System and method for machining plate-shaped workpieces for a motor vehicle

Abstract

System (10) for machining plate-shaped workpieces (31, 32) for a motor vehicle (1), comprising: - a first forming tool (11) with a first lower tool (12) and a first upper tool (13), wherein the first upper tool (13) is translationally and / or rotationally movable relative to the first lower tool (12) in order to change from a first state (Z1) by means of a translational movement and / or by flipping into a second state (Z2), so that a first cavity (14) can be formed between the first forming tool (11) and a first workpiece (31), and - a second forming tool (21) with a second lower tool (22) and a second upper tool (23), wherein the second upper tool (23) is translationally and / or rotationally movable relative to the second lower tool (22) in order to change from a first state (Z1) to a second state (Z2) by means of a translational movement and / or by flipping, so that a second cavity (24) can be formed separately from the first cavity (14) between the second forming tool (21) and a second workpiece (32) separate from the first workpiece (31), wherein the first lower tool (12) and the second lower tool (22) provide two separate lower tools of a common mold carrier or provide a common lower tool of a common mold carrier, and wherein the first and the second forming tools (11, 21) are configured to provide separate forming tools of a common mold carrier,by means of which simultaneous foaming of the first and the second workpiece (31, 32) is possible.

Description

[0001] The invention relates to a system and a method for machining plate-shaped workpieces for a motor vehicle, each of which enables a time-saving and cost-effective construction of vehicle roofs for motor vehicles.

[0002] Methods for machining a plate-shaped workpiece require special tools that enable the desired machining operation. Document DE 10 2016 105 900 A1 discloses a device for machining a workpiece for a motor vehicle, comprising a lower tool with a holding area for the workpiece and a movable flap element. A cavity can be formed on the workpiece by means of the flap element. Documents DE 10 2006 021 021 A1 and EP 1 484 151 A2 disclose further devices or methods for manufacturing or machining components for a motor vehicle.

[0003] For example, when manufacturing and attaching a foam overlay to a vehicle windshield, the windshield to be processed is treated using a special tool, and the foam overlay is formed on the windshield. This makes it possible to connect components to the windshield and also prepare for attaching the windshield to a vehicle body.

[0004] A special foaming tool required for this typically has two mold halves, which are coordinated as an upper and lower part and enable the formation of foamed parts. The tool halves must be held in respective mold carriers and movable to enable the desired formation of foamed parts. Such a foamed part formation is described, for example, in document EP 0355209 B1. After the foaming process has been completed, the processed pane can be removed, and another pane can be inserted and processed.

[0005] It is an object underlying the invention to provide a system and a method for machining plate-shaped workpieces for a motor vehicle, each of which is suitable for enabling a time-saving and cost-effective construction of vehicle roofs for motor vehicles.

[0006] The problem is solved by the features of the independent patent claims. Advantageous further developments are specified in the respective dependent claims.

[0007] A system according to the invention for machining plate-shaped workpieces for motor vehicles comprises a first molding tool with a first lower tool and a first upper tool. The first upper tool is translationally and / or rotationally movable relative to the first lower tool in order to change from a first state to a second state by means of a translational movement and / or by folding, so that a first cavity can be formed between the first molding tool and a first workpiece. The system further comprises a second molding tool with a second lower tool and a second upper tool.The second upper tool is translationally and / or rotationally movable relative to the second lower tool in order to change from a first state into a second state by means of a translational movement and / or by folding, so that a second cavity can be formed between the second molding tool and a separate second workpiece, independently of the first cavity. The first and second lower tools set up two separate lower tools of a common mold carrier or form a common lower tool of a common mold carrier. The first and second mold tools are designed such that they set up separate molding tools of a common mold carrier, by means of which simultaneous foam encapsulation of the first and second workpieces can be carried out.

[0008] The system enables a foam-encapsulation unit that allows for the simultaneous foam-encapsulation of multiple workpieces using different tools. This enables the time-saving and cost-effective construction of vehicle roofs. A plate-shaped workpiece that can be processed using the described method is, in particular, a glass pane for a vehicle. The glass pane forms, for example, a component of a cover for a vehicle roof and, as a plate-shaped workpiece, can also have a predetermined curvature.

