Rocker reinforcement for electric vehicles

Abstract

The reinforced rocker assembly has a cross-sectionally closed reinforcement located in a hollow volume formed between the rocker members, wherein the reinforcement is assembled to the rocker members in the transition zone between the upper horizontal wall and the upper flange of the rocker members and in the transition zone between the lower horizontal wall and the lower flange of the rocker members, and wherein in the transition zones the angles α and β formed between the flanges and the branches of the reinforcement extending outward from the rocker members are comprised between 90° and 180°.

Description

Technical Field

[0001] This invention relates to rocker arm reinforcement for electric vehicles. Background Technology

[0002] The increasing concentration of carbon dioxide in the atmosphere, along with environmental issues and regulations associated with local air pollution levels, are driving the rise of electric vehicles. Compared to traditional internal combustion engine vehicles, electric vehicles have smaller engines, no fuel tanks, and no exhaust systems. On the other hand, electric vehicles have considerably larger battery packs, which are absent in internal combustion engines.

[0003] In the case of electric vehicles, there is a large battery pack that needs to be protected. Several types of vehicles, including conventional internal combustion engine vehicles without battery packs, can be produced on the same platform.

[0004] The side structure near the battery must be reinforced. A necessary structural element, especially for protecting the battery pack in the event of a side collision, is a rocker assembly. The rocker assembly includes an inner rocker and an outer rocker, each of which is substantially U-shaped with an upper flange and a lower flange. The inner and outer rockers are assembled together to form a closed cross-section defining a hollow volume extending along the bottom of the vehicle.

[0005] To reinforce the joystick assembly, one possibility is to include one or more reinforcing members inside the hollow volume of the joystick assembly. Such reinforcing members can have open or closed cross-sections.

[0006] The open-section reinforcement can be easily assembled to the flange and the vertical walls of the rocker inner and outer components by welding or mechanical assembly. Such a welding process will naturally be incorporated into the vehicle assembly sequence, because in any case, even in the absence of reinforcement components, there are welding steps to secure the lower and upper flanges of the inner and outer rocker panels together.

[0007] On the other hand, stiffeners with closed cross-sections generally exhibit better resistance to compressive loads caused by impacts and will also have better stiffness performance. However, such stiffeners cannot structurally include surfaces that allow for easy assembly of the stiffener onto the flanges of the rocker inner and outer components. Furthermore, to maximize the strengthening effect, it is of interest to design a stiffener with a cross-section that occupies the maximum possible space within the hollow volume of the rocker assembly.

[0008] This configuration, where the reinforcing element occupies a large space within the rocker assembly due to its closed cross-section, presents challenges in effectively assembling the reinforcing element to the rocker inner and / or outer components. One issue is the accessibility of assembly tools, such as welding tools. Another issue is the geometric tolerances required to ensure proper assembly: the rocker inner and outer components, as well as the reinforcing element, are made of high-strength materials, such as steel, and they cover a significant portion of the vehicle's cabin length. For example, the well-known springback problem arises because dimensional tolerances of the components before assembly make it difficult to secure all parts together. Another issue is the mechanical efficiency of the rocker assembly and the reinforcing element. In fact, a simple problem with the aforementioned issues of tool accessibility and geometric tolerances is that the reinforcing element is only secured to the rocker inner and / or outer components at the front and rear ends of the assembly, which are easily accessible. However, when this is done, the reinforcing element, as well as the rocker inner and outer components, will not fit optimally in the event of a collision. For example, in the event of a pole collision, which is a very localized assembly request, the pole penetration will cause the rocker arm outer component, reinforcement, and rocker arm inner component to bend successively. Because the reinforcement is not attached to the rocker arm inner and outer components along the length of the vehicle, the bent portion of the reinforcement is not prevented from bending by the surrounding portions of the rocker arm inner and outer components. Therefore, the pole penetration will be higher than in the case where the reinforcement is fixed to the rocker arm inner and outer components along the length of the vehicle, and the resulting pole penetration into the battery pack will be higher, potentially damaging the battery itself. Summary of the Invention

[0009] One of the objectives of this invention is to overcome these challenges by providing a rocker assembly with a closed cross-section reinforcement that occupies a large portion of the hollow volume formed by the rocker assembly.

[0010] For this purpose, the present invention relates to a reinforced rocker assembly having a cross-sectionally closed reinforcing member located in a hollow volume formed between rocker components, wherein the reinforcing member is assembled to the rocker component in a transition region between the upper horizontal wall and the upper flange of the rocker component and in a transition region between the lower horizontal wall and the lower flange of the rocker component, and wherein, in the transition region, angles α and β formed between the flange and the outwardly extending branch of the reinforcing member from the rocker component are between 90° and 180°.

