Method and device for the automated application of an adhesive element to a vehicle component

Abstract

Method for the automated application of an adhesive element (1) to a vehicle component (2), wherein, by means of several joining dies (5.1 to 5.5) of a joining tool (5), an adhesive element (1) is each detached from a carrier element (3) and subsequently applied to the vehicle component (2), characterized in that the carrier element (3) with the adhesive elements (1) is positioned on a storage surface (7) and fixed on the storage surface (7) by generating a vacuum between the storage surface (7) and the carrier element (3), and that subsequently, by means of the joining dies (5.1 to 5.5), an adhesive element (1) is each removed from the carrier element (3) by generating a vacuum between the joining die (5.1 to 5.5) and the adhesive element (1) and applied to the vehicle component (2).

Description

[0001] The present invention relates to a method for the automated application of an adhesive element to a vehicle component, wherein, by means of several joining dies of a joining tool, an adhesive element is each detached from a carrier element and then applied to the vehicle component.

[0002] The invention further relates to a device for carrying out the method.

[0003] It is generally known from the prior art that openings in body components are used in the manufacture of a vehicle body to carry out various work steps, such as fixing the body components and implementing corrosion protection measures. When carrying out corrosion protection work, the openings are intended for supplying paint during dip painting and / or as drain holes for excess paint. Alternatively or additionally, wax is supplied for cavity preservation and excess wax is removed via the openings. To achieve a low noise level and a watertight seal for the vehicle, the openings are closed again in the further production process. The openings are closed and sealed with plugs or adhesive elements, also called adhesive pads.

[0004] Such an adhesive element is known from DE 10 2008 050 772 A1. The adhesive element is formed in multiple layers from a carrier film and a self-adhesive damping compound, wherein the damping compound is butyl rubber. A paintable corrosion protection layer is applied to at least one side of the carrier film facing away from the damping compound. The adhesive element is made of aluminum, an aluminum alloy, or polyethylene terephthalate.

[0005] Methods and devices for the automated application of adhesive elements for closing body openings are also known from the prior art. Such a device comprises a robot for the fully automated application of the adhesive elements, which includes so-called suction plungers. By means of these plungers, the adhesive elements can be detached from a carrier element by generating a vacuum between the suction plunger and the adhesive element, and then applied to the body component with a defined contact pressure to close the body openings.

[0006] As can be read in the Wikipedia article on the search term "vacuum component" or on the website "https: / / automationspraxiss .industrie.de / news / bildverarbeitungoptimiert-die produktion / ", it is also known from the state of the art to use vacuum grippers in the handling of body components in the manufacture of vehicles.

[0007] The invention is based on the objective of providing a method for the automated application of an adhesive element to a vehicle component that is improved compared to the prior art, and a device for carrying out the method.

[0008] With regard to the method, the problem is solved according to the invention by the features specified in claim 1 and with regard to the device by the features specified in claim 6.

[0009] Advantageous embodiments of the invention are the subject of the dependent claims.

[0010] In a process for the automated application of an adhesive element to a vehicle component, an adhesive element is detached from a carrier element by means of several joining dies of a joining tool and then applied to the vehicle component.

[0011] According to the invention, the carrier element with the adhesive elements is positioned on a storage surface and fixed on the storage surface by generating a vacuum between the storage surface and the carrier element, wherein subsequently, by means of the joining dies, an adhesive element is removed from the carrier element by generating a vacuum between the joining die and the adhesive element and applied to the vehicle component.

[0012] This advantageously results in simplified assembly of the adhesive elements on the vehicle component, which is characterized by short cycle times, low manual effort and consequently low costs.

[0013] The inventive method further enables a defined force to be applied to the adhesive element, resulting in a defined bond between the adhesive element and the vehicle component, due to the automated application using the joining tool. This achieves reproducible adhesion to the vehicle component. Additionally, closing an opening with the adhesive element is facilitated because, thanks to possible camera-controlled positioning of the joining dies, a centered arrangement of the adhesive element relative to the opening is possible even if the adhesive element is not translucent or transparent.

[0014] Furthermore, compared to manual application, there are ergonomic improvements for people processing the adhesive element, as overhead work and work in hard-to-reach positions are automated and carried out without manual effort.

