SPREADING UNIT WITH ADJUSTABLE SHAPER

Abstract

The disclosure relates to a spreading unit having a shaper for spreading viscous material, in particular sealing material, on a component, wherein the shaper has a first shaping contour for shaping the viscous material in the process of the spreading, wherein at least a second shaping contour of the shaper for shaping the viscous material can be brought by means of an actuator, in a direction of spreading, into superimposition with the first shaping contour, so that a shape of the shaper is adjustable during an application process.

Claims

1. A spreading unit having a shaper for spreading viscous material on a component, wherein the shaper has a first shaping contour for shaping the viscous material in the process of the spreading, wherein at least a second shaping contour of the shaper for shaping the viscous material is configured to be brought by an actuator, in a direction of spreading, into superimposition with the first shaping contour, so that a shape of the shaper is adjustable during an application process.

2. The spreading unit according to claim 1, wherein the second shaping contour has a course which substantially corresponds to a cross-section of the component in the region of the spreading.

3. The spreading unit according to claim 1, wherein the second shaping contour comprises at least two contour segments which are separately movable relative to one another, wherein the at least two contour segments are arranged side by side.

4. The spreading unit according to claim 3, wherein one of the separately movable contour segments is movable in a resiliently elastic manner in relation to the other of the contour segments.

5. The spreading unit according to claim 1, wherein the component is a structural component of an aircraft.

6. The spreading unit according to claim 1, wherein the viscous material is applied to a joint weld of the component, wherein the joint weld is configured as a stepped weld or a fillet weld.

7. The spreading unit according to claim 1, wherein the second shaping contour at least partially superimposes the first shaping contour at least at the beginning of a material application, wherein the second shaping contour is moved back during the application of a start region.

8. The spreading unit according to claim 1, wherein the second shaping contour at least predominantly opens up the first shaping contour during a continuous material application, wherein the second shaping contour, during the application of an end region, is brought into superimposition with the first shaping contour.

9. The spreading unit according to claim 1, wherein the spreading unit has a nozzle for the application of the viscous material on the component.

10. The spreading unit according to claim 1, wherein the spreading unit has a sensor for detecting that region of the component that is to be coated.

11. A system for spreading viscous material on a component, wherein the system has a component holder for receiving a component, wherein the system has a spreading unit according to claim 1.

12. A system according to claim 12, wherein the system has a manipulator with the spreading unit as the end effector.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Below, several illustrative embodiments are described, and explained in greater detail with reference to the accompanying drawings, wherein:

[0048] FIG. 1 shows a spreading unit of a first embodiment in lateral and in in frontal view,

[0049] FIG. 2 shows the spreading unit from FIG. 1 in three different positions of shaping contours,

[0050] FIG. 3 shows the spreading unit from FIG. 1 in several method steps for the formation of a start region of a weld,

[0051] FIG. 4 shows the spreading unit from FIG. 1 in several method steps for the formation of an end region of a weld,

[0052] FIG. 5 shows the spreading unit from FIG. 1 in several method steps for the formation of a weld from two layers applied one above the other,

[0053] FIG. 6 shows a spreading unit of a second embodiment,

[0054] FIG. 7 shows a spreading unit of a third embodiment in several method steps for the application of a fillet weld.

DETAILED DESCRIPTION

[0055] FIG. 1 shows a spreading unit 1 having a shaper 2, for spreading viscous material 3 on a component 4.

[0056] The shaper 2 has a first shaping contour 5 and a second shaping contour 6 for shaping the viscous material 3 in the process of the spreading. The viscous material 3 is here constituted by a sealing material, in particular an aircraft sealing compound or a silicone-like sealing material. The component 4 can in particular be an assembly, such as an aircraft structure component and/or a motor vehicle part, in particular a body structure component.

[0057] As can be seen in FIG. 1, for the application of the viscous material 3 on the component the spreading unit 1 can have a nozzle 8. The nozzle 8 can be arranged, in the direction of relative movement of the spreading unit 1 relative to the component 4, before the shaper 2.