[0009] Alternatively or additionally, the respective upper tool can be configured to perform a purely rotary movement. This rotary movement serves to provide accessibility during component changes. Closing the tool and thus forming a respective cavity is achieved by a translational movement of the respective lower tool and by moving the workpiece toward the corresponding upper tool.

[0010] It is a finding in connection with the invention that a conventional layout provides for one mold carrier per foaming line. A foaming line forms, for example, part of a production line for the workpiece to be processed, such as a glass lid. A conventional mold carrier therefore only accommodates one tool with one cavity, so that workpieces can only be processed one after the other. The reaction time for polyurethane, which is usually used as an overfoam material, is approximately 45 to 50 seconds. The reaction time comprises, for example, the period between the end of the material introduction and the opening of the mold and accounts for a relatively large part of the total cycle time of the foaming process. Accordingly, with a conventional mold carrier, the reaction time occurs for each foamed glass element.In addition, each foaming line requires its own mold carrier including peripherals, such as a booth, an extraction device, a release agent supply and a PU supply.

[0011] The described system is configured to simultaneously encapsulate or foam over a first and a second workpiece, which are particularly realized as discs. However, the system can also be used to encapsulate workpieces sequentially or consecutively. In this context, simultaneity does not refer to an exact time span, but rather to an overlapping period of the encapsulation processes of the first and second workpieces. For example, a reaction time for curing polyurethane foam is approximately 45 to 50 seconds. The reaction time encompasses, for example, a period from the end of material introduction into a cavity until the opening of the mold.

[0012] Furthermore, with simultaneous foaming, a further time period can be reduced, which relates to the opening and closing of the mold. This additional time period includes, for example, the requirement for the material to be introduced and the development of a predetermined operating pressure for carrying out a reliable foaming process. This additional time period is, for example, 10 to 20 seconds. Using the described system, for example, the foaming process can be started on the first workpiece and, a few seconds later, the foaming process on the second workpiece can be initiated. This results in a time saving of approximately one minute per workpiece.

[0013] In other words, the system is capable of performing a first foaming process on the first workpiece and, at the same time, a second foaming process on the second workpiece. It is therefore not necessary to wait for the first foaming process and remove the processed first workpiece before the second workpiece can be processed. Panel-shaped workpieces that are particularly suitable are windscreens for motor vehicles, which, for example, are foamed or foamed with polyurethane foam to enable attachment to a vehicle roof or body. If necessary, additional elements are foamed in and pre-positioned on the windscreen.

[0014] Furthermore, the system can also be used to process a single pane of glass. This is ideal, for example, for relatively large panes of glass used in motor vehicles, such as a panoramic roof or a large glass cover for a vehicle.

[0015] The first lower tool of the first mold and the second lower tool of the second mold form, for example, a common lower tool. The common lower tool can, for example, be formed as a single piece and accommodate a first pane in one area and a second pane in another area for motor vehicles, which can be foamed over or over-foamed simultaneously using the system.

[0016] According to a further development of the system, the first upper tool of the first forming tool and the second upper tool of the second forming tool are configured in a coordinated manner such that they each seal with each other in the second state. Such a sealing configuration is particularly suitable for relatively large workpieces that can be machined individually in the system.

[0017] The system can, in particular, comprise foldable upper tools that can be folded around predetermined pivoting or folding axes to form one or more designated cavities in interaction with a respective surface of the workpiece. In the second folded or closed state of the system, the upper tools have sealing elements, such as sealing lips, on the facing edges, for example, which enable a flush and secure sealing of the surface of the workpiece(s).

[0018] In addition, the upper tools are preferably designed such that they engage or lock with one another in the second, closed state, thus enabling secure and reliable closure of the molding tools. For example, one of the upper tools has protruding regions on the edge facing the other upper tool in the second state, which interact with corresponding recesses on the corresponding edge of the other upper tool and enable reliable locking. The edge of the upper tool with the protruding regions is then U-shaped, for example.

