HANDLING DEVICE FOR OPENING A FLAP, AND CORRESPONDING METHOD

Abstract

A handling device is provided for opening a flap portion of a component part to be coated, in particular for opening a door or hood of a motor-vehicle body component part in a painting installation. The handling device includes a handling robot with a robot arm and a gripper mounted on the robot arm. The gripper is configured for engaging an engagement region or grip region on the flap to be opened, to enable the handling robot to open the flap with the gripper. The handling device further includes a sensor for non-contact sensing of the position of the gripper relative to the flap, to enable the gripper to be positioned relative to the engagement region on the flap. The sensor measures the distance from the handling device to the outside of the flap to be opened.

Claims

1.-16. (canceled)

17. A handling device for manipulating a flap portion of a component part to be coated, the handling device comprising: a handling robot having a robot arm and a gripper, the gripper being mounted on the robot arm and configured to engage an engagement region on the flap portion of the component part, the handling robot configured to articulate the gripper to engage and open the flap portion; and a non-contact position sensor configured to measure the distance to an outside surface of the flap portion of the component part.

18. The handling device according to claim 17, wherein the sensor is mounted to the robot arm.

19. The handling device according to claim 18, wherein the sensor is connected to a sensor line, wherein the sensor line runs, at least along a part of its length, inside the robot arm.

20. The handling device according to claim 18, wherein the sensor has a measuring range that projects obliquely forward from the robot arm.

21. The handling device according to claim 17, wherein the sensor is mounted on a robot base.

22. The handling device according to claim 17, wherein the sensor measures a quantity of distance to the outside surface of the flap portion.

23. The handling device according to claim 17, wherein the sensor is one of a distance sensor, an ultrasonic sensor, an inductive sensor, and a radar sensor.

24. The handling device according to claim 17, wherein the gripper projects transversely downward from the robot arm.

25. The handling device according to claim 17, wherein the gripper has a predetermined breaking point, and the predetermined breaking point is less than the mechanical loading capacity of each of the flap portion and the handling robot.

26. The handling device according to claim 17, wherein the flap portion is a door of a motor-vehicle body, and the engagement is a window gap in the door.

27. The handling device according to claim 17, wherein the engagement region is provided on a removable attachment to the flap portion.

28. A coating installation having a handling device according to claim 17.

29. A method for manipulating a flap portion of a component part to be coated, the method comprising: positioning a gripper with a handling robot, relative to an engagement region on the flap portion; during the positioning of the gripper, measuring the distance to an outside surface of the flap portion with a sensor; engaging the flap portion and the gripper; and articulate the gripper during engagement with the flap portion to move the flap portion relative to the component part.

30. The method according to claim 29, wherein the component part is a motor-vehicle body component part and the flap portion is a motor-vehicle door, the method further comprising: positioning of the gripper relative to the door based on stored geometrical data of the motor-vehicle body component part and a predetermined position of the motor-vehicle body component part, the stored geometrical data and the predetermined position being independent of the distance measured by the sensor; positioning of the gripper above the engagement region of the door based on the distance measured by the sensor; lowering the gripper into engagement with the door at the engagement region; and opening the door by drawing back the gripper.

31. The method according to claim 29, further comprising: detecting a deformation of the gripper; and identifying an engagement of the gripper with the flap portion based on the deformation.

32. The method according to claim 29, further comprising: detecting a deformation of at least one structural member of the handling robot.

33. The method according to claim 32, further comprising: identifying a collision of the at least one structural member of the handling robot with a delimitation based on the deformation.

34. The method according to claim 29, wherein the handling robot includes a robot arm with a vertical axis of rotation and the gripper is rotatable on the robot arm about the vertical axis of rotation, the method further comprising: measuring a torque value acting about the vertical axis of rotation; and comparing the torque value to at least one predefined limit value.

