Method, device, kit of parts, arrangement and computer program for the automated production of a door leaf

Abstract

To improve the series production of high-quality door leaves with a high-quality appearance, the invention provides a method, a device, a set of parts, an arrangement, and a computer program for the automated manufacture of a door leaf with a leaf-covering door fitting. First, recesses (21, 46, 48) for receiving the lock and door fitting components are created in 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 and a cover rosette (32) are mounted in recesses on the broad side of the door leaf (15). The substructure is inserted with play into a substructure receiving recess with radial play, positioned therein in alignment with a position of a lock follower (44), and fixed.In some embodiments, the substructure for supporting a handle (36) has an insert sleeve (58) with a cover collar (60) which covers the radial gap on an inner diameter of the cover rosette, which is to be provided for tolerance compensation.

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 leaf-covering door fitting.

[0002] For the technological background and definition of the term, reference is made to the following literature, on whose knowledge the following disclosure is based: [1] BASIC KNOWLEDGE DOORS - Hörmann Technical Manual, 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 14.11.2023 from https: / / de.wikipedia.org / wiki / Einsteckschloss [3] HUGA - The Program, company brochure of HUGA KG, downloaded on 14.11.2023 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 14.11.2023 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] From literature reference [5], a door leaf with a leaf-covering door fitting and a method for manufacturing and assembling the same are known. A substructure, flush with a cover rosette, is provided for supporting a handle, such as a door handle or a toilet door olive, which handle is coupled to a lock nut of a mortise lock for rotating the handle. The substructure is precisely accommodated in a substructure receiving recess, which is CNC-machined into a door leaf body made of machined material. In particular, the substructure is precisely accommodated in a through-hole of the cover rosette, which is precisely accommodated in a cover rosette recess produced by CNC milling.

[0004] The object of the invention is to provide means by which a door leaf of the type shown in [5], which is improved in terms of function and appearance, can be automatically produced in large series.

[0005] To achieve this object, the invention provides a method, a kit of parts, a device, an arrangement and a computer program according to the appended independent claims.

[0006] Advantageous embodiments are the subject of the subclaims.

[0007] According to one aspect thereof, the invention provides a method for the automated production of a door leaf, comprising the steps: a) Providing a door leaf body which, at least in a lock-side region, is formed from machinable material; b) Providing a mortise lock with a lock nut rotatably mounted therein; c) Providing a substructure and a cover rosette, wherein the substructure is designed for the precise pivotal mounting of a handle which is to be coupled to the lock nut, 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 region, the diameter of which is larger than a through-opening of the substructure, so that the position of a rotational axis of the handle can be selected to be 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 one broad side of the door leaf body with an inner contour that is complementary to the outer contour of the substructure but larger in size, so that when the substructure is inserted there is radial play between the outer contour and the substructure receiving recess; f) numerically controlled machining of a cover rosette recess for radially and axially precise flush mounting of the cover rosette; g) inserting and fixing the mortise lock in the lock pocket; h) inserting the substructure into the substructure receiving recess, i) radially positioning the substructure in the substructure receiving opening so that the center of the substructure through-opening is aligned with the rotation axis of the lock follower and fixing the positioned substructure;and j) precise insertion of the cover rosette into the cover rosette recess. ;

[0008] The numbering of the steps a), b), ... is for ease of reference and is not intended to imply any indication of a specific order of the steps. The individual steps can be performed sequentially, in parallel, or overlapping, depending on the overall context.

[0009] If the door leaf is only provided with a handle on one broad side - e.g. the side facing in the opening direction (hinge side) or the side facing opposite the opening direction (counter-hinge side), it is sufficient if one set of substructure and cover rosette is provided for this broad side in step c) and the corresponding recesses are made for this substructure and cover rosette in steps e) and f). In most designs, at least one set of substructure and cover rosette - in particular for a door handle as a handle - is provided for each broad side of the door leaf in step c) and the recesses are made on each of the broad sides in steps e) and f). For a door leaf with several handles - e.g. door handle and olive - one set of substructure and cover rosette for the first handle - e.g.Door handle - and a set of substructure and cover rosette for the second handle - e.g. olive or coin slot element - can be provided; it is also possible to provide a common larger cover rosette for covering a first substructure for the first handle and for covering a second substructure for the second handle with a corresponding first and a second cover rosette through opening.

[0010] In particularly preferred embodiments, step b) comprises b1) 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 precise pivotal mounting of the bearing section of the handle and a cover ring for supporting a front end of the handle and for covering the inner edge region of the cover rosette.

