Repair method

Abstract

The invention relates to a method for repairing a load-bearing structural part (4) of a vehicle body (2) manufactured as a cast metal part, wherein the load-bearing structural part (4) has a repair region (9) in which damage (8) of the load-bearing structural part (4) can occur in the event of overloading of the load-bearing structural part (4), and the load-bearing structural part (4) has a rib structure (10) at least in the repair region (9), which forms cavities (11) on the load-bearing structural part (4), which cavities (11) are open at the longitudinal sides of the load-bearing structural part (4). In the event of damage (8) to the load-bearing structural part (4) in the repair region (9), the rib structure (10) is used to attach a reinforcement (12) which reinforces the load-bearing structural part (4) in the repair region (9).

Description

Technical Field

[0001] The invention relates to a method for repairing a load-bearing structural part of a vehicle body which is produced as a cast metal component. The invention also relates to a vehicle having at least one load-bearing structural part which is configured or suitable for carrying out the method or having at least one load-bearing structural part which has been repaired by the method. Background Art

[0002] In the case of passenger motor vehicles in particular, the body has load-bearing structural parts that are distinguished by high rigidity and stability in order to be able to accommodate and transmit forces and moments during vehicle operation. To date, such load-bearing structural parts have usually been constructed using a large number of formed sheet metal parts. This has the disadvantage that a relatively large number of individual parts must be manufactured, handled and connected to one another. The costs required for this are relatively high, especially in terms of the tolerances that must be adhered to. Therefore, in modern vehicles, there is a trend to manufacture the load-bearing structural parts as cast metal parts, which is made possible by modern casting methods, which make it possible to manufacture cast components even with small wall thicknesses. Of particular interest here are so-called large cast components, which combine a plurality of longitudinal and transverse members, for example in the front axle or rear axle area of ​​a vehicle.

[0003] In the case of load-bearing structural parts manufactured as cast metal components, problems arise in the event of a collision of the vehicle, in which damage, in particular cracks, may occur in the cast metal parts. Due to the thin-walled structure of these cast metal parts, cracks cannot be welded without a simultaneous weakening of adjacent areas, for example due to deformation. Therefore, vehicle bodies in which load-bearing structural parts manufactured as cast metal components are damaged are repaired by replacing the load-bearing structural parts. Due to the high degree of integration of load-bearing structural parts manufactured as cast metal components, this involves extremely high costs. In contrast, in the case of load-bearing structural parts assembled from a large number of formed sheet metal parts, ultimately only a small number of formed sheet metal parts need to be replaced in order to repair the load-bearing structural parts.

[0004] DE 100 60 784 A1 already discloses a rear end module for a motor vehicle, wherein, for economical repairs, the rear end module has a rear end center piece with a deflected bumper member screwed to two longitudinal members via deformation elements.

[0005] DE 10 2018 219 987 A1 has disclosed another rear end module for a motor vehicle, wherein the rear end module has a bumper reinforcement which is screwed to the body shell of the motor vehicle.

[0006] EP 2 091 786 B1 discloses a bumper component for a motor vehicle, which has a vibration damper, wherein the vibration damper has a plurality of reinforcement ribs and is filled with foamed aluminum.

[0007] DE 198 13 548 A1 proposes a front end structure for a motor vehicle which is welded to two longitudinal members of the motor vehicle body shell, wherein during a repair operation the welded connection is severed and a replacement part is screwed on.

[0008] US 2018 / 0 244 225 A1 proposes a front end structure of a motor vehicle, which is fastened to two longitudinal members of the motor vehicle body shell by means of replaceable brackets, thereby simplifying repairs in the event of damage to the front end structure.

[0009] DE 10 2008 027 168 A1 discloses a method for repairing a hollow component of a motor vehicle body shell, wherein a damaged area is cut off, two connecting parts are inserted into a cavity of the component and fastened to the component, wherein the connecting parts further protrude from the cavity, a likewise hollow replacement element is pushed onto the protruding section of the connecting parts, and the replacement element is welded to the component. Summary of the invention

[0010] The invention addresses the problem of specifying an improved method for repairing load-bearing structural parts of a vehicle body which are produced as cast metal parts, the method being distinguished in particular by the fact that the repair can be carried out inexpensively.

[0011] The method according to the invention, the load-bearing structural part suitable for said method and the motor vehicle equipped with said load-bearing structural part are based on the general concept of defining a repair zone in the load-bearing structural part, in which repair zone the probability of damage to the load-bearing structural part increases in the event of an overload of the load-bearing structural part. A repair zone of said type can be determined by tests and by calculation in conjunction with typical misuse forces, such as those which may occur, for example, in the event of a collision. It is further proposed that the load-bearing structural part is equipped with a rib structure at least in the repair zone, which rib structure forms cavities on the load-bearing structural part, which cavities are open at the longitudinal sides of the load-bearing structural part. Such a rib structure forming open cavities can be realized particularly easily in the case of a load-bearing structural part manufactured as a cast metal part. These cavities are open, for example, in the removal direction of the casting mold core.

