Tool for a handling device and method for manufacturing a tool for a handling device

Abstract

Tool (1) for a handling device, in particular a robot, comprising a basic structure (3), wherein the basic structure (3) comprises deflection elements (5) which are each wrapped with a fiber (7) impregnated with a binder, and wherein at least one of the deflection elements (5) comprises a functional part (9), wherein the at least one functional part (9) is configured to interact with a manufacturing device and / or parts of a manufacturing device.

Description

[0001] The invention relates to a tool for a handling device, in particular a robot, and to a method for manufacturing a tool for a handling device.

[0002] It is known to manufacture tools, especially grippers, for handling devices such as robots and / or manipulators using a winding process. For this purpose, continuous fibers or fiber strands impregnated with resin are used to create a truss structure. The resin-impregnated continuous fiber and / or fiber strand is wound around defined deflection points. The resulting paths follow the load paths and / or predetermined actuator or sensor positions. Fiber-shaped actuators are used, for example, to dampen the vibration of a tool, such as a gripper. Sensor fibers, on the other hand, can be used, among other things, to determine the condition of a component and, if necessary, detect damage or record continuously occurring forces.

[0003] Modern tools, such as hold-down devices or grippers, used for fixing and positioning components in car body manufacturing, can weigh up to 400 kg when the gripper is tasked with lifting a car hood. This pushes the handling equipment to its load limit, necessitating a reduction in its operating speed. The high load on the handling equipment also increases wear and tear, requiring more frequent maintenance. Another problem with the increased weight of the tools is that they can bend under their own weight. This can lead to quality variations in production, particularly with grippers and / or hold-down devices, as the tools also serve to maintain the correct dimensions of the components.

[0004] In car body manufacturing, tools for handling devices, such as hold-down grippers, are constructed using welded steel frames or standard profiles. This means that, especially with large component geometries, such as a tool gripper for a hood, very large handling devices with a high load-bearing capacity must be used for weight reasons. However, even the largest handling devices of their kind are at the limit of their load-bearing capacity when handling hood tool grippers. Due to the aforementioned increased wear, quality fluctuations occur in the manufacturing process during the production period in which products are manufactured using the handling device. Consequently, as also mentioned, cycle times must be reduced. This is also necessary because otherwise vibrations can occur in the tool gripper.Another problem is that the larger handling equipment required necessitates more space in the production hall for manufacturing each component. Consequently, energy consumption also increases, as the constantly higher workload demands more energy.

[0005] German patent application DE 10 2016 012 534 A1 describes a system for manufacturing components made of fiber-reinforced plastic, comprising at least one positioning plate having a plurality of attachment points for detachably fastening deflection elements to the positioning plate; a plurality of deflection elements; and a plurality of support elements, wherein the deflection elements are arranged to be attached to the positioning plate, and / or to the support elements, and / or to each other, and wherein the support elements are arranged to be attached to the positioning plate, and / or to the deflection elements, and / or to others.

[0006] DE 10 2018 008 836 A1 discloses a method for manufacturing a fiber-reinforced profile component (9), comprising the following steps: a) providing a mounting plate, a fiber material, and at least two deflection elements; b) mounting the at least two deflection elements on the mounting plate in such a way that the deflection elements define a contour of the fiber-reinforced profile component; c) laying the fiber material around or onto the at least two deflection elements mounted on the mounting plate in such a way that the fiber material is laid along a geometry of the fiber-reinforced profile component and along load paths resulting from the intended loading of the fiber-reinforced profile component; d) consolidating the fiber-reinforced profile component (9), preferably at room temperature and further preferably without pressure; e) obtaining the fiber-reinforced profile component.

[0007] DE 10 2017 011 461 A1 discloses a method for manufacturing a component from a fiber structure, wherein a fiber strand is guided by means of a fiber guiding device and laid down on a fiber laying device, the fiber laying device comprising a holding plate with a plurality of support elements and a plurality of deflection elements, the support elements being arranged on the holding plate, the deflection elements being arranged on the holding plate, on the support elements and / or on each other in a specific spatial arrangement relative to each other, and wherein the fiber strand is laid down around the deflection elements along a winding path. The method is characterized in that the fiber strand is completely wrapped around each of the deflection elements at least once.