[0011] By applying the above invention, a rocker assembly with a closed-section reinforcement can be formed, which spans the entire vertical space available within the hollow volume, and can be assembled to the rocker component in a continuous or semi-continuous manner along the entire length of the assembly. Due to the excellent mechanical resistance of the closed-section reinforcement, the maximization of available space for such a reinforcement, and the good fit between the rocker component with at least the reinforcement and the reinforcement, the resulting rocker assembly exhibits optimal mechanical resistance in the event of a side impact.

[0012] Considering, individually or in any possible combination of technologies, other optional features of the rocker component according to the invention:

[0013] - The rocker arm assembly with reinforcement is the rocker arm internals.

[0014] - The joystick assembly with reinforcement is the joystick outer part.

[0015] - The reinforcement is made from a single part.

[0016] - The reinforcement is made of at least two different parts assembled together to form the reinforcement.

[0017] - The reinforcement components are assembled using welding with filler wire.

[0018] - The reinforcement components are assembled using MAG welding.

[0019] - The reinforcement is assembled using discontinuous assembly joints in the form of stitches.

[0020] - The stitches are aligned between the upper and lower transition zones.

[0021] - The sutures are offset between the upper and lower transition zones.

[0022] - The reinforcement is also assembled to the vertical wall of the rocker arm internals.

[0023] - The reinforcement is also assembled to the vertical wall of the rocker arm outer component.

[0024] - For any given transverse cross section, the closed section of the stiffener occupies a surface area that is at least 80% larger than the total surface area defined by the hollow volume between the rocker inner and outer members.

[0025] - For any given transverse cross section, the maximum dimension of the stiffener in the elevation direction is at least 75% of the maximum dimension of the hollow volume in the elevation direction, and the maximum dimension of the stiffener in the transverse direction is at least 75% of the maximum dimension of the hollow volume in the transverse direction.

[0026] The present invention also relates to a method for producing a rocker arm assembly as described above, the method comprising the following steps:

[0027] - Provides joystick components

[0028] - Position the reinforcing member with a closed cross-section relative to the rocker arm component in the pre-assembly position.

[0029] - The reinforcing member with a closed cross section is fixed to the rocker assembly by attaching it at least in the transition area between the upper flange and the upper horizontal wall of the rocker assembly and in the transition area between the lower flange and the lower horizontal wall of the rocker assembly.

[0030] - This secures the assembled rocker arm components and reinforcements to the remaining rocker arm components, forming a reinforced rocker arm assembly.

[0031] Due to the specific shape and configuration of the assembly point between the transition zone of the rocker assembly and the reinforcement, the assembly tool necessary to fix the reinforcement to the rocker assembly will have sufficient space to reach the assembly point.

[0032] One advantage of the above process is the flexibility offered by the fact that assembling the reinforcing member with a closed cross-section does not modify the basic assembly process between the inner and outer rocker arms. This means that the same rocker inner and outer assembly process can be performed regardless of the presence of the reinforcing member. Due to this flexibility, vehicles with and without reinforcing members can be produced on the same production line. For example, vehicle platforms including internal combustion engine vehicles and battery electric vehicles can be assembled on the same platform; internal combustion engine vehicles without a battery pack will not require the reinforcing member in the rocker arm assembly, while battery electric vehicles will benefit from the additional battery pack protection provided by the reinforced rocker arm assembly.

[0033] Alternatively, the reinforcement and rocker assembly can be assembled using filler wire welding technology.

[0034] Alternatively, the reinforcement and rocker assembly can be assembled using MAG welding.

[0035] Optionally, the above assembly process may also include the following steps:

[0036] - Assemble the vertical wall of the joystick internals to the reinforcement.

[0037] - Assemble the vertical wall of the joystick outer part to the reinforcement. Attached Figure Description

[0038] Other aspects and advantages of the invention will become apparent when reading the following description, which is given by way of example and with reference to the accompanying drawings, in which:

[0039] - Figure 1This is an overall perspective view of the vehicle according to the present invention.

[0040] - Figure 2 This is a side view of the vehicle according to the present invention.

[0041] - Figure 3 Exploded view of a reinforced rocker assembly according to an embodiment of the present invention

[0042] - Figure 4 , Figure 5 and Figure 6 According to different embodiments of the present invention, the rocker arm component and the reinforcing member are based on Figure 2 The transverse cross section of axis II-II

[0043] - Figure 7 This is a perspective view of the rocker arm component and the reinforcing member according to an embodiment of the present invention.

[0044] - Figure 8a and Figure 8b This is a side view of the rocker arm component and reinforcement according to different embodiments of the present invention.

