EP0767297A1 - Process for assembling and welding resp. completing exhaust systems for motor vehicles - Google Patents

Process for assembling and welding resp. completing exhaust systems for motor vehicles Download PDF

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Publication number
EP0767297A1
EP0767297A1 EP96115447A EP96115447A EP0767297A1 EP 0767297 A1 EP0767297 A1 EP 0767297A1 EP 96115447 A EP96115447 A EP 96115447A EP 96115447 A EP96115447 A EP 96115447A EP 0767297 A1 EP0767297 A1 EP 0767297A1
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EP
European Patent Office
Prior art keywords
exhaust system
welding
exhaust
components
plausibility check
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EP96115447A
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German (de)
French (fr)
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EP0767297B1 (en
EP0767297B2 (en
Inventor
Rolf Geisel
Franz Ramusch
Thomas E. Wurster
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Friedrich Boysen GmbH and Co KG
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Friedrich Boysen GmbH and Co KG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25B—TOOLS OR BENCH DEVICES NOT OTHERWISE PROVIDED FOR, FOR FASTENING, CONNECTING, DISENGAGING OR HOLDING
    • B25B11/00—Work holders not covered by any preceding group in the subclass, e.g. magnetic work holders, vacuum work holders
    • B25B11/02—Assembly jigs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/008—Mounting or arrangement of exhaust sensors in or on exhaust apparatus
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/18—Construction facilitating manufacture, assembly, or disassembly
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/18—Construction facilitating manufacture, assembly, or disassembly
    • F01N13/1805—Fixing exhaust manifolds, exhaust pipes or pipe sections to each other, to engine or to vehicle body
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2260/00—Exhaust treating devices having provisions not otherwise provided for
    • F01N2260/24—Exhaust treating devices having provisions not otherwise provided for for identifying exhaust parts or devices, e.g. by labels, stickers or directly printing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
    • F01N2450/22—Methods or apparatus for fitting, inserting or repairing different elements by welding or brazing

Definitions

  • the invention relates to a method for assembling and welding or completing exhaust systems for motor vehicles from several prefabricated components such as manifolds, pre-pipes, catalysts, middle and rear silencers, intermediate pipes and the like.
  • the object of the invention is to provide a method with which it is possible to assemble and assemble differently designed exhaust systems for motor vehicles in a simple manner from prefabricated components in a short time, and which is also particularly suitable for automation.
  • This object is essentially achieved in that, depending on the particular embodiment of the exhaust system required, the individual components are positioned on a particularly adjustable support and fixation system, that the component arrangement formed in each case is subjected to a plausibility check that, if necessary, adjacent components are brought closer together a welding takes place to predeterminable subunits, and that at least a leakage test is then carried out on the subunit containing the catalytic converter and possibly the manifold, then after the subunits have been moved together in the correct position, the remaining interfaces are welded and then the exhaust system from the carrier and fixing system is extended.
  • the method according to the invention is comparatively simple and time-saving.
  • the method is also suitable for automation since, due to the defined positions of the components during assembly, the interfaces between the components at which welding is to be carried out are precisely determined, so that the welding processes can be carried out without difficulty can be carried out by means of a welding robot and the plausibility check and the tightness check of the subunit containing the catalyst can also be carried out automatically without any problems.
  • control steps during assembly ensure that the finished exhaust systems can be attached to the vehicles for which they are intended without difficulty and also work properly.
  • the individual components are automatically gripped, for example by a programmable robot system, from appropriate magazines and positioned and fixed on the carrier and fixing system.
  • This exhaust system includes, arranged one behind the other in the exhaust gas flow of an engine, a catalytic converter 2 that can be connected to an engine through a front pipe 1, a central silencer 4 connected to the catalytic converter 2 through a first intermediate pipe 3, and a rear silencer 6 connected to the central silencer 4 through a second intermediate pipe 5. Furthermore, the exhaust system comprises a holder 7 for fixing the exhaust system to a vehicle.
  • the exhaust system is assembled by an assembly station.
  • This includes a support and fixation system 8 with a fixed bed 9 and a slide 10 that is adjustable relative to the fixed bed 9 in the direction of arrow A in FIG. 2b.
  • Adjustable receptacles are attached to the bed 9 and the sled 10 in order to fasten the components of an exhaust system to be assembled to the bed 9 and the sled 10.
  • adjustable inductive or capacitive sensors or displacement transducers are provided on the carrier and fixing system 8 for checking the position and position accuracy of the components held on the carrier and fixing system.
  • the assembly station is a robot system in order to remove the individual components of an exhaust system from corresponding magazines and to position them on the carrier and fixing system 8. Furthermore, automatic welding machines or robots are provided for welding the components held on the carrier and fixing system 8.
  • a programmable control device is provided, by means of which the robot system, the slide 10 and the receptacles of the carrier and fixing system 8, the sensors and the welding machines are positioned and actuated in accordance with a required exhaust system.
  • the various exhaust systems are encoded as barcode identifiers and can be read in with a barcode reader of the control device.
  • the carriage 10 the receptacles and the sensors are first set up in relation to the carrier and fixing system 8. Then the individual components belonging to the exhaust system are removed by the robot system from appropriate magazines and in the appropriate order on the carrier and Fixing system 8 positioned where they are clamped by the recordings.
  • the front pipe 1 and the catalytic converter 2 are positioned and fixed on the movable carriage 10 and the other individual components of the exhaust system on the fixed bed 9.
  • the component arrangement thus formed is then subjected to a plausibility check in which the sensors use the dimensions of the components that are relevant for mounting on a vehicle to check whether the correct components are used and whether they are correctly positioned.
  • control device If errors are found here, the control device generates a corresponding error signal and the method is interrupted.
  • the front pipe 1 is welded to the catalytic converter 2 and the first intermediate pipe 3 to form a first subunit, and the center silencer 4, the second intermediate pipe 5 and the rear silencer 6 as a second subunit by the welding automats or robots .
  • the holder 7 is welded to the first intermediate pipe 3 to fix the exhaust system to a vehicle (FIG. 2a).
  • the sub-unit positioned on the slide 10 and consisting of catalytic converter 2, front pipe 1 and first intermediate pipe 5 is subjected to a leak test, which is carried out by a differential pressure measurement between the motor-side connecting flanges of the front pipes 1 and the outlet of the catalytic converter 2.
  • the positioning and operation of the test equipment used for this 11, which is adjustable in the direction of arrows B and C relative to the carrier and fixation system 8, is also controlled by the control device.
  • testing device 11 is moved away from the carriage 10 again after the testing process and the subunits positioned on the carriage 10 and the bed 9 are moved in the correct position from the position shown in FIG. 2b to the position shown in FIG. 2c by moving the carriage 10 moved together and welded together.
  • FIG. 3 shows a second embodiment of an exhaust system.
  • This exhaust system differs from the exhaust system shown in FIG. 1 only in that the exhaust pipe 1 is preceded by a manifold 12 which, as shown in FIGS. 4a to 4c, assembles the exhaust system with the exhaust pipe 1 and the catalytic converter 2 on the movable carriage 10 attached and welded to a sub-unit and subjected to the leak test.

