METHOD FOR SETTING UP A JOINING APPARATUS FOR JOINING A LIGHT LENS TO A HOUSING OF A MOTOR VEHICLE LIGHTING ARRANGEMENT

Abstract

A method for setting up a joining apparatus for joining a light lens to a housing of a motor vehicle lighting arrangement. A first virtual model is created of the joining apparatus with a light lens and a housing received therein, a relative arrangement of the light lens to the housing corresponds to a target arrangement. A plurality of virtual models are created of the joining apparatus with the light lens and the housing received therein. The relative arrangement of the light lens to the housing deviates from the target arrangement in each case by means of virtual displacement of the adjuster. A target displacement is calculated of an adjuster on the basis of a functional relationship calculated and the relative arrangement in the test construction unit measured. A light lens is joined to a housing in the target arrangement by displacing the adjuster by the target displacement.

Claims

1. A method for setting up a joining apparatus for joining a light lens to a housing of a motor vehicle lighting arrangement, wherein the joining apparatus comprises a holding device for receiving the light lens and a receiving device for receiving the housing, wherein the holding device and the receiving device are movable in translation and/or rotation relative to each other by an adjuster, the method comprising: creating a first virtual model of the joining apparatus with a light lens received therein and with a housing received therein, wherein the relative arrangement of the light lens to the housing corresponds to a target arrangement; creating a plurality of virtual models of the joining apparatus with the light lens received therein and with the housing received therein, wherein the relative arrangement of the light lens to the housing deviates from the target arrangement in each case by virtual displacement of the adjuster; calculating a functional relationship between the relative arrangements of the light lens to the housing and the displacement of the adjuster on the basis of the virtual models created; joining a light lens to a housing to form a test construction unit in a starting position of the adjuster; measuring the relative arrangement of the light lens to the housing in the test construction unit; calculating a target displacement of the adjuster on the basis of the functional relationship calculated and the relative arrangement in the test construction unit measured; displacing the adjuster from the starting position by the target displacement; and joining a light lens to a housing in the target arrangement by the displaced adjuster.

2. The method according to claim 1, wherein, when calculating the functional relationships between the relative arrangements of the light lens to the housing and the displacement of the adjuster, a linear approximation is carried out.

3. The method according to claim 2, wherein, when calculating the functional relationship, an inhomogeneous linear system is set up, wherein the variables of the linear system represent the displacement of the adjuster and the absolute elements of the linear system represent the relative arrangement of the light lens to the housing.

4. The method according to claim 3, wherein, when calculating the target displacement of the adjuster, the linear system is solved, wherein the absolute elements of the linear system represent the relative arrangement of the light lens to the housing in the test construction unit measured in the preceding method step.

5. The method according to claim 1, wherein, when creating the first virtual model, receptor points on the light lens and reference points on the housing are defined, wherein the relative arrangement of the light lens to the housing is described based on the relative position of the receptor points to the reference points.

6. The method according to claim 5, wherein when measuring the relative arrangement of the light lens to the housing, the relative positions of the receptor points on the light lens to the reference points on the housing are measured.

7. The method according to claim 1, wherein the displacement carried out by the adjuster corresponds to the following relative movements of the light lens received in the holding device to the housing received in the receiving device: translation in the vertical direction (Z); translation in two directions (X, Y) in a horizontal plane; and rotation about the vertical direction (Z) as an axis of rotation.

8. The method according to claim 1, wherein a device for carrying out a friction welding process or a heating element welding process or an adhesive process is used as a joining apparatus.

9. The method according to claim 1, wherein a coordinate measuring instrument is used for measuring the relative arrangement of the light lens to the housing.

10. A method for joining a light lens to a housing of a motor vehicle lighting arrangement by a joining apparatus, the method comprising: setting up the joining apparatus using the method according to claim 1; and joining the light lens to the housing in a target arrangement.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:

[0024] FIG. 1 is a partial view of a joining apparatus for carrying out the inventive setup and joining method,

[0025] FIG. 2 is a flow diagram of the setup and joining method according to the invention, and

[0026] FIGS. 3a to 3c show schematic representations of method steps of the inventive setup and joining methods.

DETAILED DESCRIPTION

[0027] FIG. 1 shows a partial view of a joining apparatus 1 for carrying out a friction welding process for joining a light lens to a housing of a lighting arrangement. The joining apparatus 1 comprises the base plate 14, on which the receiving device 13 is arranged for receiving a housing. The base plate 14 is arranged parallel to the horizontal plane stretched by X and Y. In the vertical direction Z thereto, the holding device 12 for the reception of a light lens is located above the base plate 14 on the underside facing the receiving device 13.

[0028] The holding device is movable along the vertical direction Z, wherein the adjuster 11 used for this purpose are not shown in more detail here, but can be designed, for example, as a portal system. Three fixing blocks 11a-c serve as adjuster 11 for the receiving device 13, by means of which the base plate 14 including the receiving device 13 can be moved in the X and Y direction and rotated to a limited extent in the X-Y plane. For this purpose, the fixing blocks 11a-c have, for example, slotted holes.

