the door hinge, replicating the actual swing center of the entire vehicle door; the flipping frame 5 is connected to the connecting bracket 6 and... The rotating shaft 4 is rigidly fixed and can swing back and forth in the range of 0°-90° along the axis of the rotating shaft 4 to simulate the complete opening and closing motion of the car door; the adjustable product mounting component 7 is provided with at least three sets of independent mounting modules, each set of modules has multi-directional displacement and multi-angle posture composite adjustment capabilities, adapting to the different mounting hole positions and tilted assembly postures of front doors, side rear doors, and hatchback tailgates of different models; each set of mounting modules includes a base 71, a linear slide 72, an angle adjustment plate, and a locking bolt 73; one set of mounting modules is rigidly fixed on the fixed base 1, and the mounting reference does not rotate synchronously with the flip frame 5; The locking mechanism 8 is mounted on the end of the rotating shaft 4 and can lock the rotating shaft 4 at any swing angle of the flipping frame 5. The locking mechanism 8 integrates an angle acquisition element and establishes an electrical interlock control logic with the adjustable product mounting assembly 7. The bottom of the bearing housing 3 is equipped with a wedge-shaped fine-adjustment positioning block. The bearing housing 3 adopts a fully sealed dustproof integrated shell and carries a double-row self-aligning roller bearing inside. The rotating shaft 4 and the connecting bracket 6 use a flat key fit interference sleeve to achieve backlash-free transmission. The surface of the rotating shaft 4 is nitrided for wear resistance and hardening.

[0026] Each set of installation modules includes a linear slide 72 comprising a transverse translation slide and a longitudinal lifting slide. The transverse slide has an adjustment range of 0-200mm, and the longitudinal lifting slide has an adjustment range of 0-80mm. The angle adjustment plate integrates a pitch pivot and a 360° horizontal rotary table, with a pitch adjustment range of ±90°. The locking bolt 73 is equipped with a disc spring pre-tightening locking structure, providing a constant locking torque of 15N·m. The three sets of installation modules are an upper hinge installation module, a lower hinge installation module, and a base-fixed lock block bracket module. The base-fixed lock block bracket module is used to clamp the door lock block, wiring harness fixing bracket, rubber buffer pad, and door controller, keeping the installation reference stationary throughout the entire process. The locking mechanism 8 is a multi-plate electromagnetic brake assembly, and the angle acquisition element is a high-precision absolute angle encoder. The electromagnetic brake adopts a power-off self-locking structure, with a static holding torque ≥80 N·m, an unlocking response time ≤0.1s, and a locking response time ≤0.05s. The electrical interlock logic is as follows: when any installed module is in the loose adjustable state, the rotating shaft 4 is forcibly unlocked; the electromagnetic brake is allowed to lock the rotating shaft 4 only after all modules have locked signals in place. A modular optional drive component is also configured; the drive component includes a servo motor, a precision planetary reducer, a real-time torque acquisition sensor, and a quick-release buckle flange; the drive component is detachably connected to the rotating shaft 4 via the quick-release flange; the servo motor has a built-in three-segment adaptive torque and speed control program adapted to light load on the front door, medium load on the rear door, and heavy load on the tailgate, and the drive component is linked and synchronously controlled with the locking mechanism 8.

[0027] The fixed base 1 is modularly assembled from 6061 industrial aluminum profiles; the adjustable feet 2 integrate a level observation bubble meter and a self-locking nut; the standardized mounting slot 9 is a T-shaped through-slot structure, in which multiple types of sensor integrated supports can be slidably mounted; the base 1 has a pre-embedded closed built-in wiring channel to uniformly accommodate all electrical control signal lines. The flip frame 5 is welded from 4040 thickened aluminum profiles, and the frame plate surface has uniformly reserved standardized threaded installation interfaces for the sliding assembly of each group of module bases 71; the standard no-load swing angular velocity of the flip frame 5 is 0.5 rad / s. The tooling-supporting control system incorporates three proprietary control methods: an adaptive door type matching method, a real-time coaxiality compensation method, and a torque fluctuation fault detection method. These methods enable adaptive parameter adjustment, real-time accuracy compensation, and intelligent fault prediction. The real-time coaxiality compensation method dynamically corrects the servo output torque based on real-time encoder fluctuation data, offsetting trajectory errors caused by minute shaft offsets. The adaptive door type matching method automatically matches corresponding torque and speed control parameters based on the installation module position and angle sensor data. The torque fluctuation fault detection method determines hinge wear and bracket loosening faults based on the torque time-domain variance threshold. Torque acquisition sensors and absolute angle encoders synchronously collect resistance and angle data in real-time and upload them to the PLC host computer. Combined with the three proprietary methods, this automatically generates angle-resistance correlation detection curves, quantitatively evaluating door sealing performance and hinge rotation durability loss, and automatically outputting test reports that meet automotive manufacturer standards.