[0015] Exemplary embodiments of the invention are explained in more detail below with reference to drawings.

[0016] This shows: Fig. 1 schematically a bonding element for application to a vehicle component, Fig. 2 schematically several adhesive elements applied to a carrier element, Fig. 3 schematically a device according to the invention for applying the adhesive elements to the vehicle component and the vehicle component in a sectional view, Fig. 4 schematically a cross-section of a joining tool of the device according to 3 and the vehicle component and Fig. 5 schematically shows the joining tool according to 4 in a top view.

[0017] Corresponding parts are marked with the same reference symbols in all figures.

[0018] In Fig. Figure 1 shows an adhesive element 1 which is formed in multiple layers from a carrier layer 1.1 and a self-adhesive damping compound 1.2.

[0019] The adhesive element 1 is intended for sealing openings O of a vehicle component 2, in particular an outer body component, as shown in more detail in Figures 3 and 4. The vehicle component 2 can be either a body component or a complete vehicle body.

[0020] The carrier layer 1.1 is made of a rigid material and exhibits high strength. The strength of the carrier layer 1.1 depends on various factors: Firstly, it depends on the strength of the material itself from which the carrier layer 1.1 is made. A second influencing factor is the specific shape of the adhesive element 1, which determines the area moment of inertia. For example, a round adhesive element 1, in which the edges of the carrier layer 1.1 are bent over, for instance by a stamping process, exhibits higher strength than a round adhesive element with a flat geometry, assuming the same material, due to its higher area moment of inertia. By selecting a suitable manufacturing process, such as a rotary stamping process, a carrier layer with a bent edge is produced, which leads to the desired increase in the area moment of inertia.Since the bending stiffness of the support layer is the product of the material's modulus of elasticity and the area moment of inertia, the stiffness of the support layer 1.1 can thus be specifically influenced via these two parameters.

[0021] In a particularly preferred embodiment, the support layer 1.1 is formed from a so-called 5xxx aluminum alloy, which has a magnesium content of 0.2% to 6.2%. The 5xxx aluminum alloy is characterized by high strength, which is in the range of 100 N / mm². 2 up to 450 N / mm 2 lies.

[0022] As an alternative to using the 5xxx aluminum alloy, the support layer 1.1 is made of stainless steel, steel or another rigid metal.

[0023] Due to this high strength, the adhesive element 1 is particularly suitable for closing openings O on vehicle components 2 and is particularly easy to apply to them.

[0024] The material from which the carrier layer 1.1 is formed is further characterized by high corrosion resistance, so that corrosion of the adhesive element 1 and resulting leaks at the opening O of the vehicle component 2 to be sealed are avoided.

[0025] To further improve corrosion resistance, a corrosion protection layer 1.3 is applied to both sides of the substrate layer 1.1. The corrosion protection layer 1.3 is formed in particular by a paint or a film, wherein the paint is preferably applied to the substrate layer 1.1 as a so-called KTL replacement coating (KTL = cathodic dip coating).

[0026] Such KTL replacement coatings or KTL paint systems are special paints optimized for their subsequent application. They are based on polyurethane, epoxy, melamine, polyester, and / or a mixture thereof. Additives intended to improve the paint's elasticity, such as polyamide, are preferably mixed into one layer of the paint. This ensures the subsequent elasticity or flexibility of the adhesive element 1, allowing it to be preferably adapted to the respective vehicle component 2.

[0027] The corrosion protection layer 1.3 formed from the paint or film can preferably be applied to the carrier layer 1.1 in a coil coating process, which is also known as coil coating or continuous metal coil coating.

[0028] In particular, the corrosion protection layer 1.3 is made of polyurethane.

[0029] Due to the corrosion protection layer 1.3, the adhesion of the damping compound 1.2, which is made of butyl rubber, to the carrier layer 1.1 is further improved. In addition, the corrosion protection layer 1.3 is paintable, so that the adhesive element 1 can be easily painted with the vehicle's color.

