Process arrangement for the production of a body outer sheet metal part

Abstract

The invention relates to a process arrangement for manufacturing a body outer sheet metal part (1), in particular a tailgate outer sheet metal part, of a vehicle, which body outer sheet metal part (1) has a light cutout (3) that is at least partially bounded by an edge flange (5) which is bent inwards from an outer skin (7) of the body outer sheet metal part (1) about a sheet metal edge (9), wherein an attachment sheet metal part (11) is connected to the edge flange (5) in a joining connection (19). According to the invention, the joining connection is a roll seam weld (19) which can be produced with a roll seam welding device (21) of the process arrangement.

Description

[0001] The invention relates to a process arrangement for manufacturing a body outer sheet metal part according to the preamble of claim 1 and a method for manufacturing such a body outer sheet metal part according to claim 10.

[0002] A lighting element, such as a taillight or turn signal, is integrated into the tailgate of a vehicle of this type. The lighting element is installed in a light cutout in the outer sheet metal panel of the tailgate. The light cutout is at least partially bounded by an edge flange. This flange is bent inwards from the visible outer skin of the tailgate's outer sheet metal panel by a sheet metal edge. A component, which forms part of the light's support structure, is welded to the edge flange in an overlap weld. The edge flange and the outer skin of the tailgate's outer sheet metal panel define an inner corner area that tapers in a wedge shape towards the sheet metal edge.

[0003] With a tailgate designed at a shallow angle and a reduced height of the light cutout, tool access to the joint between the edge flange and the attachment is severely restricted, making a flawless component connection difficult to achieve.

[0004] From DE 36 07 394 A1, a method for producing weld seams using roller seam welding machines is known, in which the roller electrode axes intersect at an angle. The roller electrodes have differently shaped contact surfaces.

[0005] From CH 715 917 A1 a method for roll seam welding is known in which the rolling welding tool is cooled by means of cooling liquid.

[0006] The object of the invention is to provide a process arrangement by means of which a joining process for connecting the attachment part to the edge flange of the body outer sheet metal part can be carried out flawlessly in comparison to the prior art despite reduced tool accessibility.

[0007] The problem is solved by the features of claim 1 or 10. Preferred embodiments of the invention are disclosed in the dependent claims.

[0008] The invention relates to a process arrangement for manufacturing a body panel, in particular a tailgate panel, of a vehicle. The body panel has a cutout for a light, which is at least partially bounded by an edge flange. The edge flange is bent inwards from a visible outer skin of the body panel around a sheet metal edge. An attachment, which is part of a light support structure, is connected to the edge flange at a joint. The edge flange and the outer skin of the body panel form an inner corner area that tapers wedge-shaped towards the sheet metal edge. According to the characterizing part of claim 1, the following measures are taken to ensure a reliable joint despite reduced tool accessibility to the joint between the edge flange and the attachment.The joining connection between the edge flange and the attachment is a roll seam weld, which can be performed using a roll seam welding device within the process setup. The roll seam welding device has electrodes, one of which is positioned in the light fixture cutout during the welding process, while the counter electrode is contour-adapted and positioned in the inner corner area, which provides access for the counter electrode.

[0009] The edge flange, which is bent away from the outer skin of the body panel, is flat and / or approximately horizontally aligned in the vehicle's structural position. The attached panel is similarly flat. The roll weld joint can be implemented as an overlap weld, in which the edge flange and the attached panel are arranged in a common horizontal plane.

[0010] In one technical implementation, the counter electrode located in the inner corner area differs from the electrode positioned in the luminaire cutout in terms of its spatial orientation and / or dimensions. In a preferred embodiment, the electrode can be an electrode roller rotatably mounted on one clamping arm. The counter electrode can be an electrode roller rotatably mounted on the other clamping arm. Due to the limited space available in the inner corner area, the roller axes of the two electrodes are not parallel to each other, but rather inclined relative to each other, in order to position the counter electrode with sufficient clearance in the inner corner area between the outer skin and the edge flange.