[0028] This also includes a vehicle door switch durability intelligent detection and control method for this tooling; it includes three interlocking operation modes, and the specific steps are as follows: S1, Type Change Debugging Mode: The PLC calls the gate type adaptive matching method to collect data from the displacement and angle sensors of each group of slides, automatically identifies the gate type to be tested, and synchronously preloads the corresponding torque parameters; at the same time, it cuts off the electromagnetic brake self-locking power supply, locks the servo output, and only opens the installation module adjustment permission; after all modules lock signal feedback, it automatically switches to the detection mode; S2, Automated Durability Detection Mode: The system runs the coaxiality real-time compensation method and torque fluctuation fault discrimination method in parallel; the controller dynamically corrects the servo output torque according to the output value, and real-time offsets the slight coaxial offset of the rotating shaft; when the torque time domain variance exceeds the preset threshold, it immediately judges the bracket / hinge fault, the servo stops, the electromagnetic instantaneous locks, and an audible and visual alarm is triggered; the controller matches the torque program corresponding to the gate type, and the servo drives the frame to reciprocate opening and closing; S3, Static Assembly Inspection Mode: After the flip frame swings to the target angle, the electromagnetic brake is continuously de-energized and self-locked, storing the current angle reference value for subsequent horizontal comparison of sealing data of multiple samples, completing the static detection of sealing gap and rubber buffer compression.

[0029] Specifically, the connection relationships of each component are as follows: The fixed base is structurally designed using modular splicing of 6061-T6 high-strength industrial aluminum profiles. Its overall dimensions are 1500mm × 800mm × 200mm, with a static load capacity of 1000kg, meeting the assembly requirements of heavy-duty SUV tailgates. Four adjustable feet are symmetrically arranged at the four corners of the base, each with an internal M16 lifting threaded rod, allowing for a lifting adjustment range of 0-50mm. A high-precision level bubble level is embedded in the top, along with a matching threaded anti-loosening self-locking nut. Two 15mm wide, continuous T-shaped standardized mounting slots are parallel to each other on the upper surface of the base. These slots allow for the sliding of sensor mounting supports, accommodating three mainstream industry-standard data acquisition sensors: tensile / compression, displacement, and noise. The base features an internal enclosed interlayer cable management channel, internally storing all electrical control cables and avoiding common workshop malfunctions such as cable pull, wear, and breakage during the reciprocating motion of the door opening and closing. The front end of the base has a rigidly welded fixed locking block bracket module, with no mechanical connection to the flip frame. The floor of the OEM testing workshop generally has a flatness deviation of 2-5mm. Conventional tooling does not have a large range of leveling feet, and the hinge coaxiality continues to deviate after long-term use. The built-in cable tray design solves the problem of exposed wire harnesses due to oil stains and dust corrosion in the workshop. The base static bracket is specially matched to the stress simulation standard of the wire harness of the whole vehicle off-line testing, which is different from the tooling structure of all brackets on the market that rotate synchronously with the door.