[0030] To ensure continued adhesion of the corrosion protection layer 1.3 to the substrate layer 1.1, an adhesion promoter layer 1.4 is applied to both sides of the substrate layer 1.1. The adhesion promoter layer 1.4 is preferably chromium-free and is applied as a thin liquid film to both sides of the substrate layer 1.1. The adhesion promoter layer 1.4 is, for example, made of Alodine. ® Henkel's NR 1453 was formed. This adhesion promoter layer 1.4 is also characterized by the fact that it provides corrosion protection for the carrier layer 1.1.

[0031] In another embodiment of the adhesive element 1, the carrier layer 1.1 is made of a high-strength plastic. Corrosion of the carrier layer 1.1 is therefore impossible, so that at least the corrosion protection layer 1.3 can be omitted. Advantageously, an adhesion promoter layer 1.4 is applied to at least one side of the plastic, thus improving the adhesion of paint applied to the carrier layer 1.1. This allows the adhesive element 1 to be easily painted over and visually adapted to the vehicle's color, so that the vehicle's appearance is not negatively affected.

[0032] The illustrated multi-layered structure of the adhesive element 1 with the carrier layer 1.1 formed from the rigid material and the damping mass 1.2 formed from butyl rubber is characterized by particularly good acoustic properties, so-called damping properties, and simple and flexible processing.

[0033] The damping compound 1.2, formed from butyl rubber, is characterized by its ability to be permanently applied to sheets lubricated with corrosion protection oil. The adhesive element 1 is also characterized by chemical resistance to water, alcohols, dilute acids, and alkalis.

[0034] In order to prevent electrical conduction between the carrier layer 1.1 and the vehicle component 2 via the damping mass 1.2 and thus corrosion of the carrier layer 1.1 and / or the vehicle component 2, the corrosion protection layer 1.3 introduced between the carrier layer 1.1 and the damping mass 1.2 is designed to be electrically insulating.

[0035] Alternatively or in addition to the application of the electrically insulating corrosion protection layer 1.3, a butyl rubber can be used to reduce the electrical conductivity of the damping compound 1.2, from which certain fillers, such as carbon black, have been removed.

[0036] As an alternative to using the adhesive element 1 in a vehicle, it is also possible to use it in other areas, for example in the construction industry, shipbuilding, aircraft construction or in the manufacture of household appliances, since the adhesive element 1 can be adapted to a wide variety of applications due to its advantageous properties.

[0037] The use of the carrier layer 1.1 formed from the rigid material has the particularly advantageous effect of allowing the adhesive element 1 to be applied automatically to the vehicle component 2. The adhesive element 1 is applied according to the description of the Fig. 3 to 5 automated by one in Fig. The carrier element 3, shown in more detail below, is separated and then automatically attached to the vehicle component 2.

[0038] Fig. Figure 2 shows several adhesive elements 1 applied to a carrier element 3. The carrier element 3, a so-called liner, is designed as a pre-fabricated flat sheet onto which several adhesive elements 1 are applied. The carrier element 3 is made of siliconized paper, polyethylene, or polyethylene terephthalate film. In a particular embodiment, all variants of adhesive elements 1 required for an entire vehicle or the vehicle component 2 are arranged as a set on one or more sheets. Designing the carrier element 3 as a flat sheet allows for managing the variety of adhesive element 1 variants for a vehicle while minimizing material waste and space requirements. Compared to using adhesive elements 1 on rolls, this also has the advantage of preventing the adhesive elements 1 from detaching uncontrollably from the carrier element 3.Furthermore, manufacturing-related material rejects can only be sorted out in sheet material. With roll or continuous material, however, malfunctions can occur in an application system for the automatic application of the adhesive elements 1.

[0039] In the illustrated embodiment, adhesive elements 1 are available in ten different sizes and

[0040] Fig. Figure 3 shows a sectional view of a device 4 for applying adhesive elements 1 to the vehicle component 2. Fig. 4 and Fig. Figures 5 show a joining tool 5 of the device 4 in different views.

[0041] The device 4 comprises the joining tool 5 with several joining dies 5.1 to 5.5.

[0042] Before the adhesive elements 1 are applied to the vehicle component 2 using the joining tool 5, the carrier element 3 with the adhesive elements 1 is picked up from a stack S of several carrier elements 3 with adhesive elements 1 and separated by a gripping tool 6. For this purpose, the gripping tool 6 is coupled (not shown) to a vacuum generation unit, by means of which a vacuum can be generated on a receiving surface 6.1 of the gripping tool 6, so that the carrier element 3 adheres to the receiving surface 6.1. Both the joining tool 5 and the gripping tool can be handled fully automatically using commercially available industrial robots.