[0012] In the context of the repair method according to the invention, in the case of damage to the load-bearing structural part in the repair zone, the rib structure can now be used for the attachment of a reinforcement, wherein the reinforcement reinforces the load-bearing structural part in the repair zone. Here, a prefabricated reinforcement can be used, since the load-bearing structural part is already suitable or ready for the attachment of such a reinforcement in the repair zone. Thus, an effective repair of the load-bearing structural part is possible without the need for a complete disassembly of the load-bearing structural part from the rest of the vehicle body for this purpose. Thus, for the repair of the vehicle, it is essentially sufficient that the corresponding load-bearing structural part is exposed to such an extent that the rib structure in the repair zone is accessible.

[0013] The load-bearing structural part can be, for example, a lateral longitudinal member located in the front or rear end region of the vehicle and can serve to support conventional longitudinal members which support the bumper. Furthermore, the load-bearing structural part can preferably be a component of the bodyshell structure of the vehicle body. In particular, the cast metal component can be a large cast part which has a plurality of longitudinal member segments and a plurality of transverse member segments and which forms the bodyshell structure, for example, at the rear end or the front end of the vehicle.

[0014] Damage to load-bearing structural parts may be material weakening, especially cracks.

[0015] According to a first embodiment, the reinforcement can be an insert part or can be formed by an insert part. Here, the insert part is configured as a negative form of the rib structure on its front side and has a slot structure complementary to the rib structure accordingly. In order to strengthen the repair area, the insert part can now be inserted into the load-bearing structure part so that the ribs of the rib structure engage in the slots of the slot structure. At the same time, the cavity in the area of ​​the insert part is therefore at least partially filled by the insert part. This significantly reinforces the rib structure and therefore the load-bearing structure part by the insert part inserted therein. The insert part is finally fixedly connected to the load-bearing structure part. This connection can be implemented, for example, by adhesives, rivets, screws, welding or brazing.

[0016] The insert part can be a metal part, such as a cast part or a milled part. Likewise, the insert part can be a plastic part, in particular made of fiber reinforced plastic, preferably made of glass fiber reinforced or carbon fiber reinforced plastic.

[0017] According to an independent second embodiment, the rib structure in the repair area can have a plurality of domes with screw holes arranged in a hole pattern. The reinforcement can now have or be formed by a plate, wherein the plate has a plurality of passage holes arranged according to the hole pattern. The plate can now be fastened to the load-bearing structural part in the repair area by screws, wherein the respective screw engages through one of the passage holes and is screwed into one of the screw holes of the dome. In this second embodiment, the load-bearing structural part is thus prepared in the repair area for subsequent mounting of the plate as required, which simplifies the repair of the load-bearing structural part by the attachment of the plate. The domes integrated into the rib structure can be easily realized during the casting of the load-bearing structural part if the longitudinal axis of the domes extends parallel to the removal direction of the casting core.

[0018] The screw holes of the domes can be configured to be unthreaded before the repair operation, wherein thread-forming screws are used for the threaded attachment of the plate. Unthreaded screw holes can be realized particularly easily during the casting of the load-bearing structural part. This second embodiment and the first embodiment can also be combined by equipping the insert part with a passage opening according to the hole pattern of the screw holes, wherein the slot structure can take into account the domes.

[0019] According to an independent third embodiment, the reinforcement may have or be formed of structural foam. The structural foam is injected into the cavity in the repair area so that the structural foam fills the cavity and reinforces the rib structure. The hardened structural foam produces a significant reinforcement and thus the rib structure in the repair area is stabilized, which produces the desired reinforcement of the load-bearing structural part. The structural foam may be a plastic foam or a metal foam. This third embodiment and the second embodiment may also be combined by filling the cavity with structural foam before or after the panels are attached.

[0020] In an advantageous improvement of the third embodiment, a cover element can be fastened to the load-bearing structural part, the cover element covering the chamber at the longitudinal side of the load-bearing structural part at least in the repair area, and the cover element has a foam introduction opening arranged in the repair area. Accordingly, after the cover element has been fastened to the load-bearing structural part, the structural foam can be injected into the chamber through the foam introduction opening. This simplifies the formation of a coherent structural foam block, which fills a plurality of chambers in the area with damage and thus achieves the desired reinforcement of the load-bearing structural part in the area with damage. The cover element can be a plastic part. However, the cover element is preferably a metal part, in particular a formed sheet metal part. In particular, the cover part can be a plate of the second embodiment, for which purpose, the plate is equipped with a foam introduction opening. The cover element can advantageously be fastened to the load-bearing structural part by screws. Threaded forming screws can be used here. Screw positions can be integrally formed on the load-bearing structural part, which are suitable for the attachment of screws. Here, such screw positions can be located inside and outside the rib structure.

