Method for the automated assembly of a door element on a corresponding vehicle frame element
Patent Information
- Application Number
- PCT/EP2026/060651
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2025-04-14
- Filing Date
- 2026-04-13
- Publication Date
- 2026-10-22
Smart Images
Figure EP2026060651_22102026_PF_FP_ABST
Abstract
Description
[0001] Description
[0002] Method for the automated assembly of a door element onto a corresponding vehicle frame element
[0003] The disclosure relates to a method for the automated assembly of a door element on a corresponding vehicle frame element.
[0004] The assembly of door elements, such as a driver's door, is a well-established process. The doors are connected to the door frame via hinges. The doors are initially positioned unpainted in the body shop. Variations from previous process steps are generally not taken into account. The painted doors are then either automatically attached to a hinge on the body or subsequently finished manually. During fine positioning in the body-in-white, the doors are adjusted without a seal. In automated assembly, gap sensors are used to position the unpainted doors in real time. In semi-automated assembly, the doors are manually positioned in the body-in-white, then painted and pre-assembled. The doors are then automatically hung. In manual assembly, the doors are manually positioned in the body-in-white. The doors are then painted and pre-assembled. The doors are then manually hung.This process is complex. Paint finishes on the doors or deviations in door installation are not taken into account in this process.
[0005] In this context, it has now become apparent that there is a need to provide a method for the automated assembly of a door element onto a corresponding vehicle frame element. In particular, there is a need to provide an improved method for the automated assembly of a door element onto a corresponding vehicle frame element.
[0006] It is an object of the present invention to eliminate, or at least partially eliminate, the disadvantages described above in the assembly of a door element to a corresponding vehicle frame element. In particular, it is an object of the present invention to provide an improved method for the automated assembly of a door element to a corresponding vehicle frame element. The foregoing object is achieved by the claims. In particular, the object is achieved by a method for the automated assembly of a door element to a corresponding vehicle frame element of independent claim 1.
[0007] A first aspect of the present disclosure relates to a method for the automated assembly of a door element on a corresponding vehicle frame element, comprising the steps of: acquiring first geometric data for the door element, acquiring second geometric data for the corresponding vehicle frame element, determining at least first position data for the arrangement of at least one first connecting element on the vehicle frame element and at least second position data for the arrangement of the at least one first connecting element on the door element based on the acquired first geometric data and the second acquired geometric data, and assembling the door element on the vehicle frame element via the at least one first connecting element using the determined at least first position data and the determined at least second position data.
[0008] The term "door element" in this context refers specifically to a movable cover on a vehicle body. The door element can, for example, include a driver's door, a passenger door, a left rear door, a right rear door, a trunk lid, a hood, a fuel filler cap, or a cargo cover. The door element is preferably painted and preferably pre-assembled.
[0009] The term "corresponding vehicle frame element" refers to a counterpart to which the door element is mounted. For example, in the case of a driver's door, the corresponding vehicle frame element can encompass the front side panel of the vehicle. Specifically, the corresponding vehicle frame element refers to the structure that defines the opening for the door element. The vehicle frame element can be painted or unpainted. It may already be fitted with adjacent exterior body panels such as the A-pillar or B-pillar.
[0010] In this context, a connecting element is understood to be, in particular, a structural component that can movably arrange two components relative to each other. Preferably, the connecting element can be multi-part. Preferably, the connecting element can include a hinge. For example, two connecting elements are required to assemble a driver's door. The connecting element can preferably comprise two interface surfaces, with a first interface surface being connected to the door element and a second interface surface being connected to the vehicle frame element. Assembly can include mounting the connecting element to the door element and the vehicle frame element. For this purpose, the first and second position data are determined. These can then be transformed into robot coordinates and transferred to a controller for the assembly robot.
[0011] In this context, the term "geometry data" refers specifically to the external and surface dimensions of the door element or vehicle frame element. This geometry data can be acquired using an optical measurement method. The geometry data can be provided as a point cloud.
[0012] In this context, the term "positional data" refers specifically to the spatial coordinates of the connecting element relative to the door element or the vehicle frame element. The positional data can differ in up to six degrees of freedom.
[0013] The disclosure is based on the finding that current assembly processes do not account for variations caused by the painting or assembly processes of the door elements and / or the vehicle frame elements. This leads to a high level of rework during assembly and lower quality results.
[0014] In particular, it leads to additional effort. The disclosure now proposes measuring the door element and the vehicle frame element separately, so that the geometric data for both components are available, and then determining, based on the acquired geometric data, first position data for the arrangement of a connecting element on the vehicle frame element and second position data for the arrangement of the connecting element on the door element. The determination of the respective position data can be carried out using an optimization algorithm that minimizes certain criteria such as a gap dimension. Thus, a mathematical optimization is applied to the acquired geometric data. The position data determined in this way are then used for mounting the door element on the vehicle frame element. Advantageously, no additional measuring or pre-assembly of the door element is required.The vehicle frame element and the door element are measured only once in reality, and then the position data is determined virtually using an optimization algorithm. This data is then used for automated assembly. This has a beneficial effect on quality, efficiency, and assembly time. According to a preferred embodiment, the determination of the at least first position data for the arrangement of at least one first connecting element on the vehicle frame element and the at least second position data for the arrangement of the at least one first connecting element on the door element can be based on a best-fit algorithm.