[0043] The isolated carrier element 3 is then positioned on a storage surface 7 by means of the gripping tool 6. The storage surface 7 is also coupled, in a manner not shown, to another vacuum generation unit of the same type as the gripping tool 6. A vacuum is generated between the storage surface 7 and the carrier element 3 by means of the vacuum generation unit, so that the carrier element 3 is fixed in its position on the storage surface 7 and can be easily detached from the carrier element 3 by means of the joining dies 5.1 to 5.5.

[0044] After the carrier element 3 and the adhesive elements 1 located on it are placed on the storage surface 7, with the adhesive elements 1 facing away from the storage surface 7, one adhesive element 1 at a time is detached from the carrier element 3 by means of the joining dies 5.1 to 5.5. For this purpose, the joining dies 5.1 to 5.5 are designed as so-called vacuum dies, whereby a vacuum is generated between the respective adhesive element 1 and the respective joining die 5.1 to 5.5 by means of the vacuum generation unit or a further vacuum generation unit, so that the adhesive element 1 adheres to the joining die 5.1 to 5.5.

[0045] In the illustrated embodiment, the joining dies 5.1 to 5.5 have five different sizes and are collectively suitable for receiving and processing the ten different adhesive elements 1, which are located together on the carrier element 3. The joining dies 5.1 to 5.5 are furthermore arranged in a "turret-like" configuration within the joining tool 5, which is rotatable about a central axis of rotation Y.

[0046] When the adhesive elements 1 are picked up by means of the joining dies 5.1 to 5.5, the joining dies 5.1 to 5.5 are preferably moved out of the joining tool 5 and positioned precisely above the respective adhesive element 1 by the rotational movement and the robot-assisted translational movements of the joining tool 5. For the precise positioning of the joining tool 5 with the joining dies 5.1 to 5.5 in relation to the adhesive elements 1, a first image acquisition unit 10, in particular designed as a camera, is arranged, by means of which the positions of the adhesive elements 1 on the carrier element 3 are detected.

[0047] Using this image acquisition unit 10, an image of the carrier element 3 with the adhesive elements 1 is captured. The image is then evaluated to verify that all adhesive elements 1 are present on the carrier element 3, and any carrier elements 3 that are not fully equipped with adhesive elements 1 are rejected. Specifically, as already described, all adhesive elements 1 for the entire vehicle are arranged on one carrier element 3.

[0048] When picking up the adhesive elements 1, each joining punch 5.1 to 5.5 picks up one adhesive element 1 in one operation, so that all joining punches 5.1 to 5.5 of the joining tool 5 are each equipped with an adhesive element 1 before the adhesive elements 1 are applied to the vehicle component 2.

[0049] By means of the joining tool 5, the adhesive elements 1 are guided to the vehicle component 2 after being picked up by the joining dies 5.1 to 5.5. For a rough positioning of the joining tool 5, the vehicle component 2 is first captured in its entirety by means of a further image acquisition unit 9, which is preferably also designed as a camera, and a position of the vehicle component 2 relative to the joining tool 5 and the respective joining die 5.1 to 5.5 is determined.

[0050] Furthermore, a precise joining position POS of the respective adhesive element 1 on the vehicle component 2 is determined based on an image captured by the image acquisition unit 8. The image acquisition unit 8 is integrated into the joining tool. In the illustrated embodiment, the joining position POS forms the opening O in the vehicle component 2. Depending on the determined joining position POS, the respective joining die 5.1 to 5.5 is positioned precisely in the so-called fine position at the joining position POS before the adhesive element 1 is applied.

[0051] In the illustrated embodiment, the joining die 5.3 is positioned precisely below the opening O of the vehicle component 2. The joining die 5.3 is then moved from the joining tool 5 towards the vehicle component 2, and the adhesive element 1 is attached to the vehicle component 2 with a defined force using the self-adhesive damping compound 1.2. The generation of this defined force is achieved, for example, by pressure monitoring at the joining cylinder. The movement of all joining dies 5.1 to 5.5 is automatically controlled and is effected by electrical or pneumatic drives coupled to the joining dies 5.1 to 5.5.