[0011] It is preferred that in steps g) and h) the substructure body is inserted, positioned and fixed in the substructure receiving recess.

[0012] It is preferred that the method further comprises the step following step j): k) inserting the insertion sleeve into the substructure body through-hole.

[0013] Preferably, step b1) comprises providing the substructure body in such a way that the side to be covered by the cover rosette is flat.

[0014] In some embodiments, step k) is carried out at the manufacturing site; the door leaf is then delivered to the installation site with the insert sleeve already inserted, where the handle is then preferably mounted.

[0015] However, step k) can also be performed later, e.g., during the preparation process up to the installation site. For example, step k) is performed together with the assembly of the handle.

[0016] The insert sleeve can be inserted simply by axially pushing it in. However, it is also possible to screw the insert sleeve into the substructure body. For this purpose, some designs provide an internal thread for the substructure body through-hole and a matching external thread for the insert sleeve.

[0017] Positioning in step i) can be performed in different ways. In some embodiments, the position of the lock follower's rotational axis is detected (measured) using any known detection method, and the position is adjusted accordingly using a substructure assembly device—e.g., an assembly robot or 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 with the cover rosette. Preferably, step i) comprises

[0018] i1) Positioning of the substructure with a positioning aid, which is inserted precisely into the lock nut on one side and precisely accommodates the substructure passage opening in the position area of ​​the substructure. Preferably, step i) comprises

[0019] i2) Fixing the substructure using adhesive.

[0020] A hot melt adhesive is preferably used. Preferably, step i) comprises

[0021] i3) Fix the substructure using clamps. Preferably, step i) comprises

[0022] i4) Fixing the substructure by means of clamps by fixing the cover rosette in such a way that it clamps the substructure in the door leaf body.

[0023] Clamping can be done in addition to or alternatively to gluing. Preferably, step f comprises:

[0024] 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 for fastening the cover rosette, wherein step j) fastening the cover rosette by introducing adhesive in the second step.

[0025] According to a further aspect, the invention provides a door leaf parts set for producing a door leaf, wherein the door leaf parts set 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 machinable material, in which a lock pocket for the precise reception of the mortise lock and on at least one of the broad sides at least one substructure receiving recess for receiving the substructure and a cover rosette recess for the flush (covering the leaf) reception of the cover rosette, which covers the substructure, are milled; wherein the substructure is designed for the precise pivot bearing of a handle which is to be coupled to the lock nut and has a substructure outer contour which can be received with radial play in 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 inserted into the substructure receiving recess during 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 region, 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 to be radially variable relative to the cover rosette.

[0026] It is preferred that the substructure is 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 pivotal mounting of the bearing section of the handle and a cover ring for supporting a front end of the handle and for covering the inner edge region of the cover rosette.

[0027] According to a further aspect, the invention provides a device for the automated production of a door leaf, comprising a processing machine for the numerically controlled machining of a door leaf body, a mortise lock mounting device for inserting and fixing a mortise lock in a lock pocket in the door leaf body, a substructure mounting device for inserting, positioning, and fixing a substructure in a substructure receiving recess in the door leaf body, and a cover rosette mounting device for mounting a cover rosette in a cover rosette recess in the door leaf body for flush covering 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.

[0028] According to a further aspect, the invention provides an arrangement comprising a device of the type mentioned above and a door leaf part set according to one of the above embodiments.

[0029] According to a further aspect, the invention provides a computer program comprising instructions which cause a device of the type mentioned above to carry out the method according to one of the embodiments explained above.

[0030] In the following, some advantages and technical effects of particularly preferred embodiments of the invention are explained in more detail.

[0031] Preferred embodiments of the invention relate to an automatic assembly of such door leaves as shown in the reference [3] under the designation "Planar" or as described and shown in the reference [5].

[0032] For this purpose, in some embodiments of the invention, the flush-mounted handle set "Planar" was further developed, as shown in [3] and [5], and the design was modified to better enable machine production and assembly.