[0045] - Figure 9 According to an embodiment of the present invention, the reinforced rocker assembly is based on... Figure 2 The transverse cross section of axis II-II. Detailed Implementation

[0046] In the following description, the terms "upper," "lower," "front," "rear," "lateral," and "longitudinal" are defined according to the usual orientation of the installed vehicle. More specifically, the terms "upper" and "lower" are defined according to the vehicle's elevation orientation (or...). Figure 2 The terms "front," "rear," and "longitudinal" are defined according to the vehicle's front / rear direction (or Z-direction). Figure 2 The term "lateral" is defined in the L direction and is defined based on the width of the vehicle.

[0047] Reference Figure 1 and Figure 2 The document describes a reinforcing rocker assembly 3 for an electric or hybrid vehicle 1 (hereinafter simply referred to as the vehicle), the reinforcing rocker assembly 3 having a battery pack 5 located below a floor plate. The reinforcing rocker assembly 3 forms part of the side structure of the vehicle. The reinforcing rocker assembly 3 spans the passenger compartment of the vehicle, which extends longitudinally. The reinforcing rocker assembly 3 can be a standalone component as described in the embodiments below, or it can be incorporated into a larger part, such as into a door ring inner and outer part, each made of a single part stamped from a welded sheet.

[0048] The vehicle's side structure is designed to protect vehicle occupants in the event of a side collision. This type of side collision is described in various standardized crash tests, such as the EuroNCAP side pole impact test, where the vehicle is struck on its side by a fixed pole with an initial relative velocity of 32 km / h. Another standardized side collision test is the EuroNCAP Advanced European Mobile Deformable Barrier (AE-MDB) side collision test, in which the vehicle is struck on its side by a 1400 kg standard barrier that spans a portion of the vehicle's length and travels at a speed of 60 km / h.

[0049] In the case where vehicle 1 has a battery pack 5 located below the floor, the side structure also serves to protect the battery pack 5 from damage. Because the reinforcing rocker assembly 3 is located at the same elevation as the battery pack 5, the reinforcing rocker assembly 3 will directly participate in protecting the battery pack.

[0050] Reference Figure 3 and Figure 9 The reinforced rocker assembly 3 includes two rocker components 31 and 39 that, when assembled together, form a hollow volume 35. The rocker component 31 located closer to the inside of the vehicle is referred to as the inner rocker component 31. The rocker component 39 located closer to the outside of the vehicle is referred to as the outer rocker component 39. The reinforced rocker assembly 3 is reinforced by a reinforcing member 34 that occupies the cross-section of the hollow volume 35 and is closed.

[0051] It should be understood that the hollow volume 35 describes the volume included between the rocker components 31 and 39. This volume does not include the assembly point between the rocker components 31 and 39. For example, this volume does not include the assembly point at the flange. In fact, the flanges are mounted flush to each other and therefore do not include the effective volume between them.

[0052] For clarity, the invention will hereafter be described using the term "rocker inner part 31" as a rocker component to which a reinforcing member with a closed cross section is attached. However, it should be noted that the invention is completely symmetrical between the rocker inner part 31 and the rocker outer part 39. Both the rocker inner part 31 and the rocker outer part 39 have a generally U-shaped cross-section with an upper flange and a lower flange, and both together form the same function of forming a hollow volume 35. Furthermore, when assembled to form the reinforced rocker assembly 3, both individually and collaboratively resist side impacts.

[0053] Reference Figure 4The rocker arm internal component 31 has a generally U-shaped cross-section and includes an upper horizontal wall 312 and a lower horizontal wall 314 connected together by vertical walls 313. It should be noted that the walls 312, 313, and 314 are not necessarily strictly straight and may include different segments, as shown in, for example... Figure 4 In the case of the lower wall 314, the lower wall 314 comprises two vertical segments 314ha and 314hb connected by a vertical segment 314v. This design may be advantageous for accommodating other components, or for securing components and making them more resistant to buckling. Figure 4 The lower wall 314 includes several segments; however, this is a non-limiting specific embodiment. Depending on the limitations and design choices made for a particular application, other walls 312 and 314 may also include several such segments.

[0054] The upper flange 311 and the lower flange 315 extend from the upper horizontal wall 312 and the lower horizontal wall 314, respectively. The flanges are designed to assemble the rocker inner member 31 into a flange facing the rocker outer member 39, for example by spot welding the flanges together in several regions along the length of the rocker inner member and the rocker outer member. Figure 9 The image above depicts the assembled configuration of the reinforced joystick assembly. Figure 9 The assembled opposing flanges of the two rocker components 31 and 39 can be clearly seen above.

[0055] Reference Figure 9 The cross-section closed reinforcement 34, which is hereafter simply referred to as reinforcement 34, occupies a portion of the volume of the hollow volume 35.