[0019] According to a particularly preferred development, the first upper tool of the first forming tool and the second upper tool of the second forming tool are each frame-shaped, so that in the second state they each establish a freely accessible inner region for further processing of the first and / or the second workpiece. Alternatively, only one of the two upper tools is frame-shaped and enables the establishment of a freely accessible inner region in the second, closed state. Thus, using the described system, it is possible to foam-coat two workpieces simultaneously and to carry out, for example, an adhesive process in an inner region without changing machines. In this way, a contribution can be made to the low-complexity, time-saving and cost-effective construction of vehicle roofs.

[0020] The respective upper tools of the first and second forming tools can further be designed in coordination with one another such that, with respect to the second closed state, they are each arranged at a distance from one another and establish a freely accessible inner region between one another for further processing of the first and / or the second workpiece. Thus, alternatively or in addition to the previously described open area within the first and / or second upper tools, a predetermined free distance can be established between the upper tools, which enables the integration of further work steps. For example, the first and second upper tools are frame-shaped and, with respect to the second state, each have a U-shape on mutually facing edges, which couples to one another and forms a further freely accessible inner region.Accordingly, a first free inner region could be formed by the frame-shaped first upper tool, a second free inner region by the frame-shaped second upper tool and a third free inner region between the upper tools, which is enclosed in a frame-like manner by the U-shaped edges of the upper tools.

[0021] The upper tools of the respective molds can be designed such that a continuous and / or a discontinuous foam coating can be formed on an edge and / or on a top or bottom side of motor vehicle windshields. In particular, several plate-shaped workpieces can be processed simultaneously, so that the described system enables reliable and time-saving processing of windshields and other plate-shaped workpieces for a motor vehicle.

[0022] Using the described system, an advanced mold carrier can be realized that can accommodate two different tools and process two workpieces simultaneously. The system can also be supplemented with additional components to enable a particularly time-saving processing of discs. By combining it with an industrial robot to guide a mixing head, the mold carrier or the system with the two tools including the necessary peripherals can be used for two foaming lines. Furthermore, an implementation without industrial robots, instead with two mixing heads, for example, is also conceivable. The system can also include two copies of the components required for supplying polyurethane, such as a universal foaming unit, piping, pressure gauges, etc. This is necessary, for example, if two mixing heads are to be used.

[0023] Thus, using the described system, the reaction time for two or, depending on the respective component size, for several glass elements can be at least partially parallel. A common mold carrier, including peripherals, can be used simultaneously for two foaming lines.

[0024] A method according to the invention for machining plate-shaped workpieces for motor vehicles using an embodiment of the system described above comprises providing a first plate-shaped workpiece and a second plate-shaped workpiece separate from the first workpiece, as well as providing a first forming tool with a first lower tool and a first upper tool, and a second forming tool with a second lower tool and a second upper tool. The first upper tool is translationally and / or rotationally movable relative to the first lower tool, and the second upper tool is translationally and / or rotationally movable relative to the second lower tool. The first and second lower tools set up two separate lower tools of a common mold carrier, or they set up a common lower tool of a common mold carrier. The first and second forming tools form separate forming tools of a common mold carrier.The method further comprises positioning the first workpiece and the first lower tool relative to one another and positioning the second workpiece and the second lower tool relative to one another. The method further comprises translating and / or folding the first upper tool from a first state into a second state and thereby forming a first cavity between the first mold and the first workpiece. The method further comprises translating and / or folding the second upper tool from a first state into a second state and thereby forming a second cavity between the second mold and the second workpiece independently of the formation of the first cavity.The method further comprises foaming the first and second workpieces by introducing a predetermined material into the first cavity and introducing a predetermined material into the second cavity and thereby forming a first foam coating on the first workpiece and forming a second foam coating on the second workpiece.

[0025] The described method enables cost-effective and time-saving machining of plate-shaped workpieces for motor vehicles. The method particularly comprises the use of an embodiment of the previously described system for machining plate-shaped workpieces, so that all features and properties of the previously described system are also disclosed for the corresponding method, and vice versa.

[0026] The foam coating of the first and second workpieces can be carried out sequentially, one after the other. In particular, the foam coating of the first and second workpieces is carried out simultaneously.

