Vehicle body structure formed from a system of interconnected monolithic vehicle body structure components and method of forming a vehicle body structure

Abstract

A vehicle body structure formed from a system of interconnected monolithic vehicle body structure components and a method of forming a vehicle body structure. A vehicle underbody includes a system of connected monolithic underbody components including a front quadrant system having a left front monolithic underbody component and a right front monolithic underbody component, a center system, and a rear quadrant system having a left rear monolithic underbody component and a right rear monolithic underbody component. A first rail element is loosely connected to the left front monolithic underbody component and the left rear monolithic underbody component, and a second rail element is loosely connected to the right front monolithic underbody component and the right rear monolithic underbody component.

Description

Technical Field

[0001] introduction This disclosure relates to vehicle manufacturing techniques, and more particularly to vehicle body structures formed by a system of interconnected, integrated body structure components. Background Technology

[0002] Many vehicle parts are manufactured through stamping, vacuum forming, molding, and other processes. Manufacturing stamping dies or molds to form parts is a time-consuming and very expensive process. The cost of a stamping die can be as high as a million dollars or more. Typically, stamping dies are formed through subtractive processing. For example, a block of metal is milled, machined, and drilled to form the desired shape. Once the desired shape is formed, a polishing process begins. Subtractive processing is both time-consuming and highly wasteful.

[0003] Other component forming equipment, injection molds, vacuum forming molds, etc., are also costly and time-consuming to produce, and their forming process results in significant material waste. The need to reduce component costs in automobile manufacturing is a long-standing issue. In particular, there is a need to reduce component costs for ultra-low volume / niche vehicles. Niche vehicle projects typically require high capital expenditures associated with the production of ultra-low volume components. To keep vehicle costs at an affordable level, ultra-low volume, ultra-low capital methods are needed.

[0004] In addition to reducing component costs, it is also necessary to reduce vehicle assembly costs. Currently, components are joined together into numerous sub-assemblies. Before the joining process (such as welding operations), each component must be correctly aligned with (multiple) mating components. Aligning each component is a time-consuming and expensive process, requiring multiple different fixtures. Besides the time required to load each fixture, the fixtures themselves are also expensive, requiring maintenance and regular calibration. Such an approach ensures the expected return on investment needed to sustain such projects. Therefore, the industry will welcome low-cost, easy-to-assemble systems for ultra-low-volume, ultra-low-capacity vehicle underbody components. Summary of the Invention

[0005] According to a non-limiting example, a vehicle underbody is disclosed, comprising a system of connected integrated underbody components. This system includes a front quadrant system with a left front integrated underbody component and a right front integrated underbody component, a central system, and a rear quadrant system with a left rear integrated underbody component and a right rear integrated underbody component. A first guide rail element is loosely connected to the left front integrated underbody component and the left rear integrated underbody component, and a second guide rail element is loosely connected to the right front integrated underbody component and the right rear integrated underbody component.

[0006] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein the first guide element includes a first end, a second end, and an intermediate portion between the first end and the second end, the first end including a first opening and a second opening, and a sleeve extending through the first opening, the sleeve including a head portion abutting against the outer surface of the first guide element.

[0007] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein the left front integrated underbody component includes a channel aligned with the first opening, the left front integrated underbody component being connected to the first guide element via a low-profile connection including a bolt passing through the channel and engaging a sleeve, such that tightening the bolt pulls the head portion of the sleeve into the first guide element.

[0008] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein the left front integrated underbody component includes a bolt that extends outward from the left front integrated underbody component into a second opening of the first guide element.

[0009] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein the first guide rail element includes a first guide rail segment connected to the second guide rail segment.

[0010] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein the first guide rail segment includes a first end segment and a second end segment connected to the left front integrated underbody component, and the second guide rail segment includes a first end segment connected to the second end segment and a second end segment connected to the left rear integrated underbody component.

[0011] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include fastening elements connecting the second end section of the first guide rail segment and the first end section of the second guide rail segment.

[0012] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein the fastening element includes a plate, a first bolt and a second bolt, the plate including a first plate opening and a second plate opening, the first bolt passing through a first guide section into the first plate opening, and the second bolt passing through a second guide section into the second plate opening.

[0013] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein the plate includes a first nut mounted at a first plate opening and a second nut mounted at a second plate opening, the first nut receiving a first bolt and the second nut receiving a second bolt.

[0014] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein the plate includes a locating pin that extends outward from the plate through one of the first guide rail segment and the second guide rail segment.

[0015] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include a support strut connecting the front quadrant system to the vehicle body.

[0016] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein the support strut includes a first member loosely connected to the left front integrated underbody component and the vehicle body, and a second member loosely connected to the right front integrated underbody component and the vehicle body.

[0017] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein the support strut includes a third member that loosely connects the first member and the second member at each of the left front integrated underbody component and the right front integrated underbody component.

