Intelligent, digitally controlled equipment in a production line in the bodywork of the automotive industry, use of such equipment and control of such equipment in production lines of the bodywork of the automotive industry

Abstract

The invention relates to an intelligent, digitally controlled device in a production line in the automotive body manufacturing industry, incorporating toggle clamping devices and / or underbody clamps and / or swivel devices. Furthermore, the invention relates to the use of such a device and the control of such devices. It is demonstrated how electric motors, each driving separate bodywork devices such as toggle clamping devices, underbody clamps, or swivel devices, can be centrally monitored and controlled.

Description

genus

[0001] The invention relates to an intelligent, digitally controlled device in a production line in the bodywork construction of the automotive industry.

[0002] Furthermore, the invention relates to the use of such a device in such a production line.

[0003] Furthermore, the invention relates to a control system for such a device. State of the art

[0004] For many decades, pneumatically driven toggle clamps, underbody clamps, centering devices, and swivel devices have been commonplace in automotive body manufacturing. Automotive body manufacturing lines often incorporate hundreds of these devices, requiring an extensive piping system to supply compressed air to their various points of use. This necessitates the maintenance of a comprehensive compressed air network and the operation of compressors and electric drives, with the efficiency of pneumatic actuators typically ranging from 5 to 10%. Furthermore, the sheer number of toggle clamps in body manufacturing lines consumes vast quantities of compressed air, most of which is released into the atmosphere.Although compressed air is cleaned today to minimize contamination by foreign substances, especially oil, achieving 100% purity of the exhausted compressed air is impossible, resulting in a corresponding environmental impact. Furthermore, the individual bodywork tools in a production line, such as toggle clamps, must be constantly monitored and adjusted. This is particularly important because the varying sheet metal thicknesses and other interfering edges caused by the body parts being processed necessitate a corresponding safety measure. The various bodywork tools, such as toggle clamps, must be precisely adjusted to these interfering edges, sheet metal thicknesses, and the different sheet metal parts being processed to prevent disruptions in the production line.

[0005] Therefore, for some time now, bodywork tools such as toggle clamps have been driven by electric motors. Electric drives have the advantage of significantly higher efficiency compared to pneumatic drives. For example, the efficiency of electric actuators is around 90%, compared to approximately 5 to 10% for pneumatic actuators. Furthermore, when using electric drives for toggle clamps, for example, no compressors are required. In addition, compressed air valves, compressed air lines, valve manifolds, and the dreaded leaks in the extensive pressure distribution networks required in automotive workshops are eliminated. In summary, it can be said that pneumatic drives are essentially energy wasters. Eliminating pneumatic drives, for example in toggle clamps, also reduces CO2 emissions.

[0006] From TÜNKERS | EK-Spanner - Electric Clamp, May 25, 2020, Internet publication (YouTube), full document, https: / / www.youtube.com / watch?v=dl3 KwkhRt4 is an EK-Spanner from Tünkers Maschinenbau GmbH, which was manufactured in a test setup to demonstrate the function of several toggle clamping devices in a production line in the automotive body shop and / or underbody clamps and / or swivel devices and / or centering devices - i.e., bodywork equipment. This setup only allows the power supply to the individual connected bodywork equipment to be switched on and off. Task

[0007] The invention is based on the objective of creating an intelligent, digitally controlled device in a production line in the bodywork construction of the automotive industry, with which toggle lever clamping device and / or underbody clamps and / or swivel devices - bodywork equipment - can be digitally controlled with regard to their parameters to be observed.

[0008] Furthermore, the invention is based on the objective of proposing an advantageous use of bodywork equipment used in production lines in the bodywork construction of the automotive industry.

[0009] Furthermore, the invention is based on the objective of providing an advantageous control system for body parts. Solution to the task concerning the establishment

[0010] This task is solved by an intelligent, digitally controlled device in a production line in the body shop of the automotive industry, with toggle clamping devices and / or underbody clamps and / or swivel devices and / or centering devices – collectively referred to as body shop equipment – ​​with a programmable PLC, whose signals are transmitted via low-voltage direct current to a signal converter, which is connected to a load voltage supply device via a transformer or the like, and the PLC is connected to the signal converter via a fieldbus line designed as a fieldbus line, referred to as Profinet or the like, and the signal converter is connected to the electric motors of the respective body shop equipment, which operate in the low-voltage direct current range.wherein the signal-conducting connection is connected via hybrid lines and a respective associated bus, wherein the relevant bus of the associated electric motor for the relevant bodywork device converts data transmitted by the signal converter in a drive-specific manner for the associated electric motor, such that the low-voltage DC motors of the associated bodywork devices each have a bus via which the electric motors can be controlled with regard to the various programmed data of the associated bodywork devices such as speeds, opening angles for clamping arms, swivel angles of clamping arms for, for example, toggle clamping devices, interference edges, sheet thicknesses and tolerance dimensions. Some advantages

[0011] Compared to pneumatically driven bodywork tools such as toggle clamps, underbody clamps, centering devices, and swivel devices, a device according to the invention, for example, consumes only 0.00003 kWh for its toggle clamps, compared to 1.71 kWh for pneumatically driven toggle clamps. This results in operating cost savings of approximately 93% compared to pneumatically driven bodywork tools, such as toggle clamps.

