Assembly method by crimping a skin and a sheet metal lining to form a door / window housing for an automobile

Abstract

The invention relates to a method for assembling a skin and a sheet metal lining forming a door / window housing for a motor vehicle using several crimping edges, characterized in that it comprises the following steps: - production by a first crimping machine (10) of the majority of said crimping edges; - transfer by a handling robot (50) of said partially crimped housing to a second crimping machine (20); - production by said second crimping machine (20) of the remaining crimping edge(s); and - transfer by said handling robot (50) of said fully crimped housing to a drop-off station (60) for unloading. Figure to be published with the abbreviation: Fig. 1

Description

Title of the invention: Method of assembling by crimping a skin and a sheet metal lining forming an opening box for a motor vehicle Technical field

[0001] The present invention relates to a method of assembling by several crimping edges a skin and a sheet metal lining forming an opening box for a motor vehicle. Prior art

[0002] Certain motor vehicle panels, in particular openings such as side doors, the rear hatch or the hood, comprise a box formed by the assembly of an outer skin made of sheet metal and an inner lining also made of sheet metal.

[0003] The assembly of these two parts can be carried out with gluing or welding, but it is preferably carried out by crimping. Crimping offers in particular the advantage of being able to separate the parts from each other to carry out a repair for example. If the vehicle suffers damage to an opening box, whether on the interior part, that is to say on the lining, or on the exterior part, that is to say on the skin, it is possible for a bodybuilder to change only the lining or only the skin.

[0004] To produce each crimping edge between these two sheet metal parts, they are arranged in a known manner (for example from document FR 2 930 181 A1) one on top of the other on a support called a die of a crimper. The latter also comprises at least one robot equipped with a hand carrying a crimping wheel adapted to roll while exerting pressure on a folded edge of the skin so that this folded edge finally comes to rest on a corresponding edge of the lining.

[0005] The main disadvantage of this type of crimping is its low rate due, in particular, to the need for the robot to make several passes to produce a crimping edge by crushing a folded edge of the skin onto a corresponding edge of the lining. In order to reduce the crimping cycle time of such an opening box, it is known to increase the number of robots used, but their relatively large footprint and high cost price do not allow in practice to use more than three on the same crimping machine. Furthermore, certain areas of the parts to be assembled are not accessible or are difficult to access by robotic arms. This type of problem can be encountered, for example, on the bottoms of the windows of opening boxes. Statement of the invention

[0006] The present invention therefore aims to improve the situation.

[0007] To this end, it proposes a method of assembling by several crimping edges a skin and a sheet metal lining forming an opening box for a motor vehicle, characterized in that it comprises the following steps: - production by a first crimper of the majority of said crimping edges; - transfer by a handling robot of said partially crimped box to a second crimping machine; - production by said second crimper of the remaining crimping edge(s); and - transfer by said handling robot of said fully crimped box to a drop-off station for unloading.

[0008] Since the first crimper does not produce all of the crimping edges provided on the box, the occupation time of the latter proves to be significantly reduced over the crimping cycle of the box in comparison with existing crimping methods (of the order of at least ten seconds), which thus allows this first crimper to move on more quickly to the next opening box to be crimped.

[0009] Of a necessarily shorter duration due to a reduced number of crimping edges to be produced, the second crimping step can be carried out by the second crimping machine while the first crimping step of the following opening box is carried out by the first crimping machine.

[0010] The invention thus makes it possible to significantly increase the production rate of crimped opening boxes.