[0018] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include a suspension component mounting assembly loosely connected to the right rear integrated underbody component.

[0019] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein the suspension component mounting assembly includes a bridging member.

[0020] According to a non-limiting example, a method for assembling a vehicle underbody formed by a system of integrated underbody components is also disclosed, the method comprising: loosely connecting a left front integrated underbody component and a left rear integrated underbody component to a first guide element; loosely connecting a right front integrated underbody component and a right rear integrated underbody component to a second guide element of the system forming the integrated underbody components; placing the system of integrated underbody components into an assembly fixture to establish selected relative positions of the left front integrated underbody component, the right front integrated underbody component, the left rear integrated underbody component, and the right rear integrated underbody component; and fixedly connecting the left front integrated underbody component, the right front integrated underbody component, the left rear integrated underbody component, and the right rear integrated underbody component to maintain the selected relative positions and form the vehicle underbody.

[0021] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein securing the left front integrated underbody component, the right front integrated underbody component, the left rear integrated underbody component, and the right rear integrated underbody component includes tightening a plurality of mechanical fasteners.

[0022] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: wherein securing the left front integrated underbody component, the right front integrated underbody component, the left rear integrated underbody component, and the right rear integrated underbody component together includes applying an adhesive.

[0023] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: loosely connecting the support strut to each of the left front integrated underbody component, the right front integrated underbody component, and the vehicle body.

[0024] In addition to one or more of the features described above or below, or as an alternative, other embodiments may include: fixing support struts to each of the left front integrated underbody component, the right front integrated underbody component, and the vehicle body when the integrated underbody system is in a selected relative position.

[0025] The present invention provides the following technical solutions.

[0026] Technical Solution 1. A vehicle underbody, comprising: A system of connected integrated underbody components, comprising a front quadrant system with a left front integrated underbody component and a right front integrated underbody component, a central system, and a rear quadrant system with a left rear integrated underbody component and a right rear integrated underbody component; A first guide rail element, loosely connected to the left front integrated underbody component and the left rear integrated underbody component; and The second guide rail element is loosely connected to the right front integrated underbody component and the right rear integrated underbody component.

[0027] Technical Solution 2. The vehicle underbody according to Technical Solution 1, wherein the first guide rail element includes a first end, a second end, and an intermediate portion between the first end and the second end, the first end including a first opening and a second opening, a sleeve extending through the first opening, the sleeve including a head portion abutting the outer surface of the first guide rail element.

[0028] Technical Solution 3. The vehicle underbody according to Technical Solution 2, wherein the left front integrated underbody component includes a channel aligned with the first opening, the left front integrated underbody component is connected to the first guide rail element via a low profile connection, the low profile connection including a bolt passing through the channel and engaging the sleeve, such that tightening the bolt pulls the head portion of the sleeve into the first guide rail element.

[0029] Technical Solution 4. The vehicle underbody according to Technical Solution 2, wherein the left front integrated underbody component includes a bolt, the bolt extending outward from the left front integrated underbody component into the second opening of the first guide rail element.

[0030] Technical Solution 5. The vehicle undercarriage according to Technical Solution 2, wherein the first guide rail element includes a first guide rail section connected to the second guide rail section.

[0031] Technical Solution 6. The vehicle underbody according to Technical Solution 5, wherein the first guide rail segment includes a first end segment and a second end segment connected to the left front integrated underbody component, and the second guide rail segment includes a first end segment connected to the second end segment and a second end segment connected to the left rear integrated underbody component.

[0032] Technical Solution 7. The vehicle undercarriage according to Technical Solution 6 further includes a fastening element connecting the second end section of the first guide rail section and the first end section of the second guide rail section.

[0033] Technical Solution 8. The vehicle undercarriage according to Technical Solution 7, wherein the fastening element includes a plate, a first bolt and a second bolt, the plate includes a first plate opening and a second plate opening, the first bolt passes through the first guide rail section and enters the first plate opening, and the second bolt passes through the second guide rail section and enters the second plate opening.

[0034] Technical Solution 9. The vehicle underbody according to Technical Solution 8, wherein the plate includes a first nut installed at the opening of the first plate and a second nut installed at the opening of the second plate, the first nut receiving the first bolt and the second nut receiving the second bolt.

[0035] Technical Solution 10. The vehicle floor according to Technical Solution 9, wherein the floor includes a positioning pin that extends outward from the floor and passes through one of the first guide rail section and the second guide rail section.

[0036] Technical Solution 11. The vehicle undercarriage according to Technical Solution 1 further includes a support strut connecting the front quadrant system to the vehicle body.

[0037] Technical Solution 12. The vehicle underbody according to Technical Solution 11, wherein the support strut includes a first component loosely connected to the left front integrated underbody component and the vehicle body, and a second component loosely connected to the right front integrated underbody component and the vehicle body.

