JP3020180B2 - Method for manufacturing flat plate and method for manufacturing three-dimensional plate using this method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention determines a two-dimensional development shape of a curved surface of a three-dimensional plate material, and determines the determined two-dimensional expansion shape.
The flat plate is manufactured based on the open shape.
The present invention relates to a manufacturing method and a method for manufacturing a three-dimensionally shaped plate using the flat plate manufacturing method.

[0002]

2. Description of the Related Art Recently, in the automobile industry, a three-dimensional glass plate is increasingly used as a windshield or a rear glass because of a need for a wide field of view from a driver together with a novel design.

For example, in the prototype stage of a car, a designer first draws a sketch of a new car, creates a somewhat accurate drawing based on the sketch, converts the contents of the drawing into digital values by a digitizer, and converts the drawing into CAD. Captured by the device. The CAD system monitors the three-dimensional shape of the prototype car using the attached high-definition CRT,
Modify the body shape to determine the optimal body shape.
This optimal body shape is prototyped with clay or the like, and then the subtle changes in appearance are further corrected to determine the final three-dimensional shape of the mass-produced vehicle. Of course, drawing
Revised by the device, the digital value is stored in the CAD device and saved to magnetic tape.
The drawing is output as a formal drawing by an XY plotter having a high resolution of 0.1 mm, for example.

For example, in the manufacturing process of a three-dimensionally shaped windshield, only the windshield portion is extracted from a vehicle body prototyped with clay or the like, and furthermore, for economic reasons or shortening of the startup period from trial production to mass production. For this reason, a ring-shaped wooden mold having a three-dimensional surface (curved surface) obtained by copying only the peripheral region of the windshield and having an open central portion is formed. This wooden mold is used not only for forming a mold but also for inspection after molding.

In order to manufacture a windshield for a mass-produced vehicle, it is essential to first use a two-dimensional glass plate having dimensions obtained by developing a three-dimensional windshield as a raw material. The two-dimensional glass plate is formed into a three-dimensional windshield by a forming device.

Heretofore, in order to obtain a two-dimensional development shape of a three-dimensional glass plate, an operator touches paper on a ring-shaped wooden mold having a three-dimensional surface and takes a copy. Since this wooden mold has a ring shape, a three-dimensional shape corresponding to the center of the glass plate is not formed. Therefore, the operator has to press the two-dimensional paper against the wooden mold while keeping in mind the central bulge.

[0007]

It is difficult for an operator to press two-dimensional paper against a wooden mold while keeping in mind the central bulge. In addition, this manual two-dimensional development of a paper contact has a problem that the two-dimensional paper is forcibly applied to a three-dimensional tree pattern to copy the three-dimensional wooden mold, and thus the dimensional accuracy is poor, that is, there are many errors. Further, the three-dimensional glass plate manufactured by this method may be in a state of being undersized or being oversized, and may not fit into a predetermined frame of the vehicle. If the dimensions are not sufficient, the width of the bonding area with the vehicle body becomes narrow, and a predetermined strength may not be obtained.

[0008] Furthermore, the copying operation by hand takes time, and the two-dimensional development operation, which takes much time, cannot be used as input data in the subsequent automatic control process. Therefore, the input data for obtaining the three-dimensional wooden shape must be input again to the computer system for automatic control.

[0009]

SUMMARY OF THE INVENTION In view of the above problems, the present invention determines a two-dimensional shape of a curved surface of a plate material such as a three-dimensional glass plate by using a computer system.
To manufacture flat materials based on the two-dimensional developed shape
An object of the present invention is to provide a method of manufacturing a flat plate material and a method of manufacturing a three-dimensional plate material using the flat plate material manufacturing method.

