METHOD AND DEVICE FOR MANUFACTURING A MULTIPLICITY OF COMPONENTS WITH AT LEAST ONE ELECTRICAL FEEDTHROUGH AND AN INFORMATION STORE, COMPONENT, AND METHOD AND DEVICE FOR THE FURTHER PROCESSING OF SUCH COMPONENTS

Abstract

A method for manufacturing a plurality of components, each of the plurality of components including at least one electrical feedthrough, in which a functional element is fastened in a feedthrough opening in a base body by way of an electrically insulating material, an information being acquired in association with each of the plurality of components, the method comprising the steps of: providing, in one of a plurality of manufacturing steps of the method, each of the plurality of components or one of a plurality of pre-stages of each of the plurality of components with an information store, at least one of (i) the information being stored in the information store, and (ii) an identifier is stored in the information store and the information is stored in a database in association with the identifier.

Claims

1. A method for manufacturing a plurality of components, each of the plurality of components including at least one electrical feedthrough, in which a functional element is fastened in a feedthrough opening in a base body by way of an electrically insulating material, an information being acquired in association with each of the plurality of components, the method comprising the steps of: providing, in one of a plurality of manufacturing steps of the method, each of the plurality of components or one of a plurality of pre-stages of each of the plurality of components with an information store, at least one of (i) the information being stored in the information store, and (ii) an identifier is stored in the information store and the information is stored in a database in association with the identifier.

2. The method according to claim 1, wherein the information is selected as one or more from a group including: an information relating to a plurality of starting materials used; an information relating to the plurality of manufacturing steps which are carried out; an information relating to a plurality of tools and a plurality of installations used; an information relating to a plurality of measurements and a unique identifier.

3. The method according to claim 1, wherein each of the plurality of components or a respective one of the plurality of pre-stages of each of the plurality of components is uniquely identified in at least one of the plurality of manufacturing steps via a position of each of the plurality of components or the respective one of the plurality of pre-stages in a component carrier and via a component carrier identifier that is assigned to the component carrier and uniquely identifies the component carrier.

4. The method according to claim 1, wherein each of the plurality of components or a respective one of the plurality of pre-stages of each of the plurality of components is uniquely identified, in at least one of the plurality of manufacturing steps of the method, by reading the information store.

5. The method according to claim 1, wherein a random sample of the plurality of components or each of the plurality of components is subjected to a final inspection, in which at least one property of a respective one of the plurality of components is measured, and a plurality of results of the final inspection are assigned to the respective one of the plurality of components as information.

6. The method according to claim 5, wherein the plurality of results obtained in the final inspection are compared with a plurality of predefined setpoint values, and respective ones of the plurality of components that exceed at least one predefined limit value are ascertained.

7. The method according to claim 6, wherein the respective ones of the plurality of components that are so ascertained to have exceeded the at least one limit value are referred to as a plurality of ascertained components, an assigned information of the plurality of ascertained components is evaluated, and, with respect to the plurality of ascertained components, a common information is determined as to which of the plurality of ascertained components are identical to or match within a predefined tolerance.

8. The method according to claim 7, wherein at least one of the plurality of manufacturing steps, a plurality of starting materials, a plurality of tools, and a plurality of process conditions that the plurality of ascertained components have in common are ascertained from the common information, and in accordance therewith a plurality of quality improvement measures for a plurality of future runs of the method are initiated, wherein the plurality of quality improvement measures are selected from the following: an exchange of a tool; an exchange of a component carrier; an exchange or a calibration of a measuring device; a correction of a plurality of process parameters; a selection of other ones of a plurality of starting materials; and a plurality of combinations of the plurality of quality improvement measures.

9. The method according to claim 1, wherein the information that is identical for a multiplicity of the plurality of components is stored only once in the database as a group information, and a respective reference to the group information is assigned to a respective one of the plurality of components.

10. The method according to claim 1, wherein the information store is designed as an optically readable marker.

11. The method according to claim 10, wherein the optically readable marker is formed on at least one of a plurality of the functional element.