[0038] Technical Solution 13. The vehicle underbody according to Technical Solution 12, wherein the support pillar includes a third component, the third component being loosely connected to the first component and the second component at each of the left front integrated underbody component and the right front integrated underbody component.

[0039] Technical Solution 14. The vehicle underbody according to Technical Solution 1 further includes a mounting surface disposed on the right rear integrated underbody component.

[0040] Technical Solution 15. The vehicle underbody according to Technical Solution 14 further includes a bridging member loosely connected to the mounting surface.

[0041] Technical Solution 16. A method for assembling a vehicle underbody formed by a system of integrated underbody components, comprising: The left front integrated chassis component and the left rear integrated chassis component are loosely connected to the first guide rail element; The right front integrated underbody component and the right rear integrated underbody component are loosely connected to the second guide rail element of the system forming the integrated underbody component; The integrated underbody system is placed in an assembly fixture to establish the selected relative positions of the left front integrated underbody component, the right front integrated underbody component, the left rear integrated underbody component, and the right rear integrated underbody component; and The left front integrated underbody component, the right front integrated underbody component, the left rear integrated underbody component, and the right rear integrated underbody component are fixedly connected to maintain the selected relative positions and form the vehicle underbody.

[0042] Technical Solution 17. The method according to Technical Solution 16, wherein fixing the left front integrated vehicle bottom component, the right front integrated vehicle bottom component, the left rear integrated vehicle bottom component and the right rear integrated vehicle bottom component includes tightening a plurality of mechanical fasteners.

[0043] Technical Solution 18. The method according to Technical Solution 16, wherein fixing the left front integrated vehicle bottom component, the right front integrated vehicle bottom component, the left rear integrated vehicle bottom component and the right rear integrated vehicle bottom component together includes applying an adhesive.

[0044] Technical Solution 19. The method according to Technical Solution 16 further includes loosely connecting the support strut to each of the left front integrated underbody component, the right front integrated underbody component, and the vehicle body.

[0045] Technical Solution 20. The method according to Technical Solution 19 further includes fixing the support strut to each of the left front integrated underbody component, the right front integrated underbody component, and the vehicle body when the system of the integrated underbody component is in the selected relative position.

[0046] The above-described features and advantages, as well as other features and advantages, of this disclosure will become apparent from the following detailed description when taken in conjunction with the accompanying drawings. Attached Figure Description

[0047] Other features, advantages, and details appear by way of example only in the following detailed description, which refers to the accompanying drawings, in which: Figure 1 A vehicle according to a non-limiting example is depicted, which includes a vehicle underside formed by a system of interconnected, integrated components; Figure 2 It is a perspective view of the underside of a vehicle formed by a system of interconnected, integrated components, based on a non-limiting example; Figure 3 The image is an exploded view of a vehicle undercarriage according to a non-limiting example, the undercarriage including: a front quadrant system having a left front integrated undercarriage component and a right front integrated undercarriage component; an integrated floor system; and a rear quadrant system having a left rear integrated undercarriage component and a right rear integrated undercarriage component, which together form a system of interconnected integrated components. Figure 4 It is a perspective view of a front quadrant system including a left front integrated underbody component and a right front integrated underbody component, based on a non-limiting example; Figure 5 It is cut from line 5-5 of the non-restrictive example. Figure 4 Cross-sectional view of the integrated underbody component in the left front quadrant; Figure 6 An integrated floor system for the vehicle underside, formed by a system of interconnected integrated components, is depicted according to a non-limiting example; Figure 7 It is cut from line 7-7 of the non-restrictive example. Figure 6 A cross-sectional view of a portion of an integrated floor system, illustrating the hollow core; Figure 8 Depicting the non-restrictive example in Figure 7 Ribs formed in the inner core; Figure 9 It is a perspective view of a rear quadrant system including a left integrated rear underbody component and a right integrated rear underbody component, based on a non-limiting example; Figure 10 The diagram depicts the section cut through line 10-10 according to the non-restrictive example. Figure 9 A cross-sectional view of a portion of the left integrated rear underbody component; Figure 11 It is based on the non-restrictive example. Figure 10 Detailed view of the core portion of the left integrated rear underbody component; Figure 12 It is based on the non-restrictive example. Figure 11 Detailed view of the inner core of the left integrated rear underbody component; Figure 13 A portion of a vehicle body, according to a non-limiting example, is depicted, which is mounted to a vehicle underside formed by a system of interconnected, integrated components; Figure 14 The passage cut through line 14-14 is depicted according to the non-restrictive example. Figure 13 The cross-section of the guide rail element in the vehicle has an integrated closed cross-section of the left front integrated undercarriage component of the front quadrant system connected to the undercarriage system formed by the interconnected integrated components. Figure 15 The passage cut from line 15-15 is depicted according to the non-restrictive example. Figure 14 Cross-sectional view of the guide rail component; Figure 16 The diagram depicts the connection to line 16-16 cut through the non-limiting example. Figure 2 A front cross-sectional view of the guide rail element of the left front integrated underbody component; Figure 17 A side view of two extruded guide rail segments of a connected guide rail element according to a non-limiting example is depicted. Figure 18 Depicting a link based on a non-restrictive example Figure 16 Fastening elements for the two guide rail sections of the guide rail component; Figure 19 Depicting based on non-restrictive examples Figure 12 The front support strut of the vehicle; Figure 20 Depicting links to, based on non-restrictive examples Figure 12 The first part of the front support pillar of the main body; Figure 21 Depicting based on non-restrictive examples Figure 19 The second part of the front support strut, which connects to the front quadrant of the vehicle floor formed by a system of interconnected, integrated components; and Figure 22 A vehicle undercarriage formed by a system of interconnected, integrated components mounted in an assembly fixture is depicted, according to a non-limiting example. Detailed Implementation