[0058] In some embodiments, the nozzle 8 can be arranged at a predefined fixed distance from the shaper 2. A robust spreading process can hereby be ensured since the viscous material 3 can precompact or partially harden in a predefined manner on the path from the nozzle 8 to the shaper 2. In the case of a compressible viscous material 3, the viscous material 3 can hereby stretch and/or slacken prior to the shaping. The distance between the nozzle 8 and the shaper 2 can be maximally 5 cm, further maximally 3 cm, further maximally 1 cm.

[0059] The shaping contours 5, 6 are arranged directly one behind the other in a direction of application or spreading V. The first shaping contour 5 here lies behind the second shaping contour 6 in the direction of spreading V and is arranged at a fixed distance relative to the nozzle 8.

[0060] The second shaping contour 6 is movable relative to the first shaping contour 5 by means of an actuator 7 in the form of a pneumatic cylinder or servo motor. The movement is realized perpendicular to the direction of spreading V towards the component 4 or away from the component 4.

[0061] In the case of the first illustrative embodiment, the second shaping contour 6 comprises, moreover, two contour segments 6a, 6b, which are separately movable relative to one another and are arranged side by side transversely to the direction of spreading V. One of the contour segments 6a is here directly connected to the actuator 7, wherein the other of the contour segments 6b is guided in a separately movable manner on the first contour segment 6a. Via a spring 6c, the second contour segment 6b is biased, so that it is at all times advanced up to a stop on the first contour segment 6a insofar as it does not bear against the component 4 and is hereby moved in relation to the first contour segment 6a out of the stop position.

[0062] Such an arrangement is in particular advantageous in respect of that stepped weld of the component that is shown in the first illustrative embodiment. The second contour segment can here rest on the top edge of the step and completely scrape off the viscous material there while the second contour segment is purposefully adjusted.

[0063] FIG. 2 shows the spreading unit 1 in three different positions of the second shaping contour 6. In the left-hand diagram, the second shaping contour 6 is fully retracted and the cross-sectional shape of the applied viscous material is fully determined by the first shaping contour 5. In the middle diagram, the second shaping contour 6 is partially advanced, so that the second contour portion 6b already rests on the upper edge of the component step and there prevents the material application. The first contour portion 6a permits in the lower region of the component step a further, height-reduced material application. In the right-hand diagram, the second shaping contour 6 is maximally advanced and completely superimposes the first shaping contour 5.

[0064] Furthermore, the spreading unit 1 here has a sensor (not represented) for detecting the region to be coated, such as a joint of the component 4. The sensor is here arranged, in the direction of relative movement, before the nozzle 8 and/or the shaper 2. In the process of the spreading, it here runs ahead of the nozzle 8 and/or the shaper 2. In some embodiments, the sensor is configured as an optical sensor, in particular a line laser. With a line laser, a reliable detection of the relevant joint is enabled.

[0065] Here, the sensor registers a region to be coated of the component 4. A control system analyses the resulting sensor data. In some embodiments, by means of the control system, the shaping contours of the shaper 2 are controlled and/or regulated in dependence on the sensor data. Additionally or alternatively, the control system can control and/or regulate the relative movement between the component 4 and the spreading unit 1 in dependence on the sensor data. By combining the controlling of the relative movement and of the shaping contours, the weld quality can be enhanced. For instance, motional deviations of a manipulator bearing the spreading unit can in this way be compensated by an adjustment of the shaping contour.

[0066] Additionally or alternatively, the control system can control and/or regulate the relative movement between the component 4 and the spreading unit 1 in dependence on the sensor data. That relative movement between component 4 and shaper 2 which is necessary for the spreading can here be generated in different ways. For instance, the spreading unit 1 can be configured as an end effector, for example of an industrial robot, and be moved relative to the component 4. Additionally or alternatively, the component 4 can be moved relative to the shaper 2. For instance, the component 4 can be received in a component holder, which can in turn be moved relative to the shaper 2.

