Method of assembling truck

Abstract

The present disclosure provides a method of assembling a truck. A method of assembling a truck includes assembling a cab structure including a rear roof rail coupling a top portion of a rearmost left pillar to a top portion of a rearmost right pillar to cooperate with the rearmost left pillar and the rearmost right pillar to at least partially define a rear opening of the cab structure. The rear opening extends downward from the rear roof rail beyond a vertical midpoint of the rearmost left pillar and the rearmost right pillar in a vertical direction of the cab structure. The method includes inserting a first internal component into an interior of the cab structure through the rear opening and attaching the first internal component to the cab structure. The method includes attaching a rear panel to the rearmost left pillar and the rearmost right pillar after attaching the first internal component to the cab structure, the rear panel spanning the rear opening.

Description

Technical Field

[0001] The present disclosure relates to a method of assembling a truck, and more particularly, to a method of assembling a cab of a truck. Background Art

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] Trucks have a cab in which passengers sit, which is separated from the truck's cargo compartment or cargo area by a rear wall. Typically, the entire cab structure (i.e., the structural portion of the cab) is assembled, and then a corrosion-resistant material, such as an electrophoretic coating and / or paint, is applied before any interior components (e.g., wiring, seat belts, HVAC ducts and fans, motors, seats, trim panels, computer modules, carpets, headliners, instrument panels) are assembled to the structural portion. The different parts of the cab structure (e.g., columns, door sills / sills, roof rails, roof panels, floor panels, and rear panels) are typically welded together to form a single body, so that the anti-corrosion coating must be performed after all these parts of the cab structure are welded together. The interior components are then typically inserted into the cab through the door opening and attached to the cab structure.

[0004] However, some interior components need to be attached in locations that are difficult for an average-sized worker to reach while passing through the door opening, causing ergonomic issues. In addition, the typical process has the cab structure being made on the main assembly line for the vehicle as the components are attached to the cab structure. To do this, the typical process requires the main assembly line for the vehicle to have many different stations, which increases the length of the assembly line and increases the chance of a shutdown if a problem occurs at any one station.

[0005] The teachings of the present disclosure address these and other problems associated with typical methods of assembling trucks. Summary of the invention

[0006] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0007] In one form, the present disclosure provides a method of assembling a truck, including assembling a cab structure of the truck. The cab structure includes a plurality of left pillars, a plurality of right pillars, and a rear roof rail, the rear roof rail coupling a top portion of a rearmost left pillar of the plurality of left pillars to a top portion of a rearmost right pillar of the plurality of right pillars to cooperate with the rearmost left pillar and the rearmost right pillar to at least partially define a rear opening of the cab structure. The rear opening extends downward from the rear roof rail in a vertical direction of the cab structure beyond a vertical midpoint of the rearmost left pillar and the rearmost right pillar. The method includes inserting a plurality of first interior components into an interior of the cab structure through the rear opening and attaching the first interior components to the cab structure. The method also includes attaching a rear panel to the rearmost left pillar and the rearmost right pillar after attaching the first interior components to the cab structure, the rear panel spanning the rear opening.