[0027] Alternatively or additionally, the respective upper tool can be configured to perform a purely rotary movement relative to the corresponding lower tool. This rotary movement serves to provide accessibility during a component change. Closing the respective upper tool and thus forming a respective cavity is achieved by a translational movement of the respective lower tool and by moving the workpiece toward the corresponding upper tool.

[0028] According to a further development of the method, in which the first and second molding tools are each in the second closed state, an attachment element is arranged on the first or second workpiece by means of an adhesive process in a freely accessible inner region of the first upper tool, the second upper tool, and / or between the first and second upper tools, which is freely accessible for further processing. The first and / or second upper tools are, in particular, frame-shaped to enable the establishment of one or more freely accessible inner regions.

[0029] According to a further development, the method comprises pretreating the first and / or second workpiece prior to the simultaneous foaming. The pretreatment comprises, for example, cleaning a surface of the first and / or a surface of the second workpiece and applying an adhesion promoter to the cleaned surface of the first and / or the cleaned surface of the second workpiece.

[0030] According to a further development, the method comprises post-treating the first and / or second workpiece following the simultaneous foaming. The post-treatment includes, for example, cleaning and deburring the foamed surface of the first and / or the foamed surface of the second workpiece.

[0031] Embodiments of the invention are explained in more detail below with reference to the schematic drawings. They show: Fig. 1 a vehicle roof in perspective view, Fig. 2 a flow chart for a method for machining plate-shaped workpieces for a motor vehicle, Fig. 3 an embodiment of a system for machining plate-shaped workpieces for a motor vehicle, Fig. 4 shows a further embodiment of the system for machining plate-shaped workpieces for a motor vehicle, and Fig. 5 an embodiment of a first and a second simultaneously foam-coated workpiece.

[0032] Elements of the same design or function are identified by the same reference symbols throughout the figures. For reasons of clarity, not all elements shown may be identified by reference symbols in all figures.

[0033] Fig. 1 schematically shows a perspective view of a motor vehicle 1 with a vehicle roof 3, which has a cover 5 machined as a plate-shaped workpiece for use in the vehicle roof 3. The cover 5 is, for example, a fixed glass element immovable relative to the vehicle roof 3. Alternatively, the cover 5 is movable relative to the vehicle roof 3 to selectively open and close an opening in the vehicle roof 3.

[0034] The lid 5 has, for example, a foaming or foaming 33, 34, which realizes a plastic molding, which is produced as part of a method for processing the lid 5 by means of a special system 10 according to the Fig. 3 and Fig. 4 can be produced with little effort, time and cost. As can be seen from the following Fig. 2 to 5, the system 10 capable of doing so implements a special forming tool and enables advantageous machining of a plate-shaped workpiece for a motor vehicle 1.

[0035] Fig. 2 shows a flowchart for a method for machining a first and a second plate-shaped workpiece 31, 32 for motor vehicles 1, which can be carried out using the system 10. The system has a first forming tool 11 with a first lower tool 12 and a first upper tool 13, and a second forming tool 21 with a second lower tool 22 and a second upper tool 23. The first upper tool 13 is translationally and / or rotationally movable relative to the first lower tool 12, and the second upper tool 23 is translationally and / or rotationally movable relative to the second lower tool 22. The first and second forming tools 11, 21 form different forming tools of a common mold carrier.

[0036] The first and second workpieces 31, 32 can, for example, be identical in terms of their geometry, i.e., have the same dimensions and be intended, for example, for installation in two vehicle roofs. Alternatively, the first and second workpieces 31, 32 can also be intended to form a front and a rear cover of a sunroof. The thickness or strength of the first and second workpieces 31, 32 can also be the same or vary.

[0037] The molds 11, 21 are configured to change from a first, open state Z1 into a second, closed state Z2 by means of a translational movement and / or by folding the respective upper tool 13, 23. In the respective closed, second state Z2, a first cavity 14 is formed between the first mold 11 and the first workpiece 31, and a second cavity 24 is formed between the second mold 21 and the second workpiece 32. The first and second molds 11, 21 form different molds of a common mold carrier, so that simultaneous foam encapsulation of the first and second workpieces 31, 32 is possible.

[0038] According to the Fig. 2, the first workpiece 31 is pretreated in a step S1A. For example, a surface of the first workpiece 31 to be foamed is cleaned and provided with an adhesion promoter.