12. The method according to claim 11, wherein the optically readable marker is obtained using a laser material machining method.

13. The method according to claim 1, wherein a device is provided for manufacturing the plurality of components, the device including a machining mechanism configured for providing the plurality of components with an information store, the device being configured for carrying out the method for manufacturing the plurality of components.

14. A component with at least one electrical feedthrough, the component comprising: a base body including a feedthrough opening; an electrically insulating material; a functional element, the at least one electrical feedthrough being that in which the functional element is fastened in the feedthrough opening by way of the electrically insulating material; and an information store.

15. The component according to claim 14, wherein the component is configured for being assembled into a plurality of the component so as to form an assembly of the components, which is configured for being received in a container which includes an assembly information store which contains a plurality of indications for identifying the plurality of the component contained in the assembly of components.

16. The component according to claim 14, wherein the component is configured for being used in an ignition unit for an airbag or in an igniter for a seatbelt tensioner.

17. A method for a further processing of a plurality of components to form a plurality of units that each contain at least one of the plurality of components, the method comprising the steps of: providing each one of the plurality of components with at least one electrical feedthrough, each one of the plurality of components including: a base body including a feedthrough opening; an electrically insulating material; a functional element, the at least one electrical feedthrough being that in which the functional element is fastened in the feedthrough opening by way of the electrically insulating material; and an information store; obtaining an information that is assigned to a respective one of the plurality of components, wherein the obtaining of the information that is assigned to the respective one of the plurality of components includes reading an information store of the respective one of the plurality of components or reading an assembly information store of a container that receives at least one of the plurality of components; and assigning the information to a respective one of the plurality of units.

18. The method for the further processing according to claim 17, wherein in at least one further processing step, at least one parameter is adapted based on the information assigned to the respective one of the plurality of components.

19. The method for the further processing according to claim 17, wherein a parameter contained in the information assigned to the respective one of the plurality of components—which is an assigned information—is measured again and compared with a previously ascertained information, thereby forming a comparison.

20. The method for the further processing according to claim 19, wherein the comparison (a) is repeated for multiple ones of the plurality of components, which are a random sample from an entirety of the plurality of components, or (b) is repeated for the entirety of the plurality of components, wherein, upon identifying a systematic deviation, a correction factor is ascertained and is used to correct the assigned information even for the plurality of components of the entirety of the plurality of components that are not surveyed again.

21. The method for the further processing according to claim 17, wherein a device is provided for the further processing of the plurality of components, the device including a reading mechanism configured for reading the information store of the plurality of components or an assembly information store of a container containing the plurality of components, the device being configured for carrying out the method for the further processing of the plurality of components.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0140] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein, in each case schematically:

[0141] FIG. 1 shows steps of a method for manufacturing components according to one embodiment of the present invention;

[0142] FIG. 2 shows steps of a further processing method according to one embodiment of the present invention;

[0143] FIG. 3 shows steps of a method according to one embodiment of the present invention;

[0144] FIG. 4 shows steps of a method according to one embodiment of the present invention; and

[0145] FIGS. 5a, 5b and 5c show exemplary embodiments of components with an information store according to the present invention.

[0146] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

[0147] FIG. 1 shows steps of an advantageous method for manufacturing components according to one embodiment of the present invention using the example of manufacturing a component for an igniter for passenger restraint systems in the form of airbags.

[0148] For this purpose, appropriate molds for manufacturing a multiplicity of feedthroughs for igniters are first of all provided, for example in the form of carbon molds, these being provided with appropriate materials for manufacturing feedthroughs (step S1: mounting). Each of the carbon molds in this case has a multiplicity of receptacles, wherein a feedthrough may be mounted in each receptacle. Accordingly, in this example, step S1 includes a base body, also called header, a blank for the electrically insulating material, and a connection pin being mounted in each of the receptacles.

