Method for mounting a foam element to a component of a motor vehicle

Abstract

Method for mounting a foam element (12) to a component (32) of a motor vehicle, comprising the steps: - Providing the foam element (12) on a receiving surface (28); - Determining the actual position of the foam element (12) relative to the receiving surface (28) using at least one optical sensor; - Picking up the foam element (12) using a robot (10) depending on the determined actual position; - Moving the foam element (12) held on the robot (10) relative to the component (32) by means of the robot (10) into a desired position; and - Mounting the foam element (12) on the component (32) using the robot (10), characterized in that the foam element (12) is picked up by the robot (10) by the robot (10) engaging in a gripping form (30) provided on the foam element (12).

Description

[0001] The invention relates to a method for mounting a foam element on a component of a motor vehicle.

[0002] In the mass production of motor vehicles, particularly passenger cars, it is common practice to use singulation devices and standard industrial robots during the assembly of small parts such as foam elements. The foam elements are delivered to an assembly station in large quantities and separated using a singulation device, such as a vibrator. This method of assembling foam elements has proven to be very complex, time-consuming, and costly. Furthermore, the foam element can be lost or damaged during assembly with the component.

[0003] German patent DE 10 2010 051 786 A1 discloses 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. According to the invention, the carrier element with the adhesive elements is positioned on a support surface and fixed on the support surface by generating a vacuum between the support 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. The invention further relates to a device for carrying out the method.

[0004] DE 10 2006 011 341 A1 discloses the following: an arrangement for mounting an attachment to a moving base component comprises a conveying device for the continuous movement of the base component, a first industrial robot with a first manipulator for joining the attachment to the base component, a system controller for controlling and regulating the industrial robot, and a sensor assigned to the first manipulator for determining an interaction between the first manipulator and the base component or the attachment. The sensor assigned to the first manipulator ensures high accuracy in the control and regulation of the manipulator.

[0005] DE 10 2008 018 848 A1 discloses a method for the automated assembly of at least one component onto an object using an industrial robot, wherein the object and / or the industrial robot is moved by means of a conveying device, and wherein the industrial robot has a base, a positioning device movable relative to the base, and an assembly tool device connected to the positioning device, and wherein during component assembly a relative movement takes place between the object and the base of the industrial robot, and wherein the industrial robot automatically grasps the component, positions it on the object, and assembles it using the assembly tool device.It is provided that the assembly tool device is rigidly connected to the positioning device and / or the base at least in one assembly direction for a period of time until the assembly tool device is rigidly coupled to the object in at least one assembly direction by means of a positive and / or force-fit connection during component assembly, and that subsequently, until the component fastening to the object is completed, the assembly tool device is at least partially floating relative to the positioning device and / or the base by means of an activatable floating bearing.

[0006] It is therefore an object of the present invention to provide a method for mounting a foam element on a component of a motor vehicle, by means of which the foam element can be mounted particularly easily without causing damage or loss of the foam element.

[0007] This problem is solved by mounting a foam element to a component of a motor vehicle with the features of claim 1. Advantageous embodiments with expedient and non-trivial further developments of the invention are specified in the remaining claims.

[0008] The method for mounting a foam element to a vehicle component comprises a first step in which the foam element is positioned on a receiving surface. In a second step, the actual position of the foam element relative to the receiving surface is determined using at least one optical sensor. This determination is achieved, for example, by capturing the contour of the foam element with the optical sensor. Specifically, the position and rotation of the foam element on the receiving surface are determined.

[0009] In a third step of the process, the foam element is then picked up by a robot based on its determined current position. This current position serves to align the robot itself relative to the foam element, enabling the robot to interact with the foam element in a designated area. This prevents damage to the foam element. Furthermore, subsequent assembly or fastening of the foam element to the component can be ensured, as the necessary alignment of the foam element, achieved by the robot, is guaranteed. According to the invention, a gripping shape is integrated into the foam element in this area, allowing the robot to interact particularly effectively with the gripping shape and thus grasp the foam element.

[0010] The robot picks up the foam element, for example, by equipping it with a gripper, in particular a two-finger gripper. Using this gripper, the robot grasps the foam element, thus holding or fixing it to the robot.