[0021] According to another development of the third embodiment, partitioning elements can be inserted into the rib structure on both sides of the damage on the load-bearing structural part. This is advantageously done before the structural foam is injected, in particular before the cover element (which is used where applicable) is attached. The area with the damage is delimited within the rib structure by the partitioning elements, so that only the cavities in this area are filled with foam.

[0022] It can advantageously be provided that the above-mentioned cover element is mounted on the load-bearing structural part after the partitioning elements have been attached and before the structural foam is applied by injection, so that the cover element covers the partitioning elements. When the structural foam is injected through the foam introduction openings located between the partitioning elements, the structural foam can only spread in the space delimited by the load-bearing structural part, the partitioning elements and the cover element. Thus, a particularly effective reinforcement is achieved in areas with damage.

[0023] For reinforcement purposes, the cover element may have a plurality of beads. The beads may advantageously be arranged to define predetermined positions of the partitioning elements so that when the cover element is attached, the partitioning elements each engage in such beads in a positively locking manner.

[0024] The partitioning element may have a configuration complementary to the rib structure so that the partitioning element may be easily inserted into the rib structure. For example, the corresponding partitioning element may have at least one slot into which the rib of the rib structure may engage.

[0025] In an advantageous development of all embodiments, it can be provided that, if the damage is formed by one or more cracks, the respective cracks are welded before the respective reinforcement is attached.

[0026] In an alternative development, which can also be implemented in all embodiments, it is proposed that before the reinforcement is attached, the end section of the load-bearing structural part with damage is cut off from the rest of the load-bearing structural part at a predetermined parting surface in the repair area and replaced by a replacement part which also has a rib structure. The parting surface is positioned in the longitudinal direction of the load-bearing structural part so that the damage in the event of a collision is likely to be located between the parting surface and the longitudinal end of the load-bearing structural part adjacent to said parting surface. Since the parting surface is predetermined, the required replacement part can be precisely defined and stored accordingly and easily installed after the damaged end section has been cut off.

[0027] The replacement part can advantageously be welded along the parting plane to the remainder of the load-bearing structural part, wherein the corresponding reinforcement is then additionally attached.

[0028] The rib structure is arranged on the replacement part such that it adjoins seamlessly with the rib structure of the rest of the load-bearing structural part, thereby forming a matching continuous transition.If a dome with screw openings is used according to the second embodiment, the replacement part is also equipped with such a dome.

[0029] The vehicle according to the invention, which is preferably a passenger motor vehicle, comprises a body having at least one load-bearing structural part manufactured as a cast metal component. The load-bearing structural part has a repair zone in which damage to the load-bearing structural part may occur in the event of an overload of the load-bearing structural part. The load-bearing structural part has a rib structure at least in this repair zone, which forms cavities on the load-bearing structural part, which cavities are open at the longitudinal sides of the load-bearing structural part. The load-bearing structural part can now be prepared in a non-repaired state for repair of the corresponding structural part according to the above-described method. Accordingly, in order to repair the load-bearing structural part in the repair zone, reinforcements can be attached, which strengthen the load-bearing structural part. In contrast, in the repaired state, the load-bearing structural part may have been repaired according to the above-described method. Therefore, the load-bearing structural part has been strengthened by attaching corresponding reinforcements.

[0030] Further important features and advantages of the invention will emerge from the text which follows, from the drawings and from the associated description of the drawings based on the drawings.

[0031] In general, the present invention provides the following technical solutions 1 and 10, and the following 2-9 are preferred technical solutions of the present invention:

[0032] 1. A method for repairing a load-bearing structural part (4) of a vehicle body (2) which is manufactured as a cast metal part,

[0033] The load-bearing structural component (4) has a repair area (9) in which damage (8) to the load-bearing structural component (4) may occur in the event of an overload of the load-bearing structural component (4).

[0034] The load-bearing structural part (4) has a rib structure (10) at least in the repair region (9), which rib structure forms cavities (11) on the load-bearing structural part (4), which cavities (11) are open at the longitudinal sides of the load-bearing structural part (4),

[0035] In the method, in the event of damage (8) to the load-bearing structural part (4) in the repair area (9), the rib structure (10) is used for the attachment of a reinforcement (12) which reinforces the load-bearing structural part (4) in the repair area (9).

[0036] 2. The method as described in 1 above,

[0037] It is characterized in that

[0038] the reinforcement (12) comprises an insert part (13) or is formed by the insert part, wherein the insert part (13) has a slot structure (14) on its front side which is complementary to the rib structure (10),

[0039] - in order to reinforce the repair area (9), the insert part (13) is inserted into the load-bearing structural part (4) so ​​that the ribs (16) of the rib structure (10) engage in the slots (15) of the slot structure (14) and so that the chambers (11) in the region of the insert part (13) are at least partially filled by the insert part (13),

[0040] - The insert part (13) is fixedly connected to the load-bearing structural part (4).