[0033] According to [1], the vast majority of locks on doors, particularly swing doors, are designed as mortise locks - see references [1] and [2]. For cost reasons, the locks for doors available on the market are manufactured with certain tolerances between the faceplate and the lock follower. In addition to normal manufacturing tolerances, these tolerances also result from the inaccurate attachment of the lock case to the lock faceplate. The interaction between the lock follower, handle pin and handle bearing, such as the handle rosette or door plate, must accommodate these tolerances without impairing function. For this purpose, the position of the handles is normally not determined until the locks are installed. In this case, for example, hand drilling templates are used on site, i.e. only on site at the construction site, which have the lock follower as the reference point.By selecting the correct drill diameter for the handle attachment, coordinated with the selected handle set, the desired positive locking is achieved. However, this requires considerable manual labor during production. Furthermore, this procedure cannot be implemented for every type of door; for example, for doors of the type shown in [5], it is desirable to mill out a recess for a door handle rosette (or other pivot bearing for a door handle on the door leaf) before installing the lock.

[0034] If, as is desired in industrial, largely automated large-scale production of door leaves, receptacles for pivot bearings of door handles (or other handles, e.g. toilet handles) are machine-made, e.g. milled out, on the door leaf, as is desired for machine-milling for flush-mounted handle sets of the type known from [5], for example, in the context of series production of the doors, the tolerances of the different individual locks to be used cannot simply be accommodated. Therefore, such machine-made bores or similar holes have to be produced with a larger bore diameter than specified by the handle manufacturers. This does not allow a positive connection between the door and handle, but only a frictional connection. Over time, this can lead to the rosettes wobbling, which can lead to functional defects and mechanical damage to the surface of the door leaf or the rosette.In conjunction with machine milling carried out during automated production for the reception of door handle bearings, such as in particular - but not exclusively - for flush-mounted handle sets, for example of the type known from [3] and [5], the tolerances of the lock in the interaction between the lock follower - handle spindle (e.g., handle square) - handle bearing (especially the handle rosette) affect the function of the handle set. Machine milling of the flush-mounted rosette receptacles on a door leaf with a previously installed lock, which would then provide a reference point for the lock follower, is very difficult to accomplish and should be avoided for safety reasons, especially on wooden doors or similar, as contact between the milling cutter and the lock can result in sparks, with 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.

[0035] For flush-mounted door handle sets (e.g., Planar), as described in [3] and [5], these tolerances are currently accommodated and compensated for during production by milling using templates and manual assembly. Thus, high personnel costs are required for series production, making production complex and expensive.

[0036] In conjunction with a machine milling for flush-mounted handle sets (e.g. Planar), the tolerances in the interaction between the lock nut, the square handle and the rosette affect the function of the handle set or show up as different widths of gaps or functional problems.

[0037] For safety reasons, machine milling of the handle sets (e.g. Planar or normal handle sets) with the lock installed is not recommended (sparks may fly when the cutter comes into contact with the lock).

[0038] Some embodiments of the invention provide for very precise lock milling (example: lock pocket) in the door leaf through CNC machining. Furthermore, flush rosette milling (example: cover rosette recess) and substructure milling (example: substructure receiving recess) are also provided very precisely through CNC machining. At this point, both millings have no direct and precise relationship to the lock follower, including the corresponding tolerances.

[0039] After the lock has been installed, the Planar substructure is positioned and fastened precisely to the handle nut (or, if necessary, to the lock nut for a deadbolt, for coupling with a toilet olive, for example).

[0040] In some designs, positioning is achieved with the help of a positioning aid, which can be designed similarly to a handle with a square spindle. This positioning aid is inserted precisely into the lock nut on one side and, in the positioning area of ​​the substructure, precisely accommodates the inner diameter of the substructure. The resulting tolerances between the milling of the substructure in the door leaf and the positioned substructure (matching the lock nut) are absorbed by fixing the substructure, e.g. using adhesive, clamping, or similar. This fixing can be carried out by an assembly robot, for example. The fixed substructure also ensures that the handle set is firmly mounted in the substructure.

[0041] In some designs, the substructure in the area of ​​the later rosette is flat (without a race for the handle), unlike the design known from [5]. Furthermore, the inner diameter of the substructure is slightly larger than the later associated handle neck.

[0042] In some designs, the corresponding rosette has an inner diameter slightly larger than the inner diameter of the substructure. The difference between the two inner diameters is large enough to accommodate all tolerances, e.g., from the lock or manufacturing, without the edge of the rosette's inner diameter protruding beyond the edge of the substructure's inner diameter.

[0043] 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 - insert sleeve.

[0044] This insert has an inner diameter that matches the diameter of the corresponding handle neck, so that the handle is guided precisely after assembly.

[0045] The outer diameter of the insert is precisely matched to the inner diameter of the substructure body.

[0046] The wider crown covers the visible tolerances between the inner diameter of the rosette and the inner diameter of the substructure body and also serves as a race and guide for the handle. This also protects the rosette from damage during handle operation.

