NL2017562B1 - A method of manufacturing a motor vehicle - Google Patents

Abstract

A method of manufacturing a motor vehicle, the motor vehicle comprising - a front section comprising - a front chassis comprising box beams, and - an engine; and - a rear section comprising - a rear chassis, rear chassis beams connected by cross bars, wherein the method comprises the step of connecting the rear chassis to the front chassis. To achieve a motor vehicle that is relatively difficult to topple over with the rear chassis firmly attached, - front end sections of the longitudinally extending rear chassis beams, and - the first connecting plate and the second connecting plate inserted into the box beams of the front chassis bolted to said box beams.

Description

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The Netherlands © 2017562

BI PATENT (51) Int. CL:

B62D 21/02 (2017.01) B62D 21/12 (2017.01) B62D 27/06 (2017.01) B62D 65/02 (2017.01) (21) Application number: 2017562 © Application submitted: 30/09/2016

AA Application registered: (73) Patent holder (s): 10/04/2018 COXX GROUP B.V. in Rijen. (43) Application published: - (72) Inventor (s): René Gerard Marie Cox in Zandhoven (BE). (G) Patent granted: 10/04/2018 (74) Agent: (45) Patent issued: ir. W.J.J.M. Kempes in Hilversum. 11/04/2018

© A method of manufacturing a motor vehicle © A method of manufacturing a motor vehicle, including the motor vehicle

- a front section including

- a front chassis including box beams, and

- an engine; and

- a rear section including

- a rear chassis, rear chassis beams connected by cross bars, the method comprising the step or connecting the rear chassis to the front chassis.

To achieve a motor vehicle that is relatively difficult to topple over with the rear chassis firmly attached,

- front end sections of the longitudinally extending rear chassis beams, and

- the first connecting plate and the second connecting plate inserted into the box beams or the front chassis bolted to said box beams.

NL BI 2017562

This patent has been granted regardless of the attached result of the research into the state of the art and written opinion. The patent corresponds to the documents originally submitted.

A method of manufacturing a motor vehicle

The present invention relates to a method of manufacturing a motor vehicle, the motor vehicle including

- a front section including

- a front chassis, and

- an engine; and

- a rear section including

- a rear chassis, including

- a first longitudinally extending rear chassis beam,

- a second longitudinally extending rear chassis beam parallel to said first rear chassis beam, and

- a variety of cross bars connecting the first longitudinally extending rear chassis beam with the second longitudinally extending rear chassis beam;

said method including the step of connecting the rear chassis to the front chassis.

It is known in the art to manufacture a motor vehicle starting from a commercially available vehicle and cutting it from another rear section and replacing it with another rear section. This makes it possible to change the purpose or core functionality of the vehicle. For example, a light truck may be converted into a multi-passenger vehicle (minibus). Obviously, a sturdy connection between the front section and the rear section has been achieved, which is achieved in the prior art by welding the rear chassis beams to the front chassis.

After modification, the motor vehicle still has various standards. With the new function, the motor vehicle may also need to satisfy more stringent standards, because passengers or the multi-passenger vehicle are not usually protected by seat belts and / or air bags. For example, in case of conversion to a multi-passenger vehicle, the occupants will have to be protected from side impact collisions, not just with respect to damage but also to rolling over.

The object of the present invention is to provide a method or provide a sturdy connection that results in a vehicle with a reduced risk or rolling over in case of a side impact.

To this end, a method according to the preamble is characterized in that the rear chassis comprises a front end section, said front end section including

- connecting plates parallel to the main plane or the rear chassis, said connecting plates containing a first connecting plate and a second connecting plate, and

- through holes for bolts;

will

- box beams or the front chassis are provided with holes for the bolts,

- the first connecting plates and second connecting plates are inserted into the box beams or the front chassis, and

- the first connecting plates and the second connecting plates are bolted to the box beams or the front chassis.

Thus a strong connection between the rear chassis and the front chassis is provided. In general the box beams or the front chassis are the remaining longitudinal sections of the original vehicle after cutting its chassis beams. Each of the first and second connecting plates and the front end sections of the rear chassis beams will have holes for the bolts.