[0011] The following configuration is particularly preferred due to the limited space available: In the inner corner area, the roller axis of the counter electrode can be oriented at an acute tool angle, oblique to the flat, especially horizontally oriented, edge flange. In contrast, the space available for the electrode is sufficiently large in the lamp section. Therefore, the roller axis of the electrode, which is designed as an electrode roller, can be oriented parallel to the flat edge flange. The acute tool angle of the counter electrode and a bend angle between the outer skin and the edge flange can preferably be of essentially the same size and be symmetrical with respect to an axis of symmetry oriented vertically to the common sheet metal part plane.In this case, the counter electrode, designed as an electrode roller, and the outer skin are aligned at approximately the same angle, so that a sufficiently large clearance is available for the counter electrode.

[0012] In an alternative design, the counter electrode can be configured not as an electrode roller, but rather as a wedge-shaped counterpart. This counterpart can also be wedge-shaped, contoured to the inner corner area, and securely attached to the clamping arm to prevent rotation.

[0013] In one specific embodiment, the two electrodes of the roll seam welding device can be made of a copper alloy. Furthermore, the two electrodes can be coolant-conducted. The resulting roll seam weld can be, for example, a continuous weld or, alternatively, a stitched weld with interrupted seams.

[0014] In one specific embodiment, the counter electrode, which can be positioned in the inner corner area, can be part of an electrode set with counter electrodes of different geometries. The counter electrode can also be interchangeably mounted on a clamping arm of the roll seam welding joint. In this case, a suitable counter electrode can be selected from the electrode set depending on the size of the inner corner area of ​​the body panel to be processed. The roll seam welding device can therefore be used for body panels with different component geometries.

[0015] The lap weld between the edge flange and the attachment can, for example, be an aluminum weld. In this case, the body's outer sheet metal part can, for example, be a 5000 or 6000 series aluminum alloy with a wall thickness of 1.0 to 1.3 mm, while the attachment sheet metal part can have a wall thickness of, for example, 1.0 to 1.7 mm. Particularly in combination with electrodes made of copper alloy, aluminum-copper phases can therefore form on the electrodes during the welding process. Against this background, a post-processing unit can be assigned to the roll seam welding device, by means of which electrode contamination, especially the aforementioned aluminum-copper phases, can be removed by grinding or milling. The post-processing unit can, for example, include a rolling milling or grinding element, such as a grinding wedge, which is contour-adapted to the two contact surfaces of the electrodes.

[0016] Exemplary embodiments of the invention are described below with reference to the accompanying figures.

[0017] They show: Fig. 1, Fig. 2, Fig. 3, Fig. 4 to Fig. 5 different views, each illustrating the structure and function of the process arrangement according to the invention.

[0018] In the Fig. Figure 1 shows an outer tailgate part 1 with a light cutout 3 in which a (not shown) taillight or turn signal can be positioned. As can be seen from the Fig. As can be seen from Figure 2, the light cutout 3 is partially bounded by a flat, horizontally oriented edge flange 5 in the illustrated construction position. The edge flange 5 extends from a sheet metal outer skin 7 of the tailgate outer part 1 with a bend angle β ( Fig. 3 or Fig. 4) bent towards the inside of the vehicle by a sheet metal edge 9.

[0019] The edge flange 5 is in the Fig. 2 in the longitudinal direction x towards the front of the vehicle is extended by an attachment sheet metal part 11, which is part of a light housing 13 that defines the light opening 3. The light housing 13 has a profiled base 15, which is attached to the attachment sheet metal part 11 by means of a known joining technique, such as semi-tubular punch riveting, resistance spot welding or clinching. Both the edge flange 5 and the attachment sheet metal part 11 are flat sheet metal parts that are located in a common sheet metal plane E ( Fig. 3 or Fig. 4) run. Between the edge flange 5 and the outer skin 7 of the tailgate outer sheet metal part 1, according to the Fig. 2, Fig. 3 to Fig. 4 an inner corner area 17 is spanned, which tapers in a wedge shape towards the sheet metal edge 9.