[0047] In some designs, since the rosette only needs to be precisely positioned and secured in the rosette cutout along the outer edge, this assembly part can also be carried out using an assembly robot, for example. The insert with crown can be pressed in at the factory or included with the handle set.

[0048] It would also be conceivable for the insert to be equipped with an external thread and the substructure body with a matching internal thread, so that it can be screwed rather than plugged in.

[0049] In some designs, the outer edge of the rosette cutout has a step. The first step is adjusted to the rosette thickness. The second step provides the necessary space to accommodate the adhesive used to secure the rosette.

[0050] Thanks to the first stage of rosette milling and the flat substructure in one plane, even rosettes that are not entirely flat and somewhat flexible can be installed automatically. The adhesive ensures that the rosette is held in place in the milling and fits snugly on the inner and outer edges.

[0051] For further features and functions, reference is made to [5], whose embodiments, through appropriate modification as indicated here, become embodiments of the present invention. Other functions and designs (mini rosettes, long plate optics, etc.) are possible through different shapes and / or dimensions of the individual parts, as indicated in particular in [6] or [7].

[0052] Preferred embodiments of the invention relate, starting from [3] (there the doors designated Planar), [5], [6] or [7], to further developed designs and assembly techniques for flush-mounted handle sets, which particularly preferably facilitate simpler, in particular automated, production in industrial large-scale production technology without impairing the function, durability, comfort, operability and / or high-quality appearance.

[0053] Examples of embodiments are explained in more detail below with reference to the attached drawings. They show: Fig. 1 is a front view of the first broad side - hinge side - of a door with a door leaf that is to be manufactured using methods, devices, parts sets and arrangements according to embodiments of the invention; Fig. 2 is a front view of a lock end face of the door leaf in the area of ​​a lock; Fig. 3 is a view comparable to Fig. 2 on a door leaf of the door wing before mounting the lock and a door fitting for operating the lock; Fig. 4 a sectional view along the line AB of Fig. 1 or along line BC from Fig. 1 , whereby a substructure and a cover rosette are mounted as parts of the door fitting, whereby Fig. 4an embodiment of a door leaf to be manufactured by an automated manufacturing process in a manufacturing plant - still without a handle set or WC olive set; Fig. 5 an exploded view of the Fig. 4shown area of ​​the door leaf with the parts of the door fitting to be mounted, in particular a substructure with substructure body, a cover rosette and an insertion sleeve as well as a handle set that is generally only to be mounted on site (shape subject to change); Fig. 6 to 8 different views of an embodiment of the substructure body with example dimensions; Fig. 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 fitting with substructure receiving recess and cover rosette recess and example dimensions; Fig. 11 a side view of an embodiment of a positioning aid; Fig. 12 and 13 different views of an embodiment of the insertion sleeve with example dimensions; Fig.14 and 15 show different views of an example of the lock, as known in principle, for example from [2]; and Fig. 16 shows a schematic representation of the principle of a device for automatically manufacturing the door leaf.

[0054] Fig. 1 shows an embodiment of a door 10 with frame 12 and door leaf 14 and flush door fitting 16.

[0055] 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 shown in Figs. 14 and 15 shown and explained in more detail in [2], is received and fixed in a lock pocket 21.

[0056] 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 is shown with a faceplate recess 22 for receiving the lock faceplate 24 and a box recess 26 for receiving the lock box 28.

[0057] Fig. 4 shows a partial section along the line AB of Fig. 1 , wherein a substructure 30 and a cover rosette 32 for flush-fitting a substructure body 34 of the substructure 30 are mounted as parts of the flush-fitting door fitting 16. The substructure 30 is designed for the precise pivoting of a handle 36 of the door fitting 16.

[0058] Fig. 5 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 handle 38 of a handle set 40 with a design that can be selected. This handle is coupled to a lock follower 44 of the mortise lock 20 by means of a handle pin 42—usually a square pin.

[0059] 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 machinable material, such as in particular a wood material, a substructure receiving recess 46 for completely receiving the substructure body 34 and a cover rosette recess 48 for flush receiving the cover rosette so that it covers the substructure body 34 are introduced.

[0060] An embodiment with exemplary dimensions of the substructure body 34 is shown in Fig.6 to 7shown. In some embodiments, the substructure body 34 is hat-shaped, with a circular-cylindrical main region 50 and a radially annularly projecting edge region 52 at the axial end region that comes into contact with the cover rosette. The axial end surface 54, on which the cover rosette 32 rests, is flat, so that no positive connection 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 substructure body through-opening 54 for inserting the bearing region 56 of the handle 36.