[0056] Figure 4 The image depicts the rocker inner member 31 and the reinforcing member 34 in their assembled position before the rocker outer member 39 is further assembled by securing the flanges of the rocker inner member and the rocker outer member together to fully form the reinforced rocker assembly 3. The reinforcing member occupies a portion of the volume included within the walls 312, 313, and 314 and extends outward from that limited volume.

[0057] The reinforcing member 34 is assembled to the rocker inner member 31 in the transition area between the upper flange 311 and the upper horizontal wall 312, and in the transition area between the lower flange 315 and the lower horizontal wall 314. (Refer to...) Figure 4To allow the assembly tool to access the assembly area in the transition zone, the angles α and β defined by the outwardly extending branches of flanges 311, 315 and reinforcement 34 from the rocker inner member are at least 90°. In fact, if either angle α or β is less than 90°, the access area where the assembly tool will need to perform the assembly will be very narrow, requiring specific measurements and the use of specific tools. This will negatively impact assembly costs and production efficiency. It is even possible that the access area will be too narrow for any existing or conceivable assembly tool, making assembly virtually impossible. Limiting angles α and β to a maximum of 180° is also a feature of the invention. In fact, if the angle is greater than 180°, the relative positioning of the outwardly extending branches of reinforcement 34 with flanges 311 or 315 becomes difficult, even outside of industrial applications, as the reinforcement and flange will not easily rest on each other after assembly.

[0058] To further illustrate the assembly between the rocker inner component 31 and the reinforcing member 34 in the upper transition area between the upper wall 312 and the upper flange 311, Figure 4 A magnified view of the assembly area is provided. The joint 316 formed by the assembly tool is embodied to better understand the invention. It should be understood that the specific shape and appearance of the depicted joint 316 are illustrations for illustrative purposes and do not limit the scope of the invention.

[0059] In a particular embodiment, the assembly technique that produces the joint 316 involves a filler wire welding operation, such as a MAG or MIG welding process, which uses filler wire to hold the components together. Another type of filler wire welding technique may be a welding head that uses a laser beam that melts the filler wire.

[0060] Advantageously, by using filler wire welding technology, gaps that may exist between the rocker inner part 31 and the reinforcing member 34 in the aforementioned assembly area can be bridged. In industrial applications, especially when using very high-strength steels susceptible to springback problems, such gaps are frequent, making it impossible to achieve very low geometric tolerances in industrial parts. Advantageously, applying filler wire welding ensures industrial robustness and reproducibility of the assembly process over a wide range of geometric tolerances. It should also be noted that the design of the assembly area between the rocker inner part 31 and the reinforcing member 34 is particularly advantageous for the application of filler wire welding technology because it provides an assembly configuration that can be designed to provide an open space around the joint 316 facing the inner volume defined by the walls 312, 313, and 314 of the rocker inner part. This, in turn, provides ample space for the escape of vapors generated by the welding operation from the joint 316, thereby minimizing the risk of air bubbles trapped within the joint 306. Trapped air bubbles weaken welded joints and are a well-known problem in filler wire welding, especially when applied to zinc-coated parts, due to zinc's low boiling point.

[0061] exist Figure 7 , Figure 8a and Figure 8b In the specific embodiment depicted, the assembly joint 316 between the rocker inner part 31 and the reinforcing member 34 is not continuous along the length of the component in the longitudinal direction. Instead, the assembly joint 316 comprises discontinuous stitches distributed along the longitudinal direction. Advantageously, using discontinuous stitches to secure the components reduces assembly time, reduces wear on assembly tools, and reduces the consumption of filler wire when using filler wire welding technology. Using discontinuous stitches to secure the components also reduces the overall weight of the assembly due to the reduced amount of molten filler wire incorporated into the components. Using discontinuous stitches to secure the components also reduces the amount of heat-affected zone, which can cause defects in the assembled components. Using discontinuous stitches to secure the components also reduces the risk of thermal deformation of the components caused by the heat input of the welding process, thereby providing a final assembly with better geometric tolerances. Furthermore, continuous spot welding when using filler wire welding also reduces the risk of bubble formation in the welded joint, as the metal vapor caused by the welding operation will have additional opportunities to escape on the sides of the stitches. Ultimately, even though the assembly joint between the rocker inner part 31 and the reinforcement is not continuous, the fact that there is a seam along a large area of ​​the length of the parts still ensures a very good mechanical fit between the parts in the event of a side collision.

[0062] The aforementioned seam forming the assembly joint 316 can be as follows: Figure 8b The seams depicted in the upper transition area are aligned with the seams in the lower transition area, or they can be as follows: Figure 8aThe depicted offset is in the longitudinal direction. Advantageously, using an offset configuration can help mitigate the thermal deformation effect caused by the heat input of the welding operation.

