Patent Application
20210063142
Method and device for sensing the position of a seal, specifically a door seal on a component, specifically on a vehicle.
The position sensing as described here relates specifically to adhesively bonded profile seals or door seals as well as to seals on a door flange, including position sensing of other or further seals on other components or surfaces.
The position sensing according to the invention allows seals applied to the respective component in an automated, manual or other manner to be inspected. Accordingly, universal application is possible. Therefore, this includes seals which are to be applied independently of each other to vehicle body openings such as hatchback doors, trunk lids, trunk doors or windows as well as to their specific constructive design with flange, folded seam or surface. Furthermore, the seals may be circumferential or partially circumferential seals or door seals or regions of seals.
The problem with profile seals, specifically on a vehicle, is that, if faultily applied or applied exceeding the specified tolerance, they may be excessively stressed and pinched, on the one hand, leading to premature ageing or wear or destruction and making the fitting of the door or even use of the door impossible or considerably more difficult. On the other hand, the seal does not fulfil its intended purpose since gaps may form, which lead to increased background noise in the vehicle or allow ingress of moisture, each of which must be avoided.
As a result of faulty application or application exceeding the specified tolerance, rework must be done, which is costly and time-consuming, resulting in considerable delays in an automated manufacturing process since any rework is manual if necessary.
Since there are also component tolerances, any evaluation of the seal position with respect to the seal tolerances must be performed during application on the component in consideration of the component tolerances.
At present, the seal position is manually realised by means of a vernier calliper, a steel ruler or templates. Other methods measure in dimensionally unstable regions. The present quality controls are performed manually and only as spot checks at few locations. This is time-consuming since the components must be removed from an automated process and re-introduced after a positive check.
Furthermore, the seals are presently applied with the component tolerances being considered only to a limited extent. Hence, components are fitted with a seal with an out-of-tolerance application of the seal, this possibly not being caused by the seal application but by the component, which is found out only after the downstream position check.
The object of the invention is therefore to create a method and device for automated seal position sensing capable of sensing also the component tolerances in addition to the seal position on the respective component, enabling quality evaluation based on the sensed position and component tolerances.
Besides sequential checking, it is intended to enable uninterrupted position sensing and quality checking.
The object is achieved by the characteristics of the independent claim. Furthermore, the object is achieved by implementing the characteristics of the additional independent claim.
A method for automated position sensing of a seal (1) relative to a component (2) or at least one component region (2) during or after automated application of the seal (1), wherein the relative position of the seal (1) to the component (2) or to the at least one component region (2) is sensed by means of at least one sensor (3).
A device for performing the method for automated position sensing of a circumferential or sectionally running seal (1) by means of at least one sensor (3) relative to a component (2) or to at least one component region (2) during or after application of the seal (1), wherein the least one sensor (3) is arranged such that its main sensing direction (6) is oriented to be perpendicular to the running direction (7) of the seal (1) or of the component (2) or of the at least one component region (2) or to deviate from it at an angle of up to 45 degrees and the at least one sensor (3) with a sensing range (8) senses the seal (1) and/or the component (2) or the at least one component region (2).
The underlying solution describes a measuring method which allows the seal position to be measured during application of a door seal, specifically in an automated process. This means that the position sensing measurement is continuous and thus also simultaneous, either on its own or already during the application process. However, this measurement can also be made sequentially, i.e. only at specified points if required by the process. In this measurement, the dimensionally stable section of the seal, for example the seal foot, is to be used as a reference point. For measuring the seal position, features of the component such as a door, i.e. contours or spatial and/or planar features, are intended to be used. This is to ensure that a relative determination of the seal position is made possible.
In the method for automated position sensing of a seal relative to a component or at least one component region, the relative position of the seal is sensed by at least one sensor on the basis of the component or the at least one component region during or after the automated application of the seal.
For this purpose, a device for performing the method for automated position sensing of a circumferential or sectionally running seal is used, using at least one sensor with one sensing range to sense the seal during or after its application relative to a component or at least one component region and/or the component or the at least one component region, wherein the at least one sensor is arranged such that it main sensing direction is oriented to be perpendicular to the running direction of the seal or of the component or of the at least one component region or to deviate from a perpendicular arrangement at an angle of up to 45 degrees. Depending on the type of sensor, the sensing range is fan-shaped or cone-shaped, flaring out from the sensor such that it senses a wide planar and also a spatial region, depending on the seal or component.
In a preferred embodiment of the device, two sensors are used. This is necessary depending on the seal and/or component since shadowing effects may occur, resulting accordingly from the constructive design of the seal or component. If, however, simple or only slightly curved seals or only slightly curved or non-curved components are used in the application and position monitoring of the seal, only one sensor can be used.