[0020] A key aspect of the invention is the joining connection between the edge flange 5 and the attached sheet metal part 11, which is produced via a roll seam weld 19, specifically in the manner of an overlap weld. To produce the roll seam weld 19, the tailgate outer sheet metal part 1 is transferred into a process arrangement which includes a roll seam welding device 21 ( Fig. 3 or Fig. 4) exhibits. Their electrodes 23, 24 are specially adapted to the confined tool accessibility of the joining point between the edge flange 5 and the attached sheet metal part 11, the joining point being realized as an overlap weld connection in which the edge flange 5 and the also flat attached sheet metal part 11 lie in a common horizontal component plane.

[0021] In the Fig. In section 3, the electrode 23 of the roll seam welding device 21 is positioned in the light fixture cutout 3, while the counter electrode 24 is positioned in the inner corner area 17 between the edge flange 5 and the outer skin 7. The electrode 23 is rotatably mounted on a movable clamping arm 25 of a roll seam welding gun 27. Similarly, the counter electrode 24 is also implemented as an electrode roll, rotatably mounted on a fixed clamping arm 29 of the roll seam welding gun 27. The roll seam welding gun 27 can preferably be operated by a robot. Due to the limited space available in the inner corner area 17, the roller axes R1, R2 of the two electrodes 23, 24 are not aligned parallel to each other, but rather are inclined relative to each other. This ensures that the counter electrode 24 can be positioned with sufficient clearance in the inner corner area 17 between the edge flange 5 and the outer skin 7.

[0022] Specifically, in the Fig. 3. Due to the limited space available, the roller axis R2 of the counter electrode 24 is aligned at an acute tool angle α obliquely to the flat, horizontally oriented edge flange 5. In contrast, the roller axis R1 of the electrode 23 is aligned parallel to the flat edge flange 5. The acute tool angle α and the bending angle β between the outer skin 7 and the edge flange 5 are essentially the same size. Furthermore, the acute tool angle α and the bending angle β between the outer skin 7 and the edge flange 5 are aligned with respect to a common sheet metal part plane E ( Fig. 3 or Fig. 4) The vertically oriented axis of symmetry is symmetrical to each other. In this way, the counter electrode 24, designed as an electrode roller, and the outer skin 7 are positioned parallel to each other at approximately the same angle.

[0023] According to the Fig. 3 The counter electrode 24, designed as an electrode roller, also has an outer circumference that is divided into a cylindrical circumferential section 26 and a conical circumferential flank 28. The conical circumferential flank 28 is in rolling contact with the joint during the roll seam welding process.

[0024] In the Fig. Figure 4 shows an alternative embodiment in which the counter electrode 24 is not designed as an electrode roller, but rather as a wedge-shaped electrode counterpart. The wedge shape of the electrode counterpart is contour-adapted to the wedge shape of the inner corner region 17. In contrast to the electrode roller, the wedge-shaped electrode counterpart is fixed to the fixed clamping arm 29 to prevent rotation.

[0025] The two electrodes 23, 24 can be made of a copper alloy, while the lap weld can be realized as an aluminum weld. In this case, intermetallic Al-Cu phases form during the welding process, which impair the functionality of the electrodes 23, 24. Against this background, according to the Fig. 5 of the roll seam welding device, a post-processing unit 31 is assigned by means of which electrode contamination, i.e., the Al-Cu phases, can be removed by grinding or milling. The post-processing unit 31 has a rotating, wedge-shaped milling or grinding element 33, which is designed in the manner of a grinding wedge. The grinding wedge is in the Fig.5 is positioned between the two electrode rollers of the roller seam gun 27. With a rotating grinding wedge, the Al-Cu phases are removed from the electrode rollers, thus restoring their functionality after a welding process. REFERENCE MARK LIST: 1 Body outer sheet metal part 3 light cutout 5 Edge flange 7 Outer skin 9 Sheet metal edge 11 Add-on sheet metal part 13 light pot 15 profile floor 17 Inside corner area 19 Roll seam weld joint 21 Roll seam welding device 23 electrode 24 Counter electrode 25 movable clamping arm 26 cylindrical circumferential section 27 Roll seam pliers 28 conical circumferential flank 29 fixed clamping arm 31 Post-processing unit 33 Milling or grinding element R1, R2 roller axles α Tool angle β Bending angle QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 36 07 394 A1