[0008] In a variation of the system of the above paragraphs that can be implemented individually or in any combination: the method also includes attaching a plurality of second interior components to the rear panel before attaching the rear panel to the rearmost left pillar and the rearmost right pillar; the plurality of second interior components include at least one of a subwoofer, an air duct, an electronic control module, an amplifier, a speaker, a cable, a wire, a power window module, a seat belt component, and an electric motor; the plurality of first interior components include at least one of a seat, a seat belt component, an interior trim panel, an air duct, a cable, a wire, a roof lining, a floor covering, and an instrument panel; the plurality of first interior components include a plurality of seats, wherein ... through the rear opening The method further comprises installing the plurality of seats on a floor panel before inserting the plurality of seats through the rear opening, wherein inserting the plurality of first interior components through the rear opening comprises inserting the plurality of seats through the rear opening when the plurality of seats are mounted to the floor panel, and attaching the floor panel to the cab structure; the method further comprises painting the cab structure before inserting the plurality of interior components through the rear opening; the method further comprises applying a coating to the rear panel before attaching the rear panel to the rearmost left pillar and the rearmost right pillar, the coating comprising at least one of a corrosion-resistant electrophoretic coating and a paint coating; the method further comprises attaching the rear panel between the rearmost left pillar and the rearmost right pillar The method further comprises attaching a rear cross brace to the cab structure before inserting the plurality of first interior components through the rear opening, wherein the rear cross brace extends from the rearmost left pillar to the rearmost right pillar; attaching the rear cross brace to the cab structure before inserting the plurality of first interior components through the rear opening; the method further comprises applying a coating to the cab structure and the rear cross brace with a corrosion resistant material after attaching the rear cross brace to the cab structure and before inserting the plurality of first interior components through the rear opening; the method further comprises attaching the rear cross brace to the rear panel before attaching the rear panel to the rearmost left pillar and the rearmost right pillar; the method further comprises attaching the rear panel to the rearmost left pillar and the rearmost right pillar a rear window glass attached to the rear panel before; the method further includes attaching the rear window glass to the rear panel after attaching the rear panel to the rear-most left pillar and the rear-most right pillar; the rear panel is attached to the rear-most left pillar and the rear-most right pillar by a plurality of fasteners, and a seal is disposed between the rear panel and the rear-most left pillar and the rear-most right pillar; the method further includes mounting the cab structure to a pair of longitudinal frame rails after attaching the plurality of first interior components to the cab structure; the cab structure further includes: a left sill, the left sill joining a corresponding bottom portion of the left pillar to define a bottom of at least one door opening on a left side of the cab structure;a right sill coupled to a corresponding bottom portion of the right pillar to define a bottom portion of at least one door opening on the right side of the cab structure; a left roof rail coupled to a corresponding top portion of the left pillar to define a top portion of the at least one door opening on the left side of the cab structure; and a right roof rail coupled to a corresponding top portion of the right pillar to define a top portion of the at least one door opening on the right side of the cab structure.;

[0009] In another form, the present disclosure provides a method of assembling a truck, including assembling a cab structure of the truck. The cab structure includes: a plurality of left and right pillars and a rear roof rail, the rear roof rail connecting the top portion of the rearmost left pillar of the plurality of left pillars to the top portion of the rearmost right pillar of the plurality of right pillars to cooperate with the rearmost left pillar and the rearmost right pillar to at least partially define a rear opening, the rear opening extending downward from the rear roof rail in the vertical direction of the cab structure beyond the vertical midpoint of the rearmost left pillar and the rearmost right pillar. The method includes inserting a plurality of first interior components into the interior of the cab structure through the rear opening and attaching the first interior components to the cab structure. The method includes attaching a plurality of second interior components to a rear panel. The method includes: after attaching the first interior components to the cab structure and after attaching the plurality of second interior components to the rear panel, attaching the rear panel to the rearmost left pillar and the rearmost right pillar, the rear panel spanning the rear opening.

[0010] In a variation of the system of the above paragraphs that may be implemented individually or in any combination: the method further includes painting the cab structure prior to inserting the plurality of interior components through the rear opening, and applying a coating to the rear panel prior to attaching the plurality of second interior components to the rear panel; the method further includes attaching a rear window glass to the rear panel prior to attaching the rear panel to the rearmost left pillar and the rearmost right pillar.

[0011] In another form, the present disclosure provides a method of assembling a truck, including assembling a cab structure of the truck. The cab structure includes: a plurality of left pillars and a plurality of right pillars; and a rear roof rail that couples a top portion of a rearmost left pillar of the plurality of left pillars to a top portion of a rearmost right pillar of the plurality of right pillars to cooperate with the rearmost left pillar and the rearmost right pillar to at least partially define a rear opening that extends downward from the rear roof rail in a vertical direction of the cab structure beyond a vertical midpoint of the rearmost left pillar and the rearmost right pillar. The method includes: painting the cab structure; inserting a plurality of first interior components into the interior of the cab structure through the rear opening after painting the cab structure and attaching the first interior components to the cab structure; applying a coating to a rear panel; attaching a plurality of second interior components to the rear panel after applying the coating to the rear panel; attaching the rear panel to the rearmost left pillar and the rearmost right pillar after attaching the first interior components to the cab structure and after attaching the plurality of second interior components to the rear panel, the rear panel spanning the rear opening; and attaching a rear window glass to the rear panel before attaching the rear panel to the rearmost left pillar and the rearmost right pillar.