[0041] 3. The method as described in 1 above,

[0042] It is characterized in that

[0043] - the rib structure (10) in the repair area (9) has a plurality of domes (17) with screw holes (18) arranged in a hole pattern,

[0044] the reinforcement (12) comprises or is formed by a plate (19) having a plurality of passage holes (20) arranged according to the hole pattern,

[0045] The plate (19) is fastened to the load-bearing structural part (4) in the repair area (9) by means of screws (21), wherein the respective screw (21) engages through one of the passage holes (20) and is screwed into one of the screw holes (18).

[0046] 4. The method as described in 3 above,

[0047] It is characterized in that

[0048] The screw holes (18) are unthreaded before the repair operation and the screws (21) are configured as thread-forming screws.

[0049] 5. The method as described in 1 above,

[0050] It is characterized in that

[0051] The reinforcement (12) comprises structural foam (28) or is formed from the structural foam, wherein the structural foam (28) is injected into the cavities (11) in the repair area (9), so that the structural foam (28) fills the cavities (11) and reinforces the rib structure (10).

[0052] 6. The method as described in 5 above,

[0053] It is characterized in that

[0054] a cover element (30) is fastened to the load-bearing structural part (4), which cover element covers the chambers (11) at the longitudinal sides of the load-bearing structural part (4) at least in the repair region (9) and which has a foam introduction opening (32) in the repair region (9),

[0055] After the cover element (30) has been fastened to the load-bearing structural part (4), the structural foam (28) is injected into the chambers (11) through the foam introduction opening (32).

[0056] 7. The method as described in 6 above,

[0057] It is characterized in that

[0058] - before the cover element (30) is attached to the load-bearing structural part (4), partitioning elements (29) are each inserted into the rib structure (10) on both sides of the lesion (8),

[0059] - the partitioning elements (29) are covered by the cover element (30) after the cover element (30) has been attached to the load-bearing structural part (4),

[0060] - During the injection of the structural foam (28), the partitioning elements (29) limit the spread of the structural foam (28) within the repair zone (9).

[0061] 8. The method according to any one of 1 to 7 above,

[0062] It is characterized in that

[0063] If the damage (8) is formed by one or more cracks, the corresponding cracks are welded before the reinforcement (12) is attached.

[0064] 9. The method according to any one of 1 to 7 above,

[0065] It is characterized in that

[0066] - before the reinforcement (12) is attached, the end section (24) of the load-bearing structural part (4) having the damage (8) is severed from the rest of the load-bearing structural part (4) at a predetermined parting plane (22) within the repair zone (9) and replaced by a replacement part (26),

[0067] - the replacement part (26) is welded to the rest of the load-bearing structural part (4) along the parting surface (22),

[0068] - The reinforcement (12) is then attached.

[0069] 10. A vehicle (1), in particular a passenger motor vehicle,

[0070] A vehicle body (2) having at least one load-bearing structural part (4) produced as a cast metal component,

[0071] The load-bearing structural component (4) has a repair area (9) in which damage (8) to the load-bearing structural component (4) may occur in the event of an overload of the load-bearing structural component (4).

[0072] The load-bearing structural part (4) has a rib structure (10) at least in the repair region (9), which rib structure forms cavities (11) on the load-bearing structural part (4), which cavities (11) are open at the longitudinal sides of the load-bearing structural part (4),

[0073] The load-bearing structural part (4) is prepared to be repaired according to any of the methods described in 1 to 9 above, so that a reinforcement (12) that strengthens the load-bearing structural part (4) is attachable in the repair area (9), or the load-bearing structural part has been repaired according to any of the methods described in 1 to 9 above, so that the load-bearing structural part (4) has been reinforced in the repair area (9) by the reinforcement (12) attached to the load-bearing structural part.

[0074] It goes without saying that the features mentioned above and those still to be discussed below can be used not only in the combination described in the corresponding manner, but also in other combinations or individually without departing from the scope of the present invention. The components of the superordinate units mentioned above and to be mentioned below and specified separately (e.g. components of devices, equipment or arrangements) can form separate structural parts or components of the units or can be constituent regions or sections of the units, even if different situations are shown in the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0075] Preferred exemplary embodiments of the invention are illustrated in the drawings and will be discussed in more detail in the following description, wherein identical or similar or functionally identical components are denoted by the same reference numerals.

[0076] In the figures, schematically in each case,

[0077] Figure 1 shows a side view of a vehicle body which is partially opened in the region of the load-bearing structural parts,

[0078] Figure 2 An enlarged side view of the load-bearing structural part in the repair area is shown.

[0079] Figure 3 shows a highly simplified isometric view of a section of a load-bearing structural part with a repair zone in a first embodiment,

[0080] Figure 4 An isometric view of the inserted part is shown.