Abstract

A procedure for assembling and welding a complete exhaust system for a car out of prefabricated components e.g. pipe bends, silencers, catalyser, intermediate pipes, etc has the components positioned according to the particular layout for the car and then a plausibility test is carried out. Then welding of certain components takes place. Next comes a test for the seals in the unit containing the catalyser and the pipe bends. Finally the remaining units are all welded together and the complete system passes out to the next stage. The individual components are selected from a store using a programmable robot system with bar codes to recognise them.

Description

Die Erfindung betrifft ein Verfahren zum Zusammenbau und Verschweißen bzw. Komplettieren von Abgassystemen für Kraftfahrzeuge aus mehreren vorgefertigten Komponenten wie Krümmern, Vorrohren, Katalysatoren, Mittel- und Nachschalldämpfern, Zwischenrohren und dergleichen.The invention relates to a method for assembling and welding or completing exhaust systems for motor vehicles from several prefabricated components such as manifolds, pre-pipes, catalysts, middle and rear silencers, intermediate pipes and the like.

Bei den Automobilkonzernen geht die Tendenz in jüngster Zeit dahin, die Montage von Modulen für Kraftfahrzeuge weitestgehend auszulagern und sich von Zulieferfirmen bereits fertig montierte Baueinheiten eines Fahrzeugs liefern zu lassen, so daß im Montagewerk nur noch die Endmontage vorgenommen zu werden braucht.In the automotive industry, there has recently been a tendency to outsource the assembly of modules for motor vehicles to the greatest possible extent and to have the pre-assembled components of a vehicle delivered by subcontractors, so that only the final assembly needs to be carried out in the assembly plant.

Insbesondere lassen sich die Automobilfirmen inzwischen komplett zusammengebaute Abgassysteme in die Montagewerke liefern, wobei die Vorlaufzeiten oftmals nur wenige Stunden betragen. Dies ist insofern problematisch, als Abgassysteme für Kraftfahrzeuge zwar in der Regel einen einheitlichen Grundaufbau besitzen, sie sich jedoch insbesondere in ihren Abmessungen und ihrer Form in Abhängigkeit vom Fahrzeug- und Motortyp stark unterscheiden können, so daß von den Zulieferfirmen zahlreiche Ausführungsvarianten von Abgassystemen bereitgestellt werden müssen.In particular, the automobile companies can now have completely assembled exhaust systems delivered to the assembly plants, with lead times often only being a few hours. This is problematic in that exhaust systems for motor vehicles generally have a uniform basic structure, but their dimensions and shape can differ greatly depending on the type of vehicle and engine, so that the suppliers provide numerous versions of exhaust systems have to.

