Method for controlling a production process for motor vehicles, production facility for motor vehicles and computer program

Abstract

Method (100) for controlling a production process for motor vehicles (10, 10a, 10b), wherein at least one motor vehicle (10, 10a, 10b) in a production process has sensors (15), wherein the sensors (15) record sensor data during the production process, wherein the sensor data are evaluated during the production process for controlling the production process, characterized in that the sensor data recorded by a sensor (15) of a first motor vehicle (10, 10a) relates to a second motor vehicle (10, 10b), wherein the sensor data are evaluated for product control and / or quality control of the second motor vehicle (10, 10b).

Description

The present invention relates to a method for controlling a production process for motor vehicles, wherein at least one motor vehicle in a production process has sensors. The present invention further relates to a production facility for motor vehicles and a computer program product for carrying out a method for controlling a production process for motor vehicles. The production process for motor vehicles is very complex. During the manufacturing of a vehicle, continuous quality controls must be carried out to detect defects early and, ideally, prevent them altogether. In current technology, quality control is usually performed by employees or by stationary sensors, such as camera systems installed on the assembly line's overhead structure. This form of quality control can only be performed between individual assembly steps, which increases production time. Furthermore, it requires additional investment in the sensor technology. DE 10 2015 214 987 A1 discloses a method for identifying a defective component of a vehicle, wherein sound waves from the vehicle are detected by means of sensor means which are arranged outside the vehicle and generate sound data depending on the detected sound waves. The defective component is identified by analyzing the sound data. US patent 2020 / 0272137A1 discloses an automated system for detecting manufacturing defects. A processing circuit receives historical part statistics relating to the failure of parts used in a vehicle assembly, vehicle sensor statistics relating to the failure of parts from vehicles after manufacturing, and assembly line statistics relating to errors in the assembly of parts during vehicle assembly. DE 10 2016 004 204 B4 relates to a method for the automated maneuvering of a motor vehicle during the production and / or development of the motor vehicle, in which maneuvering data is determined by means of a motor vehicle-external control computer and transmitted to a control unit of the motor vehicle, a control signal for the automated maneuvering of the motor vehicle is determined by means of the control unit based on the maneuvering data, environmental data is determined with at least one motor vehicle-internal sensor and the control signal is additionally determined by means of the control unit based on the environmental data, wherein the maneuvering data and the environmental data are fused to determine the control signal. DE 10 2013 016 245 A1 relates to a method for the detection and output of real non-visible objects in an environment, in particular a vehicle interior, wherein at least one digital image of the environment is taken, wherein the taken image is displayed as an output image forming a background on a display, wherein the real non-visible object, marked by means of a marker, is detected on the basis of reflected light in the non-visible wavelength range, and upon detection and identification of the marker of the real object, a virtual additional information is generated for it and superimposed in the output image. The systems and methods described in US 2017 / 0 154 386 A1 use a tracking device or system installed early in the manufacturing process to determine the location of a vehicle under construction. This tracking device allows the vehicle's status to be determined even when multiple companies are involved in its production. In certain embodiments, tracking the manufacturing process across different manufacturers can improve workload distribution among them, leading to more efficient production. Furthermore, the tracking can more accurately allocate vehicle assignments before new vehicles are received, resulting in further workload optimization. German patent application DE 10 2021 123 931 A1 provides a system and method for autonomously navigating a vehicle in a manufacturing environment. A method for autonomously navigating a specific vehicle from among a multitude of vehicles in an environment involves determining whether the vehicle should be moved from a first post-production location to a second post-production location within the environment, based on transport planning data assigned to the vehicle. The method includes executing a navigation routine in response to the transport planning data indicating that the vehicle should be moved.The navigation route includes obtaining location data associated with the multitude of vehicles, identifying a vehicle path for the vehicle in question based on the location data of the multitude of vehicles, the first post-production location, the second post-production location, or a combination thereof, and instructing the vehicle in question to autonomously drive along the vehicle path to the second post-production location. US patent 