[0063] In a particular embodiment, the reinforcement 34 can also be assembled to the rocker inner member 31 in another region besides the transition zone, for example, by using an adhesive bond to secure the reinforcement 34 to the vertical wall 313. For example, the adhesive can be applied before positioning the reinforcement 34 inside the rocker inner member 31. The adhesive can be applied to the outer side of the closed cross-section of the reinforcement 34, or to the vertical wall 313, or to both surfaces. Advantageously, further securing the reinforcement 34 to the rocker inner member 31 as described will further strengthen the bond between the two components, thereby increasing the positive cooperation between the reinforcement and the rocker inner member in the event of a side impact. Furthermore, this step of securing the reinforcement 34 to the rocker inner member 31 in a region other than the transition zone can be performed before the aforementioned step of assembling the two components in the transition zone. Advantageously, by doing so, the two components can be held stably fixed to each other, so that the reinforcement and the rocker inner member will not move during the step of assembling the reinforcement and the rocker inner member in the transition zone.

[0064] Figure 4 , Figure 5 and Figure 6 Several different possible implementations of the reinforcement 34 are shown. Figure 4 and Figure 5 Both of the reinforcing members 34 are made from a single part, which can be manufactured, for example, by a roll forming operation followed by a welding operation, to keep the cross-section closed. Figure 5 Reinforcing components and Figure 4 The difference in the reinforcement is that there is a geometric change in the wall extending outward from the rocker inner part 31 in the lower transition zone, and this geometric change is... Figure 4 The reinforcement does not exist (in Figure 4 In the lower transition zone, the wall of the reinforcing member extending outward from the rocker inner member is straight. The function of this geometric feature is to increase the angle β and thus leave more space for the assembly tool to reach the assembly area to create the assembly joint 316 in the lower transition zone.

[0065] Figure 4 and Figure 5 The reinforcement 34 depicted also exhibits specific features to enhance its resistance to compressive loads caused by side impacts. In fact, the internal horizontal walls of the reinforcement... Figure 5Extending in two separate planes: the upper inner horizontal wall extends along planes 341a and 341b, and the lower inner horizontal wall extends along planes 342a and 342b. By providing a stiffener 34 with horizontal walls extending in at least two different planes, a stiffener 34 with high resistance to compressive loads and, in particular, good resistance to buckling under compressive loads can be designed.

[0066] Figure 6 The reinforcing member 34 depicted is made of two separate parts, an inner reinforcing member 34a and an outer reinforcing member 34b, which are assembled together, for example, by MAG welding or laser welding, to form the reinforcing member 34. The inner reinforcing member 34a is made, for example, by roll forming and welding. The outer reinforcing member 34b is made, for example, by cold stamping or hot stamping. By providing a reinforcing member 34 made of several different parts assembled together, the use of material in the different parts of the reinforcing member 34 can be optimized. Reinforcing members 34 with shapes that cannot be obtained using only a single part can also be designed. In the case where a reinforcing member is made of at least two different parts assembled together, the geometric tolerances of the assembly will be a combination of the geometric tolerances of the different sub-parts constituting the reinforcing member 34. As already mentioned, the use of high-strength steel and its associated springback problem can cause higher geometric tolerances, and this effect is amplified in the case of combined geometric tolerances for a reinforcing member 34 comprising several sub-parts. In this case, it is even more advantageous to apply filler wire welding techniques as previously described to accommodate the distribution of geometric tolerances that will be encountered in industrial mass production settings.

[0067] Generally, if angles α and β fall within the range of 90° to 180°, the invention can be applied using a stiffener 34 of any shape with a closed cross-section. The shape, material, and thickness of the stiffener 34 will be customized by the designer to meet specific constraints associated with fitting the stiffener 34 into the hollow volume 35 and to meet specific requirements associated with side impacts and other possible requirements, such as body rigidity, frontal impacts, rear impacts, etc. Other constraints considered include manufacturing costs and component weight.

[0068] Once the rocker inner member 31 and the reinforcing member 34 are secured together, the rocker outer member 39 is then secured to the rocker inner member 31 in the respective flange regions of the rocker outer member 39 and the rocker inner member 31 to form the reinforced rocker assembly 3. As previously noted, one possible implementation is to assemble the reinforcing member 34 to the rocker inner member 31 and then assemble the sub-assembly to the rocker outer member 39, which has been described in more detail for simplicity. However, the invention can also be applied by first assembling the reinforcing member 34 to the rocker outer member 39 and then securing the sub-assembly to the rocker inner member 31, with the rocker members 31 and 39 acting symmetrically.