[0008] DE 10 2016 013 827 A1 discloses a gripper for a manipulator, wherein the gripper is at least partially formed from a coilable fiber material, which forms a coiled structure of a fiber-matrix composite material. The coiled structure is provided to have at least one conductor loop made of an electrically conductive material, and the gripper is configured for electrically contacting the at least one conductor loop. The invention further relates to a method for manufacturing a gripper.

[0009] EP 2 810 749 A1 discloses the following: A device for use in handling a load and a method for manufacturing the device are provided. The device comprises a three-dimensional frame comprising several individual parts, a covering made of a fiber-reinforced plastic with which the frame is coated, and at least one mounting device for a handling device for handling a part usable in the production of an article, which constitutes the load.

[0010] US Patent 9,962,828 B2 discloses the following: It describes a tool at the end of a robot arm, comprising an outer sheet and an inner sheet. The tool on the robot arm can be reinforced with a support plate attached to the inner sheet and a front plate attached to the outer sheet. The tool on the robot arm can also include spacers to provide structure and rigidity at the transitions configured for the installation of workpiece interface tools, such as spring plungers.

[0011] US patent application US 2007 / 0006462A1 discloses a tooling device for engaging a workpiece to facilitate the performance of work operations on the workpiece. The device comprises an elongated rectangular tubular spinal column element, a plurality of tubular collars positioned over the supporting bone element and attached at predetermined longitudinally spaced locations along the supporting element, and a plurality of support structures attached to one side of one or more of the collars, using a plurality of fasteners that engage in openings in the collars and aligned openings in the underlying spinal column element.

[0012] Therefore, there is a significant need to be able to manufacture lighter tools.

[0013] The invention is therefore based on the objective of creating a tool for a handling device and a method for manufacturing a tool for a handling device, without the aforementioned disadvantages. In particular, it is an objective of the invention to create a tool that is particularly lightweight compared to tools manufactured in a conventional manner.

[0014] The problem is solved by providing the present technical teaching, in particular the teaching of the independent claims and of the preferred embodiments and exemplary embodiments disclosed in the description of the independent claims.

[0015] The problem is solved by creating a tool for a handling device, in particular a robot for handling a car hood, comprising a basic structure. The basic structure has deflection elements, each of which is wrapped with a fiber impregnated with a binder, and wherein at least one of the deflection elements has a functional part, wherein the at least one functional part is configured to interact with a manufacturing device and / or parts of a manufacturing device, wherein one functional part of the at least one functional part is designed as a forming jaw for a forming process, and wherein one functional part of the at least one functional part is designed as a hold-down element of a forming tool.

[0016] This has the particular advantage that tools obtained through a topology-optimized design in hybrid / additive manufacturing, such as lightweight hold-downs and / or grippers, are especially lightweight. Here, the potential of additive manufacturing technologies is utilized – depending on the application conditions – particularly with regard to lightweight structures and functional integration. Additive manufacturing technology makes it possible to produce tools according to their load case requirements. A base frame is built, especially using FibreTec 3D technology. The deflection elements – which also serve to hold functional components – are preferably wrapped with a fiber, especially carbon fiber, impregnated with a binder, particularly a resin. A subsequent tempering process cures the binder.Load-optimized, additively manufactured functional components, such as clamping elements, are positioned on the deflection elements, preferably being produced using selective laser melting (SLM). A particular advantage is that lightweight construction allows for the creation of lightweight structures derived from nature, sometimes referred to as bionics. The functional components enable extensive functional integration, such as clips. In particular, the workpieces serve as innovation and technology demonstrators. As a result, the tooling achieves an optimized cycle time, as it weighs only approximately 200 kg instead of 400 kg. Overall, the tools according to the invention lead to improved quality and improved production processes.Furthermore, initial investment costs are reduced because maximum-load-bearing and therefore expensive handling equipment is not required. Consequently, maintenance costs are also reduced, and the space required for the handling equipment in a production hall is correspondingly decreased. Because less robust handling equipment is needed, and it also has to bear a lighter load (lighter tool), this also results in a reduction in energy consumption, which is particularly beneficial in the context of "green technology." Specifically, the tool according to the invention has a truss structure. The resulting paths follow the load paths and / or the previously defined areas in which actuators and / or sensors are to be placed. Fiber-shaped actuators, in particular, are used, for example, for vibration damping in a tool, especially a gripper.The sensor fibers can be used, among other things, to determine the condition of the component and / or detect damage, or in particular to constantly monitor the forces acting upon it, so that damage can be prevented.