2019 / 0346313A1 discloses a smart component consisting of a body manufactured using a 3D additive manufacturing (AM) process, featuring high- and low-stress areas. During operation, the high-stress area is subjected to greater stress than the low-stress area. The component also incorporates a resistive-voltage sensing strip embedded in the high-stress area during the AM process. This strip is configured to generate a variable output signal. Finally, the component is equipped with a temperature sensor embedded in the low-stress area during the AM process. This sensor is also configured to generate a variable output signal based on temperature. The present invention is based on the objective of providing a method for controlling a production process for motor vehicles, with which the manufacturing time is reduced and the costs are reduced. To solve the problem underlying the invention, a method for controlling a production process for motor vehicles is proposed, wherein at least one motor vehicle in a production process has sensors, and the sensor data are evaluated during the production process for controlling the production process. The production process can also be referred to as the manufacturing process or production method. The at least one motor vehicle involved in the production process is specifically a motor vehicle to be produced or manufactured within the framework of the production process. This can particularly mean that the motor vehicle is not yet completed during the execution of the process, or is currently in production. According to the invention, the motor vehicle, which is preferably in production, comprises sensors in the production process, i.e., while the production process is being carried out, which are suitable at the time of carrying out the process to record sensor data. Therefore, the procedure for controlling a production process for motor vehicles is preferably carried out when the motor vehicle to be produced has a predetermined degree of completion at which at least the sensors used in accordance with the procedure are present in the motor vehicle. The essential feature of the method according to the invention is that sensor data is acquired by the vehicle's sensors during the production process and that this sensor data is also evaluated during the production process for process control. In other words, the sensor data is not historical data acquired in the past and used as the basis for the process control, even though such historical data can, in principle, be incorporated into the method. Rather, the sensor data acquired by the vehicle's sensors is evaluated essentially immediately or very soon after the production process. The evaluated sensor data can then also be used essentially immediately or very soon after the production process to control it and, if necessary, to influence it. It is preferably intended that several, and in particular preferably all, motor vehicles in the production process are equipped with sensors. Thus, several or all motor vehicles manufactured or to be manufactured within the production process already have sensors suitable for carrying out the process during production. It may be further preferably provided that the sensors include radar sensors and / or LIDAR sensors and / or cameras and / or microphones and / or ultrasonic sensors. In principle, any type of sensor can be used in the process, provided that the sensor is part of the motor vehicle or the motor vehicle to be manufactured as part of the production process. The sensors are therefore not limited to radar sensors, LiDAR sensors, cameras, microphones, or ultrasonic sensors. For example, the sensor data could be image data captured by a vehicle camera. In this example, the image data is evaluated for monitoring the production process. The sensor data is preferably evaluated for product control and / or quality control and / or process control and / or production optimization. The sensor data can be used for quality control or product inspection of the vehicle being produced, or of other vehicles being manufactured within the production process. Furthermore, the sensor data can be used for process control, specifically for monitoring production or assembly steps. Finally, the sensor data can be used to support the production process, particularly production workflows and / or logistics, and thus optimize production. As part of process control, the sensor data recorded by the sensors—for example, image data captured by a vehicle's camera or audio data captured by a vehicle's microphone—can be analyzed to determine whether a robot, a worker, or a human-robot collaboration (HRC) has performed work steps correctly and / or in the correct sequence. If an error is detected during process control, corrective action can then be initiated. According to the invention, the sensor data recorded by a sensor of a first motor vehicle relates to a second motor vehicle. Furthermore, it is planned that the sensor data will be evaluated for product control and / or quality control of the second motor vehicle. In other words, the sensors of a first motor vehicle are used to record sensor data, which can be used to carry out production control and / or quality control and / or process control concerning a second motor vehicle. In this case, the vehicles in production essentially monitor each other; that is, preferably, the sensor data from one vehicle is used to perform production control, quality