Wenn auf eine kostenintensive Lagerhaltung beim Automobilhersteller verzichtet werden soll, müssen die Zulieferfirmen flexibel genug sein, um innerhalb von kurzer Zeit unterschiedliche Abgassysteme zusammenzubauen.If cost-intensive warehousing at the automobile manufacturer is to be avoided, the supplier companies must be flexible enough to assemble different exhaust systems within a short period of time.

Aufgabe der Erfindung ist es, ein Verfahren anzugeben, mit dem es möglich ist, in kurzer Zeit nacheinander unterschiedlich ausgebildete Abgassysteme für Kraftfahrzeuge auf einfache Weise aus vorgefertigten Komponenten zusammenzustellen und zusammenzubauen, und das insbesondere auch für eine Automatisierung geeignet ist.The object of the invention is to provide a method with which it is possible to assemble and assemble differently designed exhaust systems for motor vehicles in a simple manner from prefabricated components in a short time, and which is also particularly suitable for automation.

Diese Aufgabe ist im wesentlichen dadurch gelöst, daß in Abhängigkeit von der jeweils geforderten Ausführungsform des Abgassystems die einzelnen Komponenten auf einem insbesondere verstellbar ausgebildeten Träger- und Fixierungssystem positioniert werden, daß die jeweils gebildete Komponentenanordnung einer Plausibilitätsprüfung unterzogen wird, daß nach gegebenenfalls gegenseitiger Annäherung benachbarter Komponenten eine Verschweißung zu vorgebbaren Teileinheiten erfolgt, und daß anschließend zumindest eine Dichtheitsüberprüfung der den Katalysator und ggf. den Krümmer enthaltenden Teileinheit durchgeführt wird, dann nach einem lagerichtigen Zusammenfahren der Teileinheiten eine Verschweißung an den verbliebenen Schnittstellen erfolgt und daraufhin das Abgassystem aus dem Träger- und Fixierungssystem ausgefahren wird.This object is essentially achieved in that, depending on the particular embodiment of the exhaust system required, the individual components are positioned on a particularly adjustable support and fixation system, that the component arrangement formed in each case is subjected to a plausibility check that, if necessary, adjacent components are brought closer together a welding takes place to predeterminable subunits, and that at least a leakage test is then carried out on the subunit containing the catalytic converter and possibly the manifold, then after the subunits have been moved together in the correct position, the remaining interfaces are welded and then the exhaust system from the carrier and fixing system is extended.

Dadurch, daß bei dem erfindungsgemäßen Verfahren die einzelnen Komponenten des zu verbauenden Abgassystems während des gesamten Zusammenbaus an dem Träger- und Fixierungssystem fixiert sind, ist das erfindungsgemäße Verfahren vergleichsweise einfach und zeitsparend.Because the individual components of the exhaust system to be installed are fixed to the carrier and fixing system during the entire assembly in the method according to the invention, the method according to the invention is comparatively simple and time-saving.

Insbesondere ist das Verfahren auch für eine Automatisierung geeignet, da aufgrund der definierten Lagen der Komponenten während des Zusammenbaus die Schnittstellen zwischen den Komponenten, an denen geschweißt werden muß, genau bestimmt sind, so daß die Schweißvorgänge ohne Schwierigkeiten mittels eines Schweißroboters durchgeführt werden können und auch die Plausibilitätsprüfung sowie die Dichtheitsüberprüfung der den Katalysator enthaltenden Teileinheit problemlos automatisch erfolgen können.In particular, the method is also suitable for automation since, due to the defined positions of the components during assembly, the interfaces between the components at which welding is to be carried out are precisely determined, so that the welding processes can be carried out without difficulty can be carried out by means of a welding robot and the plausibility check and the tightness check of the subunit containing the catalyst can also be carried out automatically without any problems.

Durch die Kontrollschritte während des Zusammenbaus wird dabei sichergestellt, daß die fertiggestellten Abgassysteme ohne Schwierigkeiten an den Fahrzeugen, für die sie bestimmt sind, befestigt werden können und auch einwandfrei arbeiten.The control steps during assembly ensure that the finished exhaust systems can be attached to the vehicles for which they are intended without difficulty and also work properly.

In vorteilhafter Weise werden die einzelnen Komponenten in Abhängigkeit von dem geforderten Abgassystem automatisch beispielsweise durch ein programmierbares Robotersystem aus entsprechenden Magazinen gegriffen und an dem Träger- und Fixierungssystem positioniert und fixiert.In an advantageous manner, the individual components, depending on the required exhaust system, are automatically gripped, for example by a programmable robot system, from appropriate magazines and positioned and fixed on the carrier and fixing system.

