Calculation device, calculation method, and calculation program

Abstract

To make it possible to perform analysis through simulation of a welding process to be performed before performing actual processing in consideration of adjustment of a fixing jig for a metal plate to be welded.SOLUTION: A calculation device includes: a member information acquisition unit; an error amount calculation unit that calculates an error amount deviated from design values of shapes of a first member and a second member; a member correction amount setting unit that sets a correction amount for the member error amount; a correction tool information acquisition unit; a positional deviation amount calculation unit that calculates a deviation amount deviated from a design value of a height position as a position deviation amount; a position adjustment amount setting unit that sets an adjustment amount for the positional deviation amount; a calculation processing unit that performs calculation of a simulation for welding the second member to the first member on the basis of a combination of a correction amount and an adjustment amount selected from among a plurality of the correction amounts and a plurality of the adjustment amounts; a determination unit that determines whether or not a dimension of a weldment, which is a result of the simulation calculated by the calculation processing unit, is within an allowable range; and an output unit.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to an arithmetic unit, an arithmetic method, and an arithmetic program, and more particularly to an arithmetic unit, an arithmetic method, and an arithmetic program for calculating alignment conditions during welding by utilizing computer simulation.

Background Art

[0002] For example, in the sheet metal welding process using an actual machine, sheet metal welding is performed with a plurality of metal plates to be welded fixed using a fixing jig. After welding, the accuracy of the assembled object is confirmed using an evaluation jig. If the predetermined accuracy is not satisfied, the defect of the metal plate is eliminated and the height of the placement surface of the metal plate of the fixing jig used during welding is adjusted.

[0003] The fixing jig includes a receiver for placing the metal plate and a clamp for pressing the metal plate from above and clamping the metal plate together with the receiver. The height adjustment of the placement surface of the metal plate is performed by inserting a thin shim above or below the receiver and adjusting the number of shims inserted. As described above, welding is performed again after eliminating the defect between the metal plate and the fixing jig. Since the adjustment on the actual machine was performed based on the experience of the operator, reduction of the working man-hours and cost has been demanded.

[0004] Therefore, before performing the welding process using an actual machine, by analyzing the welding process by utilizing computer simulation such as CAE, the working man-hours and cost of the above-described adjustment have been reduced (see, for example, Patent Document 1). According to the technique disclosed in Patent Document 1, bidirectional communication between the design side using a CAE device and the processing side using a machine tool is realized, and various data considering the actual environment at the site can be fed back to the design side.

[0005] However, the technology disclosed in Patent Document 1 does not consider at all the adjustment of the fixture for fixing the metal plate to be welded, and is insufficient as an analysis by simulation of the welding process performed before actual processing.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] Therefore, an object of the present invention is to provide an arithmetic device, an arithmetic method, and an arithmetic program capable of performing analysis by simulation of a welding process performed before actual processing in consideration of adjustment of a fixture for fixing a metal plate to be welded.

Means for Solving the Problems

[0008] That is, the arithmetic unit according to the first aspect is an arithmetic unit that simulates welding position conditions when welding a second member to a first member that is a member to be welded. The arithmetic unit includes: a member information acquisition unit that acquires information regarding the shapes of the first member and the second member as shape information; a member error amount calculation unit that calculates, based on the shape information, an error amount from the design values of the shapes of the first member and the second member as a member error amount; a member correction amount setting unit that sets a plurality of correction amounts for the member error amount; a jig information acquisition unit that acquires, as jig information, information regarding a position corrector that is arranged on the second member side to adjust the height position of the second member with respect to the first member and the arrangement position of the position corrector when welding the second member to the first member; a position deviation amount calculation unit that calculates, based on the jig information, a deviation amount from the design value of the height position at the arrangement position of the position corrector as a position deviation amount; a position adjustment amount setting unit that sets a plurality of adjustment amounts for the position deviation amount; an arithmetic processing unit that performs an arithmetic operation for simulating welding the second member to the first member based on a combination of a selected correction amount and adjustment amount from among the plurality of correction amounts and the plurality of adjustment amounts; a determination unit that determines whether or not the dimensions of the welded object, which is the result of the simulation calculated by the arithmetic processing unit, fall within an allowable range; and an output unit that outputs a combination of the correction amount and the adjustment amount when it is determined by the determination unit that the dimensions of the welded object fall within the allowable range.