According to a favorite embodiment, at least one of i) the first connecting plate, and ii) the second connecting plate has an equal to the inner width of the box beams.

This makes it much easier to align the front chassis with the rear chassis, saving time when manufacturing the vehicle.

According to a favorite embodiment, the connecting plates are webs or connecting profiles, and said connecting profiles are provided with accessory profiles for holding flanged nuts.

This facilitates bolting the rear chassis to the front chassis.

According to a favorite embodiment, the accessory profiles include unround holes for impeding the rotation of the flanged nuts.

This facilitates bolting the rear chassis to the front chassis.

According to a favorite embodiment, the rear chassis comprises uprights, the uprights being provided with connecting plates parallel to the main plane or the rear chassis.

Thus a strong connection between the rear chassis and the front chassis is provided while at the same time the center of gravity or the rear chassis is relatively low compared to the front chassis, making the vehicle more difficult to topple over, thus improving safety.

According to a favorite embodiment, rearmost ends of the first connection plates are located at a distance from the front ends of the longitudinally extending rear chassis beams, and the box beams of the front chassis are clamped using the bolts between the upper surfaces of the front end sections of the longitudinally extending rear chassis beams and the first connecting plates.

This results in a very strong connection between the front section and the rear section.

With respect to the term located at a distance, said distance is determined in the longitudinal direction of the rear chassis. If uprights are used, it is uprights that are at a distance from the front ends of the longitudinally extending rear chassis beams.

The present invention will now be illustrated with reference to the drawing where

FIG. 1A shows a perspective view of a motor vehicle according to the invention under construction;

FIG. 1b shows a perspective view of the vehicle or FIG. IB, the cabin and chassis being separated;

FIG. 2A to FIG. 2D show a perspective view or a detail or a rear chassis under construction;

FIG. 3A to FIG. 3D correspond to Figs. 2A to FIG. 2D and show a cross-sectional view of the rear chassis under construction;

FIG. 4A shows perspective exploded rear view of a vehicle and part of a rear chassis, and Figs. 4B shows the same view in an assembled state;

FIG. 5 shows an exploded view or a connecting body;

FIG. 6 shows a perspective view of the connecting body or Fig. 5 mounted to a rear chassis beam; and

FIG. 7 shows a schematic cross-sectional view or a part or Fig.

5.

FIG. 1A shows a perspective front view of a motor vehicle 100 according to the invention under construction. FIG. IB shows said motor vehicle 100 from a perspective rear view.

The motor vehicle 100 comprises a front section 110 including a front chassis ill (front chassis beams ill ', ill shown in Fig. IB are part of this front chassis ill) provided with front wheels 112, a cabin 113 and an engine 114 for driving the motor vehicle 100.

The motor vehicle 100 also includes a rear section 120 including rear wheels 121 provided to a rear chassis 130.

The rear chassis 130 comprises a first longitudinally extending rear chassis beam 131 and a second longitudinally extending rear chassis beam 132 parallel to said first longitudinally extending rear chassis beam 131. A variety of cross bars 133 connect the first longitudinally extending rear chassis beam 131 to the second longitudinally extending rear chassis beam 132. Typically, the cross-bars 133 will have an I-beam shaped cross-section.

In FIG. IB, the rear chassis 130 is shown separated from the front section 110. The vehicle 100 is manufactured by removing the rear section of a chassis or a vehicle, and replacing said rear section with a rear chassis 130 according to the invention. To this end, the front side of the rear chassis 130 is bolted or welded to the front chassis beams 111 ', 111.

A method and vehicle as described above is known in the art.

For the new function provided by the replacement rear chassis 130, for example the transport of passengers, the rear chassis 130 should have properties not present in the original rear chassis section removed from the front section 110. In particular it side-crash resistance should meet regulatory standards. In this embodiment of the present invention, this is achieved using a first longitudinally extending side profile 141 and a second longitudinally extending side profile 142, said longitudinally extending side profiles extending along the sides of the rear chassis 130. These are discussed in more detail below .

FIG. 2A to FIG. 2D show a perspective view or a part of the rear chassis 130 or FIG. 1A and FIG. IB under construction. FIG. 3A to FIG. 3D correspond to Figs. 2A to FIG. 2D and show a cross-sectional view of the part of the rear chassis 130 or FIG. 1A and FIG. IB under construction.

