Method for commissioning an automated bodywork construction system
Patent Information
- Application Number
- EP2024701412
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-01-26
- Filing Date
- 2024-01-22
- Publication Date
- 2025-11-26
AI Technical Summary
The existing methods for commissioning automated body construction systems in vehicle manufacturing are inefficient due to the difficulty in immediately detecting faulty devices, such as incorrect plug positions and connections, leading to increased commissioning time for error corrections.
A method that includes a functional test using a digital twin, where the physical device interacts with the digital representation, allowing for pre-commissioning testing of pneumatic and electrical functions before system assembly, utilizing a test station with a test device to verify mechanical activities in response to control signals, thereby identifying and preventing faulty device installation.
This approach reduces commissioning time by identifying and correcting errors before the system is operational, ensuring that the automated body construction system is set up correctly and efficiently, thereby minimizing time-consuming corrections during production.
Smart Images
Figure EP2024051361_02082024_PF_FP
Abstract
Description
[0001] Procedure for commissioning an automated
[0002] Body shop
[0003] DESCRIPTION:
[0004] The invention relates to a method for commissioning an automated system for body construction according to the preamble of claim 1 and to a testing device for such a method according to claim 9.
[0005] In a vehicle manufacturing plant, a fully automated body shop is commonly provided for series vehicle production. The shop consists of at least one Profinet device, for example, a welding robot, a PLC device that performs control tasks within the shop, and at least one pneumatically, electrically, or hydraulically operated device. Such a pneumatically operated device typically has pneumatic units and a valve terminal as functional units. The valve terminal forms an interface in which an electrical control signal from the PLC device is converted into a pneumatic control signal, which can be used to control the pneumatic units of the shop.
[0006] The functional units of the device can, for example, be pin pullers or clamps, with which body panels can be fixed in position. In an example process sequence of the system, the PLC device controls the pneumatically operating functional units of the device via the valve terminal in order to fix body panels in a predefined position. After the correct position has been fixed, the Profinet device (e.g. the welding robot) is moved to a predefined joining point in order to join the body panels together, for example by welding, riveting or the like. The body construction system described above is set up and put into operation in the state of the art as follows: First, the control and regulation tasks are programmed in the PLC device in a programming process step.Programming of the PLC device is not performed on the physical system itself, but rather on a digital twin that virtually replicates the system using a VIBN system. Subsequently, the programmed PLC control unit, the fixture, and the Profinet device are assembled into the system in an assembly process step. The system is then commissioned.
[0007] The manufacture of the pneumatically operating device takes place in a pre-assembly process step in common practice in the device construction of the vehicle manufacturing plant, which is geographically separate from the production facility of the vehicle manufacturing plant.
[0008] The system setup and commissioning outlined above pose the following problem: A faulty fixture (e.g., due to incorrect connector positions and / or incorrect electrical / pneumatic connections in the functional units) cannot be readily detected directly during fixture construction. In this case, the faulty fixture is only detected during commissioning in the production facility. This increases the commissioning time required to correct the fault in the fixture.
[0009] DE 103 60 530 A1 discloses a system for the virtual commissioning of a machine. Based on a virtual model, a parameter set is transferred to the machine for its actual commissioning. DE 10 2019 135 575 A1 discloses a system for testing a valve terminal with a diagnostic module. The diagnostic module is coupled to a controller and serves to test a plurality of process valves. GB 2596863 A discloses a diagnostic system for testing a valve terminal with a diagnostic module. The diagnostic module is operatively connected to a central computer via a communication link. The object of the invention is to provide a method for commissioning an automated body shop in which the commissioning time can be easily reduced compared to the prior art.
[0010] The object is solved by the features of claim 1 or claim 9. Preferred developments of the invention are disclosed in the subclaims.
[0011] The invention is based on a method for setting up and commissioning an automated body shop for vehicle series production. The body shop comprises a Profinet device (e.g., a welding robot) as a processing device, a PLC device, and at least one pneumatically, electrically, or hydraulically operated device. The PLC device (PLC = programmable logic controller) performs control tasks within the shop.
[0012] For ease of understanding, the invention will be described below specifically with reference to a pneumatically operated device. In this case, the device consists of at least one pneumatic functional unit or pneumatic unit and a valve island. It should be emphasized that the invention is not limited to a pneumatically operated device. Rather, the invention also encompasses embodiments with an electrically or hydraulically operated device. In this case, the valve island is omitted.