control, and / or process control on a vehicle ahead or behind it in the production process. For example, the first vehicle could be equipped with a camera to capture image data of a second vehicle located ahead or behind it in the production sequence. This image data can then be used for quality control of the second vehicle. The sensor data can be analyzed, for example, to determine whether the second vehicle in the production process has paint defects or soiling, whether the color of add-on parts, such as the roof rails, matches the vehicle's paint color, and whether the license plate holder or add-on parts, such as the antenna, are correctly installed. Furthermore, the sensor data from the first vehicle, pertaining to the second vehicle, can be used to perform functional checks, such as of the vehicle's lighting. Additionally, by analyzing the sensor data from the second vehicle, it can be determined whether screws are missing, parts have been omitted, or whether wiring has been correctly installed. A further advantage is that the sensor data recorded by a sensor of a first motor vehicle may relate to the first motor vehicle. Preferably, the sensor data can be evaluated for product control and / or quality control of the first motor vehicle. The sensor data recorded by the sensor can therefore also relate to the motor vehicle that includes the corresponding sensor. For example, image or audio data can be recorded using an interior camera or microphones installed inside the vehicle. This data can then be analyzed to determine whether clips are properly engaged or other connections are correctly made. The image data from the interior camera can be used to check whether country labels or other written information are present and / or correct. Preferably, the sensor data recorded by a sensor of a motor vehicle relates to the environment of the motor vehicle. The sensor data recorded by the motor vehicle, that is, in particular by the first and / or the second motor vehicle, need not only relate to the respective motor vehicle itself or to another motor vehicle. The sensor data can also relate to the motor vehicle's surroundings, that is, in particular to the production facility and / or production equipment. For example, sensor data relating to the vehicle's environment can be used to support modular production. Therefore, the production process can preferably be a modular production process. The sensor data is preferably evaluated for the control and / or route planning of driverless transport systems. This allows sensor data to be analyzed to provide information for automated guided vehicles (AGVs), which can then be used for route planning. The sensor data recorded by the vehicle's sensors, relating to the environment, can be used to determine whether the route is clear for the AGV, whether people are nearby, and so on. The sensor data can also be used to support the logistics necessary for the production process. Furthermore, the sensor data can be evaluated to track the motor vehicle or components for the motor vehicle(s) before, during or after assembly in factory logistics. Preferably, the sensor data is transmitted, preferably via a wireless communication link, to a central computing unit, the central computing unit evaluating the sensor data for the control of the production process. The central processing unit can be, in particular, a server or production server for the production process. Sensor data is preferably transmitted via a wireless communication connection, which can be a WLAN or 5G connection. Alternatively, vehicle connectivity modules can be used to transmit the sensor data wirelessly. The evaluation of the sensor data is therefore preferably not carried out in the vehicle itself, but via an external computing unit or an external server. It is particularly preferred that the wireless communication connection be a 5G connection, as this reliably enables high uplink data rates. Preferably, the sensors are part of a system for autonomous driving functions of the motor vehicle, and / or the sensors are intended for integration into a system for autonomous driving functions of the motor vehicle. Current and especially future vehicles will increasingly use systems for automated or autonomous driving functions. For these systems to work, vehicles must be equipped with extensive sensor technology, meaning a large number of sensors. The sensors in question can therefore be, in particular, sensors intended for an autonomous driving system of the vehicle. The integration of these sensors into the autonomous driving system can take place during the production process. A particular advantage of using sensors that are part of a vehicle's autonomous driving system is that no additional sensors are required. Instead, the process utilizes the sensors that are already intended for installation in the vehicle. It may preferably be provided that the motor vehicle with the autonomous driving system meets at least a level 4 automation standard. Furthermore, it may be provided that the motor vehicle drives autonomously or automatically from one assembly station to the next assembly station in the production process. In particular, if the vehicle is equipped with an autonomous driving system that meets Level 4 automation, this system can also be used during the production process itself. For example, the vehicle can be configured to drive autonomously or automatically from one assembly station to the next using the