Besides the field of application shown, there is the possibility of application in other plants where the seal is applied automatedly and which need the use of reliable position sensing.
The advantage is the full inspection of the components. Currently, only random inspections are performed, or faulty application is noticed in the so-called water test or when the respective component, e.g. a vehicle door, is mounted. As a consequence, the component in question, such as the respective vehicle door, needs to be dismounted, the seal to be removed, a new seal to be applied and the component, e.g. the respective vehicle door, to be re-mounted. The burden for correcting a faulty door is about 50 min of rework. Using the above invention can shorten this time to 5 min since it is possible to react directly after application and to rework the seal immediately in the process, e.g. by manual rework or re-introduction into the automatic process.
A further advantage is that the method may also be used before application in order to measure the component, thereby performing a position correction which influences the subsequent seal application process.
Advantageous embodiments of the method and device are presented in the dependent claims.
By sensing the seal position detection relative to least one geometry of the component or at least one region of the component, more precise position sensing and thus seal application is achieved. This allows an overall assessment as well as a detailed assessment with regard to the construction design of the component or respective region of the component, making the seal position sensing more reliable and precise.
In an improved embodiment, spatial and/or planar features of the component or component region are sensed, making the position sensing more precise since the position sensing also relies on the sensing of various or further parameters of the component or component region and additionally senses component tolerances, which can immediately be taken into account or result in discarding the component.
Furthermore, spatial and/or planar features of the seal are sensed at least in some regions, making the position sensing also more precise since various or further seal parameters are sensed for the position sensing, whereby also tolerances of shape or other deviations are sensed besides the sensing of the specific position and can be fed into the application process.
Spatial and/or planar features include holes, recesses, indents, marks or colouring as well as bends or steps or edges, for example.
The contour, too, is understood to be among the spatial and/or planar features.
Advantageously, the seal is sensed in a dimensionally stable region. In this way, measurement errors can largely be avoided or at least reduced since the dimensionally stable region is hardly or not at all subject to changes by deformation during application, and thus there are largely standardized starting points or reference points based on this dimensionally stable region and for each measurement.
By changing the cross-section of the seal, specifically of the flexible profile of this seal, the reliability of the measurement increases since, on the one hand, defined and uniform cross-sections are created for the measurement and, on the other hand, shadowing caused by the flexible profile sections is eliminated or the dimensionally stable region is temporarily exposed for the measurement.
In an improved embodiment, position sensing is simultaneous, either circumferential or pointwise, ensuring that the position of the door seal is determined directly and at very small measuring distances. This embodiment measures the position of the door seal in-line, i.e. during application. A measurement result can be output, which can be narrowed down by parameters and a result in the sense of pass or fail can be output.
Already during seal application, measuring simultaneously allows the ongoing application to be corrected. Moreover, already before application, the component or component region can be measured and thus a positional correction can be performed, which influences and favours the subsequent seal application process.
Additionally, position sensing is performed as a distance measurement, improving the position sensing and making it more accurate.
By sensing the position using a triangulation method, runs and regions as well as positions of the seal or component or component region for any contour or surface profiles can be sensed more precisely.
With two or more sensors of at least two sensors, having the respective sensing ranges arranged in one plane allows complex or extended or curved or otherwise spatially shaped geometries to be sensed more reliably since a standardized or coherent measurement as well as a standardized or coherent result are made possible, which improves the quality of the measurement or position sensing. This avoids distortions in the result, which may be produced by different measuring points on different planes.
An improved embodiment that has two or more sensors along the running direction of the seal or of the component or of the at least one component region arranged in an offset manner allows sensing also longitudinally extended runs and any deviations or distortions contained in them.
With two or more sensors, having at least two sensors in a laterally offset arrangement relative to each other, curved or otherwise spatially shaped geometries can also be sensed more reliably, allowing a standardized or coherent measurement as well as a standardized or coherent result, which improves the quality of the measurement or position sensing.
Having the main sensing directions or sensing ranges of the at least two sensors oriented in parallel or at an angle of 1 to 90 degrees, preferably 50 to 70 degrees, relative to each other reliably ensures that particular spatial or angled geometries, and thus the position of the seal relative to the component or component region, are also reliably sensed. In this way, the spatial and planar features as well as the geometry of the component and, if relevant, of the seal predetermine the angle at which the main sensing directions are oriented or are to be oriented relative to each other in order to sense the respective spatial and planar features as well as the respective geometry reliably.