Therefore, the present invention described in claim 1 includes: (a) determining a development center point To on a curved surface of a three-dimensional plate material; and (b) making point contact with the curved surface at the development center point To. flat
XZ plane and Y each orthogonal to the plane and orthogonal to each other
Determining the Z plane, determining the n-th set point Tn shape line of (c) above curved surface (where, n is 1, 2, 3, is an integer of ~), (d) each of the n sets It passes through the point Tn and the XZ plane and
XZ and YZn planes that are parallel to the
If, (e) the line of intersection of the XZn surface and the curved surface intersect the Y
Find an intersection that intersects the Z plane, and set this intersection with the n-th setting.
The length Ln on the curved surface between the point Tn and
If, (f) an intersection line where the YZn surface and the curved surface intersect the X
Find an intersection that intersects the Z plane, and set this intersection with the n-th setting.
The length Mn on the curved surface between the point Tn and
And (g) professionally plotting these lengths Ln and Mn on two-dimensional coordinates.
And Tsu bets, that to determine the n-th expansion point Dn, (h) n = 1,2,3 , the (c) ~ For ~ (g)
Repeat steps step, by each <br/> determining a plurality of the expansion point Dn, to obtain the curve A corresponding to the shape line, is carried out with each computer system, based on the curve A Determine the two-dimensional development shape of the curved surface of the three-dimensional plate material , based on this determined two-dimensional development shape
The flat plate is manufactured by manufacturing the flat plate.
It is intended to provide a manufacturing method. It should be noted that the present invention
The flat plate may be a glass plate. Also,
In the present invention, the three-dimensional plate is a glass plate.
You may. Further, the flat plate manufactured according to the present invention described above.
Heat-deforms the plate to produce a three-dimensional plate
Can be built.

[0011]

1 and 2 schematically show a method of developing a three-dimensionally curved plate two-dimensionally. For example, when an automaker is creating a clay model (clay model) of a prototype vehicle, the three-dimensional shape data Px, y, and z of each part of the model are sequentially input to a CAD device, and the shape is converted to a high-resolution color image. The image is displayed by a cathode ray tube and output as a three-view diagram or a three-dimensional diagram by an XY plotter. The three-dimensional shape data is saved on a magnetic tape. Therefore, the manufacturer of the curved plate (in this case, the windshield) 1 extracts a portion corresponding to the windshield 1 of the three-dimensional shape data in the magnetic tape created by the automobile manufacturer and uses the extracted portion in its CAD device. This is convenient because it saves you from having to enter data. Of course, it is possible to read a portion corresponding to the windshield from the three views by a digitizer and input the read portion to the CAD device.

First, a three-dimensional curved surface 2 corresponding to a windshield 1 is provided on a high-definition color cathode ray tube of a CAD apparatus.
Is displayed. Steps 10 to 23 of developing the three-dimensional curved surface 2 into a two-dimensional shape using a CAD device will be described below.

Step 10: As shown in FIG. 1, one of the curved surfaces 2
The point is defined as the development center point To. This deployment center point To
When the curved surface 2 is symmetrical as shown in FIG. 3 and FIG.
The tangent line e is parallel to a straight line d connecting the upper and lower ends b and c of the curve a. Thus, the deployment center point To
Is set, the inclination direction with respect to the tangent line e of the curved surface 2 from the upper end b to the development center point To is always the same direction, and the inclination direction with respect to the tangent line e from the development center point To to the lower end c is always the same. Since it is the direction, the two-dimensional expansion calculation by the computer is simplified. Further, in the case of a side glass or the like having an asymmetric three-dimensional shape, the development center point To is set at substantially the center of the upper, lower, left, and right sides according to an empirical rule.

Step 11: An XZ plane P1 extending in the horizontal direction through the development center point To and a YZ plane P2 extending in the vertical direction through the development center point To are determined. These XZ plane and YZ plane function as reference planes.