[0069] As previously described with respect to a particular embodiment, the reinforcing member 34 and the rocker inner member 31 are also assembled in areas other than the transition zone, such as in the area of ​​the vertical wall 313. In a particular embodiment, the reinforcing member 34 may also be fixed to the rocker outer member 39, for example, along the vertical wall of the rocker outer member 39. For example, in Figure 9 In a particular embodiment, the reinforcement 34 can be secured to the rocker arm outer member 39 in regions 39a and 39b, where the two components are in contact with each other. This can be achieved, for example, by adhesive bonding. The adhesive can, for example, be applied to the reinforcement 34 or the rocker arm outer member 39 or both components. Advantageously, this will further enhance the bonding between the reinforcement 34 and the rocker arm outer member 39, thereby further improving the fit of the components under compressive loads, such as those from a side impact.

[0070] The aforementioned reinforced rocker assembly 3 is ideally suited for protecting the battery pack 5 in the event of a side impact. For example, in the event of a pole impact, which is a very localized assembly requirement, the pole penetration will cause the rocker outer component, the reinforcement, and the rocker inner component to bend successively. Because the reinforcement is well attached longitudinally to at least one of the rocker components 31 and 39 over a large length of the component, the bending portion of the reinforcement 34 will be prevented from bending by the surrounding portion of the rocker components 31 and 39 to which the reinforcement is attached. Therefore, the pole penetration will be less than if the reinforcement 34 were not fixed to the rocker components 31 and 39 along the length of the vehicle. Consequently, the pole penetration into the battery pack will be reduced, thereby protecting the battery pack and battery cells. In the event of a side impact, the aforementioned reinforced rocker assembly 3 will also help protect the vehicle occupants. In the event of a frontal or rear-end collision, the reinforced rocker assembly can also play a positive role by absorbing the collision load and transferring it to other structural components of the vehicle. The reinforced rocker assembly also helps increase the overall rigidity of the vehicle.

[0071] To maximize the effect of the stiffener 34 in strengthening the rocker assembly 3, it is advantageous to maximize the amount of space occupied by the closed section of the stiffener 34 within the hollow volume 35. In a particular embodiment, for any given transverse cross-section, the closed section of the stiffener 34 occupies a surface area at least greater than 80% of the total surface area defined by the hollow volume 35. In a particular embodiment, for any given transverse cross-section, the maximum dimension of the stiffener 34 in the elevation direction is at least 75% of the maximum dimension of the hollow volume 35 in the elevation direction, and the maximum dimension of the stiffener 34 in the transverse direction is at least 75% of the maximum dimension of the hollow volume 35 in the transverse direction.

[0072] In order to maximize the strength of the reinforced joystick assembly 3, it is noteworthy that very high-strength steel is used to manufacture the joystick parts 31, 39 and the reinforcement 34.

[0073] In a particular embodiment, at least one of the rocker components 31 and 39 is made of press-hardened steel with a tensile strength greater than 950 MPa. According to the embodiment, the composition of the press-hardened steel, by weight percentage, includes: 0.06% ≤ C ≤ 0.1%, 1% ≤ Mn ≤ 2%, Si ≤ 0.5%, Al ≤ 0.1%, 0.02% ≤ Cr ≤ 0.1%, 0.02% ≤ Nb ≤ 0.1%, 0.0003% ≤ B ≤ 0.01%, N ≤ 0.01%, S ≤ 0.003%, P ≤ 0.020%, less than 0.1% of Cu, Ni, and Mo, with the remainder being iron and unavoidable impurities resulting from refining. Within this composition range, the component has a yield strength between 700 MPa and 950 MPa, a tensile strength between 950 MPa and 1200 MPa, and a bending angle greater than 75°. For example, the component is made of... Made of 1000. In a particular embodiment, at least one of the rocker components 31, 39 is made of press-hardened steel with a tensile strength greater than 1300 MPa. According to the embodiment, the steel composition, for example, by weight percentage, includes: 0.20% ≤ C ≤ 0.25%, 1.1% ≤ Mn ≤ 1.4%, 0.15% ≤ Si ≤ 0.35%, ≤ Cr ≤ 0.30%, 0.020% ≤ Ti ≤ 0.060%, 0.020% ≤ Al ≤ 0.060%, S ≤ 0.005%, P ≤ 0.025%, 0.002% ≤ B ≤ 0.004%, with the remainder being iron and unavoidable impurities resulting from refining. Within this composition range, the tensile strength of at least one rocker component 31, 39 after press hardening is between 1300 MPa and 1650 MPa. For example, at least one rocker component 31, 39 is made of Made in 1500.