[0015] The term "best-fit algorithm" refers to a statistical optimization method based on the method of least common squares. Here, the measured initial geometry data for the door element and the measured secondary geometry data for the vehicle frame element are aligned with each other, taking into account the dimensions of the connecting element, in such a way that, for example, one or more criteria, such as the gap dimension and flushness, are achieved in the best possible way.
[0016] This allows the currently existing geometry, which is subject to tolerances due to painting, manufacturing deviations and assembly deviations, to be taken into account advantageously during assembly.
[0017] According to a preferred embodiment, the determination of at least first position data for the arrangement of at least one first connecting element on the vehicle frame element and at least second position data for the arrangement of the at least one first connecting element on the door element can be based on one or more of the following criteria: gap dimension, flushness, form line, alignment line between the at least first connecting element and a second connecting element.
[0018] The term "gap dimension" refers to the gap between the door element and the vehicle frame element. Other components on the vehicle frame element, such as the A-pillar, may already be taken into account and could be relevant to the respective gap dimension.
[0019] In this context, the term flushness refers in particular to a seamless transition of the door element to adjacent components such as the A-pillar.
[0020] The term "tornado line" refers to a characteristic line that runs along a side surface of a vehicle across several components, for example, the driver's door and the left rear door. The term "alignment line" refers to a common line or straight line in which the two axes of rotation of the connecting elements, in the case of hinges, especially pivot hinges, lie or coincide.
[0021] By taking one or more of the above-mentioned criteria into account, the appearance can be advantageously optimized virtually, thus enabling high quality without rework.
[0022] According to a preferred embodiment, the door element and / or the vehicle frame element can be pre-assembled and painted.
[0023] By providing pre-assembled and painted door elements and vehicle frame elements, a measurement can capture all tolerances due to manufacturing, painting and pre-assembly and advantageously take them into account during virtual alignment, so that no rework or remeasurement is necessary in the actual assembly.
[0024] According to a preferred embodiment, the at least one connecting element can comprise a hinge.
[0025] The hinge can preferably comprise two hinge elements, each of which can be attached to the door element and vehicle frame element and can be hooked into each other.
[0026] Preferably, the door element can comprise at least one of the following door elements: door, tailgate, hood, loading flap, fuel filler cap.
[0027] According to a preferred embodiment, the acquired first geometry data and / or the acquired second geometry data can be acquired using an optical measurement method.
[0028] The optical measurement method advantageously enables the efficient generation of a point cloud, which serves as input data for determining the first and second position data. The optical measurement method can be carried out, for example, using an optical fringe laser. According to a preferred embodiment, the acquired first geometry data can be compared with limit values, whereby the door element is rejected if the acquired first geometry data lies outside the limit values.
[0029] The limit data can include one or more geometric limits. As soon as a door element exceeds at least one of these geometric limits, it can be rejected. In other words, the process performs quality control by removing door elements with excessively large deviations before any further processing is unnecessarily carried out. This can advantageously reduce costs.
[0030] All disclosures and embodiments described herein relate to the method described above. Advantageously, the advantages offered by one embodiment and example also apply to all other embodiments and examples, and vice versa.
[0031] Further advantages, features, and details of the disclosure will become apparent from the following description, in which several exemplary embodiments of the disclosure are described in detail with reference to the drawings. The features mentioned in the claims and in the description can be essential to the invention individually or in any combination.
[0032] They each show schematically:
[0033] Figure 1 shows a flowchart for a procedure in accordance with the disclosure,
[0034] Figure 2 shows a vehicle frame element,
[0035] Figure 3 a door element,
[0036] Figure 4 shows a connecting element on the door element,
[0037] Figure 5 shows a connecting element on the door element, and
[0038] Figure 6 shows two connecting elements on the door element. Figure 1 shows a flowchart for a method for the automated assembly of a door element 10 on a corresponding vehicle frame element 11. In this case, the door element 10 is a driver's door and the vehicle frame element 11 is a side panel module.
[0039] Step S10 involves acquiring initial geometry data for the door element 10. For this purpose, the door element 10 is measured using an optical measuring method, for example by using an optical fringe laser.
[0040] Step S20 involves acquiring second geometry data for the corresponding vehicle frame element 11. For this purpose, the vehicle frame element 11 is measured using an optical measuring method, for example by using an optical fringe laser.
