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DE-102025120501-B3 - Method for controlling a plurality of joining stations arranged in series in a motor vehicle production plant, computer program product and motor vehicle

DE102025120501B3DE 102025120501 B3DE102025120501 B3DE 102025120501B3DE-102025120501-B3

Abstract

A method is described for controlling a plurality of joining stations arranged in series in a motor vehicle production plant and producing at least partially based on joining parameter setpoints, wherein at least one measured value is acquired on a produced or partially produced motor vehicle, which is compared with at least one corresponding setpoint, whereby a deviation of the measured value from the setpoint is determined, wherein if at least one deviation is greater than a permissible tolerance, the joining parameter setpoints of two or more than two joining stations are adjusted depending on the measured value and/or the deviation, wherein a relationship between the at least one measured value and/or the at least one deviation is established by a correlation algorithm, wherein the joining parameter setpoints are adjusted taking into account the correlation algorithm and the correlation algorithm is a kinematic matrix.

Inventors

  • Michael Lutz

Assignees

  • Mercedes-Benz Group AG

Dates

Publication Date
20260513
Application Date
20250526

Claims (9)

  1. Method for controlling a plurality of joining stations (6, 8, 10, 12) arranged in series in a motor vehicle production plant (2), wherein the motor vehicle production plant (2) is configured to successively transport a motor vehicle (4, 4') from one joining station (6, 8, 10, 12) to the next, wherein at least one production step is carried out at each joining station (6, 8, 10, 12), and thereby produce at least partially on the basis of joining parameter setpoints (P11, P12, P13, P22, ..., P44), wherein at least one measured value (M) is recorded on a produced or partially produced motor vehicle (4, 4'), which is compared with at least one corresponding setpoint (S), wherein a deviation (A) of the measured value (M) from the setpoint (S) is determined, wherein if at least one deviation (A) is greater than a permissible tolerance, the Joining parameter setpoints (P11, P12, P13, P22, ..., P44) of two or more than two joining stations (6, 8, 10, 12) are adjusted depending on the measured value (M) and/or the deviation (A), wherein a relationship between the at least one measured value (M) and/or the at least one deviation (A) is established by a correlation algorithm (14.2), wherein the joining parameter setpoints (P11, P12, P13, P22, ..., P44) are adjusted taking into account the correlation algorithm (14.2), characterized in that the correlation algorithm (14.2) is a kinematic matrix (14.2).
  2. Procedure according to Claim 1 , characterized in that at least one measured value is a gap dimension (M).
  3. Procedure according to Claim 1 or 2 , characterized in that the calculation of the kinematic matrix (14.2) is carried out using a recursive least-squares algorithm.
  4. Procedure according to one of the Claims 1 until 3 , characterized in that a filter with P-behavior (14.3) is used to smooth the kinematic matrix (14.2).
  5. Procedure according to one of the Claims 1 until 4 , characterized in that the kinematic matrix (14.2) is not diagonalizable.
  6. Method according to one of the preceding claims, characterized in that the method is carried out continuously.
  7. Method according to one of the preceding claims, characterized in that at least one joining station (6, 8, 10, 12) is aligned at alignment points (4.1) on a body of the motor vehicle (4, 4') using at least one joining parameter setpoint (P11, P12, P13, P22, ..., P44).
  8. Computer program product, with a computer-readable storage medium on which commands are embedded which, when executed by at least one computing unit, cause the at least one computing unit to be configured to execute the method according to one of the preceding claims.
  9. Motor vehicle (4, 4'), manufactured according to the method of one of the Claims 1 until 7 .

Description

The text describes a method for controlling a plurality of joining stations arranged in series in a motor vehicle production plant, a computer program product, and a motor vehicle. Methods for controlling a plurality of joining stations arranged in series in a motor vehicle production plant, computer program products and motor vehicles of the type mentioned above are known in the prior art. The production of car bodies in the automotive industry has been characterized by a high degree of automation for several decades, a key feature of modern production facilities across all manufacturers. Particularly in body-in-white production – the manufacturing of a vehicle's load-bearing structure – fully automated production lines are used extensively. This automation is a crucial prerequisite for the economical production of car bodies, even at locations with high labor costs. This high degree of automation is achieved through the widespread use of industrial robots. These robots enable precise, reproducible movements and contribute significantly to process reliability and cost-effectiveness. For high-volume vehicle models, automakers typically employ fully automated production lines for key joining processes, such as assembling, bolting, welding, riveting, or bonding body components and add-ons. These production lines not only reduce the personnel requirements in series production itself but also contribute to minimizing rework. Rework on car bodies is generally necessary to meet the tight tolerances specified for the final vehicle. These tolerances must be maintained either through manual rework or—preferably—by establishing a stable and repeatable automated manufacturing process. The technical challenge arises particularly from the fact that a motor vehicle consists of several thousand individual parts. Consequently, manufacturing inaccuracies can accumulate along the process chain, potentially leading to non-compliant end products in the worst-case scenario. Therefore, it is essential that all intermediate assemblies within the production chain are manufactured and assembled with high precision. Adaptive control systems, collectively known in the industry as Smart Adaptive Control (SAC), have recently gained importance. SAC refers to control concepts capable of dynamically adjusting process parameters in real time based on sensor feedback and data-driven analysis. Artificial intelligence (AI) methods are increasingly being employed in this context. Such systems are able to detect and compensate for even the smallest process deviations—for example, those resulting from tolerance variations in components, tool wear, or temperature fluctuations. This ensures consistent process quality even under varying production conditions. Currently, these SAC systems operate using one or, at most, two production stations arranged in series. A key feature of SAC systems is their ability for continuous self-optimization. Based on historical and current process data, patterns can be identified, control strategies adapted, and thus greater process robustness achieved. As a result, SAC systems contribute to reducing rework, increasing production quality, and meeting the requirements of networked and flexible manufacturing. From the DE 100 24 763 A1 The invention relates to a method for automatically detecting, checking, and correcting the gap dimension between an add-on part, preferably a vehicle door or a vehicle flap, on a vehicle body in a production line. The add-on part is installed in the designated mounting opening of the vehicle body with a gap to the vehicle body and/or to an adjacent add-on part. The invention further relates to a device for carrying out the method. The gap dimension is determined between the corresponding edges of the add-on part and the adjacent add-on part or the vehicle body. The gap dimension of each gap is checked for deviations from the permissible tolerances and/or for deviations from the other gap dimensions of the add-on part, and the deviations are automatically corrected. The invention further relates to a device for carrying out the method. Furthermore, the WO 2021 / 257 988 A1 A manufacturing system comprises one or more stations, a monitoring platform, and a control module. Each station of one or more systems is configured to perform at least one step in a multi-stage manufacturing process for a component. The monitoring platform is configured to track the progress of the component. The control module is monitored throughout the multi-stage manufacturing process. It is configured to dynamically adjust the processing parameters of each step of the multi-stage manufacturing process to achieve a desired final quality indicator for the component. The DE 10 2007 009 275 A1 This concerns a manufacturing robot system for processing workpieces with machining performed by a manufacturing robot, whereby an automatic inspection of the workpiece is carried out after the machining step has been completed