Method and Joining System for Producing a Structural Component, Computer Program Product and Computer-Readable Storage Medium

Abstract

A method for producing a structural component is provided. The structural component is formed by a base element. The method includes providing at least one insert part as part of the base element, and geometrically widening the at least one insert part to form the base element with the layered construction of at least one remaining element section on the at least one insert part by way of wire-based welding.

Claims

1.-12. (canceled)

13. A method for producing a structural component, wherein the structural component is formed by a main body, the method comprising: providing at least one insert part as part of the main body; and geometrically extending the at least one insert part to form the main body by layered construction of at least one balance body portion on the at least one insert part by way of wire-based welding.

14. The method according to claim 13, wherein the at least one insert part is a sheet-metal component, a cast component, or an extruded component.

15. The method according to claim 13, wherein the at least one insert part has a geometrically simple shape.

16. The method according to claim 15, wherein the at least one insert part is configured as a full section or a hollow section.

17. The method according to claim 13, wherein the at least one balance body portion is generated by way of wire arc additive manufacturing (WAAM) or laser direct energy deposition (DED).

18. The method according to claim 13, wherein at least one balance body portion and at least one insert part conjointly represent a load path in the main body.

19. The method according to claim 13, wherein the structural component is a bodywork component of a motor vehicle.

20. The method according to claim 19, wherein the structural component is a vehicle rear, a vehicle side panel or a vehicle front.

21. The method according to claim 13, wherein the structural component is a chassis frame component of a motor vehicle.

22. The method according to claim 21, wherein the structural component is a subframe.

23. A joining system for producing a structural component, wherein the structural component is formed by a main body, the joining system comprising: an automated positioning device which is configured to position at least one insert part in a predefined position; and an automated, wire-based welding device which is configured to geometrically extend the at least one insert part to form the main body by layered construction of at least one balance body portion on the at least one insert part.

24. The joining system according to claim 23, wherein the joining system is configured to carry out a method comprising: providing the at least one insert part as part of the main body; and geometrically extending the at least one insert part to form the main body by the layered construction of the at least one balance body portion on the at least one insert part by way of wire-based welding.

25. A computer product comprising a non-transitory computer-readable medium having stored thereon program code which, when executed on a processor, carries out the method according to claim 13.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 shows an exemplary structural component.

[0026] FIG. 2 shows a schematic method sequence for producing the structural component.

[0027] FIG. 3 shows an exemplary storage medium having a computer program product stored thereon.

DETAILED DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1 shows an exemplary structural component 1 which is able to be produced by the method according to embodiments of the invention. The structural component 1 is a front subframe of a motor vehicle. The structural component 1 contains three insert parts 10, 12 and 14 which are provided in the form of sections. Two balance body portions 20, 22 are integrally molded on the insect parts 10, 12 and 14 by way of wire-based welding, for example by way of WAAM or laser DED. The balance body portions 20, 22 are constructed layer-by-layer from a molten wire material and in the process connected to the insert parts 10, 12 14 in a materially integral manner. The insert parts 10, 12 and 14 and the two balance body portions 20, 22 conjointly form the main body 2 of the structural component.

[0029] FIG. 2 shows an exemplary method sequence for producing a structural component 1A by an exemplary joining system 100. The structural component 1A is a bodywork component, for example. The joining system 100 has an automated positioning device 110 in the form of an industrial robot, and an automated, wire-based welding device 120 having a WAAM welding unit 122 which is disposed on an industrial robot 124 and displaceable by the latter. The positioning device 110 and the welding device 120 are operatively connected to a control apparatus 130 which is specified to control the positioning device 110 and the welding device 120. A corresponding computer program product 40 for carrying out the control commands required for this purpose is installed in the control apparatus 130.

[0030] For carrying out the method, at least one insert part 16 is first provided by the positioning device 110. Subsequently, at least one balance body portion 24 is integrally molded on the insert part 16 by way of the welding device 120. For this purpose, a wire material 126 is molten and constructed layer-by-layer so as to form the balance body portion 24, wherein the latter is connected to the insert part 16 in a materially integral manner. Balance body portion 24 and insert parts 16 conjointly form a main body 2A, the latter forming the structural component 1A.

[0031] Only one insert part 16 and one balance body portion 24 are illustrated in FIG. 2. Nevertheless, the structural component illustrated in FIG. 1, or any other structural component having one or more insert parts and one or a plurality of body portions, can also be produced by the method.

[0032] FIG. 3 shows a computer-readable and non-volatile storage medium 30 having a computer program product 40 stored thereon. The computer program product 40 comprises commands that, when executing the computer program product by a computer, initiate the latter to carry out the method described for producing the structural component by a suitable joining system such as, for example, the joining system 100 from FIG. 2.

LIST OF REFERENCE SIGNS

[0033] 1, 1A Structural component [0034] 2, 2A Main body [0035] 10, 12, 14, 16 Insert parts [0036] 20, 22, 24 Balance body portion [0037] 30 Computer-readable storage medium [0038] 40 Computer program product [0039] 100 Joining system [0040] 110 Positioning device [0041] 120 Welding device [0042] 122 WAAM welding unit [0043] 124 Industrial robot [0044] 126 Wire material [0045] 130 Control apparatus