[0012] A particular advantage of an intelligent, digitally operated device according to the invention is that, for example, adjustable opening angles for the swivel arms of toggle clamping devices, speeds, for example for underbody clamps, for swivel devices or clamping forces, sheet thicknesses of the body parts to be processed, interference edges, tolerance values, times and the like can be stored in the respective associated PLC.

[0013] Several bodywork devices, for example eight or more, can be connected to the signal converter and assigned to a PLC. The entire network, consisting of the PLC, signal converter, load power supply unit, and the respective electric drives, such as electric stepper motors for the assigned bodywork devices (e.g., toggle clamps), is operated with a voltage of 24 or 48 volts DC.

[0014] The electric motors of the bodywork tools, for example toggle clamping devices or underbody clamps, are connected to the signal converter via hybrid cables.

[0015] Each electric motor is assigned a bus that converts the signals arriving from the signal converter in a signal-specific manner for the respective electric motor, making it possible to drive and control each individual bodywork device, such as toggle clamping devices, underbody clamps or the like, specifically.

[0016] If several devices consisting of PLC, load voltage supply and signal converter are arranged in a production line in the bodywork of the automotive industry, all these devices can be centrally connected to a monitoring device, so that a large number, hundreds or thousands of such bodywork devices can be centrally monitored and controlled in one production line or in several production lines in the bodywork of the automotive industry.

[0017] It is therefore noteworthy that the opening and closing of, for example, clamping arms, and the adjustable opening angles of, for example, clamping arms of toggle clamping devices, can be centrally monitored for a large number of toggle clamping devices, such as hundreds of devices arranged in a production line. This includes sheet thickness detection, for example, in underbody clamps, clamping forces, and speeds. Clamping forces and speeds can be set centrally, even for a large number of bodywork devices arranged in a production line.

[0018] Each toggle clamping device's clamping head is equipped with a compact DC electric motor for narrow designs. The load voltage is 24 VDC.

[0019] Digital input signals and digital output signals are routed via hybrid lines from the assigned DC electric motors of the relevant bodywork device to the signal converter via a bus, for example a fieldbus module, and via this to the PLC. Further inventive designs

[0020] Further inventive embodiments are described in claims 2 to 4.

[0021] Claim 2 describes a device characterized in that the control voltage of the signals transmitted from the PLC to the signal converter via the signal line, the load voltage supply device, and the hybrid lines connecting the signal converter to the respective electric motor of the associated bodywork component are 24 volts. The use of DC motors reduces the risk of injury.

[0022] According to claim 3, a further embodiment is characterized in that the control voltage of the signals transmitted from the PLC to the signal converter via the signal line, the load voltage supply device and the hybrid lines connecting the signal converter to the respective electric motor of the associated bodywork device is 48 volts.

[0023] An embodiment according to claim 4 is particularly advantageous, characterized in that the electric motors of the respective bodywork devices are low-voltage direct current stepper motors.

[0024] Stepper motors enable a cost-effective design of an entire electrical network in a factory, as they avoid the voltage spikes that typically occur otherwise. Stepper motors are also easy to control and regulate, allowing for the control and locking of any swivel angle, for example, of clamping arms. This results in significantly reduced investment costs for the entire electrical network in an industrial car body manufacturing plant. Solution to the task concerning the use

[0025] Different uses are described in claims 5 to 8.

[0026] Claim 5 is characterized in that low-voltage DC stepper motors are used for toggle clamping devices. As already explained, this allows hundreds of toggle clamping devices in one or more production lines in the automotive body manufacturing industry to be controlled with regard to their movement profile, if required.

[0027] Claim 6 is characterized in that low-voltage DC stepper motors are used for swivel devices. This applies equally to swivel devices as they are commonly used in the body construction of the automotive industry.

[0028] This also applies to the embodiment according to claim 7, which is characterized in that low-voltage direct current stepper motors are used for underfloor clamps.

[0029] Claim 8 is characterized in that several DC electric motors operating in the low-voltage range are connected to the signal converter for toggle clamping devices and / or underfloor clamps and / or swivel devices, which are connected separately to the signal converter via hybrid lines via a bus that processes the signals of the signal converter in an application-specific manner for the respective electric motor.

