DE19606779A1 - Method for mounting and painting of vehicles with self-supporting bodies - Google Patents

Abstract

The method comprises of the entire vehicle being put together encapsulating the body that is made from single modules (1-18), and that are precast independently from one another. The modules are fully functional with all equipment features, and has the necessary lacquering for a final assembly. The modules are ultimately assembled in a specific critically optimised mounting sequence. The mounting sequence of the vehicle final assembly may be carried out in view of the critical accessibility of the sequence operations and investiture expenditure, esp. optimised for mounting and lacquering equipment.

Description

The invention relates to a method for assembly and coloring of motor vehicles with self-supporting Body.

Common practice is to have a vehicle frame complete bodies of motor vehicles are manufactured, with various parts here are welded. Measures taken by the Corrosion protection carried out, and painting the finished body is made, which is extremely expensive plants required.

The bodies thus prepared are then al len other necessary vehicle components. Before this final assembly of the vehicles may be the hoods and doors from the respective body removed for better accessibility to the inside to reach the body. When assembling are diverse Carry out work in places that are difficult to access. Around To simplify this work, many Mo dule developed the prefabricated in the body too are positioned. An example is a cockpit mo dul or a motor-chassis-drive train module named, which at the so-called "wedding" with the Ka body is united.  

An example of an assembly process with very far ent is based on the content of EP-PS 0 512 576 given. Here is the vehicle body in one lower and an upper component the, whereby these body components are not already in an early assembly phase. Before this connection process, the painted Ka parts of the horse with other vehicle components to achieve the advantages of modular technology pass. In the painting itself, no simplifications are made achievements. Take very elaborate large racks the Ka to be painted, equipped with hoods and doors parts of the horse to add them to the paint shop to lead. Overall, here too there is the body still a lot of work, with many ar must be carried out in places that are difficult to access. All of this work focuses on one very gen assembly room, so that a relatively long assembly line is required.

It is an object of the invention to provide a method for the vehicle assembly and coloring to create a maximum Flexibility in the design of the assembly processes possible, low investment for assembly and color training facilities required and thus a cost-optimized Vehicle manufacturing permits.

To solve this problem, the fiction, excel moderate method by the specified in claim 1 Characteristics. Details of the invention follow from claims 2 to 5.

A self-supporting body of a motor vehicle is no longer, as is known, completely or in two large ones Prefabricated units, but the entire motor vehicle including the body is as a variety of mod  len completely prefabricated. This can be due to different Assembly lines one place or in different places consequences. The body is also prefabricated modularly, the individual modules being comparatively small and good manageable and accessible from all sides, separately from each other rust-treated, painted (if required Lich) and with all the necessary features pieces. All other components of the force vehicle are, as is partially known, modularly featured manufactures. So it becomes, for example, a seat or a seat group modules, cockpit modules, front and rear modules, Mon gate chassis powertrain modules compiled and assembled independently. The exact composition The modules are subordinated to specific criteria, the specific existing circumstances (Fahr type of tool; existing plants; Conditions at Zulie operated. . . ) depend. A particularly noteworthy one The criterion is always the maximum accessibility for To ensure follow-up operations. This is in the middle directly related to the goal of investing in Assembly and painting systems and thus as well as the Pro to minimize product costs significantly.

The completely prefabricated, i.e. painted and finished equipped modules, are in turn optimized Sequence put together, with only verb between the modules. Work on the individual modules should be agreed in advance closed, i.e. no longer during final module assembly to be carried out. This requires that übli Cross-module vehicle components such as for example a wiring harness of the electrical system or Interior cladding, in a way adapted to the modules be disassembled. The electrical system of the Modular design of the vehicle and in connection with to prefabricate the individual modules. During final module assembly only cable connections are made that are used for  Communication and power transfer between inventory parts of different modules are required. A spec The way to do this is in the DE-OS. . . (Patent application 195 47 403.1). In a comparable way also cross-module mechanical, hydraulic or pneumatic transmission means of the module design fits and be equipped with lanyards.

The complete equipment of the vehicle is mon if there are no body elements obstructing the assembly elements are present. Modules can be made with an underbody of the vehicle are mounted before side wall modules be attached to this. The fully featured pages wall modules (including belts, side airbags, electrical Investment . . . ) are only applied to the underbody when all work is completed there.

A painting of the individual body modules can ent according to the respective needs in smaller painting plants conditions than usual and with significantly improved access possibility. Here is a clear opposite Known reduced investment required and the product quality can be improved.

To avoid damage to the paintwork and equipment, the Final module assembly without using welding processes guided. Various other connection technologies such as Screw, rivet, adhesive, clamp or clinch connections are the expert in the construction of the process adapted modules available.

The final assembly of such a vehicle can be done with the help of described method under production-optimized loading conditions in a very short time on comparatively low ger mounting area, the investment for assembly and painting systems is low. The modules can be in close proximity to the final assembly site, however  also pre-assembled elsewhere at suppliers and be painted.

The following is an embodiment of the invention briefly described with reference to a figure, which is schematic Vehicle modules shows the optimized pre- and final assembly are.