[0074] In a particular embodiment, at least one of the rocker components 31 and 39 is made of press-hardened steel with a tensile strength greater than 1800 MPa. For example, the steel composition of the reinforcing non-deformable portion 36 comprises, by weight percentage: 0.24% ≤ C ≤ 0.38%, 0.40% ≤ Mn ≤ 3%, 0.10% ≤ Si ≤ 0.70%, 0.015% ≤ Al ≤ 0.070%, Cr ≤ 2%, 0.25% ≤ Ni ≤ %, 0.015% ≤ Ti ≤ 0.10%, Nb ≤ 0.060%, 0.0005% ≤ B ≤ 0.0040%, 0.003% ≤ N ≤ 0.010%, S ≤ 0.005%, P ≤ 0.025%, with the remainder being iron and unavoidable impurities resulting from refining. Within this composition range, at least one rocker component 31 or 39 has a tensile strength greater than 1800 MPa after press hardening. For example, at least one rocker component 31, 39 is made of Made in 2000.

[0075] In a particular embodiment, at least one of the rocker arm components 31, 39, or the reinforcing member 34 is made entirely of martensitic steel with a tensile strength greater than 1100 MPa. For example, at least one of the rocker arm components 31, 39, or the reinforcing member 34 is made of... Made in 1100.

[0076] In a particular embodiment, at least one of the rocker arm components 31, 39, or the reinforcing member 34 is made entirely of martensitic steel with a tensile strength greater than 1200 MPa. For example, at least one of the rocker arm components 31, 39, or the reinforcing member 34 is made of... Made in 1200.

[0077] In a particular embodiment, at least one of the rocker components 31, 39, or the reinforcing member 34 is made entirely of martensitic steel with a tensile strength greater than 1300 MPa. For example, at least one of the rocker components 31, 39, or the reinforcing member 34 is made of... Made in 1300.

[0078] In a particular embodiment, at least one of the rocker arm components 31, 39, or the reinforcing member 34 is made entirely of martensitic steel with a tensile strength greater than 1500 MPa. For example, at least one of the rocker arm components 31, 39, or the reinforcing member 34 is made of... Made in 1500.

[0079] In a particular embodiment, at least one of the rocker arm components 31, 39, or the reinforcing member 34 is made entirely of martensitic steel with a tensile strength greater than 1700 MPa. For example, at least one of the rocker arm components 31, 39, or the reinforcing member 34 is made of... Made in 1700.

[0080] In a particular embodiment, at least one of the rocker components 31, 39 or the reinforcement 34 is coated with a metallic coating, such as a zinc-based coating, that provides corrosion protection.

[0081] In a particular embodiment, the thickness of the steel used to manufacture the rocker arm components 31, 39 and the reinforcing member 34 is between 1 mm and 2 mm.

[0082] The present invention also relates to a method for producing the reinforced rocker assembly 3 as described above, the method comprising the following steps:

[0083] -Provide first joystick assembly parts 31, 39

[0084] - Position the reinforcing member 34 with its closed section relative to the first rocker arm components 31 and 39 in the pre-installation position.

[0085] - The reinforcing member 34 is fixed to the first rocker components 31 and 39 by attaching it at least in the transition area between the upper flange and the upper horizontal wall of the first rocker components 31 and 39 and in the transition area between the lower flange and the lower horizontal wall of the first rocker components 31 and 39.

[0086] - This fixes the assembly between the first rocker components 31, 39 and the reinforcing member 34 to another rocker component 31, 39 to form a reinforced rocker assembly 3.

[0087] Due to the specific shape and configuration of the assembly point between the transition area of ​​the first rocker arm components 31 and 39 and the reinforcement 34, the assembly tool necessary to fix the reinforcement 34 to the first rocker arm components 31 and 39 will have sufficient space to reach the assembly point.

[0088] One advantage of the above process is the flexibility provided by the fact that the presence of the reinforcing member 34 does not modify the basic assembly process between the first rocker assembly 31 and the first rocker assembly 39. This means that the same basic rocker assembly process can be performed regardless of the presence or absence of the reinforcing member 34. Due to this flexibility, vehicles with and without the reinforcing member can be produced on the same production line. For example, vehicle platforms including internal combustion engine vehicles and battery electric vehicles can be assembled on the same platform; internal combustion engine vehicles without a battery pack will not require the reinforcing member in the rocker assembly, while battery electric vehicles will benefit from the additional battery pack protection provided by the reinforcing rocker assembly 3.

[0089] Optionally, the reinforcing member 34 and the first rocker arm components 31 and 39 are assembled using filler wire welding technology.

[0090] Optionally, the reinforcement 34 and the first rocker components 31 and 39 are assembled by MAG welding.

[0091] Optionally, the assembly between the reinforcing member 34 and the first rocker components 31, 39 is performed using a discontinuous assembly joint 316, also referred to as a stitch. Optionally, the stitches in the upper transition zone and the stitches in the lower transition zone are aligned with each other. Optionally, the stitches in the upper transition zone and the stitches in the lower transition zone are offset from each other.