[0011] In a fourth step of the process, the foam element, held by the robot, is moved by the robot from its current position to a target position relative to the component. In this target position, the foam element can be mounted on or joined to the component. Finally, in a fifth step of the process, the foam element is mounted or attached to the component by the robot. Preferably, the component is mounted in such a way that it is snapped or clipped into place. For this purpose, the foam element, in particular at least one snap element of the foam element, is inserted, for example, into a corresponding receptacle provided on the component, in particular a snap-fit ​​receptacle, so that, for example, the snap element can interact with the snap-fit ​​receptacle in a form-fitting manner. The component is, for example, a body component of a motor vehicle, such as a passenger car.

[0012] The method according to the invention enables time- and cost-effective as well as process-reliable assembly of the foam element onto the component without damage to or loss of the foam element. In particular, complex singulation devices such as vibrators can be dispensed with. Subsequent checks and rework can also be avoided.

[0013] Furthermore, it is possible to verify the assembly of the foam element using a robot. For this purpose, after the foam element has been assembled, it is subjected to at least one test force by the robot. Depending on the test force, the assembly of the foam element on the component is checked. To apply the test force to the foam element, the robot, for example, pushes and / or pulls it, so that the test force is either a tensile or a compressive force. Using at least one force sensor on the robot, at least one actual force curve is recorded over time during the application of the test force and compared with a target force curve. If the actual force curve deviates from the target force curve, the assembly was unsuccessful, and the assembly must be repeated.If the actual force curve matches the target force curve, the assembly was successful and the foam element is firmly mounted on the component in a desired, predefinable position.

[0014] Preferably, a lightweight robot is used. A lightweight robot in this context is defined as a robot with a very low weight and highly precise control, particularly force control. Due to its low weight and precise control, the foam element can be moved very accurately into the predetermined position and joined to the component.

[0015] The lightweight robot is specifically a force-sensitive robot that enables reliable and rapid assembly. It features force, torque, and / or displacement sensors that measure the forces, torques, and resulting displacements acting on the gripper mounted on the robot arm and thus on the gripped foam element. Because these measurements can be performed very precisely, the robot can be used not only to move the foam element but also to tactilely detect its position relative to the component. In other words, internal or external sensors can be used to precisely detect when the foam element has been reached, allowing the robot to accurately position and join the foam element to the component.The method can therefore utilize the existing sensor equipment of modern force-sensitive, especially impedance-controlled, lightweight robots to position the foam element.

[0016] This makes it possible, in particular, for the lightweight robot, specifically its robot arm, to pick up the attachment before the tactile detection of the joining point's position. The position of the joining point can then be detected tactilely via the attachment, which is picked up by the robot and positioned on it, using the lightweight robot's sensors. This avoids the need for the lightweight robot to first pick up a tactile position sensor, then put it down, and finally pick up the attachment. Instead, the tactile detection can be performed via the already picked-up attachment, which then does not need to be put down but can be bonded in place.

[0017] Further advantages, features and details of the invention will become apparent from the following description of a preferred embodiment and from the drawings; these show in: Fig. 1 a schematic perspective view of a robot by means of which a foam element is mounted on a component in the form of a body part of a passenger car; Fig. 2. Partially shown is another schematic perspective view of the robot during the assembly of the foam element; Fig. 3. A further schematic perspective view of the robot during the assembly of the foam element (in part); and Fig. 4. A further schematic perspective view of the robot during the assembly of the foam element (in part).

[0018] Fig. Figure 1 shows a robot in the form of a lightweight robot 10 for mounting a foam element 12 on a surface in Fig. 1. An unrecognizable component in the form of a body panel of a passenger car. The foam element 12 is also commonly referred to as a foam part and is a small component to be assembled, which is at least partially made of foam. The lightweight robot 10 comprises several robot arms 14, 16, 18, which are articulated together and can be pivoted relative to each other. A pivotable head 20 with a tool holder 22 is arranged on the robot arm 18. As shown from Fig. As can be seen in Figure 2, a gripper 24 is arranged on the tool holder 22.