[0081] Figure 5 shows an isometric view of an insert part before it is inserted into a load-bearing structural part,

[0082] Figure 6 shows an isometric view of the insert part after it has been inserted into the load-bearing structure part,

[0083] Figure 7 shows a highly simplified isometric view of the load-bearing structural parts in the region of the repair zone in a second embodiment,

[0084] Figure 8 Shows Figure 7 Isometric view of the load-bearing structural part during removal of the end segment,

[0085] Fig. 9 Shows Figure 7 Isometric view of a load-bearing structural part during attachment of a replacement part,

[0086] Fig.10 Shows Figure 7Isometric view of the load-bearing structural parts before the panels are installed.

[0087] Fig.11 Shows Figure 7 An isometric view of the load-bearing structural parts after the panels have been installed.

[0088] Fig.12 The following diagram shows how the partitioning element is attached during the attachment according to the third embodiment. Figure 1 The isometric view shown,

[0089] Fig.13 The following diagram shows how the cover element is attached during the Fig.12 The view shown,

[0090] Fig.14 It is shown that during the introduction of the structural foam Fig.13 The view shown,

[0091] Fig.15 Shown as Fig.14 Shown is a view after the introduction of the structural foam. DETAILED DESCRIPTION

[0092] according to Figure 1 The motor vehicle 1, which is only shown in a preliminary manner and which may preferably be a passenger motor vehicle, has a body 2, which is shown here only in the rear end region. Figure 1 In the example shown, the vehicle body 2 is partially opened so that the inner hidden vehicle body shell structure 3 is at least partially visible. The vehicle body 2 has, in particular, at least one load-bearing structural part 4 manufactured as a cast metal component in the vehicle body shell structure 3. In the example shown here, the load-bearing structural part 4 can form a longitudinal member in the rear end vehicle body shell structure 3. In particular, the load-bearing structural part 4 can be a large cast part forming the load-bearing structure of the vehicle body shell, which cast part includes a plurality of longitudinal member segments and a plurality of transverse member segments. In the example shown, the longitudinal members or longitudinal member segments (shown here) of the load-bearing structural part 4 can form, for example, in the area of ​​the rear axle, a transition from the floor structure 5 to the longitudinal member 6 located at a higher level, to which the rear end bumper (not shown here) can be fastened. The longitudinal member 6 can be formed as a shaped sheet metal part in a conventional manner and inserted into the load-bearing structural part 4 and fastened to the load-bearing structural part. In the event of a collision, rear end forces 7 can be transmitted to the load-bearing structural part 4 according to the arrows via the rear end bumper and the longitudinal member 6, which forces can cause damage 8 in the load-bearing structural part 4 ( Figure 2 , Figure 3 , Figure 7 and Fig.12Since the load-bearing structural part 4 is designed as a cast metal component and can be manufactured here in particular from a light metal alloy, preferably from an oxidized aluminum alloy, it cannot be easily repaired. In particular, damage in the form of material weakening or cracks cannot be easily welded, since the associated heat introduction can be associated with deformations and sometimes also structural changes, which can significantly weaken the load-bearing structural part 4 on both sides of such a weld seam. This applies all the more the smaller the wall thickness of the cast load-bearing structural part 4.

[0093] To make repairs easier, Figures 1 to 3 and Figures 5 to 12 The load-bearing structural part 4 has a repair zone 9 in which damage 8 of the load-bearing structural part 4 preferentially occurs in the event of an overload of the load-bearing structural part 4. For example, at the transition between the conventional longitudinal member 6 and the load-bearing structural part 4, there may be a step change in stiffness. It must be expected that in the event of an overload of the load-bearing structural part 4, damage 8 will preferentially occur in the area of ​​such a step change in stiffness. The load-bearing structural part 4 is now equipped, at least in the repair zone 9, with a rib structure 10 which forms a cavity 11 on the load-bearing structural part 4, the cavity 11 being open at the longitudinal side of the load-bearing structural part 4. Figures 1 to 3 and Figures 5 to 15 In the embodiment, the longitudinal side of the load-bearing structural part 4 in question faces the observer. In the vehicle 1, accordingly, the longitudinal side preferably faces the outside of the vehicle, whereby it is easily accessible for repair work. For example, only panel parts, such as fenders, need to be removed.

[0094] If damage 8 occurs in the load-bearing structural part 4, the load-bearing structural part 4 can be repaired because in the repair area 9 the rib structure 10 is used to Figures 4 to 6 , Fig.10 , Fig.11 and Fig.14 Attachment of the reinforcement 12 shown in FIG. This reinforcement 12 then strengthens or reinforces the structural part 4 in the repair zone 9, that is to say in the rib structure 10 on both sides of the damage 8. Three embodiments of specific configurations of this reinforcement 12 will be presented below, in particular, Figures 3 to 6 The first embodiment of Figures 7 to 11 The second embodiment in, and Figures 12 to 15 These three embodiments can be used advantageously alternatively, although they can also be combined with one another as described further above.