[0009] The calculation method according to the second aspect is a calculation method in a calculation device that simulates welding position conditions when welding a second member to a first member that is a member to be welded. The computer of the calculation device includes a member information acquisition step of acquiring information regarding the shapes of the first member and the second member as shape information, a member error amount calculation step of calculating, based on the shape information, an error amount from the design values of the shapes of the first member and the second member as a member error amount, a member correction amount setting step of setting a plurality of correction amounts for the member error amount, a jig information acquisition step of acquiring, when welding the second member to the first member, information regarding a position correction jig that is disposed on the second member side and adjusts the height position of the second member with respect to the first member and the arrangement position of the position correction jig as jig information, a position deviation amount calculation step of calculating, based on the jig information, a deviation amount from the design value of the height position at the arrangement position of the position correction jig as a position deviation amount, a position adjustment amount setting step of setting a plurality of adjustment amounts for the position deviation amount, a calculation processing step of performing a simulation calculation of welding the second member to the first member based on a combination of a selected correction amount and adjustment amount from among the plurality of correction amounts and the plurality of adjustment amounts, a determination step of determining whether or not the dimensions of the welded object, which is the result of the simulation calculated in the calculation processing step, fall within an allowable range, and an output step of outputting a combination of the correction amount and the adjustment amount when it is determined in the determination step that the dimensions of the welded object fall within the allowable range.

[0010] The arithmetic program according to the third aspect is an arithmetic program in an arithmetic device that simulates welding position conditions when welding a second member to a first member that is a member to be welded. The computer of the arithmetic device has a member information acquisition function for acquiring information regarding the shapes of the first member and the second member as shape information, a member error amount calculation function for calculating, based on the shape information, an error amount from the design values of the shapes of the first member and the second member as a member error amount, a member correction amount setting function for setting a plurality of correction amounts for the member error amount, a fixture information acquisition function for acquiring, when welding the second member to the first member, information regarding a position corrector that is arranged on the second member side and adjusts the height position of the second member with respect to the first member and the arrangement position of the position corrector as fixture information, a position deviation amount calculation function for calculating, based on the fixture information, a deviation amount from the design value of the height position at the arrangement position of the position corrector as a position deviation amount, a position adjustment amount setting function for setting a plurality of adjustment amounts for the position deviation amount, an arithmetic processing function for performing an arithmetic operation of simulating welding the second member to the first member based on a combination of a selected correction amount and adjustment amount from among the plurality of correction amounts and the plurality of adjustment amounts, a determination function for determining whether or not the dimensions of the welded object, which is the result of the simulation calculated in the arithmetic processing function, fall within an allowable range, and an output function for outputting a combination of the correction amount and the adjustment amount when it is determined in the determination function that the dimensions of the welded object fall within the allowable range.

Effect of the Invention

[0011] The computing device and the like according to the present invention is a computing device that simulates welding position conditions when welding a second member to a first member that is a member to be welded. The computing device includes: a member information acquisition unit that acquires information regarding the shapes of the first member and the second member as shape information; a member error amount calculation unit that calculates, based on the shape information, an error amount from the design values of the shapes of the first member and the second member as a member error amount; a member correction amount setting unit that sets a plurality of correction amounts for the member error amount; a jig information acquisition unit that, when welding the second member to the first member, acquires, as jig information, information regarding a position corrector that is disposed on the second member side and adjusts the height position of the second member with respect to the first member, and the arrangement position of the position corrector; a position deviation amount calculation unit that calculates, based on the jig information, a deviation amount from the design value of the height position at the arrangement position of the position corrector as a position deviation amount; a position adjustment amount setting unit that sets a plurality of adjustment amounts for the position deviation amount; a calculation processing unit that performs a simulation calculation of welding the second member to the first member based on a combination of a selected correction amount and adjustment amount from among the plurality of correction amounts and the plurality of adjustment amounts; a determination unit that determines whether or not the dimensions of the welded object, which is the result of the simulation calculated by the calculation processing unit, fall within an allowable range; and an output unit that outputs a combination of the correction amount and the adjustment amount when it is determined by the determination unit that the dimensions of the welded object fall within the allowable range. Therefore, it is possible to perform analysis by simulation of a welding process that is performed before actual processing, taking into account the adjustment of a fixing jig for a metal plate to be welded.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

[0013] (Outline of the arithmetic unit 10) The arithmetic unit 10 according to an embodiment of the present disclosure will be described with reference to FIGS. 1 to 8. First, the outline of the arithmetic unit 10 according to the present embodiment will be described with reference to FIG. 1. The arithmetic unit 10 is a computer that simulates the welding position conditions when welding the second member 2 to the first member 1, which is a member to be welded. In the present embodiment, spot welding of sheet metal by resistance welding is described as an example of welding, but the present invention is not limited to spot welding of sheet metal, and the arithmetic unit 10 according to the present embodiment can be applied to various types of welding. Sheet metal welding is a method of joining two or more metal sheets. In addition, not only thin metal sheets are joined, but also cases where various shaped metals are joined by welding may be referred to as sheet metal welding.

[0014] The arithmetic unit 10 performs a simulation in the same procedure as the sheet metal welding process performed by the actual machine by utilizing CAE (Computer Aided Engineering). As shown in FIG. 1, the arithmetic unit 10 performs a simulation of the sheet metal welding process in the order of (1) component set, (2) clamp, (3) welding, and (4) evaluation.