[0012] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In order that the present disclosure may be better understood, various forms of the present disclosure will now be described by way of example with reference to the accompanying drawings, in which:

[0014] Figure 1 is a schematic front perspective view of an example truck, the truck being shown in a fully assembled state;

[0015] Figure 2 is a front perspective view of an example cab structure for a truck, shown in a typical pre-assembled state prior to assembly of interior components to the cab structure;

[0016] Figure 3 is a rear perspective view of a cab structure of a truck shown during an assembly step in accordance with the teachings of the present disclosure;

[0017] Figure 4 is a rear perspective view of a cab structure of a truck shown during an assembly step with a bed attached thereto in accordance with the teachings of the present disclosure;

[0018] Figure 5is a flow chart of a method of constructing a truck according to the teachings of the present disclosure;

[0019] Figure 6 According to the teaching of the present disclosure, the first form is shown in more detail Figure 5 A flowchart of one of the steps of the method;

[0020] Figure 7 According to the teaching of the present disclosure, the second form is shown in more detail Figure 5 A flowchart of one of the steps of the method;

[0021] Figure 8 According to the teachings of the present disclosure, Figure 5 a flowchart of a different one of the steps of the method;

[0022] Fig. 9 is a rear perspective view of a cab structure of a truck shown during an assembly step with a cross brace attached to the cab structure in accordance with the teachings of the present disclosure;

[0023] Fig.10 is a rear perspective view of a cab structure of a truck shown during an assembly step in accordance with the teachings of the present disclosure, wherein a rear panel includes a boundary defining a rear windshield aperture;

[0024] Fig.11 is a rear perspective view of a cab structure of a truck shown during an assembly step in accordance with the teachings of the present disclosure, wherein a boundary block defines a rear windshield aperture separate from a rear panel; and

[0025] Fig.12 is a rear perspective view of a cab structure of a truck shown during an assembly step in which a plurality of interior components are attached to a floor panel prior to attaching the floor panel to the cab structure in accordance with the teachings of the present disclosure.

[0026] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0027] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0028] refer to Figure 1, the example truck 10 is shown in a fully assembled condition. The truck 10 shown is a pickup truck, but other types of trucks having a passenger cab separated from a rear cargo area can be constructed according to the teachings of the present disclosure. The truck 10 generally includes: a cab portion 14, a front portion 18 in front of the cab portion 14, and a rear portion 22 behind the cab portion 14. The front portion 18 can contain powertrain components (e.g., an internal combustion engine and / or an electric drive motor) and / or can include a front cargo storage cavity commonly referred to as a "front trunk." The rear portion 22 is configured to carry cargo and, in the example provided, includes a portion commonly referred to as a truck bed 26 of the truck 10. In the longitudinal direction of the truck 10, the cab portion 14 is between the rear portion 22 and the front portion 18. The cab portion 14 is configured to carry occupants (e.g., a driver and / or passengers).

[0029] refer to Figure 2 , the structural assembly 210 of the cab portion 14 is shown in a pre-assembled state, wherein the cab structure 214 is welded to the floor panel 218 and the rear panel 222 to define the complete structural assembly 210. During a typical assembly process, the complete structural body 210 is welded together and then coated (e.g., anti-corrosion coating and painting) before any interior components (e.g., wiring, seat belts, HVAC ducts and fans, motors, seats, trim panels, computer modules, carpet, headliner, instrument panel) are attached to the complete structural assembly 210.