[0030] A particular advantage is that several DC electric motors operating in the low-voltage range, for example 24 volts or 48 volts, can be connected to the signal converter, thus enabling the control and monitoring of a large number of bodywork devices. Solution to the task concerning the control

[0031] This problem is solved according to claim 9 by controlling toggle clamping devices and / or underbody clamps and / or swivel devices arranged in a production line in the body construction of the automotive industry, each of which is connected via a bus to a signal converter by means of a DC electric motor operating in the low-voltage range, which is connected to a programmable PLC that monitors and controls current, torque, times, error measurements, tolerances and speeds individually or in predetermined combinations, and that several such devices are assigned to one or more production lines of a central monitoring center.

[0032] The drawing illustrates the invention – partly schematically – using a circuit diagram for a production line in the bodywork construction of the automotive industry.

[0033] Reference numeral 1 denotes a PLC connected to a signal converter 3 via a control line 2. In the illustrated embodiment, the control line 2 is powered by a 24VDC mains supply. A mains voltage of 230VAC-5A is applied to the PLC 1 in this embodiment. Furthermore, the PLC 1 is connected to the signal converter 3 via another fieldbus line 4, designated PROFINET. PROFINET (Process Field Network) is the open Industrial Ethernet standard of the PROFIBUS User Organization e.V. (PNO). It uses TCP / IP as an IT standard, enabling the integration of fieldbus systems. Other fieldbus signals can also be used instead of PROFINET.

[0034] Reference numeral 5 denotes a load voltage supply device to which low-voltage direct current is supplied via a transformer 6. The transformer 6 is connected to an electrical network 7, for example, with 230 VAC / 40 A. The transformer 6 can be part of the load voltage supply device 5.

[0035] The load voltage supply device 5 is connected to the signal converter 3 via a load voltage line 8 with 24 VDC.

[0036] Furthermore, signal converter 3 is connected via hybrid lines 9, 10, and 11, each via bus 12, 13, and 14, to a low-voltage DC electric motor 15, 16, and 17, respectively. Buses 12, 13, and 14 convert the programmable signals supplied to signal converter 3 by PLC 1 into drive-specific signals for the respective electric motor 15, 16, and 17. Buses 12, 13, and 14 can be components of hybrid lines 9, 10, and 11.

[0037] In the illustrated embodiment, the electric motors 15, 16, 17 all operate in the DC range with an operating voltage of 24 volts or 48 volts and each drives a bodywork device 18, 19, 20. The illustrated bodywork devices 18, 19, 20 can be, for example, toggle clamping devices, underbody clamps, centering devices, or swivel devices, which are, for example, set to different sheet metal thicknesses, interfering edges, swivel angles, and speeds and are controlled accordingly.

[0038] In the illustrated embodiment, three electric motors 15, 16, 17 with associated bodywork devices 18, 19, 20 are assigned to the signal converter 3. For example, eight such electric motors and a corresponding number of bodywork devices to be driven, such as toggle clamps or underbody clamps, can be assigned to the signal converter 3. These devices can be centrally monitored and controlled by data stored in the PLC 1. At a central control unit (not shown), several such devices, as depicted in the drawing, can be centrally monitored and controlled with regard to different sheet thicknesses, speeds, opening angles, clamping forces, torque of clamping arms, tolerance values, or the like.

[0039] The mechanism of action is as follows: For example, in the illustrated embodiment, electrical current and thus torques of the bodywork components to be controlled, position data, times, error messages, tolerances, or the like, which are stored in the higher-level controller PLC 1, can be converted from fieldbus 4 (Profinet) to a CAN bus 12, 13, 14. The converted data is then supplied to the relevant electric motor, for example, a stepper motor, 15, 16, 17, along with the associated control and load voltages, via hybrid lines 9, 10, 11. The signal converter 3 calculates, for example, based on reference positions and the position window, whether the control signals are still within the tolerance ranges. Furthermore, the signal converter 3 recognizes the connected actuator, for example, the electric motors 15, 16, or 17, and knows the maximum permissible values ​​of the respective variables. A web interface is integrated.

[0040] In summary, the signal converter 3 is responsible for transmitting the control signal to the higher-level PLC 1 from a fieldbus signal (Profinet or another bus, CAN bus) that the motor controller (bus) of the associated electric motor 15, 16, 17 understands. The signal converter 3 thus collects, for example, control voltage (e.g., 24 VDC), load voltage (e.g., 24 VDC), and CAN bus signals. It then forwards these signals to the associated motor controller (bus) via the hybrid lines 9, 10, 11. In the illustrated embodiment, this can simultaneously control up to eight electric motors 15, 16, 17 and subsequent motors, such as stepper motors.

