METHOD, DEVICE, SET OF PARTS, ARRANGEMENT AND COMPUTER PROGRAM FOR THE AUTOMATED MANUFACTURING OF A DOOR LEAF

Description

[0001] The invention relates to a method, a device, a set of parts, an arrangement and a computer program for the automated production of a door leaf with a door fitting covering the leaf.

[0002] For technological background and definition of terms, reference is made to the following literature, on whose knowledge the following revelation is based: [1] BASIC DOOR KNOWLEDGE - Hörmann Technical Handbook, Edition 1 / 2019, Publisher: Hörmann KG Sales Company, available since January 2019 at https: / / cdn.hoermann-cloud.de / fileadmin / _country / kataloge / pdf / HOER-HANDBUCH-Bd-01-Grundwissen_2019_.pdf [2] Wikipedia - Mortise lock, accessed on November 14, 2023 from https: / / de.wikipedia.org / wiki / Einsteckschloss [3] HUGA - The Program, company brochure of HUGA KG, downloaded on November 14, 2023 from https: / / www.huga.de / fileadmin / huga / Media / Medien / Downloads / PDF_Fachhaendler / Gesamtprogramm / AD_DasProgramm_06-2023_WEB.pdf [4] Wikipedia - Tolerance tables according to ISO 2768, accessed on November 14, 2023 from https: / / de.wikipedia.org / wiki / Toleranztabellen_nach_ISO_2768 [5] EP 4 019 716 A1 [6] German patent application 10 2023 117 406.1 [7] EP 4 249 707 A1

[0003] The following literature references regarding the state of the art are also cited: [8] WO 2008 / 105405 A1 [9] US 2008 / 116699 A1

[0004] Reference [5] discloses a door leaf with flush-mounted door hardware and a method for its manufacture and assembly. This involves a substructure, flush-mounted and covered with a cover rosette, for mounting a handle, such as a door lever or a WC door handle. This handle is coupled to a mortise lock follower for rotation. The substructure is precisely fitted into a recess, which is CNC-machined into a door leaf made of formable material. Specifically, the substructure is precisely fitted into a through-opening in the cover rosette, which is itself precisely fitted into a cover rosette recess produced by CNC milling.

[0005] The invention aims to provide means by which a door leaf of the type shown in [5], improved in terms of function and appearance, can be automatically manufactured in large series.

[0006] To solve this problem, the invention provides a method, a set of parts, a device, an arrangement and a computer program according to the attached independent claims.

[0007] Advantageous embodiments are the subject of the dependent claims.

[0008] According to one aspect thereof, the invention provides a method for the automated production of a door leaf, comprising the following steps: a) Providing a door leaf body which, at least in a lock-side area, is formed from a material suitable for machining; b) Providing a mortise lock with a lock follower rotatably mounted therein; c) Providing a substructure and a cover rosette, wherein the substructure is designed for the precise pivot mounting of a handle which is to be coupled to the lock follower, and wherein the cover rosette is designed for flush covering of a substructure body of the substructure, allowing radial relative displacement, and has a cover rosette through-opening bordered by an inner edge area, the diameter of which is larger than a through-opening of the substructure, so that the position of a pivot axis of the handle is radially variable relative to the cover rosette; d) numerically controlled machining of a lock pocket for the lock into the door leaf body;e) numerically controlled machining of a substructure receiving recess on a broad side of the door leaf body with an inner contour complementary to an outer contour of the substructure but larger in dimension, such that a radial clearance exists between the outer contour and the substructure receiving recess when the substructure is inserted; f) numerically controlled machining of a cover rosette recess for radially and axially precise flush mounting of the cover rosette; g) insertion and fixing of the mortise lock in the lock pocket; h) insertion of the substructure into the substructure receiving recess; i) radial positioning of the substructure in the substructure receiving opening so that the center of the substructure through-opening is aligned with the axis of rotation of the lock follower and fixing of the positioned substructure;and j) precise insertion of the cover rosette into the cover rosette recess.

[0009] The numbering of the steps with a), b), ... is for ease of reference and does not imply any specific order of the steps. The individual steps can be carried out sequentially, in parallel, or overlapping, as is evident from the overall context.

[0010] If the door leaf is fitted with a handle on only one broad side – e.g., the side facing the opening direction (hinge side) or the side facing away from the opening direction (opposite hinge side) – it is sufficient to provide a set of substructure and cover rosette for this broad side in step c), and to create the corresponding recesses for this substructure and cover rosette in steps e) and f). In most designs, at least one set of substructure and cover rosette – particularly for a door handle – is provided for each broad side of the door leaf in step c), and the recesses are created on each of the broad sides in steps e) and f). For a door leaf with multiple handles – e.g., a door handle and an olive – at least one set of substructure and cover rosette for the first handle can be provided on at least one of the broad sides.Door handle - and a set of substructure and cover rosette for the second handle - e.g. olive or coin slot element - may be provided; a common larger cover rosette may also be provided to cover a first substructure for the first handle and to cover a second substructure for the second handle with corresponding first and second cover rosette through-openings.

[0011] In particularly preferred embodiments, step b) b1) comprises providing the substructure with the substructure body and an insertion sleeve, wherein the substructure body has the substructure outer contour and a substructure body through-opening whose diameter is smaller than the diameter of the cover rosette through-opening, and wherein the insertion sleeve is designed for precise insertion into the substructure through-opening and has an insertion sleeve through-opening for precisely pivoting the bearing section of the handle and a cover ring for supporting an end face of the handle and for covering the inner edge region of the cover rosette.