[0004] CH 715 917 A1

[0005]

Claims

[1] Process arrangement for the manufacture of a body outer sheet metal part (1), in particular a tailgate outer sheet metal part, of a vehicle, which body outer sheet metal part (1) has a light cutout (3) which is at least partially bounded by an edge flange (5) which is bent inwards from an outer skin (7) of the body outer sheet metal part (1) about a sheet metal edge (9), wherein an attachment sheet metal part (11) which is part of a light support structure (13) is connected to the edge flange (5) in a joining connection (19), and wherein the edge flange (5) and the outer skin (7) span an inner corner area (17) which tapers in a wedge shape towards the sheet metal edge (9), characterized by, that the joining connection is a roll seam weld connection (19) which can be produced with a roll seam welding device (21) of the process arrangement in which an electrode (23) is arranged in the lamp cutout (3) in the roll seam welding process, and the counter electrode (24) is arranged contour-adapted in the inner corner area (17). [2] Process arrangement according to claim 1, characterized by , that the counter electrode (24) is contour-adapted to the wedge-shaped inner corner area (17) with regard to its spatial orientation and / or its dimensions. [3] Process arrangement according to claim 1 or 2, characterized by, that the electrode (23) is an electrode roller rotatably mounted on a clamping arm (25), and that in particular the counter electrode (24) is an electrode roller rotatably mounted on the other clamping arm (29), and that in particular with regard to the limited space available in the inner corner area (17) the roller axis (R2) of the counter electrode (24) is oriented at an acute tool angle (α) obliquely to the flat, in particular horizontally oriented edge flange (5), while in particular the roller axis (R1) of the electrode (23) is oriented parallel to the flat edge flange (5), and that in particular the acute tool angle (α) and a bending angle (β) spanned between the outer skin (7) and the edge flange (5) are essentially the same size and opposite to each other, so that in particular the counter electrode (24) designed as an electrode roller and the outer skin (7) are oriented at approximately the same angle. [4] Process arrangement according to claim 3, characterized by , that the counter electrode (24) designed as an electrode roller has an outer circumference which at least partially has a conical circumferential flank (28) which is in rolling contact with the joining point in the roll seam welding process. [5] Process arrangement according to one of the preceding claims, characterized by , that the counter electrode (24) is not designed as an electrode roller, but as a wedge-shaped electrode counterpart adapted to the contour of the inner corner area (17), which is fixed to the clamping arm (29) in a rotationally fixed manner. [6] Process arrangement according to one of the preceding claims, characterized by , that the roll seam electrodes (23, 24) are made of a copper alloy, and / or that the roll seam electrodes (23, 24) are permeated with coolant. [7] Process arrangement according to one of the preceding claims, characterized by, that the counter electrode (24) which can be positioned in the inner corner area (17) is part of an electrode set with counter electrodes of different geometries, and that the counter electrode (24) is interchangeably held on a clamping arm (29) of the roll seam welding device (21), and that depending on the inner corner area size of the body outer sheet metal part (1) to be processed, a suitable counter electrode (24) can be selected from the electrode set. [8] Process arrangement according to one of the preceding claims, characterized by , that the overlap weld joint (19) is an aluminum weld joint, whereby Al-Cu phases form on the copper alloy electrodes (23, 24) as a result of the welding process, and / or that The roll seam welding device (21) is assigned a post-processing unit (31) by means of which electrode contamination, such as Al-Cu phases, can be removed by grinding or milling. [9] Process arrangement according to claim 8, characterized by that the post-processing unit (31) has a rolling milling or grinding element (33), such as a grinding wedge. [10] Method for producing a car body outer sheet metal part (1) in a process arrangement according to one of the preceding claims.

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