[0013] In the case of a pneumatically operated device, this has at least one pneumatic unit and a valve island. The valve island forms an interface in which an electrical control signal from the PLC device is converted into a pneumatic control signal, which can be used to control the pneumatic unit of the device. The method comprises the following process steps: In a programming process step, the control and regulation tasks are programmed in the PLC device using a VIBN system on a digital twin that virtually simulates the system. In an assembly process step, the programmed PLC control unit, the device, and the processing device (Profinet device) are assembled to form the system. This is followed by commissioning of the system. According to the characterizing part of claim 1, a functional test is carried out before commissioning of the system, in which the pneumatically operated device is tested for functionality.The functional test is performed using the digital twin. However, in the digital twin, the physical device under test replaces the corresponding virtual device of the digital twin. This allows the physical device under test to interact with the digital twin of the plant during the functional test.
[0014] The invention allows the pneumatic and electrical functions of the device to be tested, taking into account the operating conditions in the system. The functional test is preferably performed after assembly of the device and before its delivery to the production facility where it will be installed in the system. According to the invention, errors in the pneumatically operating device can be eliminated during system assembly. Therefore, time-consuming corrections of faulty devices during system commissioning can be avoided.
[0015] To perform the functional test, a test station with a test device can be provided. The test device has electrical / pneumatic connections and acts as an interface between the digital twin or the PLC device and the physical device under test. The test device's signal input can be connected via a communication line to the valve terminal of the device under test and to the PLC device.
[0016] It is preferred if the functional unit or pneumatic unit of the device is assigned a query device. The query device checks whether or not proper mechanical operation of the functional unit has occurred in response to a pneumatic control signal. The query device transmits a corresponding query signal via the valve terminal to the PLC device, where the query signal is evaluated.
[0017] In a specific embodiment, the functional test can be implemented as follows: During the functional test, the PLC device can use the test device to control the functional unit of the physical device under test with a control signal so that the pneumatic unit performs a mechanical action (such as clamping or pulling a pin). The interrogation device then queries whether or not the pneumatic unit has performed a proper mechanical action in response to the pneumatic control signal. The interrogation device then transmits a corresponding interrogation signal via the valve terminal to the PLC device. There, the interrogation signal is evaluated: If the mechanical action is proper, the device is recognized as functioning correctly. Conversely, if the mechanical action is not proper, the device is recognized as functioning incorrectly.
[0018] The fixture is manufactured or assembled in a single assembly process step. In common practice, the assembly process step is carried out in the fixture shop of the vehicle manufacturing plant. The fixture shop may be located separately from the production facility where the system is assembled. In such a configuration, the test station can be located in the fixture shop of the vehicle manufacturing plant, allowing the functional test to be performed immediately before the fixture is delivered to the production facility. In one technical implementation, the test station can comprise a test frame with a coupling point where the fixture to be tested can be brought into pneumatic and / or electrical contact with the test device.
[0019] An embodiment of the invention is described below with reference to the accompanying figures. They show:
[0020] Fig. 1 shows a roughly schematic block diagram of a fully automated body shop,
[0021] Fig. 2 to 5 are views illustrating the structure and commissioning of the system shown in Fig. 1.
[0022] Figure 1 shows a rough schematic of a fully automated body construction system A used in a production facility P of a vehicle manufacturing plant for series vehicle production. System A is indicated in Figure 1 and the subsequent figures only to the extent necessary for understanding the invention. Thus, system A in Figure 1 consists of a welding robot 1 and a total of two devices V1, V2. In Figure 1, the two devices V1, V2 are identically constructed for the sake of simplicity.
[0023] In the embodiment shown in Figures 1 to 5, the two devices V1, V2 operate pneumatically. However, it should be emphasized that the invention is not limited to such pneumatically operated devices V1, V2. Rather, the devices V1, V2 can also operate hydraulically or electrically.