[0061] The bearing area 56 is formed, for example, at the free end of the handle neck of the door handle 38. Handle sets are available from various manufacturers, with predetermined, particularly standardized, diameters of this bearing area 56 for certain markets, e.g., the EU. For example, various door handles 38 are available that have a bearing area 56 with a diameter of 16 mm on the handle neck.

[0062] In some embodiments, the substructure body through-opening 54 is significantly larger than the predetermined diameter of the bearing area 56, wherein an insert sleeve 58 with a cover ring 60 is provided, which can be inserted with its outer diameter into the substructure body through-opening 54 with a precise fit. An embodiment of the insert sleeve 52 is shown in the Fig. 5 , 12 and 13shown. The insertion sleeve 58 is, for example, hat-shaped, with the cover ring 60 projecting radially at one axial end region and the other axial end 60 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 it or, if appropriate threads are provided, by screwing it in.

[0063] The axial end 62 facing away from the cover ring can be conical in order to facilitate insertion of the insertion sleeve 58 into the substructure body 34.

[0064] In the following, the Fig. 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 D46 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 rotation axis of the lock nut of the assembled lock 18 can be compensated for by adjusting the position of the substructure 30. Typical tolerances can be found, for example, in [4]. Accordingly, in some embodiments, the inner diameter D46 of the substructure receiving recess 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 can be variably selected within this area.

[0065] In designs with a radially projecting edge region 52, this serves for the axial positioning of the substructure 32 by resting on the edge of the substructure receiving recess 46 and accordingly has an outer diameter D52 which 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 64 of the cover rosette recess 48 which adjoins the substructure receiving recess 46 axially.

[0066] The contour and depth of the cover rosette recess 48 is precisely adapted to the cover rosette 32.

[0067] In some embodiments, the cover rosette recess 48 is stepped. A first step 66, viewed from the wide side of the door leaf 15, has an inner contour 68 that precisely matches the outer contour of the cover rosette 32 and a depth T1 that corresponds to the rosette thickness RD. The second step 70 has a smaller diameter so that an edge of the cover rosette 32 can rest thereon and a depth T2 that is adapted to the thickness of the edge region 52. When the edge region 52 rests, a gap is formed between it and the radial boundary of the second step, which gap provides space for receiving an adhesive (e.g., hot melt adhesive).

[0068] 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 above-mentioned tolerance range and thus larger than the through-opening of the insert sleeve 58 which is precisely adapted to the bearing area 56.

[0069] The outer diameter of the ring 60 is dimensioned to be larger than the inner diameter of the cover rosette through-opening 72 in such a way that it can cover the cover rosette through-opening over its entire circumference in any variably selectable radial position of the substructure 30.

[0070] The following describes in more detail the manufacture and assembly of the door leaf 14 with lock 18 and flush door fitting 16. To reduce costs, industrial mass production is desirable, which can be carried out as largely automated as possible.

[0071] In the illustrated embodiments, the substructure receiving recess 46 extends continuously up to the box recess 26. The recesses 21, 22, 26, 46, 48 are formed as milled recesses in the door leaf body 74, which is made of machined materials, such as wood-based materials, solid wood, HDF, MDF, chipboard, plywood, laminated veneer lumber, laminated wood, optionally surface-coated or veneered. Thus, the recesses 21, 22, 26, 46, 48 to be provided in the door leaf body 74 for receiving the lock 187 and the door fitting 16 can be machined very precisely with very tight tolerances using numerically controlled machining, in particular CNC milling.

[0072] Locks 18, 20 available on the market from various manufacturers have relatively large manufacturing tolerances due to cost constraints, so that the position of the lock case 28 relative to the lock face 24 and, in particular, the position of the rotational axis of the lock follower 44 is subject to relatively large tolerances. The different tolerances of the lock 18, 20 and the recesses 21, 22, 26, 46, 48 for the lock 30 and the door fitting 16 on the door leaf body 74 can result in mismatches between the rotational axis of the handle 36 defined by the recesses 46, 48 on the door leaf body 74 and the position of the rotational axis of the lock follower 44 determined by the lock case 28 and the tolerances of the lock 18, 20. These mismatches could impair the assembly of the handle set, the longevity, and the function of the lock-door fitting-handle set combination.