A longitudinally extending side profile, here first longitudinally extending side profile 141 comprising an outer first profile section 210 including at least one longitudinally extending angled edge 211, and an inner second profile section 220 facing the outer first profile section 210.

In the embodiment discussed here, the outer first profile section 210 and the inner second profile section 220 are separate parts that are placed against distal ends 233 or the cross-bars 133 and welled to said distal ends 233 and along their length to each other. To facilitate welding to the distal ends 233 and to save weight, the outer first profile section 210 comprises opening 212.

In an alternative embodiment the outer first profile section 210 comprises vertically extending slots for receiving the distal ends of the cross-bars, allowing them to be benefited more easily.

The angled edge of the outer first profile section 210 faces outward, making it hard to buckle the outer first profile section 210 and allowing a force of a side impact to be transferred to adjacent cross-bars 133 as a result of which the rear chassis 130 will absorb the impact energy which helps to reduce the risk of injury to occupants of the vehicle.

The outer first profile section 210 and the inner second profile section 220 define a U-shaped subsection 260 that extends longitudinally along the side of the rear chassis 130. An upright wall panel 270 is received in said U-shaped subsection 260. This not only results in a reduction in cost because of the simplicity of the design, but also helps to reduce the risk of injury to any passenger or the vehicle 100 because the U-shape is relatively hard to buckle.

FIG. 4A shows perspective exploded rear view of a vehicle 100 and part of a rear chassis 130.

The rear chassis 130 comprises two connecting body 450 which will be discussed in more detail with reference to Figs. 6. The connecting body 450 comprises a through hole 451 for a front end section 431 or a longitudinally extending chassis beam, here box profile section 431 or the rear chassis beams. Two connecting body 450 are attached to the two chassis beams before the rear chassis 130 is attached to the box beams 111, 111 'or the front chassis 111.

FIG. 4B agrees to FIG. 4A except that it shows the same view with the rear chassis 130 attached to the front section 110.

In FIG. 4A and FIG. 4B the rear wheels are not shown, but in general they will be present when the rear chassis 130 is attached.

Now the method according to the present invention will be discussed by way of example.

FIG. 5 shows an exploded view of the connecting body 450 for connecting the rear chassis and the front chassis of the vehicle or Fig. 1A.

Front end sections 431 of the longitudinally extending rear chassis beams or rear chassis 130 will be passed through the through holes 411 or uprights 430, which will be connected to the front chassis 111 (in particular a box beam 111 ', 111 thereof). This provides for a relatively low floor which increases the available space for cargo or passengers and / or allows for a low entry height, making entry into the vehicle 100 more comfortable.

The uprights 430 include connecting plates transverse to the uprights 430 that will be parallel to the main plane of the rear chassis 130. More specifically, a connecting body 450 comprises a (U-shaped) first connecting profile 551 that comprises a web plate, which web plate is the first connecting plate 751 (see Fig. 7) that will be connected to the box profile section 431 or the chassis beam 131 (or 132), leaving a space between the two for receiving a lower wall of a box beam 111 (or 111) or the front chassis 111.

The connecting body 450 also comprises a (U-shaped) second connecting profile 552, including a second web or the second connecting profile 552 that serves as the second connecting plate 556.

Both connecting plates comprise holes 553 for bolts 570.

The box beams 111 ', 111 are provided with corresponding holes 571 (Fig. 6).

To attach the rear chassis 130 as shown Figs. 4A, the first and second connecting profiles 551, 552 are inserted in the box beams 111 ', 111 and the first connecting plates are bolted to the box profile sections 431 clamping the lower wall of a box beam 111', 111 therein between.

The second connecting profiles 552 are bolted to the upper wall or said box beams 111 ', 111. This provides for a very sturdy connection. More importantly, this method makes it relatively easy to get a proper alignment of the front wheels and the rear wheels, which in itself saves a time and money. To this end, the outer width or a connecting profile, preferably at least the outer width or the first connecting profile, is chosen such that it is substantially agreed to the inner width of the box beam 111 ', 111 or the front chassis 111.