35. The method according to claim 34, further comprising: identifying a status of at least one of the robot arm and the gripper based on the comparison based on the comparison, the status being one of a disengagement of the gripper and the flap portion, the engagement of the gripper and the flap portion, and a collision of the robot arm and a delimitation.

36. The method according to claim 35, wherein the delimination is one of the component part and a cabin wall.

Description

DRAWINGS

[0044] The present disclosure is explained in more detail below in the description present disclosure with reference to the figures, in which are shown:

[0045] FIG. 1A a cross-sectional view through a motor vehicle door during the approach of the handling robot to open the door,

[0046] FIG. 1B a modification of FIG. 1A, wherein a gripper of the handling robot is already located over the window gap of the door to be opened,

[0047] FIG. 1C a modification of FIGS. 1A and 1B, wherein the gripper of the handling robot has already gone into the window gap of the door,

[0048] FIG. 1D a modification of FIGS. 1A-1C, wherein the sensor is disposed on the robot base,

[0049] FIG. 2 the handling method according to the present disclosure, in the form of a flow diagram,

[0050] FIG. 3 the process of opening a vehicle door, as a flow diagram,

[0051] FIG. 4 the process of opening a vehicle door, with parts control,

[0052] FIG. 5A the process of opening a hood of a vehicle body, as a flow diagram, and

[0053] FIG. 5B a perspective view of an engine hood of a vehicle body, with a gripper.

DESCRIPTION

[0054] FIGS. 1A-1C show various operating states of a handling device according to the present disclosure for manipulating a flap portion in the form of a door 1 of a motor-vehicle body, so that a painting robot, not shown, can paint the interior of the motor-vehicle body and the inside of the door 1.

[0055] For this purpose, the handling device according to the present disclosure has a multi-axis handling robot 2 which, with its robot base 3, can optionally be disposed in a stationary manner or so as to be displaceable along the conveying direction of the motor vehicle bodies.

[0056] A robot member 4 is disposed on the robot base 3, the robot member 4 being rotatable, relative to the robot base 3, about a vertical axis of rotation.

[0057] A robot arm 5 is rotatably arranged on the rotatable robot member 4, the robot arm 5 being rotatable, relative to the robot member 4, about a horizontal axis of rotation. In the drawings, this axis of rotation is oriented at right angles to the plane of the drawing.

[0058] Mounted at the distal, free end of the robot arm 5, there is a gripper 6, which projects transversely downward from the robot arm 5, so that the gripper 6 can be articulated and inserted into an engagement region or grip region in the form of a window gap 7 of the door 1, as shown in FIG. 1C.

[0059] A distance sensor 8, which measures the distance to the outside 9 of the door 1 within a predetermined measuring range 10, is disposed in the robot arm 5. The measuring range 10 of the distance sensor 8 in this case projects obliquely forward and downward from the robot arm 5. As a result, as the gripper 6 approaches the window gap 7 in the door 1, the distance sensor 8 can measure the distance to the outside 9 of the door 1, and thus enables controlled fine positioning of the gripper 6 relative to the window gap 7.

[0060] The drawings additionally show a sensor line 11, which runs within the robot arm 5.

[0061] As the window gap 7 is approached, the gripper 6 is first positioned over the window gap 7, as represented in FIG. 1B.

[0062] Next, the gripper 6 is then lowered down into the window gap 7, as represented in FIG. 1C.

[0063] Finally, the handling robot 2 can then pull open the door 1.

[0064] FIG. 1D shows a modification of FIGS. 1A-1C, such that, in order to avoid repetitions, reference is made to the above description, the same references being used for details that correspond.

[0065] In this exemplary implementation, the distance sensor 8 is mounted on the robot base 3, and measures the distance to the outside of the door 1.

[0066] The flow diagram represented in FIG. 2 illustrates an exemplary handling method according to the present disclosure.