[0092] Optionally, the above assembly process may also include the following steps:

[0093] - Assemble the vertical wall of the joystick internals to the reinforcement.

[0094] - Assemble the vertical wall of the joystick outer part to the reinforcement.

Claims

1. A reinforced rocker assembly (3) having a cross-sectionally closed reinforcement (34) located in a hollow volume (35) formed between rocker parts (31, 39), wherein, The reinforcing member (34) is assembled to the rocker components (31, 39) by welding in the assembly area, which is located in the transition area between the upper horizontal wall and the upper flange of the rocker components (31, 39) and the transition area between the lower horizontal wall and the lower flange of the rocker components (31, 39), and wherein, in the transition area, the angles α and β formed between the upper flange and the lower flange and the corresponding portions of the reinforcing member (34) extending outward from the assembly area of ​​the rocker components (31, 39) are between 90° and 180°.

2. The reinforced rocker assembly (3) according to claim 1, wherein, The rocker component assembled with the reinforcement is a rocker inner part (31).

3. The reinforced rocker assembly (3) according to claim 1, wherein, The rocker assembly with the reinforcement is the rocker outer part (39).

4. The reinforced rocker assembly (3) according to any one of claims 1 to 3, wherein, The reinforcing member (34) is made from a single part.

5. Reinforced rocker assembly (3) according to any one of claims 1 to 3, wherein, The reinforcing member (34) is made of at least two different parts assembled together to form the reinforcing member (34).

6. The reinforced rocker assembly (3) according to any one of claims 1 to 3, wherein, The reinforcing member (34) is assembled to the rocker assembly (31, 39) by welding using a filler wire welding technique.

7. The reinforced rocker assembly (3) according to any one of claims 1 to 3, wherein, The reinforcing member (34) is assembled to the rocker arm components (31, 39) by MAG welding.

8. The reinforced rocker assembly (3) according to any one of claims 1 to 3, wherein, The reinforcement (34) is assembled to the rocker assembly (31, 39) using a discontinuous assembly joint (316) in the form of stitches.

9. The reinforced rocker assembly (3) according to claim 8, wherein, Align the seams in the upper transition zone with those in the lower transition zone.

10. The reinforced rocker assembly (3) according to claim 8, wherein, The sutures in the upper transition zone and the lower transition zone are offset.

11. The reinforced rocker assembly (3) according to any one of claims 1 to 3, wherein, The reinforcing member (34) is also assembled to the vertical wall of the rocker inner part (31).

12. The reinforced rocker assembly (3) according to any one of claims 1 to 3, wherein, The reinforcing member (34) is also assembled to the vertical wall of the rocker arm outer member (39).

13. The reinforced rocker assembly (3) according to any one of claims 1 to 3, wherein, For any given transverse cross section, the closed section of the reinforcement (34) occupies a surface area that is at least 80% larger than the total surface area defined by the hollow volume (35) at the given transverse cross section.

14. The reinforced rocker assembly (3) according to any one of claims 1 to 3, wherein, For any given transverse cross section, the maximum dimension of the stiffener (34) in the elevation direction is at least 75% of the maximum dimension of the hollow volume (35) in the elevation direction, and the maximum dimension of the stiffener (34) in the transverse direction is at least 75% of the maximum dimension of the hollow volume (35) in the transverse direction.

15. An assembly process for producing a reinforced rocker assembly (3) according to any one of claims 1 to 14, the assembly process comprising the following steps: - Provide the first joystick component (31, 39). - Position the reinforcing member (34) with a closed cross section relative to the first rocker component (31, 39) in the pre-assembled position. - The reinforcing member (34) is fixed to the first rocker component (31, 39) by attaching the reinforcing member (34) at least in the transition area between the upper flange and the upper horizontal wall of the first rocker component (31, 39) and in the transition area between the lower flange and the lower horizontal wall of the rocker component (31, 39). - This secures the assembled first rocker assembly (31, 39) and the reinforcing member (34) to the remaining rocker assembly (31, 39) to form a reinforced rocker assembly (3).

16. The assembly process according to claim 15, wherein, The reinforcing member (34) and the first rocker arm components (31, 39) are assembled using filler wire welding technology.

17. The assembly process according to claim 15 or 16, wherein the reinforcing member (34) and the first rocker arm components (31, 39) are assembled using MAG welding.

18. The assembly process according to claim 15 or 16 further includes the step of assembling the vertical wall of the rocker inner part (31) to the reinforcement (34).

19. The assembly process according to claim 15 or 16 further includes the step of assembling the vertical wall of the rocker arm outer part (39) to the reinforcing member (34).

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