[0030] The structural design of the flip frame: It is formed by welding 4040 thickened industrial aluminum profiles, with overall dimensions of 1200mm×600mm×100mm and a profile wall thickness of 3mm. Its bending load-bearing capacity meets the long-term reciprocating test requirements of a 100kg tailgate. Symmetrical 304 stainless steel connecting brackets are welded to the left and right sides of the frame, with high-precision assembly holes in the center of the brackets. A rigid, gapless connection to the rotating shaft is achieved through a flat key and interference sleeve. The frame's swing range is strictly limited to 0°~90°, matching the maximum opening angle of the national standard vehicle door, with a standard no-load swing angular velocity of 0.5rad / s. Multiple sets of T-shaped threaded mounting interfaces are densely distributed on the upper and lower plates of the frame, allowing each module base to slide and be roughly positioned along the long grooves of the interfaces. Traditional steel plate flip frames weigh over 180kg, which increases hinge shaft wear with long-term reciprocating motion. This invention's lightweight aluminum profile frame reduces weight by 62%, extending the hinge shaft's service life by millions of cycles. The gapless flat key transmission eliminates swing play, and the angle encoder collects data without error, meeting the national standard's mandatory requirement of ±0.1° angle acquisition accuracy.

[0031] The hinge shaft assembly is symmetrically arranged at both ends of the base and consists of three main units: a sealed double-row self-aligning roller bearing housing, a 45# tempered and nitrided integrated shaft, and a wedge-shaped fine-tuning positioning block. The bearing housing has a fully sealed dustproof shell, internally equipped with double-row self-aligning roller bearings and axial limit rings, limiting the radial runout of the shaft to ≤0.02mm and the axial movement to ≤0.01mm. Each bearing housing is independently equipped with a wedge-shaped fine-tuning positioning block at the bottom, with a built-in micrometer precision adjusting bolt, allowing for a single-end vertical adjustment range of 0~30mm. The shaft has an overall length of 1400mm, a diameter of 25mm, and a surface nitriding treatment with a hardness of HV550, making it wear-resistant and corrosion-resistant. Commercially available simple general-purpose tooling uses only ordinary deep groove ball bearings, which cannot withstand the lateral load of the tailgate. Long-term testing shows that the bearing clearance has increased and the axis misalignment exceeds the standard. Double-row self-aligning roller bearings can simultaneously withstand radial and lateral bidirectional door loads, and are suitable for two different stress conditions of side doors and tailgates. Wedge-shaped micro-adjustment blocks can simultaneously calibrate the height of the bearings at both ends, so that the center line of the rotating shaft is completely coincident with the line connecting the two points of the upper and lower hinges of the whole vehicle, and the axis deviation is controlled within the national standard allowable within 0.02mm.

[0032] The adjustable product installation assembly features three physically independent, functionally differentiated installation modules: two modules are mounted on the flip frame and swing with the door, while one module is rigidly fixed to the base and remains stationary throughout. Each swing module integrates a base, a 0-200mm horizontal linear slide, a 0-80mm vertical lifting slide, a ±90° pitch + 360° horizontal rotation composite angle adjustment plate, and M8 disc spring locking bolts with a uniform locking torque of 15 N·m. The three modules have the following functions: Upper hinge module: focuses on longitudinal lifting and large tilt angle adjustment, and is adapted to the upper forward tilting installation point of the tailgate; Lower hinge module: focuses on lateral translation and horizontal rotation, adapting to the lateral offset of the lower door hinge of different wheelbase models; Base lock block module: non-sliding adjustment structure, fixing the door lock, wiring harness bracket, and controller, with the reference point remaining stationary throughout.

[0033] The industry generally believes that a single-flip frame cannot simultaneously accommodate the assembly postures of 0° side doors and 30°~45° tail doors. This invention's composite angle adjustment plate can continuously and steplessly adjust the forward tilt angle from 0° to 45°. Combined with a dual-axis slide table, it can adapt to different vehicle models' hole spacing. No frame or bracket needs to be replaced; the three types of door bodies can be switched simply by adjusting the module. The disc spring locking structure solves the common problem of bracket loosening caused by long-term vibration in the workshop. It has passed 100,000 durability tests without angular slippage and does not require mid-process bolt tightening, reducing the frequency of production line downtime.

[0034] The locking mechanism is designed as follows: multiple wet electromagnetic brakes are mounted on the right end of the shaft, with a built-in absolute angle encoder. The self-locking torque after power failure is ≥80N・m, the unlocking response is ≤0.1s, and the locking response is ≤0.05s. The brake signal line and the locking pressure sensors of each module are uniformly connected to the PLC industrial control computer to form a closed-loop electrical interlock logic.