[0048] The following description is merely exemplary in nature and is not intended to limit this disclosure, its application, or its uses. It should be understood that in all the drawings, corresponding reference numerals denote similar or corresponding parts and features.

[0049] According to the non-restrictive example of the vehicle in Figure 1 The vehicle 10 is generally designated by 10. The vehicle 10 includes a body 12 supported on a plurality of wheels, one of which is designated by 16. The body 12 includes a passenger compartment 20 accessible through a front door 22 and / or a rear door 24. Additional doors (not shown) may be arranged on opposite sides of the vehicle 10. The passenger compartment 20 includes front seats 28 and rear seats 30. The vehicle 10 includes a floor 34 formed by a system 38 of integrated floor components. Figure 2 ).

[0050] The term "integration" describes each of the underbody components, according to a non-limiting example, as a single, continuous member without seams, joints, etc. That is, the integrated component does not undergo any connecting processes that could influence the material selection. The integrated component has one or more continuous, uninterrupted load paths. In the non-limiting example, each of the integrated underbody component system 38 is formed by a sand casting process. That is, a liquid material such as a metal, metal composite, or nonmetal is poured into a mold formed of sand, etc. In another non-limiting example, a liquid material such as a metal, metal composite, or nonmetal is injected into a mold formed of sand. Upon hardening, the integrated component is removed from the mold as a single piece. While other processes may be employed, "integration" clearly describes a component formed as a single piece. The term "integrated system" should be understood to describe a group of integrated components.

[0051] refer to Figure 2 and Figure 3 And continue to refer to Figure 1 The integrated underbody system 38 includes a front quadrant system 42, a rear quadrant system 44, and a center system 46. In a non-limiting example, the center system 46 extends between and connects to the front quadrant system 42 and the rear quadrant system 44. In a non-limiting example, the front quadrant system 42 includes a left front integrated underbody component 52 and a right front integrated underbody component 54. The rear quadrant system 44 includes a left rear integrated underbody component 58 and a right rear integrated underbody component 60.

[0052] In a non-limiting example, the central system 46 takes the form of an integrated floor system 63, which includes a first integrated floor member 66 connected to a second integrated floor member 68. In this respect, it should be understood that the integrated component forms part of the vehicle floor, and the integrated component can be used in other areas (structural and unstructural) of the vehicle 10. Furthermore, additional floor components not discussed herein can be integrated components.

[0053] Now refer to Figure 4 and Figure 5 And continue to refer to Figure 2 and Figure 3 The description focuses on the left front integrated underbody component 52 of the front quadrant system 42, while also acknowledging that the right front integrated underbody component 54 includes a similar structure. The left front integrated underbody component 52 defines the left front corner of the underbody 34. In a non-limiting example, the left front integrated underbody component 52 includes a first guide rail member 74, a second guide rail member 76, a third guide rail member 78, and a fourth guide rail member 79 connected at intersection 80. The second guide rail member 76 defines a recess (not separately labeled) with a hollow interior, as shown at 81. Figure 4 The right front integrated underbody component 54 is connected. In a non-limiting example, the left front integrated underbody component 52 includes a hollow portion 82, which is partially defined by a bridging guide 83 at the intersection 80, such as... Figure 5 As shown in the diagram, the hollow portion 82 contributes to the weight reduction of the left front integrated underbody component 52 without sacrificing the structural integrity provided by the first guide rail 74, the second guide rail 76, and the third guide rail 78, respectively.

[0054] Now refer to Figures 6 to 8The second integrated floor member 68, according to a non-limiting example, is described, while it is understood that the first integrated floor member 66 includes a similar structure. In the non-limiting example, the second integrated floor member 68 includes a floor surface 89 having a first segment 91 and a second segment 93 offset relative to the first segment 91. In the non-limiting example, the first segment 91 includes a first plurality of hollow cores 95 and a second plurality of hollow cores 96. The first plurality of hollow cores 95 provide structural support for the first segment 91 and include a first plurality of raised bosses 97. The second plurality of hollow cores 96 provide additional structural support for the first segment 91 and include a plurality of raised bosses 99. At this point, it should be understood that although described as having hollow cores, the first integrated floor member 66 and the second integrated floor member 68 may also include raised ribs.