[0030] The cab structure 214 generally includes a plurality of pillars (e.g., A-pillars 226, B-pillars 228, C-pillars 230), a pair of roof rails 234, a front roof crossbar 238, a rear roof crossbar 242, a roof panel 246, a pair of rocker panels 250, and a front wall 254. The left and right A-pillars 226, the front roof crossbar 238, and the top of the front wall 254 cooperate to define a front windshield aperture, wherein the front windshield glass window 110 ( Figure 1 ) is configured to be plug-in. On the left and right sides, the A-pillar 226 and the B-pillar 228 cooperate with the corresponding roof rails 234 and the door sill 250 to define corresponding front door openings. The front door 114 ( Figure 1 ) is later hingedly mounted to each A-pillar 226 and is configured to close the front door opening 262. In the example provided, the truck 10 ( Figure 1 ) has a pair of optional rear doors 118 ( Figure 1). To this end, on the left and right sides, the B-pillar 226 and C-pillar 228 cooperate with the corresponding roof rails 234 and the door sill 250 to define the corresponding rear door apertures. The rear door 118 is later hingedly mounted to the B-pillar 228 or C-pillar 230 and is configured to close the rear door aperture. In an alternative form not specifically shown, the truck 10 lacks a center pillar (i.e., the B-pillar 228) so that it only includes the A-pillar 226 and the rear pillar (i.e., the C-pillar 230), but it should be understood that in this configuration, the rearmost pillar will be referred to as the "B-pillar" and the truck will lack the pillar referred to as the "C-pillar". In this configuration, the truck 10 may or may not include the rear door 118 hingedly mounted to the rearmost pillar. The roof panel 246 spans laterally between the roof rails 234 and longitudinally between the front roof rails 238 and the rear roof rails 242, and may or may not include an opening (not shown) for a sunroof (not shown). In some forms, the rear roof crossbar 242 may be integrally formed with the roof panel 246, while in other forms, the roof panel 246 is attached to the rear roof crossbar 242. In some forms, the front roof crossbar 238 may be integrally formed with the roof panel 246, while in other forms, the roof panel 246 is attached to the front roof crossbar 238.

[0031] The bottom plate 218 is attached to the rocker 250 and extends in the longitudinal direction from the rearmost pillar (C-pillar 230) to the A-pillar 226, and may be attached to the bottom of the front wall 254. The rear panel 222 is attached to the rearmost pillar (C-pillar 230) and spans the entire lateral width therebetween. The rear panel 222 is also attached to the bottom plate 218 and extends upward therefrom. In some forms, the rear panel 222 extends completely upward to the rear roof crossbar 242 and defines a rear windshield glass window 30 ( Figure 1 ) of the rear windshield aperture 270. In some forms, the rear panel 222 does not define a rear windshield aperture, and the truck lacks a rear windshield glass window. In some forms, the rear panel 222 does not extend completely upward to the rear roof rail 242, and the top of the rear panel 222 cooperates with the rearmost pillar (C-pillar 230) and the rear roof rail 242 to define the rear windshield aperture 270.

[0032] During assembly of a typical truck 10 , the structural assembly 210 is fully assembled via welding and then undergoes a coating (e.g., corrosion resistant coating and paint) process before it moves to the main assembly line where interior components are then inserted through the door holes and attached to the structural assembly 210 .

[0033] In the example provided, the truck 10 is a body-on-frame vehicle such that the cab structure 214 is mounted to the frame (not shown) of the truck 10, although other types of vehicle architectures (e.g., unibody) may be used. The frame is coupled to the wheels 34 ( Figure 1 ) are supported. In one form, the frame includes a pair of longitudinal frame rails (not shown) that extend substantially the length of the truck 10.

[0034] refer to Figure 3 , the cab portion 14 is shown in a pre-assembled state during an assembly step in accordance with the teachings of the present disclosure and described in greater detail below. In the example provided, the rearmost pillar (C-pillar 230) defines the left and right boundaries of the rear opening or aperture 310 of the cab structure 214, while the rear roof crossbar 242 defines the top boundary of the rear aperture 310. Figure 3 In the form shown in FIG. 1 , that is, when installing the base plate 218 ( Figure 2 ), the rear aperture 310 may be opened through the bottom of the cab structure 214 before installation. In other words, the rear aperture 310 may extend vertically downward from the rear roof crossbar 242 to the bottom of the rearmost pillar (C-pillar 230). Figure 4 As shown in FIG. 2 , the bottom plate 218 can define a bottom boundary of the rear aperture 310. In other words, when the bottom plate 218 is installed, the rear aperture 310 can extend downwardly from the rear roof crossbar 242 to the bottom plate 218 in a vertical direction.

[0035] exist Figure 3 and Figure 4 In the pre-assembled state shown in FIG, the rear panel 222 is not attached to the cab structure 214. To this end, the rear hole 310 extends downward from the rear roof crossbar 242 beyond the vertical midpoint of the rearmost pillar (C-pillar 230) in the vertical direction of the cab structure 214. In other words, the rear hole 310 spans a majority of the total vertical length of the rearmost pillar (C-pillar 230).