The sensors being oriented towards the dimensionally stable region of the seal and/or spatial and/or planar features of the component or of the at least one component region ensure that the sensors are oriented towards and sense largely standardized starting points or reference points so that position sensing and its evaluation is facilitated. Any dynamic adjustment to continuously changing geometries can thus be reduced or avoided.
In the improved embodiment having sensors that are movable in place or can be guided around the component or component region, the flexibility of the device for different automation solutions is increased. It is thus also possible to monitor the application of the seal onto stationary or moving components or to sense the seal position.
Overlapping or overlying sensing directions of at least two sensors allow the sensing ranges of the individual sensors to be combined or to be grouped by different perspectives, whereby complex spatial regions can also be sensed besides extended planar regions.
Different exemplary embodiments of the invention are described in greater detail below.
Of the drawings:
In the method for automated position sensing of a seal 1 relative to a component 2 or at least a component region 2 according to the invention provides for sensing of the relative position of the seal 1 to the component 2 or to the at least one component region 2 by at least one sensor 3 during or after automated application of the seal 2.
Therein, the position of the seal 1 is sensed relative to the geometry of the component 2 or the at least one component region 2. For this purpose, spatial and planar features 9 of the component 2 or the at least one component region 2 are sensed as shown in
In order to adjust the seal 1, which may have any cross-sections, for position sensing in addition to the sensing of the seal foot 4 as a dimensionally stable region 4, a change in the cross-section of the seal 1, specifically of the flexible profile 5 of this seal 1, i.e. above the seal foot 4, is intended. This can involve compressing it to obtain a very narrow cross-section or pushing it sidewards in order to hold the seal foot 4 exposed or to expose it for position sensing.
Position sensing is simultaneous, either circumferential or pointwise. This allows position sensing that is permanent, performed at given points or performed irregularly. Depending on the type of application, the component 2 with the run of the applied seal 1 is guided along the at least one sensor 3 or the at least one sensor 3 is guided along the applied seal 1. This is preferably done by a robot.
Position sensing is performed as a distance measurement, preferably by means of at least one fan-type sensor or light section sensor, the position sensing being thus performed as a triangulation process.
To improve the method, two sensors 3 are used, with the sensors 3 sensing the seal 1 from both sides in an offset arrangement relative to each other. This allows sensing the component 2 or component region 2 on both sides of the seal 1. Position sensing is thus performed based on two component regions 2, each based on the side of the seal 1 and on the seal 1. In this manner, the dimensionally stable region 4 is sensed on both sides of the seal 1.
The fan-type sensors each sense the seal 1 and the component region 2 laterally adjacent to the seal 1 with its individual contour or geometry as shown in
The method for automated position sensing of a seal 1 can be performed using the device according to the invention, wherein the at least one sensor 3 is arranged such that its main sensing direction 6 is oriented to be perpendicular to the running direction 7 of the seal 1 or of the component 2 or of the at least one component region 2 or to deviate from a perpendicular arrangement at an angle of up to 45 degrees and that the at least one sensor 3 senses the seal 1 and the component 2 or the at least one component region 2 at the seal 1 with a sensing range 8.
As shown in
The sensors 3 are oriented towards the dimensionally stable region 4 of the seal 1 and towards the spatial and planar features 9 of the component 2 or respective component region 2.
Depending on the seal and the geometry of the component 2, two or more sensors 3 are arranged such that the main sensing directions 6 or the sensing ranges 8 of the sensors 1 are oriented at an angle of about 85 degrees relative to each other as shown in
Depending on the seal 1 and the component 2, it is appropriate that the sensing ranges 8 of at least two sensors 3 overlap or overlie each other. However, depending on the type and geometry of the seal 1, it is not excluded that the overlap of the sensing ranges 8 is partly or fully shadowed by the seal 1.
The method has been performed on a door derivative as component 2 as well as by means of robot-guided sensors 3 and also performed on a robot-guided component 2.
For example, the relative position of the seal 1 as a door seal on the door flange must be sensed as component region 2. The aim should be sensing the seal foot 4 relative to the door flange in order to largely exclude any manufacturing tolerance.
In that, the measuring method allows reliable measurement at defined measuring points. The method provides that measurement results can be produced and evaluated during a complete application, i.e. circumferentially. During this, the application can immediately be influenced.
A specific embodiment of the invention is currently based on so-called light section sensors which, using a known triangulation method, produce a laser spot which allows geometries to be sensed as a spatial, planar feature 9, 10 and resultingly outputs measurement results. The method provides that the sensing is also carried out using other technologies.