autonomous driving system, which fully utilizes the sensors that generate the sensor data. The vehicle can thus drive autonomously, and in particular independently, through the assembly process from one assembly station to the next. However, it is also possible for the vehicle not to drive fully autonomously to the assembly stations. The vehicle can, in particular, be transferred from one assembly station to the next in a known manner. In this case, the sensor data can be used to support the transfer of the vehicle between the assembly stations. Preferably, the motor vehicle in the production process is a partially finished or not fully completed motor vehicle. The vehicles to be produced in the production process can therefore also be described as partially finished or not fully completed motor vehicles and are in a particularly early stage of assembly. In this context, it can be particularly advantageous to transmit the sensor data to the central processing unit via a wireless communication link. In the early stages of vehicle assembly, the sensor data is usually not processed directly within the vehicle itself; for example, no compression or sensor data fusion takes place. Since this preprocessing does not occur, or rather, since the vehicle is generally not yet equipped during the production process to process the sensor data in accordance with the method, it is particularly advantageous to transmit the sensor data to the central processing unit via the preferably wireless communication link. A further advantage is that the vehicle is designed as a rolling chassis. A rolling chassis is understood to be, in particular, a vehicle in a stage of assembly which includes at least the chassis, drive, wheels and sensors. Such a rolling chassis can, in particular, move automatically through the assembly process and flexibly control workstations or assembly stations within the framework of modular assembly or matrix production. Preferably, the vehicle is integrated into an Internet of Things via the sensors. A further advantage is that the sensors are intended to form a sensor network for controlling the production process. Another solution to the problem underlying the invention consists in providing a production facility for motor vehicles with sensors, comprising a central computing unit, designed to carry out a previously described method. The production facility is thus intended for the production of motor vehicles, which include sensors that are used according to the aforementioned procedure. The production facility also has a central processing unit that receives the sensor data acquired by the vehicle sensors during the production process and evaluates this data for the purpose of controlling the production process. Another solution to the problem underlying the invention consists of a computer program product comprising instructions which, when the program is executed by a central computing unit of a previously described production facility, cause it to execute a previously described method. In particular, the computer program product includes commands that cause the computing unit to receive sensor data from sensors of motor vehicles in the production process and to evaluate this sensor data with regard to controlling the production process. The invention is explained in more detail below with reference to the accompanying figures. Figure 1 shows a flowchart of a method for controlling a production process for motor vehicles, and Figure 2 shows a production facility for motor vehicles. A method 100 for controlling a production process for motor vehicles 10 is explained below with reference to the figures, where Fig. 1 shows a flowchart of the method 100 and Fig. 2 shows a production facility 200, which is set up for carrying out the method 100 for controlling a production process for motor vehicles 10. Motor vehicles 10 are manufactured or produced in the production facility 200 as part of a production process. The motor vehicles 10 are in an early assembly stage. The motor vehicles 10 are designed as rolling chassis 11 with a chassis 12, a drive 13, and wheels 14 and already have sensors 15, which in the completed motor vehicle 10 are part of a system for autonomous driving functions. The sensors can be, among others, radar sensors 16, LiDAR sensors, cameras 17, or microphones 18.In a first process step S1, the sensors 15 of a first motor vehicle 10a record sensor data during the production process. This sensor data can pertain to the first motor vehicle 10a itself or to a second motor vehicle 10b. The sensor data is transmitted via a wireless communication link 19, such as a 5G network, to a central computing unit 20 at the production facility 200, which is configured as a production server. In a second process step S2, the central computing unit 20 evaluates the sensor data for monitoring the production process. For this purpose, the central computing unit 20 executes a computer program 300 designed to carry out the process 100. For example, the sensor data can be used for production control or quality control of the vehicles 10, 10a, 10b during the production process. It is possible to analyze image data of the second vehicle 10b, captured by the camera 17 of the first vehicle 10a, in order to check the second vehicle 10b for paint defects, soiling, or the correct installation of add-on parts. The sensor data can also be used for quality control of the respective vehicle 10, 10a, 10b itself. For