[0011] According to preferred characteristics of said method according to the invention: - said first crimper produces all of said crimping edges provided on said box with the exception of one of them, said second crimper thus producing only the remaining crimping edge; - said second crimper comprises a frame and a die mounted on said frame and intended to receive a portion of said box comprising the edge to be crimped, this second crimper also comprising a crimping tool comprising a base mounted on said frame, a support pivotally mounted on said base and a blade holder carrying at least one crimping blade and mounted to move in translation on said support; - said remaining crimping edge is obtained by pivoting said support so as to position said crimping blade directly above a pre-folded edge (2A) of said skin, followed by sliding said blade holder relative to this support so as to cause the folding and crushing of said pre-folded edge onto a corresponding edge of said lining; - said box remains engaged by said handling robot during the second crimping step carried out by said second crimper; - said first crimper comprises a frame and a die mounted on the frame and capable of receiving said box, this first crimper also comprising at least one robot provided with a hand carrying a crimping wheel; - each crimping edge produced by said first crimper is obtained by several successive passes of the hand of a said robot; - separate holding means for said first and second crimpers are temporarily positioned before each crimping step so as to exert clamping pressure on said skin and said lining at certain peripheral zones of said box; - said method comprises, before said first crimping step carried out by said first crimper, a step of transfer by another handling robot of said box to said first crimper from a loading station where the marriage with gluing and / or mastication of said skin and said lining has been carried out beforehand; and / or - said box is a side door box of a motor vehicle. Brief description of the drawings

[0012] The description of the invention will now be continued by the detailed description of an exemplary embodiment, given below for illustrative but non-limiting purposes, with reference to the appended drawings, in which: - [Fig.l] represents a top view of a unit for crimping a skin and a sheet metal lining of an opening box for a motor vehicle; - [Fig.2] is a perspective view of the first crimper included in the crimping unit of [Fig.l]; - [Fig.3] represents a perspective view of the second crimper included in the crimping unit of [Fig.l]; - [Fig.4] is an elevational view of the second crimper of [Fig.3]; - [Fig.5] represents an enlargement in vertical cross-section of the crimping area of ​​the second crimper; and - [Fig.6] is a flowchart of the crimping assembly process according to the invention of a skin and a sheet metal lining forming an opening box for a motor vehicle. Description of the embodiments

[0013] [Fig.l] represents a top view of a crimping unit 1 of a skin and a sheet metal lining forming an opening box for a motor vehicle, such as for example a side door box, rear hatch or hood box.

[0014] This crimping unit 1 comprises: - a first crimper 10; - a second crimper 20; - a first handling robot 30 capable of ensuring the transfer of the opening box to the first crimper from a loading station 40 where the marriage with gluing and / or mastication of the skin and the lining has been carried out beforehand; - a second handling robot 50 capable of ensuring, on the one hand, the transfer of the partially crimped opening box to the second crimper 20, and on the other hand the transfer of this box to a depositing station 60 to be unloaded there.

[0015] In the present case and as illustrated by [Fig.2], the skin 2 and the lining 3 form a box 4 for a side door of a motor vehicle.

[0016] Still with reference to [Fig.2], the first crimping machine 10 comprises a frame 11, a die 12 mounted on the frame 11 and capable of receiving the box 4 by its skin 2 side, as well as at least one robot 13 (advantageously two as illustrated by [Fig.l]).

[0017] Each robot 13 comprises a base 14, an arm 15 mounted to rotate and pivot relative to the base 14, a forearm 16 mounted to pivot relative to the arm 15, a hand 17 mounted to pivot on the forearm 16 by means of a ball joint 18 secured to this forearm 16 and a crimping wheel not shown carried by the hand 17.

[0018] The robot 13 thus makes it possible to roll the wheel by exerting pressure on a folded edge of the skin 2 so that the latter rests on a corresponding edge of the lining 3 to produce a crimping edge on the box 4.

[0019] With reference to Figures 3 and 4, the second crimper 20 comprises a frame 21, a die 22 mounted on the frame 21 and intended to receive a portion of the box 4 comprising the edge to be crimped, as well as a crimping tool 23.

[0020] This crimping tool 23 comprises a base 24 mounted on the frame 21, a support 25 pivotally mounted on the base 24 via a first jack 26, as well as a blade holder 27 carrying at least one crimping blade 28 and mounted movable in translation on the support 25 via a second jack 29.