[0012] It is preferred that in steps g) and h) the substructure body is inserted into the substructure receiving recess, positioned and fixed.

[0013] It is preferred that the method further comprises the step following step j): k) Inserting the insertion sleeve into the substructure body through-opening.

[0014] Preferably step b1 includes: providing the substructure body in such a way that the side to be covered by the cover rosette is flat.

[0015] In some embodiments, step k) is carried out at the manufacturing site; the door leaf is then delivered to the installation site already with the insertion sleeve inserted, where the handle is then preferably mounted.

[0016] Step k) can also be carried out later, e.g., during the provisioning process up to the installation site. For example, step k) is carried out together with the assembly of the handle.

[0017] The insertion sleeve can be easily inserted by axially sliding it in. However, it is also possible to screw the insertion sleeve into the substructure body. For this purpose, some designs feature an internal thread in the substructure body's through-hole and a matching external thread in the insertion sleeve.

[0018] The positioning in step i) can be carried out in different ways. In some embodiments, the position of the rotation axis of the lock nut is detected (measured) by some known detection method, and the position is adjusted accordingly using a substructure assembly device – e.g., an assembly robot or a multi-axis handling device. This can be done when inserting the substructure, in particular the substructure body, into the recess, or later, before or after covering it with the cover rosette. Preferably step i) includes

[0019] i1) Positioning the substructure with a positioning aid which is inserted precisely into the lock nut on one side and precisely accommodates the substructure through-opening in the position area of ​​the substructure. Preferably step i) includes

[0020] i2) Fixing the substructure using adhesive.

[0021] Preferably, a hot melt adhesive is used. Preferably step i) includes

[0022] i3) Fixing the substructure using clamps. Preferably step i) includes

[0023] i4) Fixing the substructure by clamping the cover rosette in such a way that it clamps the substructure into the door leaf body.

[0024] Clamping can be done in addition to or as an alternative to gluing. Preferably includes step f):

[0025] Creating the outer edge of the cover rosette recess with a step, wherein a first step is matched to the thickness of the cover rosette and a second step provides space for an adhesive to secure the cover rosette, wherein step j) comprises securing the cover rosette by applying adhesive in the second step.

[0026] According to a further aspect, the invention provides a door leaf assembly for the manufacture of a door leaf, wherein the door leaf assembly comprises as parts a door leaf, a mortise lock, at least one substructure and at least one cover rosette, wherein the door leaf has a lock-side area made of machineable material in which a lock pocket for the precise reception of the mortise lock and at least one substructure receiving recess for receiving the substructure and a cover rosette recess for flush (leaf-covering) reception of the cover rosette, which covers the substructure, are milled; wherein the substructure is designed for the precise pivoting of a handle which is to be coupled with the lock nut and has a substructure outer contour which can be received with radial play into the substructure receiving recess, wherein the cover rosette can be inserted flush and precisely into the cover rosette recess in order to cover a substructure body of the substructure which is inserted into the substructure receiving recess in the intended use in such a way that the substructure is not prevented from radial displacement by the cover rosette, and has a cover rosette through-opening bordered by an inner edge area, the diameter of which is larger than a through-opening of the substructure, so that the position of a rotation axis of the handle can be selected radially variably with respect to the cover rosette.

[0027] It is preferred that the substructure be provided with the substructure body and an insertion sleeve, wherein the substructure body has the substructure outer contour and a substructure body through-opening whose diameter is smaller than the diameter of the cover rosette through-opening, and wherein the insertion sleeve is designed for precise insertion into the substructure through-opening and has an insertion sleeve through-opening for precise rotation of the bearing section of the handle and a cover ring for supporting an end face of the handle and for covering the inner edge area of ​​the cover rosette.

[0028] According to another aspect, the invention provides a device for the automated production of a door leaf, comprising A machining machine for numerically controlled machining of a door leaf body, a mortise lock mounting device for inserting and fixing a mortise lock into a lock pocket in the door leaf body, a substructure mounting device for inserting, positioning and fixing a substructure into a substructure receiving recess in the door leaf body, and a cover rosette mounting device for mounting a cover rosette into a cover rosette recess in the door leaf body for flush covering of a substructure body of the substructure inserted into the substructure receiving recess; and electronic, numerical or computer-implemented control means, wherein the device is configured to carry out the method according to one of the preceding embodiments.

[0029] According to another aspect, the invention provides an arrangement comprising a device of the aforementioned type and a door leaf set according to one of the preceding embodiments.

[0030] According to another aspect, the invention provides a computer program comprising instructions that cause a device of the aforementioned type to carry out the method according to one of the embodiments explained above.

[0031] The following section explains in more detail some advantages and technical effects of particularly preferred embodiments of the invention.

[0032] Preferred embodiments of the invention relate to the automatic assembly of such door leaves as are shown in reference [3] under the name "Planar" or as are described and shown in reference [5].

[0033] In some embodiments of the invention, the flush-mounted lever handle set "Planar", as shown in [3] and [5], was further developed and the design was modified to better enable machine manufacturing and assembly.

[0034] According to [1], the vast majority of locks on doors, especially hinged doors, are mortise locks – see references [1] and [2]. For cost reasons, commercially available door locks are manufactured with certain tolerances between the faceplate and the lock cylinder. These tolerances result not only from normal manufacturing tolerances but also from the imprecise attachment of the lock case to the faceplate.