[0015] (1) Component set The first member 1 and the second member 2, which are members to be welded, are placed on the receiver 3 and the pin receiver 4. First, the first member 1 is placed on the receiver 3 and the pin receiver 4, and the second member 2 is placed on the first member 1. The pin of the pin receiver 4 is inserted into the pin holes provided in the first member 1 and the second member 2, thereby positioning the first member 1 and the second member 2.

[0016] (2) Clamp The clamps 5 and 6 press the second member 2 from above. The clamp 5 clamps the first member 1 and the second member 2 together with the receiver 3, and the clamp 6 clamps the first member 1 and the second member 2 together with the pin receiver 4.

[0017] (3) Welding The first member 1 and the second member 2 are held by the receiver 3, the pin receiver 4, and the clamps 5 and 6, and are clamped by the first electrode 7 and the second electrode 8 of the resistance welding machine with appropriate pressure. The first electrode 7 and the second electrode 8 are energized, and they are fusion-bonded using the Joule heat (the phenomenon in which electrical energy is converted into heat energy) generated by the contact resistance between the first member 1 and the second member 2. In this embodiment, the welding is described by taking resistance welding as an example, but it is not limited thereto, and various weldings, such as laser welding and arc welding, may also be used.

[0018] (4) Evaluation The welded first member 1 and second member 2 are evaluated as to whether they satisfy a predetermined dimensional accuracy.

[0019] (Regarding the hardware configuration of the arithmetic unit 10) The hardware configuration of the arithmetic unit 10 will be described with reference to FIG. 2. FIG. 2 is a block diagram for explaining an example of the hardware configuration of the arithmetic unit 10.

[0020] The arithmetic unit 10 includes a communication interface 10a, a ROM (Read Only Memory) 10b, a RAM (Random Access Memory) 10c, a storage unit 10d, a CPU (Central Processing Unit) 10e, an input / output interface 10f, and the like.

[0021] The communication interface 10a has a function of transmitting and receiving data and the like to and from other devices via the Internet 11. The storage unit 10d can be used as a recording device, and stores an arithmetic program described later, an OS (Operating System: basic software) required for the operation of the arithmetic unit 10, various applications, and various data used by the applications.

[0022] The arithmetic unit 10 saves the arithmetic program in the storage unit 10d and fetches the arithmetic program into the main memory composed of the RAM 10c and the like. The CPU 10e accesses the main memory that has fetched the arithmetic program and executes the arithmetic program. The input / output interface 10f transmits and receives data and the like to and from external devices of the arithmetic unit 10. The external devices are an input device 10g and an output device 10h that perform input and output of data and the like to the arithmetic unit 10. The input device 10g is a keyboard, a mouse, and the like, and the output device 10h is an external monitor, a printer, an external speaker, and the like.

[0023] (Regarding the functional configuration of the arithmetic unit 10) Next, with reference to FIG. 3, the functional configuration of the arithmetic unit 10 will be described. FIG. 3 is a block diagram for explaining an example of the functional configuration of the arithmetic unit 10. By executing an arithmetic program described later, the arithmetic unit 10 provides the CPU 10e with functional units such as a member information acquisition unit 20, a member error amount calculation unit 21, a member correction amount setting unit 22, a correction tool information acquisition unit 23, a position deviation amount calculation unit 24, a position adjustment amount setting unit 25, an arithmetic processing unit 26, a determination unit 27, and an output unit 28.

[0024] The component information acquisition unit 20 acquires information regarding the shapes of the first component 1 and the second component 2 as shape information.

[0025] The shape information is information representing the shapes and sizes of the first component 1 and the second component 2 obtained by actually measuring the first component 1 and the second component 2, and is desirably three-dimensional data in order to perform a simulation close to the actual machine. The shape information is information given in advance by a user or the like of the arithmetic unit 10 and is stored in the storage unit 10d.

[0026] The component error amount calculation unit 21 calculates, based on the shape information, the amount of error from the design values of the shapes of the first component 1 and the second component 2 as the component error amount.

[0027] The shape information is information regarding the shapes of the first component 1 and the second component 2 acquired by the component information acquisition unit 20, and is the actually measured values of the first component 1 and the second component 2. The design values of the shapes of the first component 1 and the second component 2 refer to ideal values determined at the design stage of the first component 1 and the second component 2 or target values in the manufacturing process. The design values may be CAD (Computer Aided Design) data. CAD data is design data and drawing data handled by CAD, and there are various file formats. Examples of the file formats of CAD data include DXF, DWG, JWC, SFC, and P21. The error amount refers to the difference between the design value and the actually measured value of the shapes of the first component 1 and the second component 2. The component error amount refers to the error amount calculated by the component error amount calculation unit 21.

[0028] With reference to FIG. 4, the amount of error from the design values of the shapes of the first component 1 and the second component 2 will be described. FIG. 4 is a diagram for explaining the amount of error of the first component 1 and the second component 2 according to the present embodiment. FIG. 4(a) shows a state in which the first member 1 and the second member 2 having shapes as designed values (correct dimensions) are joined at the joint portion 30. The spot welding points 31 are provided at the joint portion 30. The correct dimensions mean that the shape and size are drawn as designed values.