Hinsichtlich vorteilhafter Ausgestaltungen des erfindungsgemäßen Verfahrens wird auf die Unteransprüche sowie auf die nachfolgende Beschreibung eines Ausführungsbeispiels anhand der Zeichnung verwiesen. In der Zeichnung zeigt

Figur 1
die einzelnen vorgefertigten Komponenten einer ersten Ausführungsform eines nach dem erfindungsgemäßen Verfahren zusammenzubauenden Abgassystems für Kraftfahrzeuge,
Figuren 2a bis 2c
die relevanten Arbeitsschritte beim Zusammenbau und Verschweißen des in Figur 1 dargestellten Abgassystems nach dem erfindungsgemäßen Verfahren.
Figur 3
die einzelnen vorgefertigten Komponenten einer zweiten Ausführungsform eines nach dem erfindungsgemäßen Verfahren zusammenzubauenden Abgassystems für Fahrzeuge; und
Figuren 4a bis 4c
die relevanten Arbeitsschritte beim Zusammenbau und Verschweißen des in Figur 3 dargestellten Abgassystems nach dem erfindungsgemäßen Verfahren.
With regard to advantageous embodiments of the method according to the invention, reference is made to the subclaims and to the following description of an exemplary embodiment with reference to the drawing. In the drawing shows
Figure 1
the individual prefabricated components of a first embodiment of an exhaust system for motor vehicles to be assembled using the method according to the invention,
Figures 2a to 2c
the relevant steps in the assembly and welding of the exhaust system shown in Figure 1 according to the inventive method.
Figure 3
the individual prefabricated components of a second embodiment of one according to the invention Exhaust system for vehicles to be assembled; and
Figures 4a to 4c
the relevant steps in the assembly and welding of the exhaust system shown in Figure 3 according to the inventive method.

In Figur 1 sind lediglich beispielhaft die wesentlichen Komponenten einer ersten Ausführungsform eines Abgassystems für Kraftfahrzeuge dargestellt, das nach dem erfindungsgemäßen Verfahren montierbar ist.In Figure 1, the essential components of a first embodiment of an exhaust system for motor vehicles are shown only as an example, which can be assembled by the method according to the invention.

Zu diesem Abgassystem gehören im Abgasstrom eines Motors hintereinanderliegend angeordnet ein mit einem Motor durch ein Vorrohr 1 verbindbarer Katalysator 2, ein mit dem Katalysator 2 durch ein erstes Zwischenrohr 3 verbundener Mittelschalldämpfer 4 und ein mit dem Mittelschalldämpfer 4 durch ein zweites Zwischenrohr 5 verbundener Nachschalldämpfer 6. Des weiteren umfaßt das Abgassystem einen Halter 7 zur Fixierung des Abgassystems an einem Fahrzeug.This exhaust system includes, arranged one behind the other in the exhaust gas flow of an engine, a catalytic converter 2 that can be connected to an engine through a front pipe 1, a central silencer 4 connected to the catalytic converter 2 through a first intermediate pipe 3, and a rear silencer 6 connected to the central silencer 4 through a second intermediate pipe 5. Furthermore, the exhaust system comprises a holder 7 for fixing the exhaust system to a vehicle.

Der Zusammenbau des Abgassystems erfolgt durch eine Montagestation. Zu dieser gehören ein Träger- und Fixierungssystem 8 mit einem feststehenden Bett 9 und einem gegenüber dem feststehenden Bett 9 in Richtung des Pfeils A in Fig. 2b verstellbaren Schlitten 10.The exhaust system is assembled by an assembly station. This includes a support and fixation system 8 with a fixed bed 9 and a slide 10 that is adjustable relative to the fixed bed 9 in the direction of arrow A in FIG. 2b.

An dem Bett 9 und dem Schlitten 10 sind verstellbare Aufnahmen angebracht, um die zusammenzubauenden Komponenten eines Abgassystems an dem Bett 9 und dem Schlitten 10 zu befestigen. Außerdem sind an dem Träger- und Fixierungssystem 8 verstellbare induktive oder kapazitiver Fühler oder Wegaufnehmer zur Überprüfung der Lage- und Positionsgenauigkeit der an dem Träger- und Fixierungssystem gehaltenen Komponenten vorgesehen.Adjustable receptacles are attached to the bed 9 and the sled 10 in order to fasten the components of an exhaust system to be assembled to the bed 9 and the sled 10. In addition, adjustable inductive or capacitive sensors or displacement transducers are provided on the carrier and fixing system 8 for checking the position and position accuracy of the components held on the carrier and fixing system.