[0035] The interplay between the lock follower, spindle, and lever handle bearing, such as the lever handle rosette or escutcheon, must accommodate these tolerances without impairing functionality. Normally, the lever handle position is determined only after the locks are installed. For example, on-site, at the installation location, manual drilling templates are used, with the lock follower as the reference point. By selecting the correct drill diameters for the lever handle mounting, matched to the chosen lever handle set, the desired positive fit is achieved. However, this requires a significant amount of manual labor during manufacturing. Furthermore, this approach cannot be used for every type of door. For example, with doors of the type shown in [5], it is desirable to mill out a recess for a lever handle rosette (or other pivot bearing for a lever handle on the door leaf) before installing the lock.

[0036] If, as is desirable in the industrial, largely automated mass production of door leaves, receptacles for pivot bearings of door handles (or other handles, e.g., toilet handles) are machined on the door leaf, e.g., milled out, as is desired, for example, for machine milling for flush-mounted handle sets of the type known from [5] in the context of mass production of doors, the tolerances of the various individual locks to be used cannot be easily accommodated. Therefore, such machined bores or similar features must currently be produced with a larger bore diameter than specified by the handle manufacturers. This does not allow for a positive fit between the door and the handle, but only a frictional fit. Over time, this can lead to the rosettes becoming loose, which, in addition to functional defects, can also cause mechanical damage to the surface of the door leaf or the rosette.In conjunction with machine milling for the mounting of door handle bearings during automated manufacturing, particularly—but not exclusively—for flush-mounted handle sets, such as those described in [3] and [5], the tolerances of the lock in the interaction of the lock follower, the handle spindle (e.g., the square spindle), and the handle bearing (especially the rosette) affect the function of the handle set. Machine milling of the flush rosette mountings on a door leaf with a previously installed lock, from which a reference point for the follower could then be taken, is very difficult to accomplish and should ideally be avoided, especially with wooden doors or similar materials, for safety reasons, as contact between the milling cutter and the lock can cause sparks and a corresponding fire hazard.One possible solution would be to reduce the tolerances on the lock, but this would lead to a significant increase in the cost of the locks.

[0037] In the case of flush-mounted lever handle sets (e.g., Planar), as described in [3] and [5], these tolerances are currently addressed and compensated for during manufacturing by milling with templates at the factory and manual assembly at the factory. This necessitates a high level of personnel for series production, making manufacturing complex and expensive.

[0038] In conjunction with machine milling for flush-mounted lever handle sets (e.g. Planar), the tolerances in the interaction of lock nut, lever handle square, and lever handle rosette affect the function of the lever handle set or manifest themselves as differently wide joints or through functional problems.

[0039] For safety reasons, machine milling of lever handle sets (e.g. Planar or normal lever handle sets) with a mounted lock is not recommended (sparks may fly when the milling cutter comes into contact with the lock).

[0040] Some embodiments of the invention provide for a very precise lock recess (example: lock pocket) in the door leaf, achieved through CNC machining. Furthermore, flush-mounted rosette recesses (example: cover rosette recess) and the milling of the substructure (example: substructure mounting recess) are also provided for with high precision through CNC machining. At this stage, neither of these milling operations has a direct and precise relationship to the lock follower, including the corresponding tolerances.

[0041] After the lock is installed, the Planar substructure is positioned and fastened precisely to the lever handle nut (or, if necessary, to the lock nut for a bolt, for coupling e.g. with a WC handle).

[0042] In some designs, positioning is achieved using a positioning aid, which may resemble a lever handle with a square spindle. This positioning aid is inserted precisely into the lock cylinder on one side and, within the area where it rests, precisely matches the inner diameter of the substructure. Any tolerances between the milled substructure in the door leaf and the positioned substructure (matching the lock cylinder) are accommodated by fixing the substructure, for example, using adhesive, clamps, or similar methods. This fixing can be done, for example, by an assembly robot. The fixed substructure also ensures the secure mounting of the lever handle set within the substructure.

[0043] In some embodiments, the substructure in the area of ​​the subsequent rosette is, unlike the embodiment known from [5], designed to be flat (without a bearing ring for the handle). Furthermore, the inner diameter of the substructure is slightly larger than the handle neck to which it will later be attached.

[0044] According to the invention, the associated rosette has an inner diameter that is slightly larger than the inner diameter of the substructure. The difference between the two inner diameters is particularly large enough to accommodate all tolerances, e.g., from the lock or manufacturing process, without the edge of the rosette's inner diameter protruding beyond the edge of the substructure's inner diameter.

[0045] In some embodiments, the deviation between the two inner diameters that is present and visible at that time is covered by an insert with a ring - insertion sleeve.

[0046] This insert has an inner diameter matched to the diameter of the corresponding push-button neck, so that the push button is guided precisely after installation.

[0047] The outer diameter of the insert is precisely matched to the inner diameter of the substructure body.

[0048] The wider ring covers the visible tolerances between the inner diameters of the rosette and the inner diameter of the substructure body and also serves as a bearing ring and guide for the handle. This also protects the rosette from damage when the handle is operated.

[0049] In some designs, since the rosette only needs to be precisely positioned and fixed in the rosette groove at its outer edge, this assembly part can also be manufactured, for example, using an assembly robot. The insert with the ring can be pressed in at the factory or supplied with the lever handle set.