Principally, the scanning of the transitions from a radius to a straight line as a spatial or planar feature 9 on the respective component 2, of the respective component surface as component region 2 or as a spatial or planar feature 10 on the respective seal 1 or a borehole or any other spatial or planar particularity as a spatial or planar feature 9 of the component 2 as a preferred feature is suitable for determining the position of the seal 1. What feature is suited best for this purpose is preferably based on the availably geometry of the component 2 or any other spatial or planar particularity of the seal 1 and the angle of the sensor 3 relative to the respective feature. The width of seal 1 can be sensed in parallel, however, it is not drawn for the sake of clarity.
Sensors 3 recognize the dimensionally stable back of the door seal as well as spatial and planar features 9 of the door, such as e.g. the transitions from radii to straight lines. In order to ensure this more reliably, two sensors 3 are applied in the specific exemplary embodiment, looking perpendicularly, i.e. at a right angle, at the seal 1, and, on the other hand, are attached at a varying angle of about 50-70 degrees relative to the seal 1. The measurement set-up according to
The distances are sensed as a simple profile measurement at the individual measuring points. In this, the measurement results of the left and right sensors 3 can by processed and computed synchronously.
For the specific exemplary embodiment, accessibility of the measuring points as well as measurement stability were investigated. The contour could be sensed at all measuring points, and stable profiles were delivered.
Monitoring the position of seal 1 is possible with three different concepts which differ in their degree of detail and the possibility to sense other defect causes/defect patterns.
For example, one implementation is that the sensors 3 are guided around a fixed component 2 so that the sensors 3 need to be displaced during seal application or for position sensing such that the position of the seal 1 on component 2, component 2 being the door flange, for example, attached to a static holding system is measured relatively. During this, the component 2 is fixed in place for the application process and position sensing, and the components required for application and position checking are guided or moved past the component 2, e.g. a vehicle door, while said door is temporarily stationary.
Furthermore, one implementation is to make the attachment of sensors 3 rigid, i.e. no displacement of the sensors 3 is necessary during seal application, such that the position of the seal 1 on the door flange as component 2 can be measured relatively by means of a static measurement system. In this method, the component 2, e.g. the vehicle door, is guided or moved past the respective application and position sensing components while these are stationary, for application and position sensing.
In an exemplary embodiment, two sensors 3 are arranged in an appropriate set-up. In this set-up, the door as component 2, guided by a robot, is guided past a simulated application head and the measurement is made shortly before and after the application head, respectively. Since the sealing bead presses towards the inner door side when the seal 1 is applied, one of the sensors 3 is advantageously arranged at the inner door side at a 90-degree angle to the seal. To sense the seal foot 4 in a collision-free manner on both sides of the seal 1, the sensors 3 are arranged at a distance of 200 mm from the seal, for example. It is not imperatively required to make the sensors 3 follow the door movement by means of an additional robot, because shadowing does not occur in this setting and any measuring errors caused by oblique projection can be compensated also during processing.
In the specific exemplary embodiment, a measuring head LJ-V7200 from Keyence is used as a sensor 3. This exemplary measuring head, also designated as measuring probe, has a working principle where the laser beam is spread to project a line onto the surface of the object to be measured. The light reflected by the surface impinges on the receiver, e.g. an HSEa-CMOS. The displacement and shape are measured by the sensor 3 sensing the change in position and shape. The advantages of using a measuring head, also called measuring probe, over a camera system is that the measuring head provides calibrated height values and recalibration is not required. Furthermore, there are no adjustable components such as a lens or lens aperture. Depth of field is given over the entire sensing range. In addition, the measuring head is insensitive to extraneous light up to a type-related maximal ambient brightness.
Despite this, camera systems can be used as a sensor 3, which allow sequential and continuous measurement by means of three-dimensional sensing methods.
1—Seal
2—Component, component region, vehicle door
3—Sensor
4—Dimensionally stable region, seal foot
5—Flexible profile
6—Main sensing direction
7—Running direction
8—Sensing range
9—Spatial, planar feature
10—Spatial, planar feature
11—Deviation
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2018 101 248.9 | Jan 2018 | DE | national |
| 10 2018 110 303.4 | Apr 2018 | DE | national |
This application is the U.S. national stage of International Application No. PCT/DE2019/100046, filed on 2019 Jan. 17. The international application claims the priority of DE 102018101248.9 filed on 2018 Jan. 19 and the priority of DE 102018110303.4 filed on 2018 Apr. 27; all applications are incorporated by reference herein in their entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/DE2019/100046 | 1/17/2019 | WO | 00 |