[0029] FIG. 4(b) shows an example of the measured values of the shapes of the first member 1 and the second member 2, and shows a state in which the first member 1 and the second member 2 interfere with each other at the joint portion 30. As shown in FIG. 4(b), when the first member 1 and the second member 2 interfere with each other, the error amount refers to the length between the upper surface portion 2a of the correct dimension of the second member 2 and the upper surface portion 2b of the actually measured second member 2. As shown in FIG. 4(b), the second member 2 is in a state of being bent toward the first member 1 at the joint portion 30. The state in which the first member 1 and the second member 2 interfere with each other at the joint portion 30 is a problem in welding.

[0030] FIG. 4(c) shows an example of the measured values of the shapes of the first member 1 and the second member 2, and shows a state in which a gap is generated between the first member 1 and the second member 2 at the joint portion 30. As shown in FIG. 4(c), when a gap is generated between the first member 1 and the second member 2, the error amount refers to the length between the upper surface portion 2a of the correct dimension of the second member 2 and the upper surface portion 2b of the actually measured second member 2. As shown in FIG. 4(c), the second member 2 is in a state of being bent toward the side opposite to the first member 1 at the joint portion 30. The state in which a gap is generated between the first member 1 and the second member 2 at the joint portion 30 is a problem in welding.

[0031] The member correction amount setting unit 22 sets a plurality of correction amounts for the member error amount.

[0032] The member correction amount setting unit 22 acquires the maximum range of the correction amount for the member error amount, and sets a plurality of correction amounts obtained by dividing the maximum range of the correction amount at a predetermined interval.

[0033] The correction amount refers to the amount for reducing the member error amount before performing the welding simulation, and also refers to the amount (degree) for correcting the defect in the shape of the joint portion 30 between the first member 1 and the second member 2. A plurality of correction amounts are set, combined with the adjustment amount described later, and a plurality of combinations of the correction amount and the adjustment amount are prepared, and the welding simulation is carried out for each of the combinations. The maximum range of the correction amount with respect to the member error amount refers to the maximum range up to which the correction for the member error amount calculated by the member error amount calculation unit 21 is carried out. For example, when the member error amount calculated by the member error amount calculation unit 21 is 2 mm, 1.5 mm corresponding to 75 percent of the member error amount is taken as the maximum range of the correction amount.

[0034] Note that the maximum range of the correction amount with respect to the member error amount is not limited to 75 percent of the member error amount, and may be, for example, 100 percent, 50 percent, etc., and is not particularly limited, but the result of the welding simulation must satisfy the desired accuracy. It is not always necessary to set a correction amount of 100 percent with respect to the member error amount. This is because when the first member 1 and the second member 2 are joined by welding, the member error amount may become smaller. The maximum range of the correction amount with respect to the member error amount is specified by the user or in the simulation program described later.

[0035] Dividing the maximum range of the correction amount at a predetermined interval means marking the maximum range of the correction amount at each predetermined interval, thereby obtaining a plurality of correction amounts. Dividing the maximum range of the correction amount at a predetermined interval means, for example, when the predetermined interval is set to 0.1 mm and the maximum range of the correction amount is set to 1.5 mm, setting a plurality of (in this case, 15, namely 0.1, 0.2, ···, 1.4, 1.5) correction amounts at 0.1 mm intervals for 1.5 mm.

[0036] The correction tool information acquisition unit 23 acquires, as correction tool information, information regarding the position correction tool that is arranged on the second member 2 side and adjusts the height position of the second member 2 with respect to the first member 1 and the arrangement position of the position correction tool when welding the second member 2 to the first member 1.

[0037] The position corrector refers to a jig for correcting the height position of the second member 2, and is a jig for adjusting the height of the second member 2 with respect to the first member 1. Further, as the position corrector, for example, a block gauge may be used. A block gauge is a rectangular parallelepiped gauge used as a length standard. Using a hard material with little aging change, among the six faces of the rectangular parallelepiped, a pair of opposite two faces are made extremely flat and parallel at a high level, and the distance between the two faces is finished to be correctly a predetermined dimension. The shim 34 is used for setting the adjustment amount for the sub-position corrector 33. The position adjustment amount setting unit 25 uses the thickness of the shim 34 as a predetermined interval, obtains the maximum range of the adjustment amount for the acquired position deviation amount, and divides this maximum range of the adjustment amount by the thickness of the shim 34 by changing the number of shims 34 to obtain a plurality of adjustment amounts for the sub-position corrector 33 and sets them.