Die Montagestation ein Robotersystem, um die einzelnen Komponenten eines Abgassystems aus entsprechenden Magazinen zu entnehmen und auf dem Träger- und Fixierungssystem 8 zu positionieren. Weiterhin sind Schweißautomaten bzw. -roboter zum Verschweißen der an dem Träger- und Fixierungssystem 8 gehaltenen Komponenten vorgesehen.The assembly station is a robot system in order to remove the individual components of an exhaust system from corresponding magazines and to position them on the carrier and fixing system 8. Furthermore, automatic welding machines or robots are provided for welding the components held on the carrier and fixing system 8.

Zur Steuerung der Montagestation ist eine programmierbare Steuerungseinrichtung vorgesehen, durch welche das Robotersystem, der Schlitten 10 und die Aufnahmen des Träger- und Fixierungssystems 8, die Fühler sowie die Schweißautomaten entsprechend einem geforderten Abgassystem positioniert und betätigt werden.To control the assembly station, a programmable control device is provided, by means of which the robot system, the slide 10 and the receptacles of the carrier and fixing system 8, the sensors and the welding machines are positioned and actuated in accordance with a required exhaust system.

Im Betrieb wird von einer Bedienungsperson in die Steuerungseinrichtung eingegeben, welches Abgassystem zusammengebaut werden soll. Zur Vereinfachung der Eingabe sind die verschiedenen Abgassysteme als Barcode-Kennzeichnungen verschlüsselt und können mit einer Barcode-Leseeinheit der Steuerungseinrichtung eingelesen werden.In operation, an operator enters into the control device which exhaust system is to be assembled. To simplify the input, the various exhaust systems are encoded as barcode identifiers and can be read in with a barcode reader of the control device.

In Abhängigkeit von dem ausgewählten Abgassystem werden zunächst der Schlitten 10, die Aufnahmen und die Fühler gegenüber dem Träger- und Fixierungssystem 8 eingerichtet. Dann werden die zu dem Abgassystem gehörenden einzelnen Komponenten von dem Robotersystem aus entsprechenden Magazinen entnommen und in entsprechender Reihenfolge auf dem Träger- und Fixierungssystem 8 positioniert, wo sie durch die Aufnahmen eingespannt werden. Dabei werden das Vorrohr 1 und der Katalysator 2 an dem bewegbaren Schlitten 10 und die weiteren einzelnen Komponenten des Abgassystems auf dem feststehenden Bett 9 positioniert und fixiert.Depending on the selected exhaust system, the carriage 10, the receptacles and the sensors are first set up in relation to the carrier and fixing system 8. Then the individual components belonging to the exhaust system are removed by the robot system from appropriate magazines and in the appropriate order on the carrier and Fixing system 8 positioned where they are clamped by the recordings. The front pipe 1 and the catalytic converter 2 are positioned and fixed on the movable carriage 10 and the other individual components of the exhaust system on the fixed bed 9.

Anschließend wird die so gebildete Komponentenanordnung einer Plausibilitätsprüfung unterzogen, bei der durch die Fühler anhand der für die Montage an einem Fahrzeug relevanten Maße der Komponenten überprüft wird, ob die richtigen Komponenten verwendet werden und diese korrekt positioniert sind.The component arrangement thus formed is then subjected to a plausibility check in which the sensors use the dimensions of the components that are relevant for mounting on a vehicle to check whether the correct components are used and whether they are correctly positioned.

Falls hierbei Fehler festgestellt werden, wird von der Steuerungseinrichtung ein entsprechendes Fehlersignal erzeugt und das Verfahren unterbrochen.If errors are found here, the control device generates a corresponding error signal and the method is interrupted.

Wenn jedoch keine Fehler festgestellt werden, wird das Vorrohr 1 mit dem Katalysator 2 und dem ersten Zwischenrohr 3 zur Bildung einer ersten Teileinheit sowie der Mittelschalldämpfer 4, das zweite Zwischenrohr 5 und der Nachschalldämpfer 6 als eine zweite Teileinheit durch die Schweißautomaten bzw. -roboter verschweißt. Außerdem wird an dem ersten Zwischenrohr 3 der Halter 7 zur Fixierung des Abgassystems an einem Fahrzeug angeschweißt (Fig. 2a).However, if no errors are found, the front pipe 1 is welded to the catalytic converter 2 and the first intermediate pipe 3 to form a first subunit, and the center silencer 4, the second intermediate pipe 5 and the rear silencer 6 as a second subunit by the welding automats or robots . In addition, the holder 7 is welded to the first intermediate pipe 3 to fix the exhaust system to a vehicle (FIG. 2a).