[0055] exist Figure 7 In the non-limiting example depicted, the first segment 91 defines a first thickness 104 of the second integral floor member 68, and each of the first plurality of hollow cores 95 and the second plurality of hollow cores 96 defines a second thickness greater than the first thickness, as shown at 106. In the non-limiting example, the first plurality of hollow cores 95 includes an opening (not separately labeled) that receives a bolt (also not separately labeled) that serves as an interface between the floor surface 89 and another surface 108 of the support member 109, as... Figure 7 As shown in the diagram, the first plurality of hollow cores 95 include internal units 111 that provide additional support, enabling the second integral floor member 68 to support and manage larger loads.

[0056] In a non-limiting example, the second plurality of protruding bosses 99 serve as interfaces with, for example, seat rails (not shown). Therefore, each of the second plurality of protruding bosses 99 includes, as Figure 8 The opening 110 shown can be used to receive mechanical fasteners, such as nuts (also not shown). By forming the first plurality of hollow cores 95 and the second plurality of hollow cores 96, along with the corresponding first plurality of raised bosses 97 and the second plurality of raised bosses 99, together with the second integrated floor member 68, structural integrity is enhanced and the need to provide additional interface devices is avoided.

[0057] Now refer to Figure 9To describe a rear quadrant system 44 according to another non-limiting example. The left rear integrated underbody component 58 may include a first mounting surface 118, and the right rear integrated underbody component 60 may include a second mounting surface 120. Each mounting surface 118, 120 supports bridging members 122 and 124, respectively, connecting the rear quadrant system 44 to a structure (such as a portion of body 12) disposed above the rear quadrant system 44. In the non-limiting example, bridging members 122 and 124 are initially loosely connected to mounting surfaces 118 and 120 and not only provide an interface with, for example, body 12, but also establish sliding planes to establish desired part-to-part alignment. Furthermore, in the non-limiting example, the left rear integrated underbody component 58 and the right rear integrated underbody component 60 include internal structural support members, as will be described in detail herein.

[0058] The following will refer to Figures 10 to 12 And continue to refer to Figure 9 The left rear integrated underbody component 58 is described, while it is understood that the right rear integrated underbody component 60 includes a similar structure. In a non-limiting example, the left rear integrated underbody component 58 includes a hollow portion 127 having a generally U-shaped cross-section, which includes a first sidewall 136, a second sidewall 138, and a bottom wall 140. The bottom wall 140 extends between and forms together with the first sidewall 136 and the second sidewall 138. In a non-limiting example, a vertical wall 143 is formed together with and extends outward from the bottom wall 140 between the first sidewall 136 and the second sidewall 138. The vertical wall 143 provides structural support to the left rear integrated underbody component 58 at, for example, a first mounting surface 118.

[0059] In a non-limiting example, an additional hollow core is formed in the hollow portion 127, one of which is designated 145. The additional hollow core 145 bisects the vertical wall 143 and includes a first portion 147, a second portion 148, and a third portion 149. The first portion 147 extends outward from a first sidewall 136, the second portion 148 extends outward from a second sidewall 138, and the third portion 149 extends outward from a bottom wall 140. The third portion 149 bisects the vertical wall 143. In a non-limiting example, the hollow portion 127 may also include an internal guide rail 160. Figure 11 This is formed together with the first sidewall 136 and the second sidewall 138, and spaced apart from the bottom wall 140. An internal guide rail 160 defines a guide rail within a guide rail, providing additional support that is not possible through stamping and other part forming techniques. That is, sand casting allows for the creation of an internal hollow section, which reduces weight while also providing additional structural support. Sand cores can be strategically placed within the part and then removed to form the internal hollow section.

[0060] According to a non-limiting example, the integrated underbody system 38 begins as an assembly of loosely connected parts that are aligned and ultimately fixed to each other, as will be detailed herein. The term "loosely connected" should be understood to describe the integrated underbody system 38 being mechanically connected to each other in a manner that allows for movement, adjustment, positioning, repositioning, and alignment. In contrast, welding produces a tight, immovable connection. Therefore, the assembly of loosely connected parts should be understood to describe a flexible or adjustable assembly that allows for manipulation, alignment, compliance, etc., prior to the final connection operation.

[0061] Now refer to Figures 13 to 16 And continue to refer to Figures 1 to 4 To describe the low-profile connection (not separately labeled) between the anterior quadrant system 42 and the posterior quadrant system 44 according to a non-limiting example. Figure 13 As shown, the first guide rail element 214 is initially loosely connected to the left front integrated underbody component 52 and the left rear integrated underbody component 58. The second guide rail element 216 is initially loosely connected to the right front integrated underbody component 54 and the right rear integrated underbody component 60. The first guide rail element 214 and the second guide rail element 216 may include an integrated closed cross-section. The integrated floor system 63 is initially loosely connected to the first guide rail element 214 and the second guide rail element 216. In a non-limiting example, the first integrated floor member 66 is connected to the second guide rail element 216, and the second integrated floor member 68 is connected to the first guide rail element 214.