[0019] The gripper 24 is designed as a two-finger gripper and therefore comprises two fingers 26, by means of which the foam element 12 can be grasped and thus fixed to or picked up by the lightweight robot 10. In a process for mounting the foam element 12 to the body component, the foam element 12 is first positioned on a special, reflective receiving surface 28. For this purpose, the foam element 12 is conveyed onto the receiving surface 28, for example, by means of a conveyor belt.

[0020] In a second step, the actual position of the foam element 12 relative to the receiving surface 28 is determined using at least one optical sensor. The optical sensor, for example, detects the contour of the foam element 12, so that its position relative to the receiving surface 28 is recorded in at least two mutually perpendicular spatial directions (x-direction and y-direction). Furthermore, the rotational orientation of the foam element 12 is recorded. The position and rotational orientation are transmitted to the lightweight robot 10, which can then pick up the foam element 12 in a third step, depending on the determined actual position.

[0021] Since the current position is known, the fingers 26 can be moved into a gripping shape integrated into the foam element 12 and interact with the gripping shape 30. This fixes the foam element 12 to the lightweight robot 10, for example, by force and / or form locking. Thus, the foam element 12 can be moved along with the gripper 24. The optical sensor can be either mounted on the lightweight robot 10 or held independently of the lightweight robot 10.

[0022] In a fourth step, the foam element 12, held by the lightweight robot 10, is moved into a target position relative to the body component by means of the lightweight robot 10. This is particularly well suited from Fig. Figure 3 shows the body component designated 32. At least one force, torque, and / or displacement sensor integrated into the lightweight robot 10 can be used to move the foam element 12 into the target position. This sensor allows the achievement of the target position to be detected, particularly tactilely. In other words, the tactile properties of the lightweight robot 10 are used to locate the target position by moving the foam element 12, held by the gripper 24, towards it.

[0023] As from Fig. As can be seen in Figure 3, the body component 32 has an opening 34 designed as a through-opening, into which the foam element 12 is to be inserted, at least partially, by means of the lightweight robot 10. The foam element 12 is then snapped or clipped to the body component 32.

[0024] Once the foam element 12 has been moved into the desired position, it is clipped into the opening 34 by means of the lightweight robot 10 in a fifth step, which results in Fig.4 is recognizable. The foam element 12 is joined to the body component 32. For example, three joining operations or joining tests are carried out. After joining, the assembly can be checked using the lightweight robot 10. In particular, the check can verify whether the foam element 12 is in its predetermined, desired position on the body component 23 and / or whether the foam element 12 is firmly held on the body component 32 and / or whether the foam element 12 has been joined to the body component 32 at all. For this purpose, the foam element 12 is subjected to a tensile force as a test force using the lightweight robot 10, for example, to analyze the secure fit of the foam element 12. In other words, the assembly of the foam element 12 on the body component 32 is checked depending on the test force.

[0025] During force application, a force profile over time is recorded at a predefined position, in particular height, of the lightweight robot 10. This is done, for example, using the at least one integrated force sensor of the lightweight robot 10. The force profile over time is compared as the actual profile with a target profile. If the target profile matches the actual profile, it can be concluded that the assembly was successful. If the profiles deviate from each other, the assembly was unsuccessful. In this case, the assembly is repeated, with three repetitions being performed.

Claims

[1] Method for mounting a foam element (12) to a component (32) of a motor vehicle, comprising the steps: - Providing the foam element (12) on a receiving surface (28); - Determining the actual position of the foam element (12) relative to the receiving surface (28) using at least one optical sensor; - Picking up the foam element (12) using a robot (10) depending on the determined actual position; - Moving the foam element (12) held on the robot (10) relative to the component (32) by means of the robot (10) into a desired position; and - Mounting the foam element (12) on the component (32) using the robot (10), characterized by , that the foam element (12) is picked up by the robot (10) by the robot (10) engaging in a gripping form (30) provided on the foam element (12). [2] Method according to claim 1, characterized by , that the foam element (12) is locked to the component (32). [3] Method according to any one of the preceding claims, characterized by , that after the foam element (12) has been mounted, it is subjected to at least one test force by means of the robot (10), whereby the mounting of the foam element (12) on the component (32) is checked depending on the test force.

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