[0036] exist Figure 3 and Figure 4 In the pre-assembled state shown in FIG. 2 , although the cab structure 214 is not attached to the rear panel 222 , the cab structure 214 has been coated (eg, with an anti-corrosion coating and / or paint). Figure 4 In the example provided in , the bottom plate 218 has been attached to the cab structure 214 and has been coated with the cab structure 214. In another form, the bottom plate 218 can be coated separately and then attached to the cab structure 214.

[0037] refer to Figure 5, schematically illustrates a method 510 of assembling a truck 10. The method 510 includes a step 514 in which the cab structure 214 is assembled. This may be accomplished by welding together pillars (e.g., A-pillars 226, B-pillars 228, C-pillars 230), a pair of roof rails 234, a front roof rail 238, a rear roof rail 242, a roof panel 246, a pair of rockers 250, and a front wall 254 to form the cab structure 214 discussed above.

[0038] The method 510 proceeds to step 518, where the cab structure 214 is coated with an anti-corrosion coating and / or paint as discussed above. The coating may be different at different portions of the cab structure 214. For example, the coating may include a finish coating in some areas and only an anti-corrosion coating in other areas.

[0039] The method 510 proceeds to step 522, in which a plurality of first interior components 314 are inserted through the rear apertures 310 before the rear panel 222 is attached to the cab structure 214. The first interior components 314 may be any suitable components. For example, the first interior components 314 may include, but are not limited to, wiring, seat belts, HVAC ducts and fans, motors, seats, trim panels, computer modules, carpets, headliners, instrument panels, speakers, subwoofers, and / or amplifiers. In one form, for step 522, the cab structure 214 is located on a main assembly line at an assembly plant for the truck 10. The first interior components 314 are then attached to the cab structure 214.

[0040] Method 510 proceeds to step 530, wherein the rear panel 222 and the cross brace 910 ( Fig. 9 ) is attached to the cab structure 214. The cross brace 910 is a structural member attached to the rearmost pillar (C-pillar 230) and spans therebetween. The top edge 914 ( Fig. 9 ) at the top edge 318 of the rear panel 222 ( Figure 3 ) below, and the bottom edge 918 ( Fig. 9 ) at the bottom edge 322 of the rear panel 222 ( Figure 3 ) and above the base plate 218.

[0041] As shown in phantom at step 534, during the method 510, the floor panel 218 may be attached to the cab structure 214 in any of several examples. In one form, the floor panel 218 is attached to the cab structure 214 prior to coating the two together. In another form, after the cab structure 214 is coated, the floor panel 218 is coated separately and then attached to the cab structure 214. In another form, after the first interior component 314 is attached to the cab structure 214, the floor panel 218 is coated separately and then attached to the cab structure 214.

[0042] refer to Figure 6 , showing one form of step 530 in more detail. In this form, attaching the rear panel 222 and the cross brace 910 to the cab structure 214 includes step 614. At step 614, the rear panel 222 is coated (e.g., anti-corrosion coating and / or painting) separately from the cab structure 214. As shown in phantom at step 618, the cross brace 910 can be attached to the rear panel 222 before the rear panel 222 is coated, so that the cross brace 910 is coated with the rear panel 222, or the cross brace 910 can be attached to the rear panel 222 after the rear panel 222 is coated. In one form, the cross brace 910 is coated separately from the rear panel 222 and connected to the rear panel after step 614. In another form, the cross brace 910 is formed of a composite material (e.g., a carbon fiber, fiberglass, or plastic composite material) and is not coated, and the cross brace is attached to the rear panel 222 after the rear panel 222 is coated. In the form where the cross brace 910 is attached before the rear panel 222 is coated, the cross brace 910 can be attached via welding, adhesive, rivets, screws and / or bolts. In the form where the cross brace 910 is attached after the rear panel 222 is coated, the cross brace 910 is attached via adhesive, rivets, screws and / or bolts.