[0067] In a first step S1, the handling robot 2 is operated in a rough approach of the door 1 to be opened. In this rough approach, the sensor data of the distance sensor 8 need not yet be evaluated. Rather, the rough positioning can take place solely on the basis of the known geometric data of the motor-vehicle body and the likewise known position of the motor-vehicle body on the conveyor.

[0068] During this rough positioning, it is checked, in a step S2, whether the distance sensor 8 already senses a distance signal.

[0069] If this is the case, then, in a step S3, a sensor-controlled approach of the gripper 6 to the door 1 is effected, the signals measured by the distance sensor 8 being taken into account as part of a position control.

[0070] In a step S4, it is continuously checked in this case whether the gripper 6 is located above the window gap 7.

[0071] If this is the case, the gripper 6 is lowered down into the window gap 7, in a step S5.

[0072] Then, in a step S6, it is checked whether the gripper 6 is located in the window gap 7.

[0073] If this is not the case, a search function is activated in a loop, in a step S10.

[0074] Otherwise, the door 1 can then next be pulled open, in a further step S7.

[0075] In a step S8, the door 1 can then be closed again.

[0076] Finally, a return to the initial position is effected in a step S9.

[0077] FIG. 3 shows, in the form of a flow diagram, a process, according to the present disclosure, of opening a door of a motor-vehicle body.

[0078] In a first step S1, the handling robot causes the gripper to approach the door from the outside. During this approach, the known body data of the motor-vehicle body, which represents the geometry of the motor-vehicle body, is taken into account.

[0079] During the approaching of the outside of the door of the motor-vehicle body, the signal strength of the sensor is measured and compared with a limit value x, in a step S2. If, despite the approach to the outside of the door, the signal strength does not exceed the limit value x, this indicates that the door is not at the stored location, such that, in a step S3, it is determined that there is an error. For example, an error flag may then be set.

[0080] Otherwise, the control system proceeds such that, in a step S4, the gripper can then be inserted in the engagement means (e.g. door gap) on the door, in order to open the door.

[0081] In this process, the torque, which acts in a vertical axis of rotation (“pivot axis”), is monitored in a step S5. On the one hand, this renders possible collision control, since this torque increases abruptly in the case of a collision. This torque monitoring also renders possible parts control, i.e. control of whether the part to be opened (e.g. door) is present, since the part then opposes the handling robot with a corresponding resistance.

[0082] Such a parts control is shown in FIG. 4, in the form of a flow diagram.

[0083] In a first step S1, a door of a motor-vehicle body, for example, is opened.

[0084] In this case, in a step S2, the signal strength of the sensor is measured and compared with a limit value y.

[0085] If the signal strength is less than the limit value y, this indicates an error, since the sensor does not detect the door. This may be due to the fact, for example, that the contact between the gripper and the door to be opened has been lost. An error is then identified in a step S3, in which case, for example, an error flag may then be set.

[0086] Otherwise, in a further step S4, the normal process is continued, and the part (e.g. door) is then closed again.

[0087] FIGS. 5A and 5B illustrate a process of opening an engine hood 12 of a motor-vehicle body by means of a gripper 13, which is moved by a handling robot in the manner described above.

[0088] For the purpose of opening the engine hood 12, the gripper 13 can engage in a ring 14 on the engine hood 12.

[0089] In a first step S1, in opening of the engine hood 12, the gripper 13 is then first moved towards the ring 14.

[0090] Next, in a further step S2, the gripper 13 is then moved into the ring 14.

[0091] In this case, in a step S3, the signal strength of the sensor is measured and compared with a limit value x.

[0092] If the measured signal strength does not exceed the limit value x, it is determined that the gripper 13 has not been inserted in the ring 14. In a step S4, an error is then identified, in which case, for example, an error flag may be set.

[0093] Otherwise, in a step S5, the normal handling process is effected, i.e. the engine hood 12 is opened in the usual manner and then closed again.

[0094] The present disclosure is not limited to the exemplary implementations described above. Rather, it should be understood that a plurality of variants and modifications are possible.