[0062] The following description refers to the first guide rail element 214, and it is understood that the second guide rail element 216 includes a similar structure. The first guide rail element 214 includes a first end 220 connected to the left front integrated underbody component 52 and a second end 222 connected to the left rear integrated underbody component 58. A middle portion 224 extends between the first end 220 and the second end 222.

[0063] exist Figure 14 and Figure 15 In the non-limiting examples shown, such as Figure 15 As shown, a first opening 230 is formed at a first end 220 in the first guide rail element 214. A first opening portion 232 is formed in the first end 220 of the first guide rail element 214 opposite to the first opening 230. The first opening portion 232 is spaced apart from and aligned with the first opening 230. It should be understood that the number of first openings and first opening portions can vary. Figure 16As shown, a second opening 235 is formed in the first end 220 and is longitudinally spaced from the first opening 230 toward the second end 222. A second opening portion 237 is formed in the first end 220 and is longitudinally spaced from the first opening portion 232 toward the second end 222. The second opening portion 237 is spaced from and aligned with the second opening 235. It should be understood that the number of second openings 235 and second opening portions 237 can vary.

[0064] In a non-limiting example, the left front integrated underbody component 52 includes a channel 240 formed in a first guide rail 74. When the first guide rail element 214 is installed, the channel 240 is aligned with the first opening 230 and the first opening portion 232. Figure 16 As shown, the first guide rail 74 also includes (a plurality of) bolts 243 aligned with the second opening 235 and the second opening portion 237. In a non-limiting example, the bolts 243 extend toward the second opening 235 into the second opening portion 237. At this point, it should be understood that the number of channels and the number of bolts can vary. That is, the number of channels corresponds to the number of first openings and first opening portions, and the number of bolts corresponds to the number of second openings and second opening portions.

[0065] In a non-limiting example, sleeve 246 is mounted into first guide element 214 at first end 220. Sleeve 246 includes a head portion 248 and is mounted into first opening 230 and first opening portion 232. Head portion 248 abuts against first guide element 214 at first opening 230. In a non-limiting example, mechanical fastener 250 enters sleeve 246 through first opening portion 232 and channel 240. Mechanical fastener 250 may be loosely attached to sleeve 246. However, during final assembly, mechanical fastener 250 is tightened, pulling head portion 248 of sleeve 246 against first guide element 214. Similarly, when first guide element 214 is attached to left front integrated underbody component 52, bolts 243 pass through second opening portions 237. Bolts 243 create a selected alignment between first guide element 214 and left front integrated underbody component 52. Mechanical fastener 257 can pass through (a plurality of) second openings 235 and mechanically engage with (a plurality of) bolts 243.

[0066] exist Figure 17 and Figure 18 In a non-limiting example, the first guide rail element 214 may include a first guide rail segment 262 connected to the second guide rail segment 264. In a non-limiting example, the first guide rail segment 262 includes a first end portion 220. Figure 13 The second guide rail section 264 includes a first end section 268 and a second end section 222. Figure 13 The second end segment 266 is connected to the first end segment 268 by a plurality of fastening elements, one of which is in Figure 18 It is shown at point 272. The number and position of the fastening elements can be varied. Fastening element 272 is received in slot 274.

[0067] In a non-limiting example, fastening element 272 includes a plate 275 that slides into a groove 274, a first bolt 278, and a second bolt 280. The first bolt 278 passes through a first guide rail section 262 at a second end segment 266, and the second bolt 280 passes through a second guide rail section 264 at the first end segment 268. The first bolt 278 and the second bolt 280 pass through corresponding first plate openings 284 and 286 in the plate 275. A first nut 288 is engaged with the plate 275 at the first plate opening 284, and a second nut 290 is engaged with the plate 275 at the second plate opening 286. The first bolt 278 and the second bolt 280 engage with the first nut 288 and the second nut 290, respectively. The plate 275 may also support a locating pin 292. In a non-limiting example, the locating pin 292 enters one of the first guide rail section 262 and the second guide rail section 264 to establish a selected alignment of the plate 275.

[0068] like Figure 19 As shown, in a non-limiting example, vehicle 10 includes a support strut 296 that connects the left front integrated underbody component 52 and the right front integrated underbody component 54 to the body 12, as illustrated. Figure 13 As shown in the image. Reference Figures 19 to 21 The support pillar 296 includes a first component 298 that connects the left front integrated underbody component 52 to the body 12. A second component 300 connects the right front integrated underbody component 54 to the body 12. A third component 302 connects the first component 298 and the second component 300. The third component 302 can connect the first component 298 and the second component 300 at corresponding parts in the left front integrated underbody component 52 and the right front integrated underbody component 54. A plate 304 can be disposed at the first component 298 and the second component 300 of the body 12.