[0052] In particular, the control and, if necessary, movement of all device components, i.e., the joining tool 5 with the joining punches 5.1 to 5.5, the gripping tool 6, the storage surface 7, the image acquisition units 8, 9 and the vacuum generation units, is carried out fully automatically.

[0053] After the adhesive element 1 has been applied using the joining die 5.3, the other adhesive elements 1 located on the remaining joining dies 5.1, 5.2, 5.4, 5.5 are attached to the vehicle component 2 at further joining positions (not shown) using these dies. For this purpose, the vehicle component 2 and / or the joining tool 5 are positioned and aligned depending on the images captured by the image acquisition units 8, 9.

[0054] The other joining positions can be openings in the vehicle component 2 as well as other sections, whereby the adhesive elements 1 are applied to the openings and / or the other sections of the vehicle component 2 for closing the openings and / or for structure-borne noise insulation.

[0055] In particular, the adhesive elements 1 are applied to the vehicle component 2 immediately after a cathodic dip coating, whereby the surface of the vehicle component 2 is particularly suitable for the application of the adhesive elements 1 after this dip coating and results in particularly good adhesion.

[0056] Additionally, after applying the adhesive elements 1, another layer of paint can be applied to the vehicle component 2 and the adhesive elements 1.

Claims

[1] Method for the automated application of an adhesive element (1) to a vehicle component (2), wherein, by means of several joining dies (5.1 to 5.5) of a joining tool (5), an adhesive element (1) is each detached from a carrier element (3) and subsequently applied to the vehicle component (2), characterized by , that the carrier element (3) with the adhesive elements (1) is positioned on a storage surface (7) and fixed on the storage surface (7) by generating a vacuum between the storage surface (7) and the carrier element (3), and that subsequently, by means of the joining dies (5.1 to 5.5), one adhesive element (1) is removed from the carrier element (3) by generating a vacuum between the joining die (5.1 to 5.5) and the adhesive element (1) and applied to the vehicle component (2). [2] Method according to claim 1, characterized by, that the carrier element (3) with the adhesive elements (1) is separated from a stack (S) of several carrier elements (3) with adhesive elements (1) and automatically picked up with a gripper. [3] Method according to claim 1 or 2, characterized by , that an image of the carrier element (3) with the adhesive elements (1) is captured by means of an image acquisition unit (10) and the completeness of the adhesive elements (1) on the carrier element (3) is checked by means of an evaluation of the image and / or that an image of at least a section of the vehicle component (2) is captured by means of an image acquisition unit (8), whereby a joining position (POS) of the respective adhesive element (1) on the vehicle component (2) is determined on the basis of the image and the respective joining die (5.1 to 5.5) is automatically positioned at the joining position (POS) depending on the determined joining position (POS) before the adhesive element (1) is applied. [4] Method according to any one of the preceding claims, characterized by , that by means of a further image acquisition unit (9) an image of the entire vehicle component (2) is captured and on the basis of the image a rough position of the vehicle component (2) relative to the joining tool (5) and / or the respective joining punch (5.1 to 5.5) is determined. [5] Method according to any one of the preceding claims, characterized by , that the adhesive elements (1) are applied to the vehicle component (2) immediately after a cathodic dip coating. [6] Device (4) for carrying out a method according to one of the preceding claims, characterized - by a joining tool (5) with several turret-like arranged joining dies (5.1 to 5.5) for picking up one adhesive element (1) from a carrier element (3) and for applying the adhesive element (1) to a vehicle component (2), wherein a vacuum can be generated between the joining dies (5.1 to 5.5) and the respective adhesive element (1), - by a gripping tool (6) for gripping the carrier element (3) with several applied adhesive elements (1), wherein a vacuum can be generated between the gripping tool (6) and the carrier element (3) and - by means of a storage surface (7) for storing and fixing the support element (3), wherein a vacuum can be generated between the storage surface (7) and the support element (3) for fixing. [7] Device (4) according to claim 6, characterized by, that the joining tool (5) comprises several, in particular five, turret-like arranged joining dies (5.1 to 5.5) for receiving adhesive elements (1) of, for example, ten different sizes.

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