[0095] According to the first embodiment, according to Figures 3 to 6 The reinforcement 12 can have an insert part 13 or be formed by an insert part 13. Figure 4In the embodiment of the present invention, on its front side facing the observer, the insert part 13 has a slot structure 14 which is complementary to the rib structure 10 and is therefore configured as a negative version of the rib structure 10. Correspondingly, the slot structure 14 has slots 15 into which ribs 16 of the rib structure 10 can engage if the insert part 13 is inserted into the load-bearing structure part 4.

[0096] according to Figure 5 and Figure 6 Accordingly, in order to reinforce the repair region 9 , the insert part 13 can be positioned with its front side facing the longitudinal side of the load-bearing structural part 4 and inserted into the load-bearing structural part 4 . Figure 5 shows the state before the insertion part 13 is inserted, and Figure 6 The insert part 13 is shown already inserted into the load-bearing structural part 4. For this purpose, the rib 16 engages in the slot 15, wherein the insert part 13 at least partially fills the cavity 11. This enables a positive locking, a strong reinforcement of the rib structure 10 and thus of its load-bearing structural part 4. In addition, the insert part 13 can be fixedly connected to the load-bearing structural part 4. This can be performed using a connection technique not shown here, such as adhesive bonding, rivets, screws, welding or brazing. The damage 8 can optionally be welded before the insert part 13 is inserted.

[0097] According to the second embodiment, according to Figures 7 to 11 , the rib structure 10 can have a plurality of domes 17 in the repair region 9, each dome having a screw hole 18. The domes 17 with their screw holes 18 advantageously have the same demoulding direction as the ribs 16 of the rib structure 10, so that the domes can be easily integrated into the rib structure 10. If the longitudinal side of the load-bearing structural part 4 lies in a longitudinal side plane, the demoulding direction extends perpendicularly to the longitudinal side plane. Accordingly, the domes 17 and the screw holes 18 also extend perpendicularly to the longitudinal side plane.

[0098] In this second solution, the reinforcement 12 has a plate 19 or is formed by said plate 19. The plate 19 has a plurality of passage holes 20 which are arranged in the same hole pattern as the screw holes 18 of the dome 17. Fig.10 and Fig.11 , the plate 19 can thus be fastened to the load-bearing structural part 4 in the repair region 9 by means of screws 21. Here, the respective screw 21 engages in each case through one of the passage holes 20 and is screwed into one of the screw holes 18. For this purpose, a corresponding thread can be cut in the screw hole 18. The screw 21 can advantageously be designed as a thread-forming screw, so that a thread is automatically formed in the screw hole 18 when the screw 21 is screwed in.

[0099] Figures 7 to 11Advantageous modifications are also shown, which can optionally be used for the first or second embodiment and can basically also be used for the third embodiment, although they are only described in more detail here in conjunction with the second embodiment.

[0100] according to Figure 7 , a parting surface 22 indicated by a dotted line can be defined on the load-bearing structural part 4 in the repair region 9, the parting surface being positioned on the load-bearing structural part 4 along the longitudinal direction of the load-bearing structural part 4, so that the damage 8 is likely to be located between a longitudinal end 23 of the load-bearing structural part 4 and the parting surface 22. The longitudinal end 23 is advantageously the longitudinal end of the load-bearing structural part 4 adjacent to the parting surface 22. Here, the parting surface 22 is located in the repair region 9 and in the rib structure 10.

[0101] To repair the load-bearing structural part 4, according to Figure 4 , the end section 24 of the load-bearing structural part 4 having the damage 8 can now be separated from the rest of the load-bearing structural part 4 along the parting plane 22. The removal of the damaged end section 24 is Figure 8 Indicated by arrow 25. Fig. 9 , the removed end section 24 is replaced by a replacement part 26, which is attached to the remaining undamaged load-bearing structure part 4 according to arrow 27. The replacement part 26 also has a rib structure 10 and is shaped so that it can be attached to the remaining load-bearing structure part 4 almost seamlessly or without a transition. After the replacement part 26 is attached to the rest of the load-bearing structure part 4, the two parts are welded to each other along the parting surface 22. Here, the parting surface 22 can be positioned in a targeted manner in particular so that during the welding operation along the parting surface 22, the possibility of deformation of the welding object is minimized.

[0102] After the replacement part 26 has been welded to the remaining load-bearing structural part 4, the load-bearing structural part 4 is complete again, but weakened by the weld seam. In order to compensate for this weakening, a reinforcement 12 is then attached according to the embodiment proposed here. Figures 7 to 11 In the example, plate 19 is screwed on.