[0073] In order to facilitate machine production and assembly and to counteract the aforementioned problems, a particularly Fig. 5 The door leaf parts set shown is provided, which comprises the door leaf 15, the mortise lock 20, the substructure 30 and the cover rosette 32 as parts. The door leaf 15 has the lock-side area made of machinable material, in which the lock pocket 21 for the precise reception of the mortise lock 18 as well as a number of substructure receiving recesses 46 matched to the number of pivot bearings of the door fitting for receiving the respective substructure 30 for the pivot bearing with corresponding cover rosette recesses 48 for receiving the cover rosette 32, which covers the substructure 30, in particular the substructure body 34, are milled.

[0074] The substructure 30 is designed to provide a precisely fitting pivot bearing for the handle 36, which is to be coupled to the lock nut 44. The substructure 30 has a substructure outer contour that can be received with radial play in the substructure receiving recess 46.

[0075] The cover rosette 32 can be inserted flush and precisely into the cover rosette recess 48 to cover the substructure body 34 of the substructure inserted into the substructure receiving recess 46 during intended use. The substructure 30 through 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 precise position of the cover rosette, the radial position of the substructure is variable during assembly in order to compensate for tolerances and adapt to the position of the rotation axis of the lock nut 44. The cover rosette through-opening 72, bordered by an inner edge region, has a diameter that is larger than the through-opening of the substructure 30 designed to support the handle, so that the position of the rotation axis of the handle 36 can be selected radially variable relative to the cover rosette.This means that the substructure can be adapted to the position of the lock nut during assembly and fixed accordingly.

[0076] 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 outer contour and the substructure body through-opening 54. Their diameter 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 precisely pivotally supporting the bearing section 56 of the handle and the cover ring 60 for supporting a front end 78 of the handle 36 and for covering the inner edge region of the cover rosette 32.

[0077] This allows an exact and play-free pivot bearing of the handle 36 to be achieved, so that the door gives a high quality impression and can be operated conveniently and comfortably.

[0078] Although the compensation of lock tolerances has been explained using the example of the handle set, corresponding measures can also be taken for other handles, e.g. for toilet olives - see [5] for further details. Fig. 10 The shape of the substructure receiving recess 46 is shown, as it is designed for substructures 30 for pivot mounting of door handle sets or toilet handles. A dash-dotted line shows a through-hole 82, as provided in the area of ​​a keyhole 80 of a warded mortise lock or a locking cylinder of another corresponding mortise lock.

[0079] A method 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 region; b) Providing the mortise lock 20 with a lock nut 44 rotatably mounted therein; c) Providing the substructure 30 and the cover rosette 32; d) Numerically controlled machining of the lock pocket 21 for the lock into the door leaf body 74; e) Numerically controlled machining of the substructure receiving recess 46 on at least one broad side of the door leaf body 54 with an inner contour complementary to an outer contour of the substructure 30 but of larger dimensions such that when the substructure 30 is inserted, there is radial play between the outer contour and the substructure receiving recess 46;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 nut 44 and fixing of the positioned substructure 30; and j) precise insertion of the cover rosette 32 into the cover rosette recess 48. ;

[0080] In some embodiments, step b) comprises: b1) providing the substructure 30 with the substructure body 34 and the insertion sleeve 58. In this case, in steps g) and h), initially only the substructure body 34 is inserted into the substructure receiving recess 46, positioned, and fixed. After step j), the next step is performed: k) inserting the insertion sleeve 58 into the substructure body through-opening 54.

[0081] In some embodiments, the positioning of the substructure is carried out with a positioning aid 84, an embodiment of which is shown in Fig. 11 is shown. An example of which is shown in Fig. 11is shown. The positioning aid 84 has a pin projection 86, preferably provided with a conical insertion end 87, which projects from a fitting body 88, the outer contour of which is precisely adapted to the substructure body through-opening 54. For assembly, the substructure body 34 can be placed on the fitting body 88 and mounted with the positioning aid, wherein the pin projection 86 is inserted into the lock nut 44 of the previously installed lock. Different procedures are possible. The positioning aid can, for example, also be inserted first and then the substructure body 34 is placed on it and pushed axially into stop. The substructure body can also initially be inserted unpositioned and covered with the cover rosette. Before the fixation, for example by curing the adhesive or by tightening a clamp (e.g.Once the cover rosette is pressed in, the positioning aid is inserted, thus adjusting the radial position of the substructure body 34 to the position of the rotation axis of the lock nut. Fixing then takes place.