[0021] As illustrated by [Fig. 5], the crimping tool 23 thus makes it possible to pivot, after the placement of the portion of box 4 on the die 22, the blade holder 27 so as to position the crimping blade 28 directly above a pre-folded edge 2A of the skin 2 of this box 4, then to slide this blade holder 27 in the direction of this die 22 so as to cause the folding and crushing of this pre-folded edge 2A of the skin 2 on the corresponding edge 3A of the lining 3 to produce a crimping border.

[0022] Due to its configuration, this second crimping machine 20 is only capable of producing crimping edges having a substantially rectilinear regular profile (for example for a side door box such as 4, the edge extending along the bottom window area and / or that extending along the bottom door area).

[0023] In return, its very simple mechanical operation requiring only two successive pivoting and translation movements, gives it numerous advantages such as limited floor space, reduced mass and low cost price.

[0024] Furthermore, and due to this mechanical simplicity, the time required to produce a crimping edge by this second crimper 20 is significantly shorter (a few seconds) than that required by the first crimper 10, which can reach several tens of seconds.

[0025] We will now describe the assembly process by crimping the skin 2 and the lining 3 of an opening box 4 with the support of [Fig.6].

[0026] During a first step, the box 4 (whose skin 2 and lining 3 have been previously joined with gluing and / or mastication) is transferred by the first handling robot 30 to the first crimping machine 10 so that this box 4 is positioned by its skin 2 side on the die 12 of this first crimping machine 10 (step 100).

[0027] Holding means distinct from this first crimper 10 and comprising for example one or more blank holders not shown, can then possibly be temporarily positioned by an operator or an automaton so as to exert a clamping pressure on the skin 2 and the lining 3 at certain peripheral zones of the box 4 (step 200).

[0028] This first crimper 10 will then produce, via one or more robots 13, all of the crimping edges provided on the box 4 with the exception of one of them (in this case the one extending along the bottom of the window zone) (step 300).

[0029] In a known manner, each crimping edge is obtained by several successive passes of the hand 17 of a robot 13. During a first pass, the wheel mounted on this hand 17 is inclined at 45° relative to the general plane of the crimping edge to be produced and causes the pre-folded edge of the skin 2 to fold at 45° towards the corresponding edge of the lining 3. During a second pass, the wheel is then oriented parallel to the general plane of the crimping edge to be produced and causes the pre-folded edge of the skin 2 to fold onto the corresponding edge of the lining 3. During a third pass, the wheel causes the pre-folded edge of the skin 2 to be crushed onto the corresponding edge of the lining 3.

[0030] The partially crimped box 4 will then be recovered by the second handling robot 50 on this first crimper 10 and transferred to the second crimper 20 (step 400).

[0031] As illustrated in [Fig.3], separate means for maintaining this second ser weaver 20 and comprising for example a plurality of blank holders 5 can then possibly be temporarily positioned by an operator or an automaton so as to exert a clamping pressure on the skin 2 and the lining 3 at certain peripheral zones of the opening box 4 (step 500).

[0032] The second crimper 20 will then produce the remaining crimping edge on the box 4 (step 600).

[0033] This last crimping edge is obtained by pivoting the support 25 so as to position the crimping blade 26 directly above the last edge to be crimped of this box 4, followed by sliding the blade holder 24 relative to this support 25 so as to cause the folding and crushing of the pre-folded edge 2A of the skin 2 on the corresponding edge 3A of the lining 3.

[0034] Once the box 4 is fully crimped, the latter will finally be transferred by the second handling robot 50 to the depositing station 60 to be unloaded there (step 700).

[0035] Because the first crimper 10 produces one less crimping edge, the occupation time of the latter 10 is significantly reduced over the crimping cycle of the box 4 (of the order of at least ten seconds), which thus allows it to move on more quickly to the next opening box.

[0036] It is therefore understood that the second crimping step (600) of the box 4 carried out by the second crimping machine 20 will thus be carried out during the first crimping step (300) of the following opening box carried out by the first crimping machine 10.