[0050] It would also be conceivable that the insert could be equipped with an external thread and the substructure body with a matching internal thread, so that it could be screwed in rather than simply inserted.

[0051] In some designs, the outer edge of the rosette recess has a step. The first step is aligned with the rosette thickness. The second step provides the necessary space to hold the adhesive used to secure the rosette.

[0052] Thanks to the first stage of the rosette milling process and the flat, single-level substructure, even rosettes that are not perfectly flat and somewhat flexible can be automatically mounted. The adhesive ensures that the rosette is held securely in the milling and that it fits precisely on the inner and outer edges.

[0053] For further features and functions, reference is made to [5], the embodiments of which, by appropriate modification as described here, become embodiments of the present invention. Other functions and designs (mini-rosettes, long escutcheon look, etc.) are possible by different shapes and / or dimensions of the individual parts, as described in particular in [6] or [7].

[0054] Preferred embodiments of the invention relate to further developed designs and assembly techniques for flush-mounted lever handle sets based on [3] (there the doors designated as Planar), [5], [6] or [7], which particularly preferably facilitate simpler, especially automated, production in large-scale industrial series production without impairing the function, durability, comfort, ease of use and / or the high-quality appearance.

[0055] Examples of implementation are explained in more detail below with reference to the accompanying drawings. These show: Fig. 1 a front view of the first broad side – hinge side – of a door with a door leaf to be manufactured using methods, devices, sets of parts and arrangements according to embodiments of the invention; Fig. 2 an end view of a lock end face of the door leaf in the area of ​​a lock; Fig. 3 a view comparable to Fig. 2 on a door leaf of the door wing before the installation of the lock and a door fitting for operating the lock; Fig. 4 a sectional view along line AB of Fig. 1 or along line BC from Fig. 1 , wherein a substructure and a cover rosette are mounted as parts of the door fitting, wherein Fig. 4Figure 1 shows an embodiment of a door leaf to be manufactured by an automated manufacturing process in a manufacturing plant – still without a handle set or WC handle set; Figure 5 shows an exploded view of the door leaf. Fig. 4The area of ​​the door leaf shown, with the parts of the door hardware to be mounted, in particular a substructure with substructure body, a cover rosette and an insertion sleeve, as well as a lever handle set (shape not specified), which is usually to be mounted on site; Figs. 6 to 8 different views of an embodiment of the substructure body with exemplary dimensions; Figs. 9 and 10 different views of the area of ​​the door leaf located between A and B (or B and C) for receiving the door hardware with substructure receiving recess and cover rosette recess and exemplary dimensions; Fig. 11 a side view of an embodiment of a positioning aid; Figs. 12 and 13 different views of an embodiment of the insertion sleeve with exemplary dimensions; Fig.Figures 14 and 15 show different views of an example of the lock, as is generally known, for example from [2]; and Figure 16 shows a schematic representation of a device for automatically manufacturing the door leaf.

[0056] Fig. 1 Figure 1 shows an embodiment of a door 10 with frame 12 and door leaf 14 and flush door fitting 16.

[0057] Fig. 2 shows a front view of the lock area of ​​the door leaf 14, where the lock 18 is a mortise lock 20, as is the case in Figs. 14 and 15 as shown and explained in more detail in [2], is received and fixed in a lock pocket 21.

[0058] Fig. 3 shows a view like in Fig. 2 on a door leaf 15 of the door wing 14 without the lock 18 and without the door fitting 16, wherein the lock pocket 21 with faceplate recess 22 for receiving the lock faceplate 24 and box recess 26 for receiving the lock case 28 is shown.

[0059] Fig. 4 shows a partial section along line AB of Fig. 1 , wherein a substructure 30 and a cover rosette 32 for flush covering of a substructure body 34 of the substructure 30 are mounted as parts of the flush door fitting 16. The substructure 30 is designed for the precise pivot mounting of a handle 36 of the door fitting 16.

[0060] Fig. 5 Figure 1 shows the area between A and B of the door leaf 15 and the parts of the flush-mounted door fitting 16 in an exploded view. The handle 36 shown here is a door lever 38 from a lever handle set 40, which can be selected in terms of design and is coupled to a lock follower of the mortise lock 20 by means of a lever spindle 42 – usually a square spindle.

[0061] As particularly in Fig. 3 , Fig. 5 and Figs. 9 and 10As shown, in the door leaf 15, which at least in the lock area consists of a material that can be machined, such as in particular wood, a substructure receiving recess 46 for the complete receiving of the substructure body 34 and a cover rosette recess 48 for the flush receiving of the cover rosette, so that it covers the substructure body 34, are provided.

[0062] An exemplary embodiment with exemplary dimensions of the substructure body 34 is shown in Figs. 6 to 7As shown, in some embodiments, the substructure body 34 is hat-shaped, with a circular cylindrical main area 50 and a radially annular projecting edge area 52 at the axial end area, which comes into contact with the cover rosette. The axial end surface on which the cover rosette 32 rests is flat, so that no positive locking is formed with the cover rosette 32 and thus the radial relative position of the substructure body 34 and the cover rosette is not fixed, but is variable, at least within certain tolerances. The substructure body 34 has a through-opening 54 for inserting the bearing area 56 of the handle 36.