As body modules are on different assembly prefabricated lines:

• - An underbody module 1 (platform), which consists of various welded individual parts, is finished with anti-rust treatment and with elements of the electrical system of the motor vehicle, seat guides, belt buckles for the front seat belts, floor mats. . . Is provided,
• - Two side wall modules 2 , 3 , which are finished after welding and finished (belts, side airbags, electrical system...),
• - A roof module 4 , which is also painted and fitted (handles, sunroof if necessary, electrical system - e.g. interior lighting, antenna, sunroof drives),
• a front module 5 , optionally with a body riequer beam and with a bumper, grille and primarily with elements of a lighting system of the vehicle,
• - A rear module ( 6 ) with bumpers, taillights, lock elements. . . ,

as well as non-load-bearing modules:

• - A painted bonnet 7 with hinges, closures, soundproofing material, nozzles of the windscreen washer system,
• - a tailgate 8 with hinges and locks, rear window heating, if necessary, rear window wiper,
• - Doors 9 to 12 , which are also painted and which, in addition to panes, mirrors, closures, interior cladding and other standard elements, have all the equipment desired by the customer, which primarily belongs to the electrical system.

A windshield 13 can be delivered separately to who, but also part of a module (for example, the roof module 4 ) or be provided in the form of a windshield module with elements of a window frame and wipers.

Additional modules that complete the motor vehicle are provided. These are seat modules 14 , 15 , 16 , as are already partially prefabricated today. They contain all components for seat adjustment, seat heating and for achieving occupant safety. A cockpit module 17 with various components and assemblies (as is also known today) is supplied by a supplier or a cockpit assembly line. Furthermore, a motor chassis powertrain module 18 , which is also known per se, is shown. All modules 1 to 18 are designed to optimize the final assembly. Equipment work is no longer required on modules 1 to 18 . All rust protection and coloring work is completed after the completion of modules 1 to 18 . This work can be carried out as required with the aid of systems which require less investment than with known methods.

The process of final assembly of the motor vehicle can now take place under optimized conditions. The Op Timing is particularly evident when viewed of time savings resulting from good accessibility surrendered during assembly work and in mental retaliation waiting for a very short final assembly line, the one requires little investment.

For example, a final vehicle assembly in the fol following order:

• a) connection of underbody module 1 with engine chassis to drive train module 18 by means of vertical screw connections with optimum accessibility from above;
• b) Connection of the cockpit module 17 with a partition (between the passenger compartment and engine compartment) of the Unterbo denmoduls 1 ;
• c) placing the seat modules 14 to 16 on the Unterbo denmodul 1 ;
• d) connecting the side wall modules 2 , 3 with the Unterbo denmodul 1 (gluing, locking, screwing, riveting, jamming or clinching) and the cockpit module 17 ;
• e) connecting the front module 5 and the rear module 6 with the underbody module 1 and the side wall modules 2 , 3 ;
• f) placing the roof module 4 on the side wall modules 2 , 3 ;
• g) gluing the windshield 13 with Unterbodenmo module 1 , side wall modules 2 , 3 and roof module 4 ;
• h) pivotable connection of the door modules 9 to 12 , the hood 7 and the tailgate 8 .

With such an assembly technology, the vehicle is to be completed at eight assembly stations and can completed quality and functional control will.

It is essential that no welding processes are used that could damage the paintwork. When two or more modules are put together, mechanical connections are created as well as electrical, hydraulic and / or pneumatic transmission means. For this purpose, the modules preferably have coupling means oriented in the mounting direction. For example, a plug-socket connection between door modules 9 to 12 and the side walls 2 , 3 is to be created and a further plug-socket connection is to be provided between the side wall modules 2 , 3 and the cockpit module 17 . The work to be carried out during final assembly can thus be reduced to a minimum. Un assuming that the assembly of modules 1 to 18 takes place at a high quality level, vehicles can be manufactured inexpensively with the assembly method described. The effort for a production changeover is less than with today's assembly processes.

Claims (7)

1. A method for assembling and coloring a motor vehicle with a self-supporting body, characterized in that the entire motor vehicle, finally the body is composed of individual modules ( 1 to 18 ), which are prefabricated independently of each other so that they with all the features fully functional and painted according to the requirements for a final assembly, and that the modules ( 1 to 18 ) are finally assembled in an assembly order optimized according to almost any specific criteria, whereby only connections between individual modules ( 1 to 18 ) are made however assembly or other work on the module ( 1 to 18 ) must be carried out by yourself. 2. The method according to claim 1, characterized in that that the order of motor vehicle final assembly primarily with regard to the criteria access possibility for follow-up operations and investment wall, especially for assembly and painting systems is optimized, with a prior determination of module components and their technical design subordinate to these criteria. 3. The method according to claims 1 and 2, characterized in that modules

• - underbody ( 1 ) with or without a front and / or a rear end,
• - Front module ( 5 ), if not part of the underbody module ( 1 ),
• - rear module ( 6 ), if not part of the underbody module ( 1 ),
• - Side walls ( 2 , 3 ) and
• - roof ( 4 )

pre-assembled as later components of a self-supporting part of the body,
Modules:

• - bonnet ( 7 ),
• - rear hood or hatch ( 8 ) and
• - doors ( 9 to 12 )

preassembled to complete the body of the motor vehicle and a rust protection treatment and painting of components of these modules ( 1 to 12 ) is carried out individually and as required. 4. The method according to claims 1 to 3, characterized in that all the motor vehicle laterally delimiting body modules ( 2 , 3 , 5 , 6 , 9 to 12 ) only after assembly of all modules belonging to the interior ( 14 to 16 , 17 ) to be assembled. 5. The method according to claims 1 to 4, characterized ge indicates that during final module assembly, conn between elements of self-supporting checks series by locking, screwing, riveting, adhesive ben, clamps or clinching.