In this case, the development center point To is defined as Pxo,
defined as yo and zo. In addition, a first line including the line symmetry curve a and orthogonal to the curved surface 2 at the development center point To
The plane is defined as the YZ plane P2. Furthermore, this curved surface a
A second plane that includes the upper and lower ends b and c and is orthogonal to the YZ plane P2 is defined as an XY plane. Since the second plane is inclined approximately 30 degrees with respect to the horizontal plane f in the case of the windshield 1 shown in FIGS. 3 and 4, the second plane is rotated together with the curved surface 2 by approximately 30 degrees with respect to the horizontal plane f. Thus, the second plane is made substantially coincident with the horizontal plane f. Note that this calculation is based on CA
It can be easily performed by the D device. further,
A third plane passing through the development center point and orthogonal to the first plane (YZ plane P2) and the second plane, respectively, is defined as the XZ plane P1.
The leveling by rotation may be performed before setting the development center point To when the curved surface 2 is particularly symmetric.

Step 12: An intersection line S1, which intersects the curved surface 2 with the XZ plane P1 and the YZ plane P2 passing through the development center point To,
Create S2. Therefore, the intersection line S2 coincides with the line symmetric curve a on the curved surface 2 when the curved surface 2 to be two-dimensionally developed is bilaterally symmetric.

Step 13: Next, the CAD data corresponding to the windshield 1 includes a shape line of the windshield 1 (an outline of the windshield 1, a heater wire printed on the windshield 1, an antenna wire, or Data about an area where an opaque ceramic color is applied, which functions as a blindfold for a bonding portion with a vehicle body, is stored in advance. Therefore, a curve So corresponding to the inner edge of the ceramic color application area is displayed on the curved surface 2.

Step 14: Specify the n-th set point Tn on these curves So, that is, Pxn, yn, zn. Where n is 1,
1, 3, and are shown in FIG. 1. In FIG.
n is shown.

Step 15: As in Step 11, the XZn plane extending in the horizontal direction through the n-th set point Tn and the YZn plane extending in the vertical direction through the n-th set point Tn are determined. However, the XZn plane and the YZn plane are the reference XZ plane P
1 and the YZ plane P2. In FIG. 1, n = 1
XZ1 plane P3 and YZ1 passing through the n-th set point Tn in the case of
The plane P4 is shown.

Step 16: As in Step 12, intersection lines S (2n + 1) and S (2n + 2) at which the XZn plane and the YZn plane intersect the curved surface 2 at the n-th set point Tn are created. In the case of the first set point T1, as shown in FIG. 1, intersection lines S3 and S4 are created.

Step 17: An intersection Tn2 where the intersection line S2 and the intersection line S3 intersect is determined, and the intersection Tn2 and the n-th set point T
The length Ln on the curved surface 2 between n and n is determined. This length Ln
Is calculated by a subroutine (program) in the CAD apparatus.

The procedure of the subroutine for obtaining the length Ln will be described below. Here, n is 1, 2, 3,.
First, an intersection between the intersection line S2 and the intersection line S3 is obtained. These S
2 and S3,

(Equation 1) Defined as

(Equation 2) Becomes The intersection is obtained by mathematically solving the two unknowns t and u by a method such as the Newton-Raphson method for simultaneous equations. The obtained intersection is defined as T12 (generally, Tn2).

Next, a curve Ln on the curved surface 2 between the intersection Tn2 between the intersection S2 and the intersection S (2n + 1) and the n-th set point Tn is determined. This curve Ln has a small length code (ch
ord), and the code vector when the parameter changes by Δt is approximately

(Equation 3) The length of this curve Ln when the value of the parameter Δt goes from one end to to the other end tn of the curve Ln is

(Equation 4) Can be calculated by The length of the curve Ln can be obtained by obtaining the solution of this equation by a method such as Gauss' quadrature.

In the CAD device, a screen displaying the three-dimensional shape of the windshield 1 (see FIG. 1).
Is a screen of XY coordinates (coordinates of orthogonal axes) (see FIG. 2)
Can be replaced with the display. The deployment center point To is
This corresponds to the origin Do of the two-dimensional coordinates (XY coordinates).