[0103] According to the third embodiment, according to Figures 12 to 15 , a reinforcement 12 formed of a suitable structural foam 28 (not shown here) can be provided or have such a structural foam 28. Hardened plastic foams or metal foams are particularly suitable here. For this purpose, the structural foam 28 is injected into some or all of the cavities 11 in the repair area 9, so that the structural foam 28 fills the cavity 11 in question and thus reinforces the rib structure 10. Fig.12Optionally, before the structural foam 28 is injected, the spread of the structural foam 28 can be limited by partitioning elements 29, which for this purpose are inserted into the rib structure 10 on both sides of the damage 8. In the example shown here, the load-bearing structural part 4 has a substantially U-shaped cross-sectional profile in its longitudinal direction. The area to be filled with foam is delimited in the longitudinal direction of the load-bearing structural part 4 by the partitioning elements 29, while the lateral spread of the structural foam 28 with respect to the longitudinal direction is delimited by the profile of the load-bearing structural part 4, except for the longitudinal side to which the cavity 11 is open. In order to enable the area to be filled with foam to be delimited also at this longitudinal side, according to Figures 13 to 15 , a cover element 30 can optionally be used which is fastened to the load-bearing structural part 4 so that at least in the repair area 9 the chamber 11 is covered at the longitudinal sides of the load-bearing structural part 4. Here, the cover element 30 also covers the partitioning elements 29 which may be provided. Figures 13 to 15 , the cover element 30 can have a plurality of beads 31 which, on the one hand, reinforce the cover element 30 and, on the other hand, are positioned on the side of the cover element 30 facing the rib structure 10 so that the partitioning elements 29 can engage therein. In this way, the positioning of the partitioning elements 29 within the rib structure 10 can be specified by the beads 31 of the cover element 30. At the same time, by this positive locking engagement between the partitioning elements 29 and the cover element 30, the area that can be filled with foam is defined in an effective manner.

[0104] In the repair area 9, the cover element 30 has a foam introduction opening 32, according to Fig.14 The structural foam 28 can be introduced into the rib structure 10 by foam introduction into the rib opening, in particular by injection, wherein the propagation of the structural foam 28 is bounded by the partitioning element 29, the cover element 30 and the load-bearing structural part 4 to the area on both sides of the damage 8.

[0105] The cover element 30 may be fastened to the load-bearing structure part 4 and / or to the periphery of the load-bearing structure part 4, for example by means of screws 33. The partitioning element 29 and the cover element 30 may be plastic parts or metal parts, in particular formed sheet metal parts.

[0106] according to Fig.15 After the rib structure 10 has been filled with foam in the region having the damage 8 , the foam introduction opening 32 can be closed by a closing element 34 , which can be a plastic plug, for example.

Claims

1. A method for repairing a load-bearing structural part (4) of a vehicle body (2) which is manufactured as a cast metal part, The load-bearing structural component (4) has a repair area (9) in which damage (8) to the load-bearing structural component (4) may occur in the event of an overload of the load-bearing structural component (4). The load-bearing structural component (4) has a rib structure (10) at least in the repair area (9), The rib structure forms cavities (11) on the load-bearing structural part (4), which cavities (11) are open at the longitudinal sides of the load-bearing structural part (4), which longitudinal sides face the outside of the vehicle, whereby the longitudinal sides are easily accessible for repair work; In the method, in the case of damage (8) to the load-bearing structural part (4) in the repair area (9), the rib structure (10) is used for the attachment of reinforcements (12), which reinforce the load-bearing structural part (4) in the repair area (9) within the rib structure on both sides of the damage (8), characterized in that: the reinforcement (12) comprises an insert part (13) or is formed by the insert part, wherein the insert part (13) has a slot structure (14) on its front side which is complementary to the rib structure (10), - in order to reinforce the repair area (9), the insert part (13) is inserted into the load-bearing structural part (4) so ​​that the ribs (16) of the rib structure (10) engage in the slots (15) of the slot structure (14) and so that the chambers (11) in the region of the insert part (13) are at least partially filled by the insert part (13), - The insert part (13) is fixedly connected to the load-bearing structural part (4).

2. The method according to claim 1, It is characterized in that If the damage (8) is formed by one or more cracks, the corresponding cracks are welded before the reinforcement (12) is attached.

3. The method according to claim 1, It is characterized in that - before the reinforcement (12) is attached, the end section (24) of the load-bearing structural part (4) having the damage (8) is severed from the rest of the load-bearing structural part (4) at a predetermined parting plane (22) within the repair zone (9) and replaced by a replacement part (26), - the replacement part (26) is welded to the rest of the load-bearing structural part (4) along the parting surface (22), - The reinforcement (12) is then attached.

4. A method for repairing a load-bearing structural part (4) of a vehicle body (2) which is manufactured as a cast metal part, The load-bearing structural component (4) has a repair area (9) in which damage (8) to the load-bearing structural component (4) may occur in the event of an overload of the load-bearing structural component (4). The load-bearing structural component (4) has a rib structure (10) at least in the repair area (9), The rib structure forms cavities (11) on the load-bearing structural part (4), which cavities (11) are open at the longitudinal sides of the load-bearing structural part (4), which longitudinal sides face the outside of the vehicle, whereby the longitudinal sides are easily accessible for repair work; In the method, in the case of damage (8) to the load-bearing structural part (4) in the repair area (9), the rib structure (10) is used for the attachment of reinforcements (12) which reinforce the load-bearing structural part (4) in the repair area (9) within the rib structure on both sides of the damage (8). It is characterized in that - the rib structure (10) in the repair area (9) has a plurality of domes (17) with screw holes (18) arranged in a hole pattern, the reinforcement (12) comprises or is formed by a plate (19) having a plurality of passage holes (20) arranged according to the hole pattern, The plate (19) is fastened to the load-bearing structural part (4) in the repair area (9) by means of screws (21), wherein the respective screw (21) engages through one of the passage holes (20) and is screwed into one of the screw holes (18).