[0024] As can be seen from the figures, each of the devices V1, V2 has two pneumatic units 3, such as tensioners or pin pullers, and a valve island 7 as functional units. The pneumatic units 3 are signal-connected to the valve island 7 via pneumatic lines 11 and electrical lines 10. The valve island 7 is in turn connected via a communication line to a PLC device 9, which performs control and regulation tasks in system A. The valve island 7 of the device V1, V2 forms an interface in which an electrical control signal from the PLC device 9 is converted into a pneumatic signal SP, with which the pneumatic units 3 can be controlled. Each of the pneumatic units 3 is assigned a query device 13. This query device 13 is signal-connected to the valve island 7 via an electrical line 10.The interrogation device 13 queries whether or not the respective pneumatic unit 3, 4, 5 has performed a proper mechanical operation in response to a pneumatic signal SP. The interrogation device 13 then generates a corresponding interrogation signal SA, which is transmitted via the electrical line 10 to the valve terminal 7 and from there to the PLC device 9, where it is evaluated.
[0025] In an exemplary process sequence of system A shown in Figure 1, the PLC device 9 controls the pneumatic units 3 of the devices V1, V2 via the valve terminal 7 in order to fix the body panels to be joined in a predefined position. After the body panels have been correctly fixed in position, the welding robot 1 is moved to a predefined joining point to join the body panels together by welding.
[0026] The construction and commissioning of system A indicated in Figure 1 is carried out as follows: According to Figure 2, the control and regulation tasks of the PLC control unit 9 are first programmed in a programming process step. The programming of the PLC control unit 9 is not carried out on the physical system A (Figure 1), but rather with the help of a VIBN system (VIBN = virtual commissioning) on a digital twin Z that simulates system A. In Figure 2, the digital twin Z of system A has a virtual welding robot 1 ' and virtual devices V1 ', V2'. The devices V1 ', V2' are each equipped with the virtual pneumatic units 3 ', the virtual query devices 13 ' and a virtual valve island 7 '.
[0027] In addition, an assembly process step takes place (Figures 3a and 3b) in which the fixtures V1, V2 are manufactured as individual components. The manufacture of the fixtures V1, V2 takes place in the fixture construction VB of the vehicle manufacturing plant, which is geographically separate from the production site P (Figure 1) of the vehicle manufacturing plant in which the system A is assembled and put into operation. After the fixtures V1, V2 have been manufactured, they are delivered from the fixture construction VB to the production site P, where they are assembled together with the welding robot 1 and the programmed PLC device 9 to form system A, which is then put into operation.
[0028] A core element of the invention is that a functional test is performed during the fixture construction VB, in which the fixtures V1 and V2, which are still available as individual components, are tested for functionality. Figures 4 and 5 illustrate the functional test of fixture V2 as an example. The functional test of fixture V1 (not shown) is performed in the same way.
[0029] According to Figures 4 and 5, a test station 18 (Figure 5) is located in the fixture construction VB, which consists of a test device 17 (VIBN I / O Checker) and a test frame 19. For the functional test, the device V2 in Figure 5 is positioned on the test frame 19 and is pneumatically and electrically connected to the test device 17 at a coupling point 21. The test device 17 acts as an interface between, on the one hand, the digital twin Z or the PLC device 9 and, on the other hand, the physical device V2 to be tested. During the functional test, the physical device V2 to be tested replaces the corresponding virtual device V2' in the digital twin Z, as indicated in Figure 4. During the functional test, the virtual device V2' of the digital twin Z is thus hidden, while the physical device V2 to be tested interacts with the digital twin Z of system A.In this way, the pneumatic and electrical functions of device V2 can be tested taking into account the operating conditions in Annex A.
[0030] For this purpose, the signal input of the test device 17 is connected via communication lines 20 on the one hand to the PLC device 9 and on the other hand to the valve terminal 7 of the device V2 to be tested.
[0031] The functional test is implemented as follows: First, the PLC device 9 controls the physical device V2 to be tested via the valve terminal 7 with a pneumatic control signal SP so that the pneumatic units 3 perform a mechanical action (such as clamping or pulling a pin). The assigned interrogation devices 13 then query whether or not proper mechanical action of the pneumatic units 13 has occurred in response to the pneumatic control signal SP. The interrogation devices 13 then transmit corresponding interrogation signals SA via the valve terminal 7 to the PLC device 9. There, the interrogation signals SA are evaluated: If proper mechanical action of the pneumatic units 3 is present, faulty operation of the device V2 is detected. Conversely, if proper mechanical action is not present, faulty operation of the device V2 is detected.