[0043] exist Figure 6 In the form shown in FIG. 5 , step 530 proceeds to step 622, where a plurality of second interior components 326 are attached to the rear panel 222 and / or the cross brace 910. The second interior components 326 may be any suitable components. For example, the second interior components 326 may include, but are not limited to, wiring, seat belts, HVAC ducts and fans, motors, decorative panels, computer modules, speakers, subwoofers, and / or amplifiers.

[0044] This version of step 530 advances to step 626 where the rear panel 222 with attached cross brace 910 is attached to the cab structure 214 via adhesive, rivets, screws, and / or bolts.

[0045] As shown in phantom at step 630, the rear windshield glass window 30 may be attached to the rear panel 222 before or after step 626. The rear windshield glass window 30 may be attached by any suitable method, such as fasteners and / or adhesives.

[0046] exist Fig.10 In one form shown in FIG. 1 , the rear panel 222 has a border 1014 that extends completely to and is attached to the rear roof rail 242. The border 1014 and the top edge 318 of the rear panel 222 define the rear windshield aperture 270. The rear windshield glass window 30 is attached to the border 1014 and the top edge 318.

[0047] In another form, the rear panel 222 lacks the border 1014 and ends vertically at the top edge 318. In this form, the rear windshield aperture 270 is defined by the top edge 318, the rearmost pillar (C-pillar 230), and the rear roof rail 242. The rear windshield glass window 30 can then be attached to the top edge 318, the rearmost pillar (C-pillar 230), and the rear roof rail 242. Fig.11 In one form shown in , a separate border block 1114 is mounted to the top edge 318, the rearmost pillar (C-pillar 230), and the rear roof rail 242 to provide a continuous surface to which the rear windshield glass window 30 can be attached and sealed.

[0048] refer to Figure 7 , another version of step 530 is shown in more detail. In this version, the cross brace 910 is not attached to the rear panel 222 before the rear panel 222 is attached to the cab structure 214. Alternatively, at step 714, the rear panel 222 is coated (e.g., anti-corrosion coating and / or painting) separately from the cab structure 214.

[0049] This form of step 530 advances to step 718, where the plurality of second interior components 326 are attached to the rear panel 222. Some other of the second interior components 326 may optionally be attached to a cross brace 910, which is separated from the rear panel 222 at this step.

[0050] In this form, step 530 advances to step 722 where the cross brace 910 is attached to the cab structure 214 while the rear panel 222 is still separated from the cab structure 214 .

[0051] This form of step 530 proceeds to step 726, where the rear panel 222 is attached to the cab structure 214. In addition to the cab structure 214, the rear panel 222 may also be attached to the cross brace 910. The rear panel 222 may cover or enclose the cross brace 910 within the cab structure 214.

[0052] In this form, as shown in phantom at step 730 , the rear windshield window 30 may be attached to the rear panel 222 before the rear panel 222 is attached to the cab structure 214 , or the rear windshield window 30 may be attached to the rear panel 222 after the rear panel 222 is attached to the cab structure 214 .

[0053] exist Fig.10 In one form shown in FIG. 1 , the rear panel 222 has a border 1014 that extends completely to and is attached to the rear roof rail 242. The border 1014 and the top edge 318 of the rear panel 222 define the rear windshield aperture 270. The rear windshield glass window 30 is attached to the border 1014 and the top edge 318.

[0054] In another form, the rear panel 222 lacks the border 1014 and ends vertically at the top edge 318. In this form, the rear windshield aperture 270 is defined by the top edge 318, the rearmost pillar (C-pillar 230), and the rear roof rail 242. The rear windshield glass window 30 can then be attached to the top edge 318, the rearmost pillar (C-pillar 230), and the rear roof rail 242. Fig.11 In one form shown in , a separate border block 1114 is mounted to the top edge 318, the rearmost pillar (C-pillar 230), and the rear roof rail 242 to provide a continuous surface to which the rear windshield glass window 30 can be attached and sealed.

[0055] refer to Figure 8 , shows one form of step 522 in more detail. In this form, step 522 includes step 814, where the floor 218 is coated (eg, an anti-corrosion coating and / or paint) separately from the cab structure 214.

[0056] Step 522 advances to step 818, where a plurality of first interior components 314 (e.g., seats, carpet, console, instrument panel, air ducts, wiring) are attached to the floor panel 218 while the floor panel 218 is separated from the cab structure 214, such as Fig.12 as shown in .