[0149] For the mounting step S1, a carbon mold is provided as component carrier, wherein the carbon mold that is used is identified via a component carrier identifier. The component carrier identifier is stored for example in an information store arranged on the carbon mold, for example an optically readable marker. The optical readable marker is designed for example as a data matrix code. Since the melting step S2, carried out later, is carried out at a higher temperature, the matrix code on the respective carbon mold is optionally designed to be resistant to the thermal loads that occur in the process. New carbon molds are provided in a step V1, provided with an information store and registered. Carbon molds that have already been used once may be reused and are in this case identified by the pre-existing information store or the component information carrier stored therein. In the flowchart of FIG. 1, the flow of the carbon mold is identified by lines of medium thickness provided with arrows.

[0150] Further indications about the carbon mold may be stored in the information store of the carbon mold or in an associated database in the course of the method. These indications may for example include the type of carbon mold, indications about the material, number of previous uses and the like.

[0151] Information relating to the pre-stages of the header to be manufactured is already assigned to the header to be manufactured in the mounting step S1, wherein the respective header or its pre-stage is identified via the corresponding receptacle of the carbon mold and its component carrier identifier. In step S1, the information is for example selected from indications regarding the mounting team, the batch number of the starting materials or pre-stages used for the headers, metals used for the pre-stages of the components, in particular manufacturer, batch and type, geometry of the headers or the pre-stages, the mounting time and parameters for the mounting. These data are stored for example in a database DB in datasets of the respective headers (see FIG. 2).

[0152] Following the mounting step S1, the electrical feedthroughs are produced in a furnace in a melting step S2, wherein the individual components or their pre-stages are assigned the information relevant for the melting step S2. In the flowchart of FIG. 1, the flow of the components is identified by thick arrows.

[0153] In this case, as long as the headers or their pre-stages do not yet have an information store, they are uniquely identified and tracked using the respective carbon mold and their position within this carbon mold, which serves as a first information carrier T1 in the method. For this purpose, in the illustrated example of the manufacturing method, the information store of the carbon mold is read and the component carrier identifier stored therein is read. The process parameters used in the melting step, such as for example an identifier of the furnace, time of carrying out, temperature, duration, position of the carbon mold in the furnace and/or operator of the furnace are then assigned to all of the headers or their pre-stages received in the respective carbon mold.

[0154] Following the melting in step S2, the components are removed from their previous component carriers and repackaged for transportation to the next manufacturing step. For this purpose, the components, here the headers, are singulated/separated, and, in step S3, they are put into a transport container for further transportation to the next manufacturing step. The transport container, as new component carrier, is likewise provided with an information carrier in the present example, and serves as a second information carrier T2. The information store again in particular contains an individual component carrier identifier of the transport container. The data that were applied to the carbon mold or the like may additionally be stored in the information store itself or in an associated database. The information store of the transport container may in this case be configured for example in the form of a label with an optically readable marker, an RFID tag or the like. Information relating to the respective igniters may in each case be represented by a dataset in a database and be linked with the respective ID code of the transport container. The data such as separation time, separation team, position of the header in the carbon mold, state parameters of the carbon mold, in particular its oxidation level, identifier of the header or the like may then for example likewise be stored in the database in the respective datasets of the respective headers.

[0155] The component or its pre-stage may be tracked even following the repackaging using the component carrier identifier and an indication about which component is located at which position in the component carrier. However, provision is optionally made to provide the headers or their pre-stages with an individual information store following the melting step S2 and before the singulation and repackaging according to step S3. In this example, the information store of the igniters is configured as an optically readable marker in the form of a data matrix code that codes an individual identifier of the corresponding header.

[0156] The marking of the headers for the application of the information store designed as a data matrix code takes place in particular through laser etching, optionally directly following the melting process, since the base bodies or headers of the igniters are in this case singulated and aligned in the carbon mold. The optically readable marker with the individual ID code or the unique identifier on the respective header is in this case resistant to chemicals in the subsequent machining steps and has a specific surface area of for example 1.5 mm×5 mm, optionally 0.8 mm×3 mm.