[0063] The bearing area 56 is, for example, located at the free end of the handle neck of the door handle 38. Handle sets are available from various manufacturers on the market, and for certain markets, such as the EU, there are predetermined, and in particular standardized, diameters for this bearing area 56. For example, various door handles 38 are available that have a bearing area 56 with a diameter of 16 mm at the handle neck.

[0064] In some embodiments, the substructure body through-opening 54 is significantly larger than the predetermined diameter of the bearing area 56, and an insertion sleeve 58 with a cover flange 60 is provided, the outer diameter of which fits precisely into the substructure body through-opening 54. An embodiment of the insertion sleeve 58 is shown in the Fig. 5 , 12 and 13The insertion sleeve 58 is, for example, hat-shaped, with the cover ring 60 projecting radially at one axial end and the other axial end 62 being insertable from the outside into the substructure body through-opening 54 when the substructure body 34 is mounted and covered with the cover rosette 32. This can be done by inserting the sleeve or, if appropriate threads are provided, by screwing it in.

[0065] The axial end 62 facing away from the cover ring can be conical to facilitate the insertion of the insertion sleeve 58 into the substructure body 34.

[0066] The following will be used as an example to illustrate the Figs. 3 to 5 , 9 and 10The design of the recesses 46 and 48 for the substructure 30 and the cover rosette 32 is explained in more detail. The substructure receiving recess 46 has an inner diameter that is so much larger than the outer diameter D34 of the substructure 30 (measured at the main area 50 of the substructure body 34) that tolerances in the position of the pivot axis of the lock follower of the mounted lock 18 can be compensated for by adjusting the position of the substructure 30. Typical tolerances are given, for example, in [4]. Accordingly, in some embodiments, the inner diameter of the substructure receiving recess 46 is at least 0.3 mm, preferably at least 0.5 mm, for example 0.5 mm to 2 mm larger than the outer diameter D34 of the substructure, so that the radial position of the substructure in this area can be variably selected.

[0067] In designs with a radially projecting edge area 52, this serves for the axial positioning of the substructure 32 by bearing on the edge of the substructure receiving recess 46 and accordingly has an outer diameter that is larger than its inner diameter D34 but by at least the above-mentioned tolerance range, preferably significantly smaller than a minimum diameter of a radially outer boundary 68 of the cover rosette recess 48 which axially adjoins the substructure receiving recess 46.

[0068] The contour and depth of the cover rosette recess 48 is precisely adapted to the cover rosette 32.

[0069] In some embodiments, the cover rosette recess 48 is stepped. A first step 66, viewed from the broad side of the door leaf 15, has an inner contour 68 that is precisely formed to fit the outer contour of the cover rosette 32 and a first depth that corresponds to the rosette thickness. The second step 70 has a smaller diameter so that an edge of the cover rosette 32 can rest on it and a second depth that is adapted to the thickness of the edge area 52. When the edge area 52 rests on it, a gap is formed between it and the radial boundary of the second step, providing space for the application of an adhesive (e.g., hot melt adhesive).

[0070] According to Fig. 5 The cover rosette 32 has a cover rosette through-opening 72 which is larger than the bearing area 56 by at least the tolerance range mentioned above and thus larger than the through-opening of the insertion sleeve 58 which is precisely adapted to the bearing area 56.

[0071] The outer diameter of the ring 60 is dimensioned to be larger than the inner diameter of the cover rosette passage opening 72, such that it can cover the cover rosette passage opening on its entire circumference in any variably selectable radial position of the substructure 30.

[0072] The following section describes in more detail the manufacture and assembly of the door leaf 14 with lock 18 and flush door hardware 16. To reduce costs, large-scale industrial production is desirable, ideally carried out using automated machinery to the greatest extent possible.

[0073] In the illustrated embodiments, the substructure mounting recess 46 extends continuously to the box recess 26. The recesses 21, 22, 26, 46, 48 are formed as milled grooves in the door leaf body 74, which is made of materials suitable for machining, such as wood-based materials, solid wood, HDF, MDF, particleboard, plywood, laminated veneer lumber, laminated wood, optionally surface-coated or veneered. Thus, the recesses 21, 22, 26, 46, 48 in the door leaf body 74 for receiving the lock 18 and the door hardware 16 can be manufactured very precisely with very low tolerances by numerically controlled machining, in particular CNC milling.

[0074] Locks 18 and 20 available on the market from various manufacturers have relatively large manufacturing tolerances due to cost constraints. This means that the position of the lock case 28 relative to the lock faceplate 24, and especially the position of the pivot axis of the lock follower, is subject to relatively large tolerances. Due to the differing tolerances of the locks 18 and 20 and the recesses 21, 22, 26, 46, and 48 for the lock 30 and the door hardware 16 on the door leaf 74, misalignments can occur between the pivot axis of the handle 36 (defined by the recesses 46 and 48 on the door leaf 74) and the position of the pivot axis of the lock follower (determined by the lock case 28 and the tolerances of the locks 18 and 20). These misalignments could impair the installation of the handle set, the durability, and the function of the lock-door hardware-handle set combination.

[0075] To facilitate machine manufacturing and assembly and to counteract the aforementioned problems, a special type of mold is used for the production of the door leaf, particularly in the following ways: Fig. 5 The door leaf assembly shown comprises the door leaf 15, the mortise lock 20, the substructure 30, and the cover rosette 32. The door leaf 15 has a lock-side area made of a machinable material in which the lock pocket 21 is milled for the precise fit of the mortise lock 18, as well as a number of substructure mounting recesses 46, corresponding to the number of pivot bearings of the door hardware, for receiving the respective substructure 30 for pivot bearings, with corresponding cover rosette recesses 48 for receiving the cover rosette 32, which covers the substructure 30, in particular the substructure body 34.