In the embodiment shown here, the connecting body 450 comprises a flange 554 for bolting the connecting body 450 to the rear chassis beams 131, 132, which allows the connecting body 450 to be attached to said rear chassis beams. The flange 554 does not or not significantly contribute to the strength of the final connection between the front section 110 and the rear section 120.

To make it easy to make the bolt connection, flanged nuts 580 are used, which are hero in place using accessory profiles 590. These accessory profiles 590 are provided with unround holes 591 to prevent the flanged nuts 580 from rotating when the bolts 570 are tightened . The accessory profiles 590 do not or not significantly contribute to the strength of the connection between the front section and the rear section.

In the embodiment discussed here, to easily mount the accessory profiles 590, they are provided with lips 592, and opposite walls of the connecting profiles comprises holes 555 for receiving these lips 592 when they are.

FIG. 6 shows a perspective view of the connecting body 450 or Fig. 5 mounted to the rear chassis beam 13a. Between the first connecting profile 551 and the box profile section 431 there is a gap 651 for receiving the lower wall of the front box beam ill '.

The outer distance between the first connecting profile 551 and the second connecting profile 552 is chosen such that it corresponds to the inner height of the box beam ill '.

FIG. 7 shows a schematic cross-sectional view or a part or Fig.

5, and in particular a through-hole 771 in a first connecting plate 751 (web) or the first connecting profile 551 for a bolt 570 and the flanged nut 580 hero in place by an accessory web 791 or the accessory profile 590.

Walls 792 or the accessory profile 590 include the lips 592 which are received in the holes 555 or the first connecting profile, keeping the accessory profiles 590 in place. Thus, when bolts 570 are inserted from below, the flanged nuts 580 are not lifted up, facilitating the quick assembly of the vehicle 100.

For the second connecting profile 552, a corresponding Fig. would look the same, but rotated through 180 °.

Claims (6)

CONCLUSIONS A method for manufacturing a motor vehicle (100), wherein the motor vehicle (100) comprises the following - a front section (110) that - a front chassis (lil), and - a motor (114); and - a rear section (120) that - a rear chassis (130) comprising - a first longitudinally extending rear chassis beam (131), - a second longitudinally extending rear chassis beam (132) parallel to said first rear chassis beam (130), and - a plurality of cross members (133) connecting the first longitudinally extending rear chassis beam (131) to the second longitudinally extending rear chassis beam (132); said method comprising the step of connecting the rear chassis (130) to the front chassis (III); characterized in that the rear chassis (130) comprises a front end section, said front end section comprising - connecting plates parallel to the main surface of the rear chassis (130), said connecting plates comprising a first connecting plate (751) and a second connecting plate (556), and - through holes for bolts (570); at which - box girders (lil ', lil) of the front chassis (lil) are provided with through holes (411) for the bolts (570), - the first connecting plates (751) and second connecting plates (556) are inserted into the box girders (lil ') of the front chassis (lil), and - the first connecting plates (751) and the second connecting plates (556) are bolted to the box girders (lil ', lil) of the front chassis (lil). The method of claim 1, wherein at least one of i) the first connecting plate (751), and ii) the second connecting plate (556) has a width equal to the internal width of the box girders (lil ', lil). A method according to claim 1 or 2, wherein the connecting plates are bodies of connecting profiles, and said connecting profiles are provided with auxiliary profiles (792) for holding flanged nuts (580). The method of claim 3, wherein the auxiliary profiles (590) include non-circular holes (591) to inhibit the rotation of the flanged nuts (580). A method according to any one of the preceding claims, wherein the rear chassis comprises uprights (430), wherein the uprights (430) are provided with connecting plates parallel to the main surface of the rear chassis (130). The method of any one of the preceding claims, wherein rear ends of the first connecting plates (751) are spaced from the front ends of the longitudinal rear chassis beams (131, 132), and the box beams (lil ', lil ) of the front chassis (11a) are clamped using the bolts (570) between the upper surfaces of the front end sections (431) of the longitudinal rear chassis beams (131, 132) and the first connecting plates (751). ² / 12-9 IB 3/12 6/12 133 FIG. 3A 133 Ί / 12 Fig 3C FIG. 3D 8/12 120 O FIG. 4A 9/12 10/12 LSS SSg