5. The method according to claim 4, It is characterized in that The screw holes (18) are unthreaded before the repair operation and the screws (21) are configured as thread-forming screws.

6. The method according to claim 4, It is characterized in that If the damage (8) is formed by one or more cracks, the corresponding cracks are welded before the reinforcement (12) is attached.

7. The method according to claim 4, It is characterized in that - before the reinforcement (12) is attached, the end section (24) of the load-bearing structural part (4) having the damage (8) is severed from the rest of the load-bearing structural part (4) at a predetermined parting plane (22) within the repair zone (9) and replaced by a replacement part (26), - the replacement part (26) is welded to the rest of the load-bearing structural part (4) along the parting surface (22), - The reinforcement (12) is then attached.

8. A method for repairing a load-bearing structural part (4) of a vehicle body (2) which is manufactured as a cast metal part, The load-bearing structural component (4) has a repair area (9) in which damage (8) to the load-bearing structural component (4) may occur in the event of an overload of the load-bearing structural component (4). The load-bearing structural component (4) has a rib structure (10) at least in the repair area (9), The rib structure forms cavities (11) on the load-bearing structural part (4), which cavities (11) are open at the longitudinal sides of the load-bearing structural part (4), which longitudinal sides face the outside of the vehicle, whereby the longitudinal sides are easily accessible for repair work; In the method, in the case of damage (8) to the load-bearing structural part (4) in the repair area (9), the rib structure (10) is used for the attachment of reinforcements (12) which reinforce the load-bearing structural part (4) in the repair area (9) within the rib structure on both sides of the damage (8). It is characterized in that the reinforcement (12) comprises a structural foam (28) or is formed from the structural foam, wherein the structural foam (28) is injected into the chambers (11) in the repair area (9) so that the structural foam (28) fills the chambers (11) and reinforces the rib structure (10), a cover element (30) is fastened to the load-bearing structural part (4), which cover element covers the chambers (11) at the longitudinal sides of the load-bearing structural part (4) at least in the repair region (9) and which has a foam introduction opening (32) in the repair region (9), After the cover element (30) has been fastened to the load-bearing structural part (4), the structural foam (28) is injected into the chambers (11) through the foam introduction opening (32).

9. The method as claimed in claim 8, It is characterized in that - before the cover element (30) is attached to the load-bearing structural part (4), partitioning elements (29) are each inserted into the rib structure (10) on both sides of the lesion (8), - the partitioning elements (29) are covered by the cover element (30) after the cover element (30) has been attached to the load-bearing structural part (4), - During the injection of the structural foam (28), the partitioning elements (29) limit the spread of the structural foam (28) within the repair zone (9).

10. The method according to claim 8, It is characterized in that If the damage (8) is formed by one or more cracks, the corresponding cracks are welded before the reinforcement (12) is attached.

11. The method according to claim 8, It is characterized in that - before the reinforcement (12) is attached, the end section (24) of the load-bearing structural part (4) having the damage (8) is severed from the rest of the load-bearing structural part (4) at a predetermined parting plane (22) within the repair zone (9) and replaced by a replacement part (26), - the replacement part (26) is welded to the rest of the load-bearing structural part (4) along the parting surface (22), - The reinforcement (12) is then attached.

12. A vehicle (1), A vehicle body (2) having at least one load-bearing structural part (4) produced as a cast metal component, The load-bearing structural component (4) has a repair area (9) in which damage (8) to the load-bearing structural component (4) may occur in the event of an overload of the load-bearing structural component (4). wherein the load-bearing structural component (4) has a rib structure (10) at least in the repair region (9), which rib structure forms cavities (11) on the load-bearing structural component (4), which cavities (11) are open at a longitudinal side of the load-bearing structural component (4), which longitudinal side faces the outside of the vehicle, whereby the longitudinal side is easily accessible for repair work; The load-bearing structural part (4) is prepared to be repaired according to the method described in any one of the preceding claims 1 to 11, so that a reinforcement (12) that strengthens the load-bearing structural part (4) is attachable in the repair area (9), or the load-bearing structural part has been repaired according to the method described in any one of the preceding claims 1 to 11, so that the load-bearing structural part (4) has been reinforced in the repair area (9) within the rib structure on both sides of the damage (8) by the reinforcement (12) attached to the load-bearing structural part.

13. The vehicle according to claim 12, It is characterized in that The vehicle is a passenger motor vehicle.

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