[0076] The substructure 30 is designed to be a precisely fitting pivot bearing for the handle 36, which is to be coupled to the lock nut. The substructure 30 has an outer contour that can be received into the substructure receiving recess 46 with radial play.

[0077] The cover rosette 32 is flush-mounted and fits precisely into the cover rosette recess 48 to cover the substructure body 34 of the substructure which, in normal use, is inserted into the substructure receiving recess 46. The substructure 30 and the cover rosette 32 do not engage with each other and are therefore not prevented from radially shifting relative to each other. In other words, despite the cover rosette's precise fit, the radial position of the substructure is variable during installation to compensate for tolerances and to adapt to the position of the lock cylinder's axis of rotation. The cover rosette's through-opening 72, bordered by an inner edge, has a diameter larger than the through-opening of the substructure 30 designed to hold the handle, so that the position of the handle's axis of rotation 36 can be radially variable relative to the cover rosette 32.This allows the substructure to be adjusted to the position of the lock nut during assembly and to be properly fixed.

[0078] In some embodiments, the substructure 30 is provided with the substructure body 34 and the insertion sleeve 58. The substructure body 34 has the substructure's outer contour and the substructure body through-opening 54. The diameter of this through-opening is smaller than the diameter of the cover rosette through-opening 72. The insertion sleeve 58 is designed for precise insertion into the substructure through-opening 54. The insertion sleeve 58 has an insertion sleeve through-opening 76 for the precise rotation of the bearing section 56 of the handle and a cover ring 60 for supporting an end face of the handle 36 and for covering the inner edge region of the cover rosette 32.

[0079] This allows for precise and backlash-free rotary bearing of the handle 36, so that the door conveys a high-quality impression and is easy and comfortable to operate.

[0080] Although the compensation of lock tolerances has been explained using the example of the lever handle set, corresponding measures can also be taken for other handles, e.g. for WC handles – see [5] for further details. Fig. 10 Figure 1 shows the shape of the substructure mounting recess 46, as designed for substructures 30 for the rotary mounting of lever handle sets or WC handles. A through-hole 82, as provided in the area of ​​a keyhole of a mortise lock or a cylinder of another corresponding mortise lock, is shown with a dashed line.

[0081] A process for the automated production of the door leaf 14 comprises the following steps: a) Providing the door leaf body 74 (as a blank), which is formed from machinable material at least in a lock-side area; b) Providing the mortise lock 20 with a lock follower rotatably mounted therein; c) Providing the substructure 30 and the cover rosette 32; d) CNC machining of the lock pocket 21 for the lock into the door leaf body 74; e) CNC machining of the substructure receiving recess 46 on at least one broad side of the door leaf body 74 with an inner contour complementary to an outer contour of the substructure 30 but with larger dimensions, such that a radial clearance exists between the outer contour and the substructure receiving recess 46 when the substructure 30 is inserted;f) numerically controlled machining of the cover rosette recess 48 for radially and axially precise flush mounting of the cover rosette 32; g) insertion and fixing of the mortise lock 20 in the lock pocket 21; h) insertion of the substructure 30 into the substructure receiving recess 46; i) radial positioning of the substructure 30 in the substructure receiving opening 46 so that the center of the substructure through-opening 54 is aligned with the axis of rotation of the lock follower and fixing of the positioned substructure 30; and j) precise insertion of the cover rosette 32 into the cover rosette recess 48.

[0082] In some embodiments, step b) comprises b1) providing the substructure 30 with the substructure body 34 and the insertion sleeve 58. In steps g) and h), only the substructure body 34 is initially inserted into the substructure receiving recess 46, positioned, and fixed. After step j), the following step is performed: k) Inserting the insertion sleeve 58 into the substructure body through-opening 54.

[0083] In some embodiments, the substructure is positioned using a positioning aid 84, one embodiment of which is shown in Fig. 11The positioning aid 84 has a pin projection 86, preferably with a conical insertion end 87, which projects from a fitting body 88 whose outer contour is precisely adapted to the through-opening 54 of the substructure body. For assembly, the substructure body 34 can be placed onto the fitting body 88 and mounted with the positioning aid 84, whereby the pin projection 86 is inserted into the lock follower of the previously mounted lock. Different procedures are possible. For example, the positioning aid 84 can be inserted first, and then the substructure body 34 is placed on it and pushed axially into position. Alternatively, the substructure body 34 can initially be inserted without being positioned and covered with the cover rosette 32. Before the fixing, for example by curing the adhesive or by tightening a clamp (e.g.,After the cover rosette has been pressed into place, the positioning aid 84 is inserted, thereby adjusting the radial position of the substructure body 34 to the position of the rotation axis of the lock nut. Fixing then takes place.

[0084] In Fig. 16 A schematic diagram shows a possible setup of a device 100 for the automated production of the door leaf 14. The device 100 is, for example, part of a door production line in a manufacturing plant, wherein a conveyor belt 102 can be provided for conveying the door leaf body 74 through individual stations.