[0157] Using the transport container as carrier for the components, which is itself inscribed and serves as second information carrier T2 and thus enables identification, the singulated headers are then transported further and then pickled in a further step S4 and gold-plated in a further step S5. The individual components do already have an individual information store that allows unique identification. Reading in a single information store of the transport container before carrying out the next step S4 is however optional here, since in this case only a single information store has to be read in order, for the step carried out, here step S4, to assign relevant information to all of the components received in the transport container at once.

[0158] During the cleaning in step S4, use is made of drums whose respective number while carrying out this production step serves as identification or information carrier for the machined components (reference sign T3) and is noted during the further processing. Corresponding parameters of the process step “cleaning” may likewise be noted, for example start and end time of the cleaning, cleaning line, cleaning drum, installation operator and installation parameters. During the gold plating in step S5, corresponding parameters of the process step “gold plating” may likewise be noted, that is to say stored appropriately in the database in the dataset of the igniter, for example start and end time of the gold plating, gold-plating line, installation operator and installation parameters. In this case, an inscribed transport container is again used for transportation between the corresponding pickling and gold-plating apparatus as fourth information carrier T4. During step S5, the ID code applied to the respective header serves as fifth information carrier T5.

[0159] Following step S5—gold plating—the components—here the gold-plated headers—are then transported on for grinding by way of a transport container. In this case, the transport container is again identified individually and serves as sixth information carrier T6 and this identification may then again be allocated to the datasets of the respective headers in a database based on the ID code of the respective components.

[0160] In a further optional step S6, the headers are then ground. Newly provided grinding receptacles as component carriers are provided, in a step V2, with an information store that again contains a unique identifier of the respective grinding receptacle. The information store is again configured for example as an optically readable marker in the form of a data matrix code. Before using a new or reused grinding receptacle for the grinding step S6, the identifier thereof is read by reading the information store. The flow of the grinding receptacles is identified in the flowchart of FIG. 1 using thin lines provided with arrows.

[0161] As long as the headers or their pre-stages are located in a grinding receptacle, this may serve as information carrier T7, wherein the individual headers are identified via the identifier of the grinding receptacle and their position within the grinding receptacle.

[0162] Data relating to the respective grinding receptacle may then be stored in the database in association with this identifier and also be stored in the database DB in the respective datasets of the headers that were machined in the respective grinding receptacle. The indications acquired in grinding step S6 in association with a component include for example time of the grinding, grinding machine, grinding receptacle, operator team, installation parameters or the like.

[0163] Following the grinding S6, the ground headers are subjected to an individual inspection in a further step S7, wherein, following the removal of the headers from the grinding receptacle, the information store of the components or headers again serves as eighth information carrier T8. In this inspection, for example, the headers are subjected to a function test, and the time of the inspection, the inspection installation number, the test results of each header, installation operator and installation parameters are established. The quality of the header and/or the dimensional tolerance/dimensioning may furthermore be established. The abovementioned data and parameters may then again be added to the dataset of the respectively inspected header on the basis of its unique identifier or ID code. The headers are then sorted (step S8) and subjected to a final inspection (step S9). In this case, as an alternative to the inspection in step S7 or in addition, the quality of the header and/or the dimensional tolerance/dimensioning may be established and added, in addition to further data such as time of the final inspection and inspector, to the dataset of the respectively inspected header on the basis of its ID code. The commissioning may optionally be performed on the basis of client specifications. Packaging and dispatch to a further processor then take place in a further step S10.

[0164] From mounting to dispatching of the headers, high and adjustable transparency of the manufacturing process of each individual header is thus possible. Corresponding data are thus stored for each header individually in the database and available for optimizing processes, analyses, establishing causes of production faults or the like. In particular when analysing the data of the carbon molds and/or the grinding receptacles, the appearance of wear is able to be identified early, such that the corresponding receptacles and molds are able to be exchanged in a timely manner, thereby reducing the rejection rate. In addition to this, correlations in the stored information may be identified, for example using neural networks or the like, and the production may thus be improved or optimized by adjusting material and/or process parameters.