[0035] Modular optional drive component structure design: servo motor + precision planetary reducer integrated unit, output end equipped with real-time torque acquisition sensor, front end equipped with quick-release buckle flange, disassembly and assembly can be completed by a single person in 5 minutes; PLC has built-in three-segment adaptive torque program for front door light load (0~20N・m), rear door medium load (20~50N・m), and tail door heavy load (50~80N・m), and the switching speed is steplessly adjustable from 0.1 to 1 rad / s; motor operation is synchronized with electromagnetic brake.

[0036] Overall machine electronic control operation mode Type change and debugging mode: PLC locks servo output, forcibly unlocks electromagnetic brake, only opens module adjustment permissions, and automatically jumps to detection mode after all module locking signals are uploaded; adapts to workshop door type switching operation process; automated durability mode: matches the corresponding door type torque program, servo reciprocating drive, module loosening immediately stops and locks with alarm, adapts to continuous durability testing on production line; static detection mode: manually swings to a 45° standard detection angle, brake continuously self-locks, completes static measurement of seals and rubber parts, matches the off-line sampling inspection specifications for parts.

[0037] Referring to Figures 6 and 7, as one implementation method, the specific method of gate type adaptive matching is as follows: 1. Input values: X value of the horizontal slide displacement sensor of the three sets of installation modules, Y value of the vertical lifting slide, and θ value of the composite angle plate pitch angle; 2. Core computational logic (original judgment logic): Construct a three-dimensional feature judgment model F(X,Y,θ), and divide the threshold intervals for three types of gate features: Front door determination interval: X∈[900,1200], Y∈[850,980], θ∈[-5°,5°]; Backdoor determination interval: X∈[950,1250], Y∈[820,950], θ∈[-10°,10°]; The hatchback tailgate determination interval is: X∈[1250,1400], Y∈[980,1150], θ∈[25°,45°]. The PLC collects three sets of real-time data (X, Y, and θ) and inputs them into the system. It then automatically matches the gate type and retrieves the corresponding torque range T, opening and closing speed V, and reciprocating cycle C, providing a complete set of control parameters without requiring manual input.

[0038] Linked execution logic: After identifying the gate type, the corresponding servo control program is automatically loaded, and the electromagnetic brake locking torque matching parameters are switched synchronously. If a parameter change across ranges is detected (gate type change), an automatic pop-up window prompts to switch to the gate type change mode. This method eliminates the need for manual table lookup and parameter modification, reducing the gate type change parameter matching time from 5 minutes to 0.5 seconds, eliminating manual parameter setting errors, and breaking the traditional manual parameter adjustment mode of tooling.

[0039] refer to Figure 8 As one implementation method, the specific method for real-time coaxiality compensation is as follows: 1. Input quantities: Real-time radial runout difference ΔS of the absolute angle encoder at both ends of the shaft, and real-time output torque T0 of the servo. 2. Core Compensation Calculation Formula (Original Correction Model) Corrected Torque Output Value: T1=T0+k・ΔS, where k is the coaxial offset compensation coefficient, assigned by the gate type weight by the gate type adaptive method (front gate k=0.08, rear gate k=0.12, tail gate k=0.20, the tail gate has a larger self-weight and a higher offset compensation weight); the PLC collects ΔS every 10ms to dynamically correct the servo output torque and offset the swing trajectory offset caused by the slight runout of the rotating shaft; at the same time, the average value of ΔS within 1 hour is accumulated. If the average value is >0.02mm, an automatic pop-up window prompts manual stop to calibrate the wedge positioning block.

[0040] In durability testing, minor offsets in bearings and slides do not require mid-process calibration and trajectory error can be corrected dynamically in real time, reducing dynamic detection error from more than 10% to less than 1%, overcoming the defect of continuous accuracy decay after static calibration of traditional tooling.