[0029] FIG. 2 shows a flow diagram of the method steps of the setup and joining method according to the invention, wherein steps 100 to 700 represent the setup process. For the reference signs mentioned below concerning the joining apparatus and parts, reference is made to the description of FIGS. 1 and 3a-c.

[0030] The creation 100 of a first virtual model of the joining apparatus 1 with a light lens 2 received therein and with a housing 3 received therein, wherein the relative arrangement of the light lens 2 to the housing 3 corresponds to the target arrangement suitable for dimensionally accurate joining, is preferably based on already existing CAD data sets of the joining apparatus 1 and the two construction units 2, 3 to be joined. To quantify the relative arrangement, 2 receptor points are defined on the surface of the light lens and referenced to a reference point system on the housing 3. Commonly, gap and surface dimensions are specified, i.e., the relative position of each receptor point is determined by specifying, for example, two dimensions, and thus the relative arrangement of the light lens 2 to the housing 3 is quantified by the sum of all receptor points. A vector B=(B.sub.1, . . . , B.sub.2N) contains in pairs the gap and surface dimensions of N receptor points and thus represents the relative arrangement of the light lens 2 to the housing 3. In the model created in the first method step 100, the light lens 2 is in target arrangement B=B.sup.(0) to the housing 3 and the associated position D=(x, y.sub.1, y.sub.2, z) of the adjuster 11 is defined as a target position D.sup.(0)=(x.sup.(0), y.sub.1.sup.(0), y.sub.2.sup.(0), z.sup.(0)). The elements x, y.sub.1, y.sub.2 and z represent in it the positions of the adjuster 11, i.e., of the three fixing blocks 11a, 11b and 11c as well as the adjuster designed to displace the holding device 12 in the Z direction, wherein in principle arbitrary and preferably practicable units, for example scale parts or the number of visible threads of an adjusting screw, can be used.

[0031] Starting from the first virtual model of the joining apparatus 1 with a light lens 2 in target arrangement to a housing 3, a large number of corresponding virtual models is created in the second method step 200, wherein in each case by virtual displacement d=(d.sub.x, d.sub.y1, d.sub.y2, d.sub.z) of the adjuster 11, the relative arrangement B of the light lens 2 to the housing 3 varies.

[0032] In the subsequent method step 300, a functional relationship between the relative arrangements B of the light lens 2 to the housing 3 and the associated displacement D of the adjuster 11 is set up on the basis of the virtual models, wherein this relationship is assumed to be linear. In the case of a purely translational displacement of the light lens 2 relative to the housing 3, this assumption is identically fulfilled, while with regard to a relative rotation it is only approximately valid in the limiting case of sufficiently small changes. The functional relationship corresponds to an inhomogeneous linear system with the displacement D as variables and the relative arrangement B as an absolute element, i.e., A*D=A*(D.sup.(0)+d)=B. The coefficients of the matrix A are determined in a simple manner by inserting concrete values for D and B into the linear system of equations, wherein such concrete values are obtained from the virtual models set up at the start.

[0033] In practice, after equipping the real joining apparatus 1 with holding and receiving device 2, 3, the adjuster 11 are in a starting position D.sup.(1), which is usually not well defined, because, for example, the fixing blocks 11a-c are designed as pure tolerance compensating components. The method according to the invention is now aimed at determining the target displacement d.sup.(0), by means of which the adjuster 11 can be transferred from the starting position D.sup.(1) to the target position D.sup.(0), i.e., the following applies: D.sup.(1)−d.sup.(0)=D.sup.(0).

[0034] For this purpose, in method step 400, a test construction unit formed of a light lens 2 and a housing 3 is joined in the starting position D.sup.(1) of the adjuster 11, and in the subsequent method step 500, the relative arrangement B.sup.(1) of the light lens 2 is measured in this test construction unit.

[0035] The following then applies:

[00001]${\overline{B}}^{\left(1\right)}=\stackrel{\stackrel{\_}{\_}}{A}*{\overline{D}}^{\left(1\right)}=\stackrel{\stackrel{\_}{\_}}{A}*\left({\overline{D}}^{\left(0\right)}+{\overline{d}}^{(0}\right)={\overline{B}}^{\left(0\right)}+\stackrel{\stackrel{\_}{\_}}{A}*{\overline{d}}^{\left(0\right)},$

[0036] and thus, the sought target displacement is:

[00002]$\begin{array}{cc}{\overline{d}}^{\left(0\right)}={\stackrel{\stackrel{\_}{\_}}{A}}^{-1}*\left({\overline{B}}^{\left(1\right)}-{\overline{B}}^{\left(0\right)}\right).& \end{array}$

[0037] This calculation of the target displacement d.sup.(0) is carried out in method step 600 using the coefficient matrix A determined in method step 300 or using a pseudoinverse A.sup.−1 of the specified target arrangement B.sup.(0) of the light lens 2 to a housing 3 in a perfectly dimensionally accurate lighting arrangement and using the relative arrangement B.sup.(1) of the light lens 2 in the test construction unit measured in method step 500. In the simplest case, the relative arrangement B can be defined only by N=2 receptor points, each of which is given by a gap and surface dimension. This has the advantage that the coefficient matrix A then assumes a square 4×4 shape and, in the calculation of the target displacement d.sup.(0) therefore the ordinary inverse can be calculated in a mathematically simple way.