[0069] In a non-limiting example, the first plurality of mechanical fastener components 306 pass through the plate 304 into the second component 300 and connect to the body 20, as shown below. Figure 20 As shown in the diagram. An additional fastener (not separately labeled) passes through plate 304 via first member 298 and is connected to body 12. Mechanical fastener member 306 also passes through third member 302, second member 300, and enters left front integrated underbody component 52, as shown. Figure 21As shown in the diagram, an additional mechanical fastener component (not separately labeled) passes through the third component 302, the second component 300, and connects to the right front integrated underbody component 54. In a non-limiting example, the mechanical fastener component 306 may reside within the third component 302. That is, the third component 302 may include an opening 310 for receiving the mechanical fastener component 306. In this way, for example, a direct surface-to-surface pressure is established between the third component 302 and the first component 298. With this arrangement, all components forming the integrated underbody 34 can initially be loosely connected. The loosely connected components can then be placed... Figure 22 In the fixture or assembly fixture 400 shown, the fixture is positioned, repositioned and aligned to the selected size, and then tightened.

[0070] For example, the left front integrated underbody component 52 and the left rear integrated underbody component 58 can be loosely connected via a first guide rail element 214. The right front integrated underbody component 54 and the right rear integrated underbody component 60 can be loosely connected via a second guide rail element 216 to form an integrated underbody system 34. Once loosely connected, the integrated underbody system 38 can be placed in, for example, Figure 22 In the fixture or assembly fixture 400 shown, selected relative positions are established for the left front integrated underbody component 52, right front integrated underbody component 54, left rear integrated underbody component 58, and right rear integrated underbody component 60. Once in the selected positions, the left front integrated underbody component 52, right front integrated underbody component 54, left rear integrated underbody component 58, and right rear integrated underbody component 60 are fixedly connected to each other to maintain the selected relative positions and form the vehicle underbody. Although shown positioned in the fixture 400 as a complete assembly, each of the front quadrant system 42, rear quadrant system 44, and center system 46 can be loosely assembled before being assembled in the fixture 400, or ultimately assembled in a separate fixture.

[0071] In a non-limiting example, securingly connecting the left front integrated underbody assembly 52, right front integrated underbody assembly 54, left rear integrated underbody assembly 58, and right rear integrated underbody assembly 60 includes tightening a plurality of mechanical fasteners 250, mechanical fastener components 257, fastening elements 272, bolts 278 and 280. In another non-limiting example, securingly connecting the left front integrated underbody assembly 52, right front integrated underbody assembly 54, left rear integrated underbody assembly 58, and right rear integrated underbody assembly 60 includes applying an adhesive.

[0072] The use of integrated components and bolt / adhesive connections not only eliminates the need for and associated costs of producing stamping dies and other expensive formed elements, but also reduces the need for robots programmed for complex operations. That is, the underbody can be formed using a single jig and robot programmed for simple tasks such as spot welding, flow drilling screw connections, and / or self-piercing riveting. Furthermore, although described from the perspective of underbody components, integrated components as described herein can be used in other areas of the vehicle's body structure.

[0073] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit this disclosure. As used herein, the singular forms “a,” “an,” and “the” are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that, when used in this specification, the terms “comprising” and / or “including” specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or combinations thereof.

[0074] While the above disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes may be made without departing from its scope, and equivalents may be substituted for its elements. Furthermore, many modifications may be made to adapt particular situations or materials to the teachings of this disclosure without departing from its essential scope. Therefore, it is intended that this disclosure be limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A vehicle chassis, comprising: A system of connected integrated underbody components, comprising a front quadrant system with a left front integrated underbody component and a right front integrated underbody component, a central system, and a rear quadrant system with a left rear integrated underbody component and a right rear integrated underbody component; A first guide rail element, loosely connected to the left front integrated underbody component and the left rear integrated underbody component; and The second guide rail element is loosely connected to the right front integrated underbody component and the right rear integrated underbody component. The central system (46) includes a first integrated floor member (66) connected to a second integrated floor member (68), each of the first integrated floor member (66) and the second integrated floor member (68) including a first segment (91) and a second segment (93) offset relative to the first segment (91). Each of the left front integrated underbody component and the right front integrated underbody component includes a first guide rail component (74), a second guide rail component (76), a third guide rail component (78) and a fourth guide rail component (79) connected at an intersection (80). The second guide rail component (76) of the left front integrated underbody component (52) defines a recess with a hollow interior for connection with the second guide rail component (76) of the right front integrated underbody component (54). The first integrated floor component (66) is connected to the second guide rail component (216), and the second integrated floor component (68) is connected to the first guide rail component (214).