[0057] Step 522 advances to step 822 , where the floor panel 218 with the first interior component 314 attached forms a modular interior, which is then at least partially moved through the rear aperture 310 to a suitable position within the cab structure 214 .

[0058] Step 522 advances to step 826 where the floor panel 218 is attached to the cab structure 214 .

[0059] In this form, while some of the first interior components 314 are attached to the floor 218 , some additional first interior components 314 may optionally be inserted through the rear apertures 310 and attached to the cab structure 214 independent of the floor 218 .

[0060] In an alternative form, the floor 218 is attached to the cab structure 214 before any interior components are attached thereto, and the first interior component 314 is inserted through the rear aperture 310 and attached to the cab structure and / or floor 218 .

[0061] The method 510 described herein can reduce the number of stations on the main assembly line of the truck 10. For example, step 622 or 718 can be completed at a workstation away from the main assembly line. To this end, fewer main assembly line stations are required to install interior components. Similarly, when step 630 or 730 is performed before step 626 or 726, the rear windshield glass window 30 can be attached to the rear panel 222 at a workstation away from the main assembly line. Similarly, step 818 can be completed at a workstation away from the main assembly line.

[0062] Unless otherwise expressly indicated herein, all numerical values ​​indicating mechanical / thermal properties, composition percentages, dimensions and / or tolerances or other characteristics when describing the scope of the present disclosure should be understood to be modified by the word "about" or "approximately". Such modifications are desirable for a variety of reasons, including: industrial practice; material, manufacturing and assembly tolerances; and testing capabilities.

[0063] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical "or", and should not be construed to mean "at least one of A, at least one of B, and at least one of C."

[0064] The description of the present disclosure is merely exemplary in nature, and therefore, variations that do not depart from the essence of the present disclosure are intended to be within the scope of the present disclosure. Such variations should not be regarded as a departure from the spirit and scope of the present disclosure.

[0065] In one aspect of the invention, the first plurality of interior components includes at least one of a seat, a seat belt component, an interior trim panel, an air duct, a cable, a wire, a headliner, a floor covering, and an instrument panel.

[0066] According to the present invention, a method for assembling a truck comprises: assembling a cab structure of the truck, the cab structure comprising: a plurality of left pillars and a plurality of right pillars; and a rear roof rail, the rear roof rail connecting the top portion of the rearmost left pillar of the plurality of left pillars to the top portion of the rearmost right pillar of the plurality of right pillars to cooperate with the rearmost left pillar and the rearmost right pillar to at least partially define a rear opening, the rear opening extending downward from the rear roof rail in the vertical direction of the cab structure beyond the vertical midpoint of the rearmost left pillar and the rearmost right pillar; inserting a plurality of first interior components into the interior of the cab structure through the rear opening and attaching the first interior components to the cab structure; attaching a plurality of second interior components to a rear panel; and after attaching the first interior components to the cab structure and after attaching the plurality of second interior components to the rear panel, attaching the rear panel to the rearmost left pillar and the rearmost right pillar, the rear panel spanning the rear opening.

[0067] In one aspect of the invention, the method includes painting the cab structure prior to inserting the plurality of interior components through the rear opening; and applying a coating to the rear panel prior to attaching the plurality of second interior components to the rear panel.

[0068] In one aspect of the invention, the method includes attaching a rear window glass to the rear panel before attaching the rear panel to the rearmost left pillar and the rearmost right pillar.

[0069] According to the present invention, a method for assembling a truck comprises: assembling a cab structure of the truck, the cab structure comprising: a plurality of left pillars and a plurality of right pillars; and a rear roof rail, the rear roof rail connecting the top portion of the rearmost left pillar of the plurality of left pillars to the top portion of the rearmost right pillar of the plurality of right pillars to cooperate with the rearmost left pillar and the rearmost right pillar to at least partially define a rear opening, the rear opening extending downward from the rear roof rail in the vertical direction of the cab structure beyond the vertical midpoint of the rearmost left pillar and the rearmost right pillar; painting the cab structure; and after painting the cab structure and applying the paint After the first interior components are attached to the cab structure, inserting a plurality of first interior components into the interior of the cab structure through the rear opening; applying a coating to a rear panel; attaching a plurality of second interior components to the rear panel after applying the coating to the rear panel; attaching the rear panel to the rearmost left pillar and the rearmost right pillar after attaching the first interior components to the cab structure and after attaching the plurality of second interior components to the rear panel, the rear panel spanning the rear opening; and attaching a rear window glass to the rear panel before attaching the rear panel to the rearmost left pillar and the rearmost right pillar.