[0017] It is particularly preferred that the deflection points are designed as connection elements for other components. Furthermore, it is preferred that the fiber impregnated with a binder is a carbon fiber. The deflection elements are preferably coil-shaped, and preferably have radially projecting deflection arms. It is particularly preferred that the deflection elements are mounted on support pins. A resin is particularly preferred as the binder.

[0018] According to a further development of the invention, the forming jaw is designed for a folding forming process, such as folding. This has the particular advantage that such a tool is set up for a single forming process, so that no additional tool needs to be arranged or changed on the handling device.

[0019] According to a further development of the invention, the at least one functional part has a support structure which is formed by a winding process and / or by an additive manufacturing process, such as fused deposition modeling, in particular SLM. This has the particular advantage that a particularly lightweight yet particularly stable functional part can be obtained in a simple manner.

[0020] According to a further development of the invention, the functional parts are entirely formed by an additive manufacturing process, particularly for aluminum. This has the particular advantage that the functional parts can be manufactured to be especially lightweight and stable due to the high-precision production.

[0021] According to a further development of the invention, the deflection elements are formed by means of 3D sand printing or fused deposition modeling (SLM), preferably from a light metal, in particular aluminum. This has the particular advantage that the deflection elements can also be made correspondingly light, so that an even lighter tool can be obtained overall.

[0022] According to a further development of the invention, the deflection elements are designed as receptacles for attachments, preferably having an internal thread. This has the particular advantage that attachments can be easily mounted to the tool – for example, by means of an internal thread.

[0023] According to a further development of the invention, the parts are designed as holders for suction cups and / or sensors and / or actuators using SLS, are stable, but have a shape similar to a knitted textile.

[0024] The task is also solved in particular by creating a method for manufacturing a tool for a handling device - wherein the tool is tailored to a specific load requirement - by carrying out the following steps: a) Providing a fiber, in particular a continuous fiber, a binder and at least two deflection elements, b) Arranging the deflection elements in such a way that forces occurring permanently, in particular constantly, under the specific load requirement can be absorbed, c) Wrapping the deflection elements with the continuous fiber impregnated with the binder, d) Curing of the impregnated continuous fibers in a tempering process, e) Preservation of the basic structure with at least two deflection elements, f) Arranging and / or attaching at least one functional part in or to one of the deflection elements, g) Receipt of the tool for a handling device.

[0025] The process makes it possible, in particular, to easily manufacture a suitable tool for a handling device.

[0026] According to a further development of the invention, the deflection elements arranged in process step b) are arranged on support pins, and the support pins themselves are in turn arranged on a manufacturing base plate, sometimes also referred to as a positioning plate. This also has the advantage that the tool for a handling device can be manufactured in a particularly simple manner.

[0027] The invention will be explained in more detail below with reference to the drawing. The drawing shows: Fig. 1 an embodiment of the tool, Fig. 2 a tool known from the prior art, Fig. 3 a schematic flow chart of a procedure for manufacturing a tool for a specific load requirement and handling device.

[0028] Fig. Figure 1 shows a tool 1 for a specific load requirement, a handling device (not shown in the figures), in particular a robot, comprising a basic structure 3, wherein the basic structure 3 has deflection elements 5, each of which is impregnated with a fiber 7 (in Fig. 1. The fiber 7, impregnated with a binder (already cured), is wrapped, and at least one of the deflecting elements 5 has a functional part 9. The at least one functional part 9 is configured to interact with a manufacturing device (not shown in the figures) and / or parts of a manufacturing device (not shown in the figures).

[0029] Furthermore, the Fig. 1 can be seen that at least one functional part 9 is designed as a forming jaw 11 for a forming process, such as folding.

[0030] Furthermore, the Fig. 1 can be seen that the at least one functional part 9 is designed as a hold-down element 13 of a forming tool.

[0031] Furthermore, the Fig. 1 can be seen that the at least one functional part 9 has a support structure 15 which is formed by a winding process and / or by an additive manufacturing process, such as fused deposition modeling, in particular SLM.