[0082] In Fig. 16 A possible structure of a device 100 for the automated production of the door leaf 14 is shown schematically. 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.

[0083] The device 100 comprises a processing machine 104, for example a machining center, for the numerically controlled machining of the door leaf body 74 in order 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 in 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 in 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 for controlling the device 100 to carry out the method explained above.

[0084] For this purpose, some embodiments have a controller 114 with a processor 116 and a memory 118 in which a computer program with corresponding control instructions is stored.

[0085] In some embodiments, an adhesive application device 120 is provided for applying adhesive in the cover rosette recess 48. An assembly robot of the substructure assembly device 108 is configured to insert and position the substructure body 34 with the aid of the positioning aid 84. The adhesive already ensures adhesion at this stage, so that the position is maintained until the assembly robot of the cover rosette assembly device 110 installs and presses on the cover rosette, thus additionally fixing the substructure body 34 by clamping. A press 122 can also be provided for pressing the lock area until the adhesive has partially hardened or cured.

[0086] The insert sleeve 58 can be delivered together with the door leaf 14 and transported to the construction site. It can also be provided with the handle set. The insert sleeve 58 can thus be used during assembly of the handle set, for example, at the construction site.

[0087] In some embodiments of the device 100, an insertion sleeve assembly device 124 is provided, which is configured to insert the insertion sleeve 58 into the substructure body 34 in the manufacturer's factory after the cover rosette 32 has been installed.

[0088] The embodiments illustrated in the figures show only a standard version of the door leaf 14. Further possible versions are obtainable by adopting modifications to the shape and function of the substructure and the cover rosette as described in [5], [6] or [7]. In other words, the measures described here in the claims and the drawings for improving automated production can also be applied to the other variants described in [5], [6], [7]. For further features of further embodiments of the invention, express reference is made to these references [5], [6] and [7].

[0089] To improve the series production of high-quality door leaves with a high-quality appearance, the invention provides a method, a device, a set of parts, an arrangement, and a computer program for the automated manufacture of a door leaf with a leaf-covering door fitting. First, recesses (21, 46, 48) for receiving the lock and door fitting components are created in 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 and a cover rosette (32) are mounted in recesses on the broad side of the door leaf (15). The substructure is inserted with play into a substructure receiving recess with radial play, positioned therein in alignment with a position of a lock follower (44), and fixed.In some embodiments, the substructure for supporting a handle (36) has an insert sleeve (58) with a cover collar (60) which covers the radial gap on an inner diameter of the cover rosette, which is to be provided for tolerance compensation. List of reference symbols:

[0090] 10 Door 12 Frame 14 Door leaf 15 Door panel 16 Door fitting 18 Lock 20 Mortise lock 21 Lock pocket 22 Forend recess 24 Lock forend 26 Case recess 28 Lock case 30 Substructure 32 Cover rosette 34 Substructure body 36 Handle 38 Door handle 40 Handle set 42 Handle pin 44 Lock follower 46 Substructure receiving recess 48 Cover rosette recess 50 Main area 52 Edge area 54 Substructure body through opening 56 Bearing area 58 Insert sleeve 60 Cover crown 62 Free axial end 66 First step 68 Radial outer limit 70 Second step 72 Cover rosette through opening 74Door leaf body 76Insert sleeve through-hole 78Front end 80Keyhole 82Through recess 84Positioning aid 86Pin projection 87Conical insertion end 88Fitting body 100Device 102Conveyor belt 104Processing machine 106Mortise lock assembly device 108Substructure assembly device 110Cover rosette assembly device 112Control means 114Control system 116Processor 118Memory120 Adhesive application device 122 Press 124 Insert sleeve assembly device D34 Outer diameter of substructure D46 Inner diameter of substructure receiving recess D52 Diameter of edge area T1 Depth of first step T2 Depth of second step