[0165] FIG. 2 shows steps of a method for the further processing of components according to one embodiment of the present invention using the example of the further processing of headers of igniters for airbags.

[0166] In detail, the example of FIG. 2 shows method steps that are performed by a further processor as client of the manufacturer of the igniters upon receipt of the igniters.

[0167] In a first step K1, a receiving inspection is performed. This involves scanning a control group of headers in order to read the data matrix codes applied thereto and acquiring the individual identifiers or ID codes of the headers. The individual headers are also surveyed. Following this, in a further step D1, a new dataset is generated by the further processor, containing data about the dimensional tolerance/dimensioning of the headers of the control group. Based on the individual ID codes of the headers, the further processor requests corresponding data of the headers from the database DB of the manufacturer of the components. Based on these data, the further processor then performs a comparison in a step K2: It in this case compares its measurement results obtained in step K1 with those from the database DB of the manufacturer of the headers.

[0168] The further processor then has two options: The further processor may, on the one hand, in a step K3, decide that the dimensional tolerance meets its requirements on the basis of the comparison performed in step K2. In a further step K4, it then performs the further processing of all of the obtained headers. Beforehand, the further processor, based on the individual ID codes of all of the obtained headers, queries corresponding data of the igniters from the database DB of the manufacturer (step D4). The obtained data from the manufacturer are then used by the further processor to control its further processing.

[0169] As an alternative or in addition, the further processor may, on the other hand, based on the comparison in step K2, determine an individual correction factor for each header or an averaged correction factor for a group of headers or all of the headers in a step K5. For this purpose, the further processor generates a respective new dataset (step D2) that contains the corresponding deviations or the respective correction factor in general or individually for each header. In a further step K6, it then performs the further processing of all of the obtained headers taking into consideration the respective or general correction factor. Beforehand, the further processor, based on the individual ID codes of all of the obtained headers, queries corresponding data of the headers from the database DB of the manufacturer (step D3). The obtained data from the manufacturer are then used by the further processor, together with its own obtained datasets from steps D1 and D2, to control its further processing.

[0170] The further processor may furthermore use the identifiers of the components to track these components in the obtained units. For this purpose, for example, a new dataset relating to each individual unit may be generated, into which the data acquired about this component from the manufacturer of the components are copied. For unique identification of the datasets, the unit may in turn be provided with a unique identifier or, if the information store arranged on the component is still accessible and readable following the further processing, an identifier present in the information store of the component may be reused.

[0171] The further processor may thereby, in this example, precisely track which igniter was installed in which unit and which properties the installed igniter has. In the event of a fault with a unit, the entire production chain may thus be traced back to the pre-products of the component installed in the unit. This makes it possible in particular, by evaluating the information stored in the database, to identify further components and accordingly the produced units that may possibly likewise be impacted by a quality problem, without having to discard all of the components or produced units of a batch from the outset.

[0172] FIG. 3 schematically shows the optimization of a method for manufacturing components using component-specific information according to one embodiment of the present invention using the example of components for use in passenger restraint systems or the like.

[0173] In a first step A1, material data of the pre-stages or materials provided for the manufacture of the components are ascertained.

[0174] In a further step A2, at least one manufacturing process parameter for a manufacturing process for manufacturing the components is ascertained.

[0175] In a further step A3, the components are manufactured based on a manufacturing process having the ascertained process parameters.

[0176] In a further step A4, an individual identification feature is provided for each component in the form of a unique identifier.

[0177] In a further step A5, an information store is arranged on each of the manufactured components, wherein the provided identification feature is stored in the information store.

[0178] In a further step A6, the component-specific material data and the manufacturing process parameters are stored in a database of a computer apparatus, wherein the identification feature identifies the corresponding dataset in the database.

[0179] In a further step A7, a state of at least one of the manufactured components is ascertained, wherein the component is identified via the identification feature, and the result of the ascertainment is stored in the database in association with this component.

[0180] In a further step A8, the ascertained state of the component is compared with predefined setpoint values. In this case, components that exceed limit values or fall below limit values are ascertained.