[0041] The signal converter 3 detects which toggle clamping device, swivel device, underbody clamp, or pin cylinder is connected and which signals are to be used for control, for example, regarding swivel angle and / or opening and closing times; it also detects the associated tolerances and position windows. An integrated web interface allows the bodywork devices 18, 19, 20 to be controlled, such as toggle clamping devices or the like, to be grouped together and moved or operated simultaneously via corresponding control signals. When controlling multiple devices simultaneously, a time delay can be set to reduce the overall current. An IP address can be assigned to access error histories in the signal converter 3; in addition, a counter and a display that records the last opening and closing times can be integrated.Furthermore, a reference program can be saved and manual operation of PLC 1 can be performed if necessary.

[0042] The features described in the patent claims and in the description, as well as those shown in the drawing, can be essential for the realization of the invention, both individually and in any combination.

Claims

[1] Intelligent, digitally controlled equipment in a production line in the body shop of the automotive industry with toggle clamping devices and / or underbody clamps and / or swivel devices and / or centering devices - collectively referred to as body shop equipment (18, 19, 20) -, with a programmable PLC (1), the signals of which are transmitted by direct current via low-voltage voltage to a signal converter (3), which is connected in a signal-conducting manner to a load voltage supply device (5), wherein the load voltage supply device (5) is connected to an electrical network (7) via a transformer (6) or the like, and the PLC (1) is connected in a signal-conducting manner to the signal converter (3) via a fieldbus line (4) referred to as Profinet or the like, and the signal converter (3) is connected to electric motors (15, 16, 17) of the respective body shop equipment (18, 19, 20) operating in the low-voltage direct current range.20) is connected by a signal conductor, , characterized by , that the signal-conducting connection is connected via hybrid lines (9, 10, 11) and a respective associated bus (12, 13, 14), wherein the relevant bus (12, 13, 14) of the associated electric motor (15, 16, 17) converts data transmitted by the signal converter (3) for the relevant body unit (18, 19, 20) in a drive-specific manner for the associated electric motor (15, 16, 17), such that the low-voltage DC motors (15, 16, 17) of the associated body units (18, 19, 20) each have a bus (12, 13, 14) via which the electric motors (15, 16, 17) are connected with regard to the various programmed data of the associated body units (18, 19, 20) such as speeds, opening angles for clamping arms, Swivel angles of clamping arms for, for example, toggle clamping devices, interfering edges, sheet thicknesses and tolerance dimensions can be controlled. [2] Device according to claim 1, characterized by, that the control voltage of the signals transmitted by the PLC (1) via the signal line to the signal converter (3), the load voltage supply device (5) and the hybrid lines (9, 10, 11) that connect the signal converter (3) to the respective electric motor (15, 16, 17) of the associated bodywork device (18, 19, 20) is 24 volts. [3] Device according to claim 1 or 2, characterized by , that the control voltage of the signals transmitted by the PLC (1) via the signal line to the signal converter (3), the load voltage supply device (5) and the hybrid lines (9, 10, 11) that connect the signal converter (3) to the respective electric motor (15, 16, 17) of the associated bodywork device (18, 19, 20) is 48 volts. [4] Device according to claim 1 or any of the following claims, characterized by , that the electric motors (15, 16, 17) of the respective body equipment (18, 19, 20) are low-voltage DC stepper motors (15, 16, 17). [5] Use of a device according to claim 1 or any one of claims 2 to 4, characterized by , that low-voltage DC stepper motors (15, 16, 17) are used for toggle clamping devices. [6] Use of a device according to claim 1 or any one of claims 2 to 4, characterized by , that low-voltage DC stepper motors (15, 16, 17) are used for swivel devices. [7] Use of a device according to claim 1 or any one of claims 2 to 4, characterized by that low-voltage DC stepper motors are used for underfloor clamps. [8] Use of a device according to claim 1 or any one of claims 2 to 4, characterized by, that several DC electric motors (15, 16, 17) operating in the low-voltage range are connected to the signal converter (3) for toggle clamping devices and / or underfloor clamps and / or swivel devices, which are separately connected to the signal converter (3) via hybrid lines (9) via a bus (12, 13, 14) which processes the signals of the signal converter (3) in an application-specific manner for the respective electric motor (15, 16, 17). [9] Control of toggle clamping devices and / or underbody clamps and / or swivel devices arranged in a production line in the body construction of the automotive industry according to claim 1 or one of claims 2 to 8, characterized by, that each of these is connected via a bus (12, 13, 14) to a signal converter (3) via a low-voltage DC electric motor (15, 16, 17), which is connected via a signal converter to a programmable PLC (1) which monitors and controls current, torque, times, error measurements, tolerances and speeds individually or in predetermined combinations, and that several such devices are assigned to one or more production lines of a central monitoring center.

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