[0038] The information regarding the position corrector and the arrangement position of the position corrector refers to the information regarding the height of the position corrector and the information regarding the arrangement position of the position corrector. The height of the position corrector is the height (thickness) of the position corrector itself and includes both the height (thickness) of the main position corrector 32 and the sub-position corrector 33. The arrangement position of the position corrector is the position where the position corrector is arranged, and includes both the positions where the main position corrector 32 and the sub-position corrector 33 are arranged. The position corrector is arranged at a predetermined arrangement position below the second member 2, places the second member 2 on the upper surface, and maintains the second member 2 at a predetermined height.

[0039] The adjustment amount of the sub-position corrector 33 is generated for each sub-position corrector 33. A plurality of position correctors are provided. The position corrector consists of a main position corrector 32 and a sub-position corrector 33, and an adjustment amount is generated for the sub-position corrector 33.

[0040] The position corrector will be described with reference to FIGS. 5 and 6. FIGS. 5 and 6 are diagrams for explaining the position corrector according to the present embodiment. The main position corrector 32 serves as a reference for adjusting the height position of the second member 2, and the height position of the second member 2 is determined by the main position corrector 32. The height of the main position corrector 32 is not adjusted by the shim 34. The sub-position corrector 33 is used together with the main position corrector 32, and the height of the sub-position corrector 33 is adjusted according to the posture or shape of the second member 2 before use. The height of the sub-position corrector 33 is adjusted using the shim 34. The shim 34 has a predetermined height (thickness), for example, 0.5 mm, and by stacking a plurality of shims, the height (thickness) of the sub-position corrector 33 is adjusted while creating a predetermined interval. The shim 34 may be a gauge block, similar to the position corrector.

[0041] FIG. 6(a) shows a state in which the metal plate 35 is placed on the position corrector before shim adjustment. The left diagram in FIG. 6(a) is a top view, and the right diagram in FIG. 6(b) is a cross-sectional view taken along line A-A' in the top view. The metal plate 35 in FIG. 6(a) is drawn according to the nominal dimensions. FIG. 6(b) shows a state in which the metal plate 35 is placed on the position corrector after shim adjustment. The left diagram in FIG. 6(b) is a top view, and the right diagram in FIG. 6(b) is a cross-sectional view taken along line A-A' in the top view. The metal plate 35 in FIG. 6(b) is drawn according to the measured values. As shown in FIG. 6(b), when a deviation amount described later occurs in the measured value of the metal plate 35 at the arrangement position of the sub-position corrector 33a, a plurality of shims 34 corresponding to the deviation amount are inserted between the sub-position corrector 33a and the metal plate 35.

[0042] The position deviation amount calculation unit 24 calculates, based on the corrector information, the deviation amount from the design value of the height position at the arrangement position of the position corrector as the position deviation amount.

[0043] The corrector information refers to information regarding the height of the position corrector and information regarding the arrangement position of the position corrector. The amount of deviation from the design value of the height position at the arrangement position of the position corrector refers to the difference between the design value and the measured value of the second member 2 at the arrangement position of the sub-position corrector 33. The design value may be CAD (Computer Aided Design) data.

[0044] Referring to FIG. 7, the amount of deviation from the design value of the height position of the second member 2 at the arrangement position of the position corrector will be described. FIG. 7 is a diagram for explaining the amount of deviation from the design value of the height position of the second member 2 at the arrangement position of the position corrector according to the present embodiment. FIG. 7(a) shows the height position of the second member 2 at the arrangement position of the sub-position corrector 33 according to the design value (correct dimensions). As shown in FIG. 7(b), the amount of deviation refers to the difference between the height position of the lower surface portion 2c of the sub-position corrector 33 of correct dimensions and the height position of the lower surface portion 2d of the actually measured sub-position corrector 33a when the upper surface portion of the sub-position corrector 33a is brought into contact with the lower surface portion of the second member 2 at the arrangement position of the sub-position corrector 33a. FIG. 7(b) shows a state in which the second member 2 is deformed into a convex shape upward at the arrangement position of the sub-position corrector 33a. Note that the amount of deviation may be the difference between the height position of the upper surface portion of the sub-position corrector 33a and the height position of the lower surface portion of the second member 2 when the height positions of the lower surface portion 2c of the sub-position corrector 33 of correct dimensions and the lower surface portion 2d of the actually measured sub-position corrector 33a are made to coincide at the arrangement position of the sub-position corrector 33a. Also, as shown in FIG. 7(c), the amount of deviation refers to the difference between the height position of the lower surface portion 2c of the sub-position corrector 33 of correct dimensions and the height position of the lower surface portion 2d of the actually measured sub-position corrector 33a when the upper surface portion of the sub-position corrector 33a is brought into contact with the lower surface portion of the second member 2 at the arrangement position of the sub-position corrector 33a. FIG. 7(c) shows a state in which the second member 2 is deformed into a convex shape downward at the arrangement position of the sub-position corrector 33a. The position deviation amount calculation unit 24 calculates the above-described amount of deviation as the position deviation amount.