[0181] In step A9, from the database for the ascertained components that exceed limit values or fall below limit values, the information assigned thereto is retrieved from the database and analyzed. In this case, common causes for the deviations from the predefined setpoint values are identified and the results are fed back to the method as feedback, for example in the form of changed parameters or an instruction to exchange a tool or a component carrier, in order to optimize the manufacture of the components.

[0182] FIG. 4 schematically shows the provision of information in a method for the further processing of a plurality of components.

[0183] In a first step B1, a number of components are combined to form a group.

[0184] In a further step B2, a respective component of the group is identified based on its individual identification feature, which is read for example from an information store of the component.

[0185] In a further step B3, each identified component of the group is measured at least with regard to an individual piece of state inspection information.

[0186] In a further step B4, at least one of the individual pieces of state inspection information for the respective component is requested from the database of the manufacturer of the component.

[0187] In a further step B5, at least one of the individual pieces of state inspection information for the respective component is received.

[0188] In a further step B6, deviations between at least the measured pieces of state inspection information and the received pieces of state inspection information are ascertained.

[0189] In a further step B7, one or more correction parameters are ascertained individually for each component on the basis of the ascertained deviations and, in a further step B8, the respective component is processed further without or with at least partial consideration to the ascertained correction parameters.

[0190] FIGS. 5a, 5b and 5c each show one example of a component with an information store according to the present invention.

[0191] In the three illustrated exemplary embodiments, the component 1 in each case includes a base body 10 in which an electrical feedthrough 20 is arranged. The electrical feedthrough 20 is arranged in a through-opening in the base body 10 and has a first metal pin 24 that is held with an electrically insulating material 22. In the illustrated examples, a second metal pin 40 is furthermore electrically connected to the base body 10. The first metal pin 24 serves, in a unit that contains the component 1, for example as signal connection, and the second metal pin 40 serves for example as ground connection.

[0192] According to the present invention, the components 1, illustrated by way of example, each have an information store in the form of an optically readable marker 30.

[0193] In the first exemplary embodiment of FIG. 5a, the optically readable marker 30 is designed as a matrix code and arranged on the base body 10 such that the first metal pin 24, the second metal pin 40 and the optically readable marker 30 form an angle.

[0194] In the second exemplary embodiment of FIG. 5b and the third exemplary embodiment of FIG. 5c, the first metal pin 24, the second metal pin 40 and the optically readable marker 30 are arranged in a line. In the second exemplary embodiment, the optically readable marker 30 is in this case designed as a barcode and, in the third exemplary embodiment, the optically readable marker 30 is configured as an alphanumeric code that is machine-readable, for example by way of optical character recognition.

[0195] At least one of the embodiments of the present invention has at least one of the following advantages:

[0196] Assigning essential parameters of the respective component already before manufacture thereof.

[0197] Individual storage of the essential parameters in a database based on the respective identifier.

[0198] Simple provision of a multiplicity of parameters relevant to the manufacture, production and further processing of the component.

[0199] Simple, faster and more efficient troubleshooting in the production chain in the case of components identified as defective.

[0200] Close monitoring of production.

[0201] Faster identification and rejection of faulty components, possibly even before dispatching to clients or further processors.

[0202] Reduced rejection rate during production.

[0203] Higher overall quality of the components.

[0204] Provision of selected data individually for each procured component for further processors or clients, such that their receiving inspection is able to be entirely or at least partially dispensed with, which saves time and costs for clients.

[0205] Although the present invention has been described with reference to optional exemplary embodiments, it is not restricted thereto, but rather may be modified in many ways.

LIST OF REFERENCE SIGNS

[0206]

TABLE-US-00001 DB Database A1-A9 Method steps B1-B8 Method steps D1-D4 Dataset method steps K1-K6 Client process steps  S1-S10 Manufacturing method steps T1-T8 Information V1, V2 Registration steps  1 Component 10 Base body 20 Electrical feedthrough 22 Insulating material 24 First metal pin 30 Optically readable marker 40 Second metal pin

[0207] While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.