[0039] Accordingly, in step S1B, the second workpiece 32 is pretreated. In this step, too, for example, a surface of the second workpiece 32 to be foamed is cleaned and provided with an adhesion promoter.

[0040] In a subsequent step S2, the first and second workpieces 31, 32 are simultaneously foam-coated using the system 10. The respective foam-coating processes do not have to start and end at exactly the same time, but at least some temporal overlap is present. The foam-coating of the first workpiece 31 takes place at least partially at the same time as the foam-coating of the second workpiece 32, so that one foam-coating process does not have to be completed before the other can be carried out. Step S2 includes, for example, positioning the first workpiece 31 and the first lower tool 12 relative to one another and positioning the second workpiece 32 and the second lower tool 22 relative to one another.Furthermore, the first upper tool 13 is moved translationally and / or folded over from the first state Z1 into the second state Z2, thereby forming the first cavity 14 between the first mold 11 and the first workpiece 31. The second upper tool 23 is also moved translationally and / or folded over from the first state Z1 into the second state Z2, thereby forming the second cavity 24 between the second mold 21 and the second workpiece 32. The first and second workpieces 31, 32 are then simultaneously foamed over by introducing a predetermined material into the first cavity 14 and introducing a predetermined material into the second cavity 24, thereby forming a first foam 33 on the first workpiece 31 and forming a second foam 34 on the second workpiece 32 (see . Fig. 5).

[0041] In a step S3A, for example, a post-treatment of the foamed first workpiece 31 takes place. For example, the foamed surface of the first workpiece 31 is cleaned and deburred.

[0042] Accordingly, in a step S3B, the second foamed workpiece 32 is post-treated and the foamed surface of the second workpiece 32 is cleaned and deburred.

[0043] The Fig. 3 and Fig. 4 show schematic views of embodiments of the system 10. According to Fig. 3, the respective upper tools 13 and 23 of the first and second molds 11 and 21 are in the open, first state Z1 and can change into the second, closed state Z2 by folding about respective pivot or folding axes A1 and A2. The lower tools 12 and 22 of the two molds 11, 21 can form a common, in particular one-piece, lower tool or be configured separately from one another. The lower tools 12 and 22 can also form components that are coupled to a common mold carrier.

[0044] According to Fig. 4, the system 10 is illustrated in the respectively closed, second state Z2, in which the respective molds 11 and 21 together with the inserted workpieces 31 and 32 form one or more predetermined positioned cavities 14, 24.

[0045] By means of the described system 10, a tool for machining plate-shaped workpieces 31, 32 for a motor vehicle 1 can be realized, which can contribute to a particularly cost-effective and time-saving machining of the workpieces 31, 32. List of reference symbols 1 motor vehicle 3 Vehicle roof 5 lids 10 systems 11 first mold 12 first lower tool of the forming tool 13 first upper tool of the forming tool 14 first cavity 21 second mold 22 second lower tool of the forming tool 23 second upper tool of the forming tool 24 second cavity 31 first plate-shaped workpiece 32 second plate-shaped workpiece 33 first foam coating 34 second foam coating A1 first axis of the first forming tool A2 second axis of the second forming tool S(i) Steps of a process for simultaneous foaming with two molds Z1 first, open state of the first or second mold Z2 second, closed state of the first or second mold