[0032] Furthermore, the Fig. It can be seen from Figure 1 that the functional parts 9 are entirely formed by an additive manufacturing process, especially for aluminum. This is particularly evident in the case of the mold jaws 11.

[0033] Furthermore, it is preferably provided that the deflection elements 5 are formed by means of 3D sand printing or SLM, preferably from a light metal, in particular aluminium.

[0034] Furthermore, it is preferably provided that the deflection elements 5 are designed as receptacles for attachments, preferably having an internal thread.

[0035] Furthermore, the Fig. 1 can be seen that the functional parts 9 are designed as holders for suction cups 17 and / or sensors (not visible in the figures) and / or actuators (not visible in the figures) using SLS, are stable, but have a shape similar to a knitted textile.

[0036] The Fig. 2 is a standard tool 19 to be taken, whereby this standard tool 19 has a steel frame welded construction, which is why this tool can weigh up to 400 kg.

[0037] Fig.Figure 3 shows a schematic flow chart of a process for manufacturing a tool 1 for a handling device, wherein the tool is adapted to a specific load requirement (not shown in the figures), wherein the following steps are carried out: a) Providing a fiber (7), in particular a continuous fiber, a binder and at least two deflection elements 5, b) Arranging the deflection elements 5 in such a way that forces occurring permanently, in particular constantly, under the specified load requirement can be absorbed, c) Wrapping the deflection elements 5 with the fiber 7, which is impregnated with the binder, d) Curing of the impregnated fiber 7 in a tempering process, e) Preservation of the basic structure 3 with at least two deflection elements 5, f) Arranging and / or attaching at least one functional part 9 in or to one of the deflection elements 5, g) Receipt of tool 1 for a handling device.

[0038] Furthermore, it is preferably provided that the deflection elements 5 arranged in process step b) are arranged on support pins (not shown in the figures), the support pins themselves being arranged on a manufacturing plate (not shown in the figures), sometimes also referred to as a positioning plate.

Claims

[1] Tool (1) for a handling device, in particular a robot, comprising a basic structure (3), wherein the basic structure (3) comprises deflection elements (5) which are each wrapped with a fiber (7) impregnated with a binder, and wherein at least one of the deflection elements (5) comprises a functional part (9), wherein the at least one functional part (9) is configured to interact with a manufacturing device and / or parts of a manufacturing device. [2] Tool according to claim 1, characterized by , that at least one functional part (9) is designed as a forming jaw (11) for a forming process, such as folding. [3] Tool according to claim 1 or 2, characterized by , that the at least one functional part (9) is designed as a hold-down element (13) of a forming tool. [4] Tool according to any one of the preceding claims, characterized by, that the at least one functional part (9) has a support structure (15) which is formed by a winding process and / or by an additive manufacturing process, such as fused deposition modeling, in particular SLM. [5] Tool according to any one of the preceding claims, characterized by , that the functional parts (9) are entirely formed by an additive manufacturing process, especially for aluminium. [6] Tool according to any one of the preceding claims, characterized by , that the deflection elements (5) are formed by means of 3D sand printing or SLM, preferably from a light metal, in particular aluminium. [7] Tool according to any one of the preceding claims, characterized by , that the deflection elements (5) are designed as receptacles for attachments, preferably having an internal thread. [8] Tool according to any one of the preceding claims, characterized by, that the functional parts (9) are designed as holders for suction cups (17) and / or sensors and / or actuators using SLS, stable, but shaped in the manner of a knitted textile. [9] Method for manufacturing a tool (1) for a handling device, wherein the tool is adapted to a specific load requirement, comprising the following steps: a) Providing a fiber (7), in particular a continuous fiber, a binder and at least two deflection elements (5), b) Arranging the deflection elements (5) in such a way that forces which occur permanently under the specified load requirement can be absorbed, c) Wrapping the deflection elements (5) with the fiber (7) which is impregnated with the binder, d) Curing the impregnated fiber (7) in a tempering process, e) Preservation of the basic structure (3) with the at least two deflection elements (5), f) Arranging and / or attaching at least one functional part (9) in or to one of the deflection elements (5), g) Receipt of the tool (1) for a handling device.

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