Step 18: An intersection Tn3 where the intersection line S1 and the intersection line S4 intersect is determined, and the intersection Tn3 and the n-th set point T
Then, a length Mn on the curved surface 2 between n and n is determined. This length Mn
Can be executed by a subroutine (program) in the CAD apparatus, as in the case of step 17, and can be displayed on the XY coordinate screen. The calculation procedure for obtaining Mn is the same as the calculation procedure of step 17, except that Ln is Mn, S3 is S4, S2 is S1,
This can be done by reading Tn2 into Tn3.

Step 19: The development point Dn represented by Xn = Ln and Yn = Mn is plotted on the XY coordinates, and the development point Dn is stored. Therefore, the three-dimensional set point Tn
Corresponds to a development point Dn that has been two-dimensionally developed.

Step 20: The above steps 14 to 19 performed for n = 1 are repeated for n = 2, 3,.

Step 21: A curve A1 passing through the two-dimensional development point Dn of n = 1, 2, 3,. This curve A1 is
This corresponds to, for example, one-dimensionally developing one of the boundary lines of the ceramic color application region on the three-dimensional windshield 1.

Step 22: Steps 13 to 21 are represented by curves A2, A
3. Repeat as many times as the number of lines. In the case of a symmetrical windshield, for example, the upper half, the right half, and the lower half of the inner edge of the ceramic color (the boundary line along the outer edge of the outer edge of the windshield, for example, 2 cm inside).
Repeat for book.

Step 23: These curves A1, A2, A
3. Plot the data of ~ on an XY plotter.

The sampling interval of the set point Tn depends on the radius of curvature of the curved surface 2. That is, in the case of the windshield 1, sampling is usually performed at a pitch of 50 mm.
When the radius of curvature is large, sampling is performed at a pitch of 100 mm. Conversely, when the radius of curvature is small, sampling can be performed at a pitch smaller than the 50 mm pitch.

FIG. 5 shows a configuration of a CAD apparatus for developing a three-dimensional shape into a two-dimensional shape in the present invention.
In this figure, the shape data of the windshield 1 can be input by digitizing the design drawing 7 with a digitizer 8. Alternatively, shape data can be input by, for example, applying a magnetic tape on which the design data is written to a magnetic tape device 9. Also, a floppy disk can be used instead of a magnetic tape.

The input shape data is stored in the computer 10.
The computer 10 sequentially performs a two-dimensional expansion calculation of a three-dimensional curved surface model corresponding to the shape data of the windshield 1. The progress of the calculation and the result are monitored by a graphic display, that is, a high-definition color CRT 11, numerical data is output by a printer 12, or a display screen of the color CRT 11 is output by a hard copy device 13. The color cathode ray tube 11 and the printer 12 are provided as checking means for the above calculation. The two-dimensional developed shape of the three-dimensional curved surface 2 as the final result has a high resolution XY
Output by the plotter 14. Then, based on the two-dimensional shape, a large number of glass plates having a predetermined shape (such as an outline, a heater wire, an antenna wire, and an inner edge of a ceramic color application area) are manufactured, and then the glass plate is formed by a molding apparatus. The windshield 1 is manufactured by being bent into a three-dimensional shape. The size and the degree of curvature of the windshield 1 are inspected by placing the windshield 1 on a wooden mold.

In FIG. 5, when CAD data is obtained from the design drawing 7, a number of points Q1, Q on the front and side views of the curved surface 2 called a Mylar diagram as shown in FIG.
2, Q3,... Are designated by the digitizer 8 to take in three-dimensional coordinates. Next, a geometric three-dimensional shape model of the curved surface 2 is created in the computer 10 operating as a CAD system. That is, first, a lattice-shaped three-dimensional spline curve passing through a sequence of points captured by the digitizer 8 is generated, and then the curved surface is divided into quadrilateral patches (surface elements) with the spline curve as a boundary, and the surface is divided along each side of the patch. Create a bicubic parametric surface such as a Coons surface represented by parameters u and v.

In the same manner, a three-dimensional spline curve such as an outline of a glass plate is also generated. Note that a patch of a curved surface can be represented by a Bezier surface, a B-spline curved surface, or the like. When the shape of the curved surface 2 is designed by a CAD system, a three-dimensional model can be obtained from a magnetic tape or the like on which the design data is written.