example, audio data from the microphone 18 can be analyzed to determine whether clip connections are correctly engaged. Process control can also be carried out by evaluating the sensor data. For example, the image data from the cameras 17 of the vehicles 10, 10a, 10b can be used to determine whether work steps were carried out correctly or in the correct sequence by a robot 21 or a worker 22. Furthermore, it may be provided that the sensor data recorded by the sensors 15 of the motor vehicles 10, 10a, 10b relate to the environment 23, that is, in particular to the production facility 200. Such sensor data can then be evaluated to support the production process. For example, the sensor data can be evaluated for route planning of driverless transport systems 24. A particular advantage arises when the motor vehicles 10, 10a, 10b have systems for autonomous driving functions, preferably with a high degree of automation of level 4. In this case, the production process can be highly automated, with the motor vehicles 10, 10a, 10b driving independently from one assembly station 25a to the next assembly station 25b. Reference symbol list 100 Methods for controlling a production process 200 Production facility 300 Computer program product 10 Motor vehicle 10a First motor vehicle 10b Second motor vehicle 11 Rolling chassis 12 Chassis 13 Drive 14 Wheel 15 Sensor 16 Radar sensors 17 Camera 18 Microphone 19 Wireless communication link 20 Central computing unit 21 Robot 22 Worker 23 Environment 24 Automated guided vehicle 25a Assembly station 25b Assembly station S1 Process step S2 Process step

Claims

Method (100) for controlling a production process for motor vehicles (10, 10a, 10b), wherein at least one motor vehicle (10, 10a, 10b) in a production process has sensors (15), wherein the sensors (15) record sensor data during the production process, wherein the sensor data are evaluated during the production process for controlling the production process, characterized in that the sensor data recorded by a sensor (15) of a first motor vehicle (10, 10a) relates to a second motor vehicle (10, 10b), wherein the sensor data are evaluated for product control and / or quality control of the second motor vehicle (10, 10b). Method (100) according to claim 1, wherein several, preferably all, motor vehicles (10, 10a, 10b) have sensors (15) in the production process. Method (100) according to claim 1 or 2, wherein the sensors (15) comprise radar sensors (16) and / or LIDAR sensors and / or cameras (17) and / or microphones (18) and / or ultrasonic sensors, and / or wherein the sensor data are evaluated for product control and / or quality control and / or process control and / or production optimization. Method (100) according to one of the preceding claims, wherein the sensor data recorded by a sensor (15) of a first motor vehicle (10, 10a) relates to the first motor vehicle (10, 10a), wherein preferably the sensor data are evaluated for product control and / or quality control of the first motor vehicle (10, 10a). Method (100) according to one of the preceding claims, wherein the sensor data recorded by a sensor (15) of a motor vehicle (10, 10a, 10b) relate to the environment (23) of the motor vehicle (10, 10a, 10b), wherein preferably the sensor data are evaluated for the control and / or route planning of driverless transport systems (24). Method (100) according to one of the preceding claims, wherein the sensor data are transmitted, preferably via a wireless communication link (19), to a central computing unit (20), wherein the central computing unit (20) evaluates the sensor data for the control of the production process. Method (100) according to one of the preceding claims, wherein the sensors (15) are part of a system for autonomous driving functions of the motor vehicle (10, 10a, 10b), and / or wherein the sensors (15) are provided for integration into a system for autonomous driving functions of the motor vehicle (10, 10a, 10b), wherein preferably the motor vehicle (10, 10a, 10b) with the system for autonomous driving functions fulfills at least a level of automation of level 4. Method (100) according to claim 7, wherein the motor vehicle (10, 10a, 10b) drives autonomously or automatically from one assembly station (25a) to the next assembly station (25b) in the production process. Method (100) according to one of the aforementioned claims, wherein the motor vehicle (10, 10a, 10b) in the production process is a partially finished, in particular not fully completed, motor vehicle (10, 10a, 10b). Method (100) according to one of the preceding claims, wherein the motor vehicle (10, 10a, 10b) is designed as a rolling chassis (11). Method (100) according to one of the preceding claims, wherein the motor vehicle (10, 10a, 10b) is integrated into an Internet of Things by means of the sensors (15). Method (100) according to one of the preceding claims, wherein the sensors (15) form a sensor network for controlling the production process. Production facility (200) for motor vehicles (10, 10a, 10b) with sensors (15), comprising a central computing unit (20), configured to carry out a method (100) according to one of the aforementioned claims. Computer program product (300), comprising instructions which, when the program is executed by a computing unit (20) of a production facility (200) according to claim 13, cause it to execute the method (100) according to any one of claims 1 to 12.

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