2. The vehicle undercarriage according to claim 1, wherein, The first guide rail element includes a first end, a second end, and an intermediate portion between the first end and the second end. The first end includes a first opening and a second opening. A sleeve extends through the first opening, and the sleeve includes a head portion that abuts against the outer surface of the first guide rail element.

3. The vehicle undercarriage according to claim 2, wherein, The left front integrated underbody component includes a channel aligned with the first opening. The left front integrated underbody component is connected to the first guide rail element via a low-profile connection. The low-profile connection includes a bolt passing through the channel and engaging the sleeve, such that tightening the bolt pulls the head portion of the sleeve into the first guide rail element.

4. The vehicle undercarriage according to claim 2, wherein, The left front integrated underbody component includes a bolt that extends outward from the left front integrated underbody component into the second opening of the first guide rail element.

5. The vehicle undercarriage according to claim 2, wherein, The first guide rail element includes a first guide rail section connected to the second guide rail section.

6. The vehicle undercarriage according to claim 5, wherein, The first guide rail segment includes a first end segment and a second end segment connected to the left front integrated underbody component, and the second guide rail segment includes a first end segment connected to the second end segment and a second end segment connected to the left rear integrated underbody component.

7. The vehicle underbody according to claim 6 further includes a fastening element connecting the second end section of the first guide rail section and the first end section of the second guide rail section.

8. The vehicle undercarriage according to claim 7, wherein, The fastening element includes a plate, a first bolt, and a second bolt. The plate includes a first plate opening and a second plate opening. The first bolt passes through the first guide rail section and enters the first plate opening, and the second bolt passes through the second guide rail section and enters the second plate opening.

9. The vehicle undercarriage according to claim 8, wherein, The plate includes a first nut installed at an opening in the first plate and a second nut installed at an opening in the second plate, the first nut receiving the first bolt and the second nut receiving the second bolt.

10. The vehicle undercarriage according to claim 9, wherein, The plate includes a positioning pin that extends outward from the plate through one of the first guide rail section and the second guide rail section.

11. The vehicle underbody according to claim 1, further comprising a support strut connecting the front quadrant system to the vehicle body.

12. The vehicle undercarriage according to claim 11, wherein, The support strut includes a first component loosely connected to the left front integrated underbody component and the vehicle body, and a second component loosely connected to the right front integrated underbody component and the vehicle body.

13. The vehicle undercarriage according to claim 12, wherein, The support pillar includes a third component that loosely connects the first component and the second component at each of the left front integrated underbody component and the right front integrated underbody component.

14. The vehicle underbody according to claim 1 further includes a mounting surface disposed on the right rear integrated underbody component.

15. The vehicle underbody of claim 14, further comprising a bridging member loosely connected to the mounting surface.

16. A method for assembling a vehicle underbody formed by a system of integrated underbody components, comprising: The left front integrated underbody component and the left rear integrated underbody component are loosely connected to the first guide rail element. Each of the left front integrated underbody component and the right front integrated underbody component includes a first guide rail member (74), a second guide rail member (76), a third guide rail member (78), and a fourth guide rail member (79) connected at the intersection (80). The second guide rail member (76) of the left front integrated underbody component (52) defines a hollow socket for connection with the second guide rail member (76) of the right front integrated underbody component (54). The right front integrated underbody component and the right rear integrated underbody component are loosely connected to the second guide rail element of the system forming the integrated underbody component; The central system (46) is loosely connected to the first guide rail element and the second guide rail element. The central system (46) includes a first integrated floor member (66) connected to a second integrated floor member (68). Each of the first integrated floor member (66) and the second integrated floor member (68) includes a first segment (91) and a second segment (93) offset relative to the first segment (91). The first integrated floor member (66) is connected to the second guide rail element (216), and the second integrated floor member (68) is connected to the first guide rail element (214). The integrated underbody system is placed in an assembly fixture to establish the selected relative positions of the left front integrated underbody component, the right front integrated underbody component, the left rear integrated underbody component, and the right rear integrated underbody component; and The left front integrated underbody component, the right front integrated underbody component, the left rear integrated underbody component, and the right rear integrated underbody component are fixedly connected to maintain the selected relative positions and form the vehicle underbody.

17. The method according to claim 16, wherein, The fixed connection of the left front integrated underbody component, the right front integrated underbody component, the left rear integrated underbody component, and the right rear integrated underbody component includes tightening a plurality of mechanical fasteners.

18. The method according to claim 16, wherein, The fixed connection of the left front integrated underbody component, the right front integrated underbody component, the left rear integrated underbody component, and the right rear integrated underbody component includes the application of an adhesive.

19. The method of claim 16, further comprising loosely connecting a support strut to each of the left front integrated underbody component, the right front integrated underbody component, and the vehicle body.

20. The method of claim 19, further comprising securing the support strut to each of the left front integrated underbody component, the right front integrated underbody component, and the vehicle body when the system of the integrated underbody components is in the selected relative position.

Images