FIG. 7 is a schematic flowchart of the two-dimensional expansion method shown in FIGS. In FIG. 7, steps 10 to 23 are schematically shown as S10 to S23, respectively.

In the present embodiment, for example, a two-dimensional unfolding method used for manufacturing a windshield is shown, but the present invention can also be applied to manufacturing a rear glass or a roof glass. Also,
The present invention can also be applied to manufacture a three-dimensional curved plate from a two-dimensional plate material such as a hard non-ductile hard metal plate (for example, an iron plate) or a plastic plate. Further, as shown in FIG. 2, the case where the set point Tn is developed on the orthogonal axis coordinates (XY coordinates) has been described, but it may be developed on the polar coordinates.

[0038]

As described above, according to the present invention, a two-dimensional developed shape can be determined by developing a curved surface of a three-dimensional plate into a plane by numerical calculation in a computer system. It is possible to improve the accuracy of the entire flat material manufactured based on the two-dimensional developed shape, particularly the accuracy of the four corners, and to obtain a flat material having few errors. Moreover, since the calculation can be performed by the computer, labor can be saved and time is not required. Further, since the numerical data of the two-dimensionally expanded plate material is stored in the computer, it can be used as data of a subsequent process.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view of a curved surface schematically showing a two-dimensional expansion method of the present invention.

FIG. 2 is an XY coordinate development diagram at a set point of the curved surface in FIG. 1;

FIG. 3 is a plan view of a right half of a windshield to which the two-dimensional expansion method of the present invention is applied.

FIG. 4 is a side view of the windshield of FIG. 3;

FIG. 5 is a schematic block diagram of a CAD apparatus used in the two-dimensional expansion method of the present invention.

FIG. 6 is a diagram showing the CAD apparatus shown in FIG.
It is the front view and side view of the curved surface 2 when obtaining AD data.

FIG. 7 is a schematic flowchart of the two-dimensional expansion method of the present invention shown in FIGS. 1 and 2;

[Explanation of symbols]

 2 Curved surface To expansion center point Tn n-th set point Dn n-th expansion point A curve

Claims (4)

(57) [Claims] 1. A (a) determining a deployment center point To on the curved surface of the plate material of the three-dimensional shape, (b), respectively orthogonal and orthogonal to the plane of point contact in the curved surface and deployment center point To XZ plane and Y
(C) Determining an n-th set point Tn on the shape line of the curved surface (where n is an integer of 1, 2, 3, ...); (d) Each of the n-th settings XZ planes and YZn planes that pass through the point Tn and are parallel to the XZ plane and the YZ plane, respectively, are obtained. (E) The intersection line between the XZn plane and the curved surface is Y
Finding an intersection that intersects the Z plane and finding the length Ln on the curved surface between this intersection and the n-th set point Tn. (F) The intersection line between the YZn plane and the curved surface is X
Finding an intersection that intersects the Z plane and finding a length Mn on the curved surface between this intersection and the n-th set point Tn. (G) Put these lengths Ln and Mn on two-dimensional coordinates. Plotting to determine the n-th development point Dn; (h) above (c) to (g) for n = 1, 2, 3,.
By repeating the operation of the steps and determining a plurality of development points Dn, a curve A corresponding to the shape line is obtained by using a computer system, and the three-dimensional shape of the three-dimensional shape is determined based on the curve A. The two-dimensional unfolded shape of the curved surface of the plate is determined, and based on the determined two-dimensional unfolded shape,
The flat plate is manufactured by manufacturing the flat plate.
Manufacturing method. 2. The method according to claim 1, wherein the flat plate is a glass plate.
The method of claim 1, wherein 3. The process as claimed in claim 1 or 2 plate of the three-dimensional shape, characterized in that a glass plate. 4. Is produced by the method according to claim 1, 2 or 3
The manufacture of plate material of a three-dimensional shape, characterized in that the flat plate to produce a plate material thus three-dimensional shape to heat deformation
Method.