Claims

1. A method of assembling a truck, the method comprising: Assembling the cab structure of the truck, the cab structure comprising: multiple left columns and multiple right columns; and a rear roof rail coupling a top portion of a rearmost left pillar of the plurality of left pillars to a top portion of a rearmost right pillar of the plurality of right pillars to cooperate with the rearmost left pillar and the rearmost right pillar to at least partially define a rear opening of the cab structure, the rear opening extending downwardly from the rear roof rail beyond a vertical midpoint of the rearmost left pillar and the rearmost right pillar in a vertical direction of the cab structure; inserting a plurality of first interior components into the interior of the cab structure through the rear opening and attaching the first interior components to the cab structure; and A rear panel is attached to the rearmost left pillar and the rearmost right pillar after the first interior component is attached to the cab structure, the rear panel spanning the rear opening.

2. The method according to claim 1, further comprising: A second plurality of interior components are attached to the rear panel prior to attaching the rear panel to the rearmost left pillar and the rearmost right pillar.

3. The method of claim 2, wherein the plurality of second interior components comprises at least one of a subwoofer, an air duct, an electronic control module, an amplifier, a speaker, a cable, a wire, a power window module, a seat belt component, and an electric motor.

4. The method of claim 1, wherein the plurality of first interior components comprises a plurality of seats, wherein the method further comprises: mounting the plurality of seats to the floor prior to inserting the plurality of seats through the rear opening, wherein inserting the plurality of first interior components through the rear opening comprises inserting the plurality of seats through the rear opening while the plurality of seats are mounted to the floor; as well as The floor is attached to the cab structure.

5. The method according to claim 1, further comprising: The cab structure is painted prior to inserting the plurality of interior components through the rear opening.

6. The method according to claim 5, further comprising: A coating is applied to the rear panel prior to attaching the rear panel to the rearmost left pillar and the rearmost right pillar, the coating comprising at least one of a corrosion resistant electrophoretic coating and a paint coating.

7. The method according to claim 1, further comprising: A rear cross brace is attached to the cab structure prior to attaching the rear panel to the rear-most left and right pillars, wherein the rear cross brace extends from the rear-most left pillar to the rear-most right pillar.

8. The method of claim 7, wherein the rear cross brace is attached to the cab structure prior to inserting the first plurality of interior components through the rear opening.

9. The method according to claim 8, further comprising: A coating is applied to the cab structure and the rear cross brace with a corrosion resistant material after the rear cross brace is attached to the cab structure and before the plurality of first interior components are inserted through the rear opening.

10. The method according to claim 1, further comprising: A rear cross brace is attached to the rear panel prior to attaching the rear panel to the rearmost left pillar and the rearmost right pillar.

11. The method according to claim 10, further comprising: A rear window glass is attached to the rear panel before attaching the rear panel to the rearmost left pillar and the rearmost right pillar.

12. The method according to claim 10, further comprising: A rear window glass is attached to the rear panel after the rear panel is attached to the rearmost left pillar and the rearmost right pillar.

13. The method of claim 1, wherein the rear panel is attached to the rearmost left and right pillars by a plurality of fasteners, and a seal is disposed between the rear panel and the rearmost left and right pillars.

14. The method according to claim 1, further comprising: The cab structure is mounted to a pair of longitudinal frame rails after attaching the plurality of first interior components to the cab structure.

15. The method of claim 1, wherein the cab structure further comprises: a left door sill joining a corresponding bottom portion of the left pillar to define a bottom of at least one door opening on a left side of the cab structure; a right sill joining a corresponding bottom portion of the right pillar to define a bottom of at least one door opening on a right side of the cab structure; a left roof rail joining a respective top portion of the left pillar to define a top portion of the at least one door opening on the left side of the cab structure; as well as A right roof rail joins a corresponding top portion of the right pillar to define a top of the at least one door opening on the right side of the cab structure.

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