[0041] refer to Figure 9 As one implementation method, the specific method for determining the time-domain variance of torque fluctuation faults is as follows: Input: A timing array [T1, T2, ..., T] representing all torque acquisitions within a complete 0° → 90° opening / closing cycle. n ]; Calculation method: Step 1: The average torque value in a single cycle satisfies: .

[0042] Step 2: The time-domain variance satisfies: .

[0043] Step 3: Dual threshold layer discrimination (layer judgment logic, normal fluctuation / rubber strip aging / bracket / hinge mechanical failure); D1 and D2 are thresholds set according to the on-site conditions during the judgment process.

[0044] Low threshold D < D1: Under normal operating conditions, there is only slight fluctuation in the resistance of the sealing strip, and no alarm is triggered. D1≤D<D2: Rubber strip aging warning, only records data, does not interrupt the test; D≥D2: If a major fault is determined to be loose mounting bracket or worn hinge bearing, the servo stop, electromagnetic lock, and audible and visual alarm will be triggered immediately. Traditional tooling only provides single torque upper and lower limit alarms, which cannot distinguish fault types and has a high false alarm rate. This method uses time-domain variance hierarchical discrimination to greatly reduce the false alarm rate, achieve fault classification and prediction, avoid unnecessary downtime, and reduce production line time losses.

[0045] Specifically, as one possible implementation method, the algorithm initialization steps after tooling calibration are as follows: 1) The mechanical system completes the coaxial calibration of the wedge hinge and connects all sensors for slide displacement, angle, dual-end encoder, and torque. 2) Upon power-up, the PLC automatically initializes the gate type adaptive matching algorithm, inputs the X / Y / θ feature thresholds for the three types of gate types, loads the gate type weight coefficient table for the coaxial compensation algorithm, and writes the torque variance dual fault thresholds D1 and D2. 3) Manually drag the frame back and forth from 0° to 90° once, and the algorithm collects the no-load reference torque to establish a basic compensation model.

[0046] Front door assembly process Step 1: Loosen the module locking bolts and adjust the horizontal X=1050mm, the vertical Y=920mm, and the pitch θ=0°; Step 2: All sensor data are transmitted to the door type adaptive matching algorithm in real time. F(1050,920,0) falls into the front door range and is automatically identified as the front door in 0.5s. The algorithm automatically retrieves the light load torque of 0~20N・m, speed of 0.3rad / s, and compensation coefficient k=0.08. Step 3: The algorithm synchronously sends parameters to the servo, switches the detection mode, and starts the coaxiality real-time compensation algorithm. Every 10ms, it collects the runout difference ΔS at both ends of the shaft to dynamically correct the output torque. Step 4: Manual 45° static inspection, algorithm stores the current angle reference, batch samples can be automatically compared with sealing gap data.

[0047] Tailgate switching process (1) In the model change mode, loosen the bolts and adjust X=1320mm, Y=1080mm, θ=36°; (2) The door type algorithm determines the tailgate in real time, automatically loads the torque to 50-80 N·m, and automatically switches the compensation coefficient k=0.20 (the tailgate has a larger self-weight, and the offset compensation weight is increased). (3) During the durability test, the coaxial compensation algorithm continuously offsets the axis offset caused by the slight wear of the bearing, and the torque variance algorithm collects the torque timing in real time. If D>D2, an audible and visual alarm is immediately triggered and the shaft is electromagnetically locked.

[0048] Combining servo-driven door switching methods: The first step is to change the tailgate type and adjust it. The tailgate type adaptive algorithm automatically identifies and loads the complete set of control parameters. The second step is to start the endurance program. The gate algorithm outputs the k value, the coaxial compensation algorithm corrects the servo torque in real time, and the torque variance algorithm calculates the time domain variance cycle by cycle. The three sets of algorithms communicate and operate in parallel. The third step is that under normal operating conditions, D < D1, there is no alarm, and the cycle continues for 100,000 times. The fourth step involves endurance testing for 60,000 cycles. If the lower module becomes slightly loose and the torque timing fluctuation increases, the algorithm calculates that D≥D2 and immediately issues a stop command. The servo is powered off, the electromagnetic brake is locked, and an audio-visual warning is issued indicating "mechanical failure of the mounting bracket." The fault torque curve is stored simultaneously for engineers to trace the source. The fifth step is fault repair and restart. The algorithm re-acquires the idle reference and resumes the compensation calculation without the need for manual recalibration of coaxiality.