Nach Beendigung dieses Schweißvorgangs wird die an dem Schlitten 10 positionierte Teileinheit bestehend aus Katalysator 2, Vorrohr 1 und erstem Zwischenrohr 5 einer Dichtheitsüberprüfung unterzogen, die durch eine Differenzdruckmessung zwischen den motorseitigen Anschlußflanschen der Vorrohre 1 und dem Auslaß des Katalysators 2 erfolgt. Die Positionierung und Betätigung der hierfür verwendeten Prüfeinrichtung 11, die gegenüber dem Träger- und Fixierungssystem 8 in Richtung der Pfeile B und C verstellbar ist, wird ebenfalls durch die Steuerungseinrichtung gesteuert.After completion of this welding process, the sub-unit positioned on the slide 10 and consisting of catalytic converter 2, front pipe 1 and first intermediate pipe 5 is subjected to a leak test, which is carried out by a differential pressure measurement between the motor-side connecting flanges of the front pipes 1 and the outlet of the catalytic converter 2. The positioning and operation of the test equipment used for this 11, which is adjustable in the direction of arrows B and C relative to the carrier and fixation system 8, is also controlled by the control device.

Wenn bei dem Prüfvorgang festgestellt wird, daß die den Katalysator 2 umfassende Teileinheit undicht ist, wird von der Steuerungseinrichtung ein Fehlersignal erzeugt und das Verfahren unterbrochen.If it is determined during the test process that the subunit comprising the catalytic converter 2 is leaking, an error signal is generated by the control device and the process is interrupted.

Ansonsten wird die Prüfeinrichtung 11 nach dem Prüfvorgang wieder von dem Schlitten 10 weggefahren und die an dem Schlitten 10 und dem Bett 9 positionierten Teileinheiten werden durch eine Verstellung des Schlittens 10 lagerichtig aus der in Fig. 2b gezeigten Position in die in Fig. 2c gezeigte Position zusammengefahren und miteinander verschweißt.Otherwise, the testing device 11 is moved away from the carriage 10 again after the testing process and the subunits positioned on the carriage 10 and the bed 9 are moved in the correct position from the position shown in FIG. 2b to the position shown in FIG. 2c by moving the carriage 10 moved together and welded together.

Nachdem noch gegebenenfalls zusätzliche Bauteile wie Sonden und Kleinteile an dem Abgassystem angebracht worden sind, wird dieses durch beispielsweise Roboter oder Bandförderer aus der Montagestation ausgefahren. Alternativ können die zusätzlichen Bauteile und Kleinteile auch nach dem Ausfahren der Montagestation an dem Abgassystem angebracht werden.After additional components such as probes and small parts have been attached to the exhaust system, this is moved out of the assembly station by, for example, robots or belt conveyors. Alternatively, the additional components and small parts can also be attached to the exhaust system after the assembly station has been extended.

In Figur 3 ist eine zweite Ausführungsform eines Abgassystems dargestellt. Dieses Abgassystem unterscheidet sich von dem in Figur 1 dargestellten Abgassystem nur dadurch, daß dem Vorrohr 1 ein Krümmer 12 vorgeschaltet ist, der, wie die Figuren 4a bis 4c zeigen, beim Zusammenbau des Abgassystems mit dem Vorrohr 1 und dem Katalysator 2 an dem bewegbaren Schlitten 10 angebracht und zu einer Teileinheit verschweißt und der Dichtheitsüberprüfung unterzogen wird.FIG. 3 shows a second embodiment of an exhaust system. This exhaust system differs from the exhaust system shown in FIG. 1 only in that the exhaust pipe 1 is preceded by a manifold 12 which, as shown in FIGS. 4a to 4c, assembles the exhaust system with the exhaust pipe 1 and the catalytic converter 2 on the movable carriage 10 attached and welded to a sub-unit and subjected to the leak test.

Mit dem erfindungsgemäßen Verfahren lassen sich unterschiedliche Abgassysteme nacheinander vollautomatisch zusammenbauen. Dabei ist die gleichbleibende Positionierung der einzelnen Komponenten an dem Bett 9 und an dem Schlitten 10 von besonderer Bedeutung, da durch diese erreicht wird, daß die Schweiß- und Prüfstellen genau festliegen. Durch die vorgesehenen Plausibilitäts- und Dichtheitsüberprüfungen wird dabei sichergestellt, daß die zusammengebauten Abgassysteme ohne Schwierigkeiten an den Fahrzeugen, für die sie bestimmt sind, montiert werden können und funktionstüchtig sind.With the method according to the invention, different exhaust systems can be assembled fully automatically one after the other. The constant positioning of the individual components on the bed 9 and on the slide 10 is of particular importance, since this ensures that the welding and test points are precisely fixed. The envisaged plausibility and tightness checks ensure that the assembled exhaust systems can be easily fitted to the vehicles for which they are intended and are functional.