[0067] According to a further embodiment, it can be provided that the control system, in dependence on the sensor data, regulates and/or controls the volume flow and/or mass flow of viscous material through the nozzle 8 onto the region to be coated.

[0068] The disclosure according to the first illustrative embodiment now functions as follows:

[0069] According to the representations in FIG. 3, a start region of the weld can be shaped in a controlled manner by firstly the second shaping contour 6 being maximally advanced and fully covering the first shaping contour 5 (FIG. 3a). Next, a dispensing of the viscous material from the nozzle 8 is commenced and the spreading unit 1 is moved in the direction of spreading V. The second shaping contour 6 is then transported continuously upwards, so that increasingly material is applied with increasing thickness in the lower region of the component step (FIG. 3b). Finally, according to FIG. 3c, the second shaping contour is fully retracted, so that only the first shaping contour determines the cross-section of the applied material. This is a quasi-stationary state, in which an optionally long middle region of the weld is applied.

[0070] According to the representations in FIG. 4, an end region of the weld can be shaped in a controlled manner by firstly the second shaping contour 6 being maximally retracted and the aforementioned middle region of the weld being coated (FIG. 4a). Next, the second shaping contour 6 is transported continuously downwards, so that the cross-section is increasingly limited (FIG. 4b). Finally, according to the right-hand diagram, the second shaping contour is pushed fully against the component 4, so that all material is scraped off (FIG. 4c). Once or shortly before this state is reached, the material flow from the nozzle 8 is expediently halted.

[0071] According to the representations in FIG. 5, a method in which the viscous material 3 is applied in two steps, one above the other, to the same region of the component 4 is explained.

[0072] Here, a first, smaller weld 9 is firstly applied by means of the second shaping contour in order to ensure the filling of a corner of the component step (FIG. 5a). The shape of the first weld is here expediently shaped in the second shaping contour 6, in the present case on the contour segment 6a. According to requirements, the shape of the contour segment 6a in this region can be configured as in the methods in FIG. 3 and FIG. 4, or an appropriate clearance can be provided.

[0073] Below, the spreading unit is then transported back into a starting position and, by means of the first shaping contour 5, a larger, second weld 10 is applied (FIG. 5b). The second weld 10 can in particular fully cover the first weld. Expediently, it is applied in good time before the first weld sets.

[0074] In just such a multi-stage application of the material, a controlled shaping of the start and/or end regions can be provided, moreover, through the relative movement of the shaping contours 5, 6. Accordingly, the methods according to FIG. 3/FIG. 4 on the one hand, and the dual application according to FIG. 5, can be realized in combination.

[0075] FIG. 6 shows a simplified embodiment, in which the second shaping contour 6 is configured in one piece or is not divided into contour segments. The second shaping contour 6 is connected via a guide 11 to the first shaping contour and is movable relative to the latter by means of an actuator (not represented). Even with a simplified arrangement of this kind, all of the above- described application methods, namely the formation of start and end regions or the two-layered application of a weld, are able to be carried out analogously. Only the early bearing contact of the one contour segment against the component is not available.

[0076] FIG. 7 shows a further embodiment, in which the shaping contours 5, 6 are optimized for the application of a fillet weld. Accordingly, the second shaping contour has an acute-angled shape, which, in the advanced state into the fillet weld, can fully engage in a fillet of the component 4.

[0077] Analogously to the above descriptions, in the diagrams of FIG. 7a the configuration of a start region of the weld is represented, whilst in the diagrams of FIG. 7b the configuration of an end region of the weld is represented.

[0078] It should also be pointed out that, here, the first shaping contour 5 and the second shaping contour 6 are of dimensionally stable, here, rigid design, as far as the respective portions which enter into shaping engagement with the viscous material are concerned. These portions can respectively, for instance, be formed of at least one sheet-metal element or at least one elastic, yet dimensionally stable shaping element, in particular wall element.