[0049] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A universal door opening and closing fixture applicable to the front door, rear door, and tailgate of an automobile, characterized in that, Includes a fixed base (1), a flip frame (5), a hinge shaft assembly, an adjustable product mounting assembly (7), and a locking mechanism (8); The fixed base (1) serves as the bearing reference for the entire machine, and is equipped with adjustable feet (2) at the bottom. The base plate has a standardized installation groove (9). The hinge shaft assembly is arranged in pairs at the left and right ends of the fixed base (1), including bearing seat (3) and through-type rotating shaft (4). The center line of the rotating shaft (4) serves as the reference axis of the simulated door hinge, replicating the real swing center of the whole vehicle door. The flipping frame (5) is rigidly connected to the rotating shaft (4) via the connecting bracket (6), and can swing back and forth along the axis of the rotating shaft (4) in the range of 0°-90° to simulate the complete opening and closing motion of the car door; The adjustable product mounting assembly (7) is provided with at least three sets of independent mounting modules. Each set of modules has multi-directional displacement and multi-angle posture composite adjustment capabilities to adapt to the different mounting hole positions and tilted assembly postures of front doors, side rear doors and hatchback tail doors of different models. Each set of mounting modules includes a base (71), a linear slide (72), an angle adjustment plate and a locking bolt (73). One set of mounting modules is rigidly fixed on the fixed base (1), and the mounting reference does not rotate synchronously with the flip frame (5). The locking mechanism (8) is mounted on the end of the rotating shaft (4) and can lock the rotating shaft (4) at any swing angle of the flip frame (5); the locking mechanism (8) integrates an angle acquisition element and establishes an electrical interlock control logic with the adjustable product mounting assembly (7).

2. A universal door opening and closing fixture applicable to the front door, rear door, and tailgate of an automobile, as described in claim 1, characterized in that, The bearing housing (3) is equipped with a wedge-shaped fine-adjustment positioning block at the bottom. The bearing housing (3) adopts a fully sealed dustproof integrated shell and is equipped with a double-row self-aligning roller bearing. The shaft (4) and the connecting bracket (6) adopt a flat key fit interference sleeve to achieve backlash-free transmission. The surface of the shaft (4) is nitrided for wear resistance and hardening.

3. A universal door opening and closing fixture applicable to the front door, rear door, and tailgate of an automobile, as described in claim 1, characterized in that, Each set of installation modules includes a linear slide (72) comprising a transverse translation slide and a longitudinal lifting slide. The transverse slide has an adjustment range of 0-200mm, and the longitudinal lifting slide has an adjustment range of 0-80mm. The angle adjustment plate integrates a pitch pivot and a 360° horizontal rotary table, with a pitch adjustment range of ±90°. The locking bolt (73) is equipped with a disc spring pre-tightening locking structure with a constant locking torque of 15N·m.

4. A universal door opening and closing fixture applicable to the front door, rear door, and tailgate of an automobile, as described in claim 1, characterized in that, The three sets of installation modules are the upper hinge installation module, the lower hinge installation module, and the base-fixed lock block bracket module. The base-fixed lock block bracket module is used to clamp the door lock block, the wiring harness fixing bracket, the rubber buffer pad, and the door controller, keeping the installation reference stationary throughout the process.

5. A universal door opening and closing fixture applicable to the front door, rear door, and tailgate of an automobile, as described in claim 1, characterized in that, The locking mechanism (8) is a multi-plate electromagnetic brake assembly, and the angle acquisition element is a high-precision absolute angle encoder; the electromagnetic brake adopts a power-off self-locking structure, with a static holding torque ≥80N・m, an unlocking response time ≤0.1s, and a locking response time ≤0.05s; The electrical interlock logic is as follows: when any installed module is in the loose adjustable state, the shaft (4) is forcibly unlocked; the electromagnetic brake is allowed to lock the shaft (4) only after all modules have locked signals in place.