[0085] The device 100 comprises a machining machine 104, for example a machining center, for numerically controlled machining of the door leaf body 74 to create the recesses 21, 22, 26, 46, 48; a mortise lock assembly device 106, for example with a first assembly robot, for inserting and fixing the mortise lock 20 into the lock pocket 21 in the door leaf body 74; a substructure assembly device 108, for example with a second assembly robot, for inserting, positioning and fixing the substructure 30 into the substructure receiving recess 46 in the door leaf body 74; a cover rosette assembly device 110, for example with a third assembly robot, for mounting the cover rosette 32 in the cover rosette recess 48; and electronic, numerical or computer-implemented control means 112 that control the device 100 to carry out the procedure described above.

[0086] Some embodiments include a control unit 114 with a processor 116 and memory 118 in which a computer program with corresponding control instructions is stored.

[0087] In some embodiments, an adhesive application device 120 is provided for applying adhesive to the cover rosette recess 48. An assembly robot of the substructure assembly device 108 is designed to insert and position the substructure body 34 with the aid of the positioning aid 84. The adhesive ensures adhesion at this stage, so that the position is maintained until the assembly robot of the cover rosette assembly device 110 mounts and presses on the cover rosette 32, thus additionally fixing the substructure body 34 by clamping. A press 122 can also be provided for compressing the lock area until the adhesive has partially or fully hardened.

[0088] The insertion sleeve 58 can be delivered together with the door leaf 14 and transported to the construction site. It can also be supplied with the lever handle set. The insertion sleeve 58 can then be used during the installation of the lever handle set, for example, on the construction site.

[0089] In some embodiments of the device 100, an insertion sleeve mounting device 124 is provided, which is designed to insert the insertion sleeve 58 into the substructure body 34 at the manufacturer's factory after the cover rosette 32 has been mounted.

[0090] The embodiments shown in the figures depict only a standard version of the door leaf 14. Further possible versions are available by adopting modifications to the form and function of the substructure and the cover rosette as described in [5], [6], or [7]. In other words, the measures for improving automated production described here in the claims and drawings can also be applied to the other variants described in [5], [6], and [7]. For further features of other embodiments of the invention, reference is expressly made to these references [5], [6], and [7].

[0091] To improve the mass production of high-quality door leaves 14 with a premium appearance, the invention provides a method, a device 100, a set of parts, an arrangement, and a computer program for the automated production of a door leaf 14 with flush-mounted door hardware. First, recesses 21, 46, 48 for receiving a lock 18 and door hardware components are machined into a door leaf body 74 made of machinable material by numerically controlled machining; then, a mortise lock 20 is mounted in a lock recess, and subsequently, a substructure 30 and a cover rosette 32 are mounted in recesses on the broad side of the door leaf 15, the substructure 30 being inserted with play into a substructure receiving recess 46 with radial play, aligned with the position of a lock follower, and fixed in place.In some embodiments, the substructure 30 for supporting a handle 36 has an insertion sleeve 58 with a cover collar 60, which covers a radial gap on an inner diameter of the cover rosette 32, which is provided for tolerance compensation. Reference symbol list:

[0092] 10 Door 12 Frame 14 Door leaf 15 Door leaf 16 Door hardware 18 Lock 20 Mortise lock 21 Lock pocket 22 Faceplate recess 24 Lock faceplate 26 Case recess 28 Lock case 30 Substructure 32 Cover rosette 34 Substructure body 36 Handle 38 Door lever 40 Lever handle set 42 Spindle 46 Substructure mounting recess 48 Cover rosette recess 50 Main area 52 Edge area 54 Substructure body through-hole 56 Bearing area 58 Insertion sleeve 60 Cover ring 62 Free axial end 66 First step 68 Radial outer limit 70 Second step 72 Cover rosette through-hole 74 Door leaf body 76 Insertion sleeve through-hole 82 Through-hole 84 Positioning aid 86 Pin projection 87 Conical insert 88 Dowel 100 Device 102 Conveyor belt 104 Machining machine 106 Mortise lock assembly device 108 Substructure assembly device 110 Cover rosette assembly device 112 Control device 114 Control 116 Processor 118 Memory 120 Adhesive application device 122 Press124 Insert sleeve mounting device D34 Outer diameter substructure

Claims

1. Method for automated production of a door wing (14), the method comprising the steps of: a) providing a door leaf body (74) that is formed from a machined material at least in a lock-side area; b) providing a mortise lock (20) having a lock nut rotatably supported therein; c) providing a substructure (30) and a cover rosette (32), wherein the substructure is designed for tailored swivel mounting of a handle (36) to be coupled to the lock nut and wherein the cover rosette (32) is designed for covering a substructure body (34) of the substructure (30) in a flush-fitted manner and allowing radial displacement and the cover rosette (32) having a cover rosette through opening (72) bordered by an inner edge area, the diameter of the through opening being larger than a through opening (54, 76) of the substructure (30), so that the position of a rotational axis of the handle (36) can be radially variably selected with respect to the cover rosette (32); d) numerically controlled machining of a lock pocket (21) for the mortise lock (20) into the door leaf body (74); e) numerically controlled machining of a substructure receiving recess (46) on a broadside of the door leaf body (74) with an inner contour complementary to the outer contour of the substructure (30) but large in dimension, so that a radial play exists between the outer contour and the substructure receiving recess (46) when the substructure (30) is inserted; f) numerically controlled machining of a cover rosette recess (48) for the radial and axial tailored flush-mounting receipt of the cover rosette (32); g) inserting and fixing the mortise lock (20) in the lock pocket (21); h) inserting the substructure (30) into the substructure receiving recess (46); i) radial positioning of the substructure (30) in the substructure receiving opening (48) in such a way that the center of the substructure through opening (54) is aligned with the rotational axis of the lock nut (44), and fixing the positioned substructure (30); and j) precise fitting of the cover rosette (32) into the cover rosette recess (48).