[0045] The position adjustment amount setting unit 25 sets a plurality of adjustment amounts for the position deviation amount.

[0046] The position adjustment amount setting unit 25 acquires the maximum range of the adjustment amount with respect to the position deviation amount, and sets a plurality of adjustment amounts obtained by dividing the maximum range of the adjustment amount at predetermined intervals.

[0047] The adjustment amount means that, before performing the welding simulation, the position deviation amount calculated by the position deviation amount calculation unit 24 is regarded as the shortage amount (see FIG. 7(b)) or the excess amount (see FIG. 7(c)) of the height position of the auxiliary position corrector 33a, and the amount for filling the shortage amount or the amount for reducing the excess amount. A plurality of adjustment amounts are set, combined with the aforementioned correction amount, a plurality of combinations of the correction amount and the adjustment amount are prepared, and the welding simulation is performed for each combination. The maximum range of the adjustment amount with respect to the position deviation amount refers to the maximum range up to which the adjustment for the position deviation amount calculated by the position adjustment amount setting unit 25 is performed. For example, when the position deviation amount calculated by the position adjustment amount setting unit 25 is 1.5 mm, it means that 1.0 mm corresponding to 67 percent of the member error amount is set as the maximum range of the correction amount.

[0048] Note that the maximum range of the adjustment amount with respect to the position deviation amount is not limited to 67 percent of the position deviation amount, and may be, for example, 100 percent, 50 percent, etc., and is not particularly limited, but the result of the welding simulation must satisfy the desired accuracy. It is not necessarily required to set an adjustment amount of 100 percent with respect to the position deviation amount. This is because when the first member 1 and the second member 2 are joined by welding, the position deviation amount may become smaller. The maximum range of the adjustment amount with respect to the position deviation amount is specified by the user or in the simulation program described later.

[0049] Dividing the maximum range of the adjustment amount at predetermined intervals means marking the maximum range of the adjustment amount at each predetermined interval, thereby obtaining a plurality of adjustment amounts. Dividing the maximum range of the adjustment amount at predetermined intervals means, for example, when the predetermined interval is set to 0.5 mm and the maximum range of the correction amount is set to 1.0 mm, setting a plurality of correction amounts (in this case, two, 0.5 mm and 1.0 mm) at 0.5 mm intervals. Note that the predetermined interval (0.5 mm) here is the thickness of a single shim 34.

[0050] The arithmetic processing unit 26 performs an arithmetic operation for simulating welding the second member 2 to the first member 1 based on a combination of a selected correction amount and an adjustment amount from among a plurality of correction amounts and a plurality of adjustment amounts.

[0051] As described above, the plurality of correction amounts are set by the member correction amount setting unit 22. As described above, when the maximum range of the correction amount is set to 1.5 mm and the predetermined interval is set to 0.1 mm, the member correction amount setting unit 22 sets a plurality of correction amounts to 15 values: 0.1 mm, 0.2 mm, ···, 1.4 mm, 1.5 mm.

[0052] As described above, the plurality of adjustment amounts are set by the position adjustment amount setting unit 25. As described above, when the maximum range of the adjustment amount is set to 1 mm and the predetermined interval is set to 0.5 mm, the position adjustment amount setting unit 25 sets a plurality of adjustment amounts to two values: 0.5 mm and 1.0 mm.

[0053] For example, the arithmetic processing unit 26 performs an arithmetic operation for simulating welding the second member 2 to the first member 1 for each of 30 combinations of a correction amount and an adjustment amount, each combination being selected one by one from among 30 combinations of 15 correction amounts and 2 adjustment amounts as described above. The arithmetic processing unit 26 performs the simulation using an existing CAE application.

[0054] The determination unit 27 determines whether or not the dimensions of the welded product, which is the result of the simulation calculated by the arithmetic processing unit 26, fall within the allowable range. The determination unit 27 determines whether or not the dimensions after welding the second member 2 to the first member 1 satisfy the preset dimensional accuracy. If the dimensions of the first member 1 and the second member 2 after welding do not satisfy the predetermined accuracy, the determination unit 27 may determine that there is a welding defect.

[0055] When it is determined by the determination unit 27 that the dimensions of the welded product fall within the allowable range, the output unit 28 outputs a combination of a correction amount and an adjustment amount. When it is determined that the dimensions of the welded product after welding the second member 2 to the first member 1 fall within the allowable range, if there are a plurality of combinations of a correction amount and an adjustment amount, the output unit 28 may output all the combinations, or may output the combination with the highest accuracy.

[0056] (Regarding the application example of the arithmetic unit 10) With reference to FIG. 8, an application example of the arithmetic unit 10 will be described. FIG. 8 is a diagram for explaining an application example of the arithmetic unit 10 according to the present embodiment. The arithmetic unit 10 is used for the simulation of resistance welding of metal plates used for the underbody and side members constituting the chassis 40 of a passenger car. The number of resistance welding points generated in the manufacturing process of a passenger car is several thousand. The black circles shown in FIG. 8 indicate the resistance welding points at representative positions. As shown in FIG. 8, the pillar 41 of the side member and the front cross member 42 of the underbody are representative examples where a large number of resistance weldings are used.