Claims (11)

Verfahren zum Zusammenbau und Verschweißen bzw. Komplettieren von Abgassystemen für Kraftfahrzeuge aus mehreren vorgefertigten Komponenten wie Krümmern, Vorrohren, Katalysatoren, Mittel- und Nachschalldämpfern, Zwischenrohren und dergleichen,
dadurch gekennzeichnet, daß
in Abhängigkeit von der jeweils geforderten Ausführungsform des Abgassystems die einzelnen Komponenten auf einem insbesondere verstellbar ausgebildeten Träger- und Fixierungssystem positioniert werden,
daß die jeweils gebildete Komponentenzusammenstellung einer Plausibilitätsprüfung unterzogen wird,
daß nach gegebenenfalls gegenseitiger Annäherung benachbarter Komponenten eine Verschweißung zu vorgebbaren Teileinheiten erfolgt, und
daß anschließend zumindest eine Dichtheitsüberprüfung der den Katalysator und ggf. den Krümmer enthaltenden Teileinheit durchgeführt wird, dann nach einem lagerichtigen Zusammenfahren der Teileinheiten eine Verschweißung an den verbliebenen Schnittstellen erfolgt und daraufhin das Abgassystem aus dem Träger- und Fixierungssystem ausgefahren wird.Process for assembling and welding or completing exhaust systems for motor vehicles from several prefabricated components such as manifolds, pre-pipes, catalytic converters, middle and rear silencers, intermediate pipes and the like,
characterized in that
depending on the particular embodiment of the exhaust system required, the individual components are positioned on a particularly adjustable support and fixing system,
that the component composition formed in each case is subjected to a plausibility check,
that after possible mutual approximation of adjacent components, welding to predetermined sub-units takes place, and
that at least a leak test is then carried out on the subunit containing the catalytic converter and possibly the manifold, then after the subunits have been moved together in the correct position, the remaining interfaces are welded and the exhaust system is then moved out of the carrier and fixing system. Verfahren nach Anspruch 1,
dadurch gekennzeichnet, daß
die einzelnen Komponenten in Abhängigkeit von dem ausgewählten und zu verbauenden Abgassystem automatisch, insbesondere durch ein programmierbares Robotersystem, aus entsprechenden Magazinen gegriffen und auf dem Träger- und Fixierungssystem positioniert und fixiert werden.Method according to claim 1,
characterized in that
the individual components depending on the selected and to be installed exhaust system automatically, in particular by a programmable robot system, gripped from appropriate magazines and positioned and fixed on the carrier and fixing system. Verfahren nach Anspruch 2,
dadurch gekennzeichnet, daß
die unterschiedlichen Abgassysteme zur automatischen Erkennung durch Barcode-Kennzeichnungen identifizierbar sind.Method according to claim 2,
characterized in that
the different exhaust systems for automatic detection can be identified by barcode labeling. Verfahren nach einem der Ansprüche 1 bis 3,
dadurch gekennzeichnet, daß
das Träger- und Fixierungssystem, insbesondere die Halterungen des Träger- und Fixierungssystems zur Fixierung der einzelnen Komponenten, in Abhängigkeit von der ausgewählten zu verbauenden Variante eines Abgassystems automatisch positioniert und eingestellt wird.Method according to one of claims 1 to 3,
characterized in that
the carrier and fixation system, in particular the brackets of the carrier and fixation system for fixing the individual components, is automatically positioned and adjusted depending on the selected variant of an exhaust system to be installed. Verfahren nach einem der Ansprüch 1 bis 4,
dadurch gekennzeichnet, daß
die Plausibilitätsprüfung anhand der für die Montage des Abgassystems an einem Fahrzeug relevanten Maße durchgeführt wird.Method according to one of claims 1 to 4,
characterized in that
the plausibility check is carried out on the basis of the dimensions relevant for mounting the exhaust system on a vehicle. Verfahren nach einem der Ansprüche 1 bis 5,
dadurch gekennzeichnet, daß
nach der Plausibilitätsprüfung als eine Teileinheit der Katalysator mit den Vorrohren sowie als zweite Teileinheit der hintere Teil des Abgassystems mit Mittel- und Nachschalldämpfern verschweißt werden.Method according to one of claims 1 to 5,
characterized in that
After the plausibility check, the catalytic converter is welded to the front pipes as a sub-unit and the rear part of the exhaust system to the center and rear silencers as a second sub-unit. Verfahren nach einem der Ansprüche 1 bis 6,
dadurch gekennzeichnet, daß
die Dichtheitsüberprüfung der den Katalysator und ggf. den Krümmer enthaltenden Teileinheit durch Differenzdruckmessung erfolgt.Method according to one of claims 1 to 6,
characterized in that
the leak test of the partial unit containing the catalytic converter and possibly the manifold is carried out by differential pressure measurement. Verfahren nach einem der Ansprüche 1 bis 7,
dadurch gekennzeichnet, daß
die Plausibilitätsprüfung durch Fühler, insbesondere durch kapazitive oder induktive Fühler oder Wegaufnehmer erfolgt.Method according to one of claims 1 to 7,
characterized in that
the plausibility check is carried out by sensors, in particular by capacitive or inductive sensors or displacement sensors. Verfahren nach Anspruch 8,
dadurch gekennzeichnet, daß
die Fühler in Abhängigkeit von dem geforderten Abgassystem insbesondere automatisch verstellt werden.A method according to claim 8,
characterized in that
the sensors are in particular automatically adjusted depending on the required exhaust system. Verfahren nach einem der Ansprüche 1 bis 9,
dadurch gekennzeichnet, daß
bei der Plausibilitätsprüfung Fehler signalisiert und das Verfahren unterbrochen wird.Method according to one of claims 1 to 9,
characterized in that
errors are signaled during the plausibility check and the process is interrupted. Verfahren nach einem der Ansprüche 1 bis 10,
dadurch gekennzeichnet, daß
die Ergebnisse der Plausibilitätsprüfung sowie der Dichtheitsüberprüfung der den Katalysator enthaltenden Teileinheit dokumentiert werden.Method according to one of claims 1 to 10,
characterized in that
the results of the plausibility check and the tightness check of the subunit containing the catalyst are documented.
EP96115447A 1995-10-04 1996-09-26 Process for assembling and welding resp. completing exhaust systems for motor vehicles Expired - Lifetime EP0767297B2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19536908 1995-10-04
DE19536908A DE19536908C2 (en) 1995-10-04 1995-10-04 Assembly station for exhaust systems on motor vehicles