6. A universal door opening and closing fixture applicable to the front door, rear door, and tailgate of an automobile, as described in claim 1, characterized in that, It is also equipped with a modular optional drive component; the drive component includes a servo motor, a precision planetary reducer, a real-time torque acquisition sensor, and a quick-release buckle flange; the drive component is detachably connected to the rotating shaft (4) via the quick-release flange; the servo motor has a built-in three-segment adaptive torque and speed control program adapted to the front door light load, the rear door medium load, and the tail door heavy load, and the drive component is linked and synchronously controlled with the locking mechanism (8).

7. A universal door opening and closing fixture applicable to the front door, rear door, and tailgate of an automobile, as described in claim 1, characterized in that, The fixed base (1) is formed by modular splicing of 6061 industrial aluminum profile; the adjustable foot (2) integrates a horizontal observation bubble meter and a self-locking nut; the standardized installation groove (9) is a T-shaped through groove structure, in which multiple types of sensor integrated supports can be slidably mounted; the base (1) has a pre-embedded closed built-in wiring groove to uniformly store all electrical control signal lines.

8. A universal door opening and closing fixture applicable to the front door, rear door, and tailgate of an automobile, as described in claim 1, characterized in that, The flip frame (5) is welded from 4040 thickened aluminum profiles. The frame plate is uniformly reserved with standardized threaded installation interfaces for sliding assembly of each group of module bases (71). The standard swing angular velocity of the flip frame (5) under no-load is 0.5 rad / s.

9. A universal door opening and closing fixture applicable to the front door, rear door, and tailgate of an automobile, as described in claim 6, characterized in that, The tooling-supporting control system has three exclusive control methods built-in: gate type adaptive matching method, coaxiality real-time compensation method, and torque fluctuation fault discrimination method, which realize tooling adaptive parameter adjustment, real-time accuracy compensation, and intelligent fault prediction. The coaxiality real-time compensation method dynamically corrects the servo output torque based on the real-time jump data of the angle encoder, thus offsetting the trajectory error caused by the slight offset of the rotating shaft; the door type adaptive matching method automatically matches the corresponding torque and speed control parameters based on the installation module position and the data collected by the angle sensor; the torque fluctuation fault discrimination method determines hinge wear and bracket loosening faults based on the torque time domain variance threshold. Torque acquisition sensors and absolute angle encoders synchronously collect resistance and angle data in real time and upload them to the PLC upper industrial control computer. Combined with three exclusive methods, angle-resistance correlation detection curves are automatically generated to quantitatively evaluate the door sealing performance and hinge rotation durability wear, and automatically output test reports that meet the standards of car manufacturers.

10. A universal door opening and closing fixture applicable to the front door, rear door, and tailgate of an automobile, as described in any one of claims 1-9, characterized in that, It also includes a vehicle door switch durability intelligent detection and control method for this tooling; it includes three interlocking operation modes, and the specific steps are as follows: S1, Type Change Debugging Mode: The PLC calls the gate type adaptive matching method to collect data from the displacement and angle sensors of each group of slide table, automatically identifies the gate type to be tested, and synchronously preloads the corresponding torque parameters; at the same time, it cuts off the electromagnetic brake self-locking power supply, locks the servo output, and only opens the installation module adjustment permission; after all modules are locked, it automatically switches to the detection mode. S2, Automated durability testing mode: The system operates in parallel with a real-time coaxiality compensation method and a torque fluctuation fault detection method; The controller dynamically corrects the servo output torque based on the output value, and compensates for the slight coaxial offset of the rotating shaft in real time; when the torque time domain variance exceeds the preset threshold, the bracket / hinge fault is immediately determined, the servo stops, the electromagnetic instantaneous lock is activated, and an audible and visual alarm is triggered; the controller matches the torque program corresponding to the door type, and the servo drives the frame to reciprocate opening and closing. S3, Static Assembly Inspection Mode: After the flip frame swings to the target angle, the electromagnetic brake is continuously de-energized and self-locked, storing the current angle reference value for subsequent horizontal comparison of sealing data of multiple samples, completing the static detection of sealing gap and rubber buffer compression.

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