[0041] Step S30 includes determining at least first position data for the arrangement of at least one first connecting element 12 on the vehicle frame element 11 and at least second position data for the arrangement of the at least one first connecting element 12 on the door element 10 based on the acquired first geometry data and the acquired second geometry data.
[0042] The connecting element 12 is a rotary hinge with two hinge elements. Step S30 is executed by a data processing unit, such as a processor or CPU, which receives the first and second geometry data from the strip laser via a data interface.
[0043] The determination of at least the first position data for the arrangement of at least one first connecting element 12 on the vehicle frame element 11 and the at least the second position data for the arrangement of at least one first connecting element 12 on the door element 10 is based on a best-fit algorithm.
[0044] Determining at least first position data for the arrangement of at least one first connecting element 12 on the vehicle frame element 11 and at least second position data for the arrangement of the at least one first connecting element 12 on the door element 10 can preferably be based on one or more of the following criteria: gap dimension, flushness, tornado line 13, alignment line 14 between the at least first connecting element 12 and a second connecting element 15. Step S40 comprises mounting the door element 10 on the vehicle frame element 11 via the at least one first connecting element 12 based on the determined at least first position data and the determined at least second position data.
[0045] For this purpose, the specified first position data and second position data are passed to a robot controller as command input, which then mounts a part of the hinge to the specified first position of the vehicle frame element 11 and a second part of the hinge to the specified second position of the door element 10.
[0046] The door element 10 can then be hooked into the vehicle frame element 11.
[0047] Figure 2 shows a vehicle frame element 11. The vehicle frame element 11 is in this case a side panel module of a vehicle, to which a door element 10 is to be mounted.
[0048] Figure 3 shows a door element 10, in this case a driver's door. A tornado line 13 is marked on the door element 10 as an example.
[0049] Figure 4 shows a connecting element 12 on the door element 10. The connecting element 12 is a hinge. Only the first part of the hinge is visible. This part can be moved and mounted in the plane by means of a screw connection according to the specified second position data.
[0050] Figure 5 shows a connecting element 12 on the door element 10. In contrast to Figure 4, the second part is shown here suspended in the hinge for illustrative purposes. However, in the course of the process, this part will be mounted on the vehicle frame element 11.
[0051] Figure 6 shows two connecting elements 12 and 15 with their associated alignment line on the door element 10. Reference numeral list
[0052] 10 door elements
[0053] 11 Vehicle frame element
[0054] 12 Connecting element
[0055] 13 Tornado Line
[0056] 14. Line of flight
[0057] 15 second connecting element
[0058] S10 Acquisition of initial geometry data for the door element
[0059] S20 Acquisition of second geometry data for the corresponding vehicle frame element
[0060] S30 Determine at least first position data for the arrangement of at least one first connecting element on the vehicle frame element and at least second position data for the arrangement of the at least one first connecting element on the door element based on the acquired first geometry data and the acquired second geometry data
[0061] S40 Mounting the door element on the vehicle frame element via the at least one first connecting element based on the determined at least first position data and the determined at least second position data
Claims
Patent claims 1. Method for the automated assembly of a door element (10) on a corresponding vehicle frame element (11), comprising the steps: Acquisition of initial geometry data for the door element (10) (S10), Acquisition of second geometry data for the corresponding vehicle frame element (11 ) (S20), Determine at least first position data for the arrangement of at least one first connecting element (12) on the vehicle frame element (11) and at least second position data for the arrangement of the at least one first connecting element (12) on the door element (10) based on the recorded first geometry data and the second recorded geometry data (S30), Mounting the door element (10) to the vehicle frame element (11) via the at least one first connecting element (12) based on the determined at least first position data and the determined at least second position data (S40).
2. Method according to claim 1 , wherein the determination of at least the first position data for the arrangement of at least one first connecting element (12) on the vehicle frame element (11) and the at least the second position data for the arrangement of the at least one first connecting element (12) on the door element (10) is based on a best-fit algorithm.
3. Method according to claim 1 , wherein the determination of at least first positional data for the arrangement of at least one first connecting element (12) on the vehicle frame element (11) and at least second positional data for the arrangement of the at least one first connecting element (12) on the door element (10) is based on one or more of the following criteria: gap dimension, flushness, tornado line 13, alignment line 14 between the at least first connecting element (12) and a second connecting element (15).
4. Method according to one of the preceding claims, wherein the door element (10) and / or the frame element (11) are pre-assembled and painted.
5. Method according to any of the preceding claims, wherein at least one connecting element (12) comprises a hinge.
6. Method according to any of the preceding claims, wherein the door element (10) comprises at least one of the following door elements: door, tailgate, bonnet, loading flap, fuel filler cap.
7. Method according to any of the preceding claims, wherein the first geometry data and / or the second geometry data are acquired using an optical measurement method.
8. Method according to any of the preceding claims, wherein the initial geometry data acquired are compared with limit value data, and wherein, if the initial geometry data acquired are outside the limit value data, the door element (10) is rejected.