[0038] The setup method according to the invention ends with the method step 700, in which the adjuster 11 are displaced from the starting position D.sup.(1) by the previously determined target displacement d.sup.(0) such that the adjuster 11 then assume the target position D.sup.(0), in which a light lens 2 can be joined to a housing 3 in the desired target arrangement B.sup.(0).

[0039] On the apparatus side, the prerequisite for the production of dimensionally accurate lighting arrangements has thus been created with little time and effort.

[0040] The method step 800, the joining of a light lens 2 with a housing 3 in a target arrangement B.sup.(0) represents in particular the start of a whole production series, during which, in the ideal case, it is no longer necessary to intervene in the present target position D.sup.(0) of the adjuster 11. Any dimensional deviations of the lighting arrangements manufactured with it are then due in particular to the fact that the joined components, i.e., the light lens 2 and the housing 3, were already affected by dimensional scattering in the single-part production. One exception may be if the starting position D.sup.(1) of the adjuster 11 deviates greatly from its target position D.sup.(0) and the target displacement d.sup.(0) causes such a pronounced rotation of the housing 3 received in the receiving device 13 to the light lens 2 that the linear approximation underlying the method step 300 is not valid. In this case, it is necessary to join and measure a further test construction unit and to update the target displacement d.sup.(0) of the adjuster 11 on this basis. This operational procedure corresponds to a repetition of method steps 400 to 800 and is represented in FIG. 2 by the dashed arrow. If necessary, these steps are to be iterated so often that the position of the adjuster 11 has been brought close enough to their target position D.sup.(0) that the calculation of the target displacement d.sup.(0) is valid in linear approximation, or dimensionally accurate lighting arrangements are joinable with the prepared joining apparatus 1.

[0041] FIGS. 3a-c illustrate different method steps of the setup or joining method according to the invention. In FIGS. 3a-b various working steps of the joining process by means of a heating element welding device 1 are shown. The light lens 2 is received in the holding device 12 and the housing 3 in the receiving device 13. The adjuster 11 comprise the fixing blocks 11a-c as well as a device for the displacement of the holding device 2 along the vertical axis Z not further specified here. By means of the fixing blocks 11a-c, the base plate 14 including the receiving device 13 is movable on the base plate 15 in the X-Y plane and also rotatable to a certain extent.

[0042] In FIG. 3a, the holding device 12 is moved to a position far away from the receiving device 13, and the heating element 5 has been retracted into the gap between light lens 2 and housing 3. The heating element 5 is used to plasticize the joining surface on the light lens 2. The heat is introduced, for example, contactless by means of laser or infrared radiation or by means of hot gas. The resulting degree of plasticization of the joining surface of the light lens 2 is sufficiently large that a subsequent pressing of the joining surfaces of light lens 2 and housing 3 leads to the production of the desired joining connection. Alternatively, the joining surface of housing 3 can also be plasticized by means of heat input.

[0043] The pressing together of the two joining partners 2, 3 is shown in FIG. 3b. For the purposes of the method according to the invention, this may correspond either to the method step 400, i.e., the joining of a test component at a starting position of the adjuster 11, or the method step 800, i.e., the joining of a dimensionally accurate lighting arrangement at the target position of the adjuster 11.

[0044] Finally, FIG. 3c illustrates the method step 500, in which in particular a test construction unit formed of joined light lens 2 and housing 3 is measured in a coordinate measuring instrument 4. The test construction unit is received with the housing 3 in the measuring receptacle 42, so that position and spatial orientation of housing 3 in relation to the internal coordinate system of the coordinate measuring instrument 4 are specified and well known. the probe 41 hits defined receptor points on the surface of the light lens 4, thus determining their relative position in relation to the reference points on the housing 3. Each receptor point is usually assigned a gap and surface dimension and, from the sum of the measured points, the relative arrangement B of the light lens 2 to the housing 3 results.

[0045] The invention is not limited in its embodiments to the preferred embodiment given above. Rather, a number of variants are conceivable, which make use of the presented solution even with fundamentally different embodiments. All features and/or advantages resulting from the claims, the description, or the drawings, including structural details, spatial arrangements, and method steps, can be essential to the invention both by themselves and in the most diverse combinations.

[0046] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.