[0037] Due to the simplicity of design and operation of the second crimper 20 (the latter requiring only two simple mechanical actions of pivoting and sliding to produce a crimping edge), but also due to the fact that the latter only has to produce a single crimping edge, the second crimping step 600 extends over a significantly shorter duration than the first 300 so as to allow the second handling robot 50 to have time to transfer the fully crimped box 4 to the depositing station 60 and to return to the waiting position at the first crimper 10 before the end of the first crimping step 300 of the following box.

[0038] As illustrated by [Fig. 3] and in order to further reduce the duration of the second crimping step 600 by facilitating the positioning and removal of the box 4 while ensuring that it is retained in the desired position, the latter advantageously remains engaged by the second handling robot 50 during this second crimping step 600.

[0039] According to alternative embodiments of the invention not shown, the second crimper may be of a different design (for example a crimper similar to the first crimper 10 and comprising one or more robots each equipped with a hand carrying a crimping wheel, although this solution is not preferred for obvious reasons of significantly higher cost price).

[0040] The use of such a second crimper would in return make it possible to produce more than one crimping edge (for example, two), the main thing being that the majority of the crimping edges to be produced on the box are produced by the first crimper.

[0041] Many other variants are conceivable and it is recalled in this regard that the present invention is not limited to the embodiments described and shown, but also encompasses all the variants of execution within the reach of those skilled in the art.

Claims

Claims

1. Method for assembling by several crimping edges a skin (2) and a lining (3) made of sheet metal forming an opening box (4) for a motor vehicle, characterized in that it comprises the following steps: - production by a first crimper (10) of the majority of said crimping edges (200); - transfer by a handling robot (50) of said partially crimped box (4) to a second crimper (20) (400); - production by said second crimper (20) of the remaining crimping edge(s) (600); and - transfer by said handling robot (50) of said fully crimped box (4) to a depositing station (60) to be unloaded there (700).

2. Crimping method according to claim 1, characterized in that said first crimper (10) produces all of said crimping edges provided on said box (4) with the exception of one of them, said second crimper (10) thus producing only the remaining crimping edge.

3. Crimping method according to claim 2, characterized in that said second crimper (20) comprises a frame (21) as well as a die (22) mounted on said frame (21) and intended to receive a portion of said box (4) comprising the edge to be crimped, this second crimper (20) also comprising a crimping tool (23) comprising a base (24) mounted on said frame (21), a support (25) pivotally mounted on said base (24) as well as a blade holder (27) carrying at least one crimping blade (28) and mounted movable in translation on said support (25).

4. Crimping method according to claim 3, characterized in that said remaining crimping edge is obtained by pivoting said support (25) so as to position said crimping blade (28) directly above a pre-folded edge (2A) of said skin (2), followed by sliding said blade holder (27) relative to this support (25) so as to cause the folding and crushing of said pre-folded edge (2A) on a corresponding edge of said lining (3).

5. Crimping method according to one of claims 1 to 4, characterized in that said box (4) remains engaged by said handling robot (50) during the second crimping step (600) carried out by said second crimper (20).

6. Crimping method according to one of claims 1 to 5, characterized in that said first crimper (10) comprises a frame (11) as well as a die (12) mounted on the frame (11) and capable of receiving said box (4), this first crimper (10) also comprising at least one robot (13) provided with a hand (17) carrying a crimping wheel.

7. Crimping method according to claim 6, characterized in that each crimping edge produced by said first crimper (10) is obtained by several successive passes of the hand (17) of a said robot (13).

8. Crimping method according to one of claims 1 to 7, characterized in that holding means (5) distinct from said first and second crimpers (10, 20) are temporarily positioned before each crimping step (200, 600) so as to exert a clamping pressure on said skin (2) and said lining (3) at certain peripheral zones of said box (4).

9. Crimping method according to one of claims 1 to 8, characterized in that it comprises, before said first crimping step (200) carried out by said first crimper (10), a transfer step (100) by another handling robot (30) of said box (4) to said first crimper (10) coming from a loading station where the marriage with gluing and / or mastication of said skin (2) and said lining (3) has been carried out beforehand.

10. Crimping method according to one of claims 1 to 9, characterized in that said box is a box (4) of a side door of a motor vehicle.

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