2. Method according to claim 1, characterized in that step b) comprises: b1) providing the substructure (30) with the substructure body (34) and an insert sleeve (58), wherein the substructure body (34) has the substructure outer contour and a substructure body through opening (54) the diameter of which is smaller than the diameter of the cover rosette through opening (72) and wherein the insert sleeve (58) is designed for precise fitting into the substructure through opening (54) and comprises an insert sleeve through opening (76) for tailored swivel mounting of the bearing portion (56) of the handle (36) and a cover ring (60) for supporting a front end of the handle (36) and for covering the inner edge area of the cover rosette (32); and comprises that in steps g) and h) the substructure body (34) is inserted, positioned and fixed in the substructure receiving recess (46) and that the method further includes the following step after step j): k) inserting the insert sleeve (58) into the substructure body through opening (54).

3. Method according to claim 2, characterized in that 3.1 step b1) comprises: providing the substructure body (34) in such a way that the side to be covered by the cover rosette (32) is flat, and / or 3.2 step k): 3.2.

1. is carried out at the place of manufacture or at the installation site; and / or 3.2.2 is carried out together with mounting the handle (36); and / or 3.2.3 comprises axial insertion of screwing of the insert sleeve (58) into the substructure body (34).

4. Method according to any of the preceding claims, characterized in that step i) comprises at least one or more of the steps: i1) positioning the substructure (30) using a positioning aid (84) that is inserted in a precisely fitting manner into the lock nut on one side and receives the substructure through opening (54) in the location area of the substructure (30) in a precisely fitting manner; i2) fixing the substructure (30) by means of an adhesive; i3) fixing the substructure (30) by means of clamps; i4) fixing the substructure (30) by means of clamps by fixing the cover rosette (32) in such a way that it clamps the substructure (30) in the door leaf (15).

5. Method according to any of the preceding claims, characterized in that step f) comprises: creating a radially outer border (68) of the cover rosette recess (48) with steps, wherein a first step is adjusted to the thickness of the cover rosette (32) and a second step (70) provides room for an adhesive for fixing the cover rosette (32), wherein step j) comprises fixing the cover rosette (32) while introducing adhesive in the second step (70).

6. Door wing kit of parts for producing a door wing (14), the kit of parts comprising: a door leaf (15), a mortise lock (20), a substructure (30) and a cover rosette (32), wherein the door leaf (15) has a lock-side area from a machined material having milled into it a lock pocket (21) for receiving the mortise lock (20) in a precisely fitting manner, as well as at least one substructure receiving recess (46) for receiving the substructure (30) and a cover rosette recess (48) for receiving the cover rosette (32); wherein the substructure (30) is designed for tailored swivel mounting of a handle (36) to be coupled to lock nut of the mortise lock (20) and comprises a substructure outer contour that can be received with radial play in the substructure receiving recess (46), wherein the cover rosette (32) can be inserted into the cover rosette recess (48) in a flush-mounted and precisely fitting manner in order to cover a substructure body (34), which is inserted into the substructure receiving recess (46) when used as in intended, in such a way that the substructure (30) is not prevented from a radial displaced by the cover rosette (32), and comprises a cover rosette through opening (72) which is bordered by an inner edge area and which has a diameter larger than a through opening (54, 76) of the substructure (30), so that the position of a rotational axis of the handle (36) can be radially variably adjusted with respect to the cover rosette (32) in a selectable manner.

7. Door wing kit of parts according to claim 6, characterized in that the substructure (30) is provided with the substructure body (34) and an insert sleeve (58), wherein the substructure body (34) has the substructure outer contour and a substructure body through opening (54) the diameter of which is smaller than the diameter of the cover rosette through opening (72), and wherein the insert sleeve (58) is designed for its insertion into the substructure through opening (54) in a precisely fitting manner and comprises an insert sleeve through opening (76) for tailored swivel mounting of a mounting section (56) of the handle (36) and a cover ring (60) for supporting a front end of the handle (36) and for covering the inner edge area of the cover rosette (32).

8. Device (100) for automated production of a door wing (14), the device (100) comprising: a processing machine (104) for the numerically controlled machining of a door leaf body (74), a mortise lock mounting device (106) for inserting and fixing a mortise lock (20) in a lock pocket (21) in the door leaf body (74), a substructure mounting device (108) for inserting, positioning and fixing a substructure (30) in a substructure receiving recess (46) in the door leaf body (74), and a cover rosette mounting device (110) for mounting a cover rosette (32) in a cover rosette recess (48) in the door leaf body (74) for covering a substructure body (43) of the substructure (30) inserted into the substructure receiving recess (46) in a flush-mounting manner; and electronic, numeric or computer-implemented control means (112), wherein the device (100) is configured to carry out the method according to any one of claims 1 to 5.

9. Arrangement, comprising a device (100) according to claim 8 and a door wing kit of parts according to any one of claims 6 or 7.

10. Computer program comprising instructions which cause a device (100) according to claim 8 to carry out the method according to any one of claims 1 to 5.