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EP0767297A1 true EP0767297A1 (en) 1997-04-09
EP0767297B1 EP0767297B1 (en) 2001-08-29
EP0767297B2 EP0767297B2 (en) 2010-12-15

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CZ (1) CZ291028B6 (en)
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US6691536B2 (en) 2000-06-05 2004-02-17 The Procter & Gamble Company Washing apparatus
EP1787748A2 (en) * 2005-11-18 2007-05-23 Dipl.-Ing. H. Schulz HDS Hydraulic GmbH & Co. KG Auxiliary device for manufacturing hydraulic hoses
WO2009027035A1 (en) * 2007-09-01 2009-03-05 Heinrich Gillet Gmbh Modular system for exhaust gas units of motor vehicles
CN104827271A (en) * 2015-05-21 2015-08-12 吴中区横泾嘉运模具厂 Muting column pushing-in mechanism of simple pneumatic filter pipe assembling device
CN104842319A (en) * 2015-05-08 2015-08-19 广东骏驰科技股份有限公司 Automotive irregular-shaped tube assembling device
CN112441175A (en) * 2019-08-30 2021-03-05 徐州市贾汪区怀强工贸有限公司 Electric motor car head pipe connecting device

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DE102011086465B4 (en) * 2011-11-16 2021-01-07 Eberspächer Exhaust Technology GmbH & Co. KG Method for providing exhaust systems

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Publication number Priority date Publication date Assignee Title
US6691536B2 (en) 2000-06-05 2004-02-17 The Procter & Gamble Company Washing apparatus
EP1787748A2 (en) * 2005-11-18 2007-05-23 Dipl.-Ing. H. Schulz HDS Hydraulic GmbH & Co. KG Auxiliary device for manufacturing hydraulic hoses
EP1787748A3 (en) * 2005-11-18 2007-08-08 Dipl.-Ing. H. Schulz HDS Hydraulic GmbH & Co. KG Auxiliary device for manufacturing hydraulic hoses
WO2009027035A1 (en) * 2007-09-01 2009-03-05 Heinrich Gillet Gmbh Modular system for exhaust gas units of motor vehicles
CN104842319A (en) * 2015-05-08 2015-08-19 广东骏驰科技股份有限公司 Automotive irregular-shaped tube assembling device
CN104842319B (en) * 2015-05-08 2016-05-11 广东骏驰科技股份有限公司 A kind of automobile special pipe assembling device
CN104827271A (en) * 2015-05-21 2015-08-12 吴中区横泾嘉运模具厂 Muting column pushing-in mechanism of simple pneumatic filter pipe assembling device
CN112441175A (en) * 2019-08-30 2021-03-05 徐州市贾汪区怀强工贸有限公司 Electric motor car head pipe connecting device

Also Published As

Publication number Publication date
DE59607576D1 (en) 2001-10-04
DE19536908C2 (en) 2002-02-14
ES2159669T5 (en) 2011-05-04
EP0767297B1 (en) 2001-08-29
DE19536908A1 (en) 1997-04-17
EP0767297B2 (en) 2010-12-15
ES2159669T3 (en) 2001-10-16
CZ291028B6 (en) 2002-12-11
CZ270896A3 (en) 1997-05-14

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