[0032] LIST OF REFERENCE SYMBOLS:
[0033] I Processing device
[0034] T virtual editing device
[0035] 3 functional unit
[0036] 3' virtual functional unit
[0037] 7 valve island
[0038] 7' virtual valve island
[0039] 9 PLC device
[0040] 10 electrical cables
[0041] II Pressure line
[0042] 13 Interrogation device
[0043] 13' virtual interrogator
[0044] 17 Test device
[0045] 18 test stations
[0046] 19 Test frame
[0047] 20 Communication line
[0048] A system
[0049] P Production facility
[0050] VB Fixture Construction
[0051] Z digital twin
[0052] V1 , V2 devices of Annex A
[0053] V1 V2' virtual devices
[0054] SP pneumatic signal
[0055] SA query signal
Claims
PATENT CLAIMS:
1. A method for commissioning an automated system (A) for a body shop, which comprises at least one processing device (1), a PLC device (9) and at least one pneumatically, electrically or hydraulically operating device (V1, V2), wherein the device (V1, V2) consists of at least one functional unit (3) which can be controlled by a control signal (SP) from the PLC device (9), and wherein the method comprises the following process steps: - programming process step in which the control and regulation tasks are programmed in the PLC device (9) by means of a VIBN system on a digital twin (Z) which virtually replicates the system (A); - Assembly process step in which the programmed PLC control unit (9), the device (V1, V2) and the processing device (1) are assembled to form the system (A) and the system is put into operation, characterized in that before the system (A) is put into operation, a functional test is carried out in which the physical device (V2) is checked for functionality, and that the functional test is carried out using the digital twin (Z), in which the physical device (V2) to be tested replaces the corresponding virtual device (V2'), so that the physical device (V2) to be tested interacts with the digital twin (Z) of the system (A) during the functional test, so that in particular the device (V2) is tested taking into account the operating conditions in the system (A).
2. Method according to claim 1, characterized in that the device (V1, V2) operates pneumatically, that the pneumatically operating device (V1, V2) has a pneumatic unit and a valve island (7) as a functional unit (3), and that the valve island (7) forms an interface in which an electrical control signal from the PLC Device (9) is converted into a pneumatic control signal (SP) with which the pneumatic unit (3) of the device (V1, V2) can be controlled.
3. Method according to claim 1 or 2, characterized in that the functional test is carried out in a test station (18) with a test device (17) which has in particular electrical / pneumatic connections, and / or that the test device (17) forms an interface between, on the one hand, the digital twin (Z) or the PLC device (9) and, on the other hand, the physical device (V2) to be tested.
4. Method according to claim 3, characterized in that the signal input of the testing device (17) is connected via a communication line (20) both to the device to be tested (V2) and to the PLC device (9).
5. Method according to one of the preceding claims, characterized in that the functional unit (3) of the device (V1, V2) is assigned an interrogation device (13) which carries out an interrogation as to whether a perfect mechanical operation of the functional unit (3) has taken place in response to a control signal (SP), and in that the interrogation device (13) sends a corresponding interrogation signal (SA), in particular via the valve island (7), to the PLC device (9), which is evaluated there.
6. Method according to claim 5, characterized in that during the functional test the PLC device (9) controls the physical device (V2) to be tested with the control signal (SP) to carry out a mechanical operation of the functional unit (3), that the interrogation device (13) carries out an interrogation as to whether a perfect mechanical operation of the pneumatic unit (3) has taken place in response to the control signal (SP), and that the interrogation device (13) a corresponding query signal (SA), in particular via the valve terminal (7), is sent to the PLC device (9), which is evaluated there, and in particular if the mechanical activity is correct, a faulty function of the device (V2) is detected, or if the mechanical activity is not correct, a faulty function of the device (V2) is detected.
7. Method according to one of the preceding claims, characterized in that in an assembly process step the device (V1, V2) is manufactured as a single component, and that in particular the assembly process step takes place in the device construction (VB) of the vehicle manufacturing plant, and that in particular the device construction (VB) is spatially separated from a production site (P) in which the system (A) is constructed, and that in particular the functional test is carried out directly in the device construction (VB).
8. Method according to one of claims 3 to 7, characterized in that the testing station (18) has a testing frame (19) with a coupling point (21) at which the device to be tested (V1, V2) can be brought into pneumatic and / or electrical contact with the testing device (17).
9. Testing device for carrying out a method according to one of the preceding claims.