Claims

[1] System (10) for machining plate-shaped workpieces (31, 32) for a motor vehicle (1), comprising: - a first molding tool (11) with a first lower tool (12) and a first upper tool (13), wherein the first upper tool (13) is movable translationally and / or rotationally relative to the first lower tool (12) in order to change from a first state (Z1) by means of a translational movement and / or by folding into a second state (Z2), so that a first cavity (14) can be formed between the first molding tool (11) and a first workpiece (31), and - a second mold (21) with a second lower tool (22) and a second upper tool (23), wherein the second upper tool (23) is translationally and / or rotationally movable relative to the second lower tool (22) in order to change from a first state (Z1) by means of a translational movement and / or by folding into a second state (Z2), so that a second cavity (24) can be formed separately from the first cavity (14) between the second mold (21) and a second workpiece (32) separate from the first workpiece (31), wherein the first lower tool (12) and the second lower tool (22) establish two separate lower tools of a common mold carrier or establish a common lower tool of a common mold carrier, and wherein the first and the second mold (11, 21) are designed such that they establish separate tools of a common mold carrier,by means of which a simultaneous foam coating of the first and the second workpiece (31, 32) can be carried out., [2] System (10) according to claim 1, wherein the first upper tool (13) of the first forming tool (11) and the second upper tool (23) of the second forming tool (21) are designed in coordination with one another such that they are each sealingly coupled to one another in the second state (Z2). [3] System (10) according to one of claims 1 to 2, wherein the first upper tool (13) of the first forming tool (11) and the second upper tool (23) of the second forming tool (21) are each frame-shaped, so that in the second state (Z2) they each establish a freely accessible inner region for further processing of the first and / or the second workpiece (31, 32). [4] System (10) according to one of claims 1 or 3, insofar as this is dependent on claim 1, in which the first upper tool (13) of the first forming tool (11) and the second upper tool (23) of the second forming tool (21) are designed in coordination with one another such that they are each arranged at a distance from one another in the second state (Z2) and establish a freely accessible inner region between one another for further processing of the first and / or the second workpiece (31, 32). [5] Method for machining plate-shaped workpieces (31, 32) for a motor vehicle (1) by means of a system (10) according to one of the preceding claims, comprising: - Providing a first plate-shaped workpiece (31) and a second plate-shaped workpiece (32) separate from the first workpiece (31), - Providing a first molding tool (11) with a first lower tool (12) and a first upper tool (13), wherein the first upper tool (13) is translationally and / or rotationally movable relative to the first lower tool (12), - Providing a second molding tool (21) with a second lower tool (22) and a second upper tool (23), wherein the second upper tool (23) is translationally and / or rotationally movable relative to the second lower tool (22), wherein the first lower tool (12) and the second lower tool (22) establish two separate lower tools of a common mold carrier or establish a common lower tool of a common mold carrier, and wherein the first and the second molding tools (11, 21) are designed such that they establish separate molding tools of a common mold carrier (10), - positioning the first workpiece (31) and the first lower tool (12) relative to each other, - positioning the second workpiece (32) and the second lower tool (22) relative to each other, - translational movement and / or folding of the first upper tool (13) starting from a first state (Z1) into a second state (Z2) and thereby forming a first cavity (14) between the first mold (11) and the first workpiece (31), - translational movement and / or folding of the second upper tool (23) starting from a first state (Z1) into a second state (Z2) and thereby forming a second cavity (14) between the second mold (21) and the second workpiece (32) independently of the formation of the first cavity (14), and - Foaming the first and second workpieces (31, 32) by introducing a predetermined material into the first cavity (14) and introducing a predetermined material into the second cavity (24) and thereby forming a first foaming (33) on the first workpiece (31) and forming a second foaming (34) on the second workpiece (32). [6] Method according to claim 5, wherein the foaming of the first and second workpieces (31, 32) is carried out simultaneously. [7] Method according to claim 5 or 6, wherein the first and second molding tools (11, 21) are each in the second state (Z2), comprising: Arranging an attachment element on the first and / or the workpiece (31, 32) by means of an adhesive process in an inner region of the first upper tool (13) and / or the second upper tool (23) and / or between the first and the second upper tool (13, 23), which is freely accessible for further processing. [8] A method according to any one of claims 5 to 7, comprising: Pretreating the first and / or second workpiece (31, 32) prior to the simultaneous foaming. [9] Method according to claim 8, wherein the pretreatment of the first and / or second workpiece (31, 32) comprises: Cleaning a surface of the first and / or a surface of the second workpiece (31, 32) and applying an adhesion promoter to the cleaned surface of the first and / or the cleaned surface of the second workpiece (31, 32). [10] A method according to any one of claims 5 to 9, comprising: Post-treatment of the first and / or second workpiece (31, 32) following the simultaneous foaming. [11] Method according to claim 10, wherein the post-treatment of the first and / or second workpiece (31, 32) comprises: Cleaning and deburring the foamed surface of the first and / or the foamed surface of the second workpiece (31, 32).

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