[0057] (Regarding the arithmetic program and arithmetic method) Next, with reference to FIG. 9, an arithmetic program according to an embodiment of the present disclosure will be described together with an arithmetic method. FIG. 9 is a flowchart of the arithmetic program according to the present embodiment. The arithmetic method is executed by the CPU 10e of the arithmetic unit 10 based on the arithmetic program.

[0058] The arithmetic program includes a member information acquisition step S20, a member error amount calculation step S21, a member correction amount setting step S22, a corrector information acquisition step S23, a position deviation amount calculation step S24, a position adjustment amount setting step S25, an arithmetic processing step S26, a determination step S27, and an output step S28, etc. The arithmetic program causes the CPU 10e of the arithmetic unit 10 to exhibit various functions such as a member information acquisition function, a member error amount calculation function, a member correction amount setting function, a corrector information acquisition function, a position deviation amount calculation function, a position adjustment amount setting function, an arithmetic processing function, a determination function, and an output function. Since the various functions overlap with the descriptions of the various functional parts of the arithmetic unit 10 described above, the detailed description thereof is omitted.

[0059] The member information acquisition function acquires information regarding the shapes of the first member 1 and the second member 2 as shape information (S20: member information acquisition step).

[0060] The member error amount calculation function calculates, based on the shape information, the amount of error from the design values of the shapes of the first member 1 and the second member 2 as the member error amount (S21: member error amount calculation step).

[0061] The member correction amount setting function sets a plurality of correction amounts for the member error amount (S22: member correction amount setting step).

[0062] The corrector information acquisition function, when welding the second member 2 to the first member 1, acquires information regarding the position corrector that is arranged on the second member 2 side and adjusts the height position of the second member 2 with respect to the first member 1 and the arrangement position of the position corrector as corrector information (S23: corrector information acquisition step).

[0063] The position deviation amount calculation function calculates, based on the corrector information, the amount of deviation from the design value of the height position at the arrangement position of the position corrector as the position deviation amount (S24: position deviation amount calculation step).

[0064] The position adjustment amount setting function sets a plurality of adjustment amounts for the position deviation amount (S25: position adjustment amount setting step).

[0065] The arithmetic processing function performs an arithmetic operation for simulating welding the second member 2 to the first member 1 based on a combination of a correction amount and an adjustment amount selected from a plurality of correction amounts and a plurality of adjustment amounts (S26: arithmetic processing step).

[0066] The determination function determines whether or not the dimensions of the welded object, which is the result of the simulation calculated by the arithmetic processing function, fall within an allowable range (S27: determination step).

[0067] The output function outputs a combination of a correction amount and an adjustment amount when it is determined in the determination function that the dimensions of the welded object fall within the allowable range (S28: output step).

[0068] According to the arithmetic unit 10 according to the above-described embodiment, since the correction amount of the dimensional error in the joint portion 30 of the second member 2 can be known before welding on the actual machine, the occurrence of welding defects can be suppressed in welding by the actual machine. Further, according to the arithmetic unit 10 according to the above-described embodiment, since the adjustment amount of the position corrector for placing the second member 2 can be known before welding on the actual machine, the occurrence of welding defects can be suppressed in welding by the actual machine.

[0069] Note that the present disclosure is not limited to the arithmetic unit 10, the arithmetic method, and the arithmetic program according to the above-described embodiment, and can be implemented by various other modification examples or application examples without departing from the gist of the invention described in the claims.

Explanation of reference numerals

[0070] 1 First member 2 Second member 2a Upper surface portion with correct dimensions 2b Upper surface portion of actual measurement 2c Lower surface portion of the sub-position corrector with correct dimensions 2d Lower surface portion of the sub-position corrector of actual measurement 3 Receiver 4 Pin receiver 5 First clamp 6 Second clamp 7 First electrode 8 Second electrode 10 Arithmetic unit 10a Communication interface 10b ROM (Read Only Memory) 10c RAM (Random Access Memory) 10d Memory unit 10e CPU (Central processing Unit) 10f Input / output interface 10g Input device 10h Output device 11 Internet 20 Member information acquisition unit 21 Member error amount calculation unit 22 Member correction amount setting unit 23 Fixture information acquisition unit 24 Position deviation amount calculation unit 25 Position adjustment amount setting unit 26 Arithmetic processing unit 27 Judgment unit 28 Output unit 30 Joint part 31 Dotting part 32 Main position corrector 33 Sub-position corrector 33a Sub-position corrector 34 Shim 35 Metal plate 40 Chassis 41 Welding dotting group 42 Welding dotting group