Claims

1. A method for the automated production of a door leaf (14), comprising the steps of: a) providing a door leaf body (74) formed from machinable material at least in a lock-side region; b) providing a mortise lock (20) with a lock nut (44) rotatably mounted therein;c) Providing a substructure (30) and a cover rosette (32), wherein the substructure is designed for the precise pivotal mounting of a handle (36) to be coupled to the lock nut (44), and wherein the cover rosette (32) is designed for flush covering of a substructure body (34) of the substructure (30), allowing radial relative displacement, and has a cover rosette through-opening (72) bordered by an inner edge region, the diameter of which is 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 selected to be radially variable relative 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 broad side of the door leaf body (74) with an inner contour complementary to an outer contour of the substructure (30) but of larger dimensions such that when the substructure (30) is inserted there is radial play between the outer contour and the substructure receiving recess (46); f) numerically controlled machining of a cover rosette recess (48) for the radially and axially precise flush mounting 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) radially positioning the substructure (30) in the substructure receiving opening (48) so that the center of the substructure through-opening (54) is aligned with the rotation axis of the lock nut (44) and fixing the positioned substructure (30); and j) precisely inserting the cover rosette (32) into the cover rosette recess (48).; 2. Method according to claim 1, characterized by thatStep b) comprises: b1) providing the substructure (30) with the substructure body (34) and an insertion sleeve (58), wherein the substructure body (34) has the substructure outer contour and a substructure body through-opening (54) whose diameter is smaller than the diameter of the cover rosette through-opening (72), and wherein the insertion sleeve (58) is designed for precise insertion into the substructure through-opening (54) and has an insertion sleeve through-opening (76) for precisely pivotally supporting the bearing section (56) of the handle (36) and a cover ring (60) for supporting a front end (78) of the handle (36) and for covering the inner edge region of the cover rosette (32), that in steps g) and h) the substructure body (34) is inserted, positioned and fixed in the substructure receiving recess (46) and thatthe method further comprises the step following step j): k) inserting the insert sleeve (58) into the substructure body through-opening (54).

3. Method according to claim 2, characterized by , 3.1 that 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 that step k): 3.2.1 is carried out at the place of manufacture or at the place of installation; and / or 3.2.2 is carried out together with the assembly of the handle (36); and / or 3.2.3 comprises axially pushing or screwing the insertion sleeve (58) into the substructure body (34).

4. Method according to one of the preceding claims, characterized by thatStep i) comprises at least one or more of the steps: i1) positioning the substructure (30) with a positioning aid (84) which is inserted precisely into the lock nut (44) on one side and which precisely accommodates the substructure through-opening (54) in the position area of ​​the substructure (30); i2) fixing the substructure (30) by means of 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 one of the preceding claims, characterized by thatStep f) comprises: creating a radially outer boundary (64) of the cover rosette recess (48) with a step, wherein a first step (66) is matched to the thickness of the cover rosette (32) and a second step (70) provides space for an adhesive for fastening the cover rosette (32), wherein step j) comprises fastening the cover rosette (32) by introducing adhesive in the second step (70).

6. A set of door leaf parts for producing a door leaf (14), 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 region made of machinable material, in which a lock pocket (21) for precisely receiving the mortise lock (20) and at least one substructure receiving recess (46) for receiving the substructure (30) and a cover rosette recess (48) for receiving the cover rosette (32) are milled; wherein the substructure (30) is designed for the precise pivoting of a handle (36) which is to be coupled to a lock nut (44) of the mortise lock (209) and has a substructure outer contour which can be received with radial play in the substructure receiving recess (46), wherein the cover rosette (32) can be inserted flush and precisely into the cover rosette recess (48),to cover a substructure body (34) of the substructure (30) inserted into the substructure receiving recess (46) during intended use in such a way that the substructure (30) is not prevented from radial displacement by the cover rosette, and has a cover rosette through-opening (72) bordered by an inner edge region, the diameter of which is 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 selected and variably adjusted radially relative to the cover rosette (32).

7. Door leaf parts set according to claim 6, characterized by thatthe substructure (30) is provided with the substructure body (34) and an insertion sleeve (58), wherein the substructure body (34) has the substructure outer contour and a substructure body through-opening (54) whose diameter is smaller than the diameter of the cover rosette through-opening (72), and wherein the insertion sleeve (58) is designed for precise insertion into the substructure through-opening (54) and has an insertion sleeve through-opening (76) for precisely pivotally supporting a bearing section (56) of the handle (36) and a cover ring (60) for supporting a front end (78) of the handle (36) and for covering the inner edge region of the cover rosette (32).

8. Device (100) for the automated production of a door leaf (14), 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 flush covering a substructure body (43) of the substructure (30) inserted into the substructure receiving recess (46);and electronic, numerical or computer-implemented control means (112), wherein the apparatus (100) is arranged to carry out the method according to one of claims 1 to 5; 9. Arrangement comprising a device (100) according to claim 8 and a door leaf part set according to one of claims 6 or 7.

10. A computer program comprising instructions that cause a device (100) according to claim 8 to perform the method according to any one of claims 1 to 5.

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