Claims

1. An arithmetic unit that simulates welding position conditions when welding a second member to a first member that is a member to be welded, wherein the arithmetic unit, a member information acquisition unit that acquires information regarding the shapes of the first member and the second member as shape information; a member error amount calculation unit that calculates, based on the shape information, an error amount from the design values of the shapes of the first member and the second member as a member error amount; a member correction amount setting unit that sets a plurality of correction amounts for the member error amount; a jig information acquisition unit that, when welding the second member to the first member, acquires, as jig information, information regarding a position corrector that is disposed on the second member side and adjusts the height position of the second member with respect to the first member and the arrangement position of the position corrector; a position deviation amount calculation unit that calculates, based on the jig information, a deviation amount from the design value of the height position at the arrangement position of the position corrector as a position deviation amount; a position adjustment amount setting unit that sets a plurality of adjustment amounts for the position deviation amount; an arithmetic processing unit that performs an arithmetic operation for simulating welding the second member to the first member based on a combination of the selected correction amount and adjustment amount from among the plurality of correction amounts and the plurality of adjustment amounts; a determination unit that determines whether or not the dimensions of a welded object, which is the result of the simulation calculated by the arithmetic processing unit, fall within an allowable range; an output unit that outputs a combination of the correction amount and the adjustment amount when it is determined by the determination unit that the dimensions of the welded object fall within the allowable range; An arithmetic unit characterized by comprising the above.

2. The arithmetic unit according to claim 1, wherein the member correction amount setting unit acquires a maximum range of correction amounts for the member error amount and sets a plurality of correction amounts obtained by dividing the maximum range of the correction amounts at predetermined intervals.

3. The arithmetic unit according to claim 1, wherein the position adjustment amount setting unit acquires a maximum range of adjustment amounts for the position deviation amount and sets a plurality of adjustment amounts obtained by dividing the maximum range of the adjustment amounts at predetermined intervals.

4. The arithmetic unit according to claim 1, wherein a plurality of the position correctors are provided, the position correctors include a main position corrector and a sub-position corrector, and the adjustment amount is generated for the sub-position corrector.

5. The arithmetic unit according to claim 4, wherein the adjustment amount of the sub-position corrector is generated for each sub-position corrector.

6. The arithmetic unit according to claim 1, wherein the welding is resistance welding.

7. A calculation method in a computing device for simulating welding position conditions when welding a second member to a first member which is a member to be welded, wherein a computer of the computing device performs a member information acquisition step of acquiring information regarding the shapes of the first member and the second member as shape information, a member error amount calculation step of calculating, based on the shape information, an error amount from the design values of the shapes of the first member and the second member as a member error amount, a member correction amount setting step of setting a plurality of correction amounts for the member error amount, a fixture information acquisition step of, when welding the second member to the first member, acquiring, as fixture information, information regarding a position corrector that is arranged on the second member side and adjusts a height position of the second member with respect to the first member and an arrangement position of the position corrector, a position deviation amount calculation step of calculating, based on the fixture information, a deviation amount from the design value of the height position at the arrangement position of the position corrector as a position deviation amount, a position adjustment amount setting step of setting a plurality of adjustment amounts for the position deviation amount, a calculation processing step of performing a simulation calculation of welding the second member to the first member based on a combination of the selected correction amount and adjustment amount from among the plurality of correction amounts and the plurality of adjustment amounts, a determination step of determining whether or not dimensions of a welded object, which is a result of the simulation calculated in the calculation processing step, fall within an allowable range, an output step of outputting a combination of the correction amount and the adjustment amount when it is determined in the determination step that the dimensions of the welded object fall within the allowable range, characterized by executing the above. **Claim 8** A calculation program in a computing device for simulating welding position conditions when welding a second member to a first member which is a member to be welded, wherein a computer of the computing device has a member information acquisition function of acquiring information regarding the shapes of the first member and the second member as shape information, a member error amount calculation function of calculating, based on the shape information, an error amount from the design values of the shapes of the first member and the second member as a member error amount, a member correction amount setting function of setting a plurality of correction amounts for the member error amount, When welding the second member to the first member, a position corrector that is disposed on the second member side to adjust the height position of the second member with respect to the first member and information regarding the arrangement position of the position corrector are acquired as corrector information, a position deviation amount calculation function that calculates, based on the corrector information, a deviation amount from the design value of the height position at the arrangement position of the position corrector as a position deviation amount, a position adjustment amount setting function that sets a plurality of adjustment amounts for the position deviation amount, an arithmetic processing function that performs an operation of a simulation of welding the second member to the first member based on a combination of the selected correction amount and the adjustment amount from among the plurality of correction amounts and the plurality of adjustment amounts, a determination function that determines whether or not the dimensions of the welded object, which is the result of the simulation calculated by the arithmetic processing function, fall within an allowable range, an output function that outputs a combination of the correction amount and the adjustment amount when it is determined in the determination function that the dimensions of the welded object fall within the allowable range, An arithmetic program characterized by realizing the above.

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