Method for producing a motor vehicle and motor vehicle

Abstract

The invention relates to a method for producing a motor vehicle, comprising the following steps: producing a plurality of structural modules (10, 20, 30, 130), each structural module (10, 20, 30, 130) comprising at least one structural component (100, 200, 300) of a vehicle body and at least one vehicle component (122, 220, 340), and assembling the plurality of structural modules (10, 20, 30, 130) for producing a motor vehicle, as a result, the motor vehicle has already been equipped with a plurality of vehicle components when the load-bearing motor vehicle structure is produced, the structural modules (10, 20, 30, 130) are joined to one another on the structural component side using only cold connection techniques. A motor vehicle is also provided.

Description

Technical Field

[0001] The invention relates to a method for producing a motor vehicle and to a motor vehicle. Background Art

[0002] A vehicle with conventional distribution has a corrosion-resistant and sealed body, which is provided with vehicle components such as accessories in the interior space and in the exterior space, electronic equipment, seat belts, seats, etc. In addition, the complete vehicle has a drive train including a drive motor, a transmission and axles.

[0003] In the conventional production concept for manufacturing motor vehicles, the vehicle components are first manufactured, the body in white is assembled in body construction and then protected and painted. The final assembly of the complete vehicle takes place on a master belt, where the drive train is joined to the body and the vehicle is finally equipped with vehicle components in the interior and exterior.

[0004] Major technical changes affect the entire vehicle along with the above-mentioned production chain and are expensive to implement. Radical changes in vehicles can only be achieved at very high economic costs. Summary of the invention

[0005] Against the backdrop of volatile market conditions, rapid technological development and stricter regulation by legislators, low-cost production solutions are needed to manufacture vehicles. On the other hand, production solutions should allow for a high degree of change flexibility while reducing or minimizing change costs.

[0006] Against this background, the object of the present invention is to provide possibilities for improving motor vehicle construction. In particular, the above-mentioned disadvantages should be avoided.

[0007] This object is achieved by a method for producing a motor vehicle according to claim 1 and a motor vehicle according to claim 11. Further advantageous embodiments are apparent from the dependent claims and the following description.

[0008] A method for manufacturing a motor vehicle is provided, the method comprising the following steps:

[0009] manufacturing a plurality of structural modules, wherein each structural module comprises at least one structural member of a vehicle body and at least one vehicle component, and

[0010] Assembling the plurality of structural modules to produce a motor vehicle, whereby the motor vehicle is already equipped with a plurality of vehicle components when the load-bearing motor vehicle structure is produced,

[0011] The structural modules are joined to one another on the structural component side only by using cold joining technology.

[0012] The structural module includes at least one structural member. The structural member plays a role of providing structure in the whole vehicle and absorbs forces and / or moments, for example. The structural member can be, for example, a front end, a rear end, a column, a side frame, a roof beam, a roof, etc. In a structural module, two or more structural members can also be joined into a structural assembly. In order to manufacture a structural assembly, all known joining methods can be used in principle. The structural assembly can, for example, have two or more structural members, each of which can be welded, riveted, screwed and / or bonded to each other. The structural member can, for example, be a metal member, a fiber-reinforced plastic member or a composite member, which not only contains metal materials but also contains plastic materials, and if necessary, contains fiber-reinforced plastic materials. The structural member can, for example, be manufactured using a prototyping method, a deformation molding method, an additive method and a combination of these methods and in particular has a metal sheet member, a cast member, an additively manufactured member or a hybrid member with a metal sheet section, a cast section and / or an additively manufactured member section. The structural member or structural assembly can, for example, be provided with an anti-corrosion coating. Preferably, the structural member or structural assembly has been painted.

[0013] Furthermore, the structural module comprises at least one vehicle component. In the context of the present application, a vehicle component is a component of a vehicle that is not part of the body of the motor vehicle. Such a vehicle component is usually connected to the vehicle body, for example, only after the vehicle body has been manufactured. For example, the vehicle component is a control unit, a sensor, a vehicle interior and / or vehicle exterior panel, accessories such as mirrors, signaling devices such as lights or horns, window glass, cables, etc. The structural module is produced by mounting one or more vehicle components on the above-mentioned structural member or structural assembly.

[0014] In order to manufacture a motor vehicle, a plurality of structural modules are now assembled. Here, on the one hand, a load-bearing structure of the entire vehicle is provided (comparable to a conventional body), while the assembly already includes a plurality of vehicle components. In other words, the method breaks down the hitherto common body frame and replaces it with a plurality of structural modules, which are already pre-installed with other vehicle components. The load-bearing structure of the motor vehicle preferably consists mainly of structural modules, for example more than 70% or more than 80% or more than 90% of the structural components are first equipped with other vehicle components and installed as structural modules. In these cases, some structural components may remain, which are installed on the structural modules as individual components or component groups, but not as modules.

[0015] By using the described structural modules, the number of components and the installation process on the main belt is reduced. The required complexity and length of the main belt are thereby reduced and costs can be reduced. In addition, the flexibility of production is increased. The impact of changes on some structural modules on the entire production process is reduced to those sections of the production process in which the corresponding structural modules are manufactured. As a result, changes can be implemented faster and better integrated into existing production.

[0016] During assembly, the structural modules are joined on the structural component side. Here, the structural components or structural assemblies of adjacent structural modules are permanently connected to each other. According to the present invention, the connection on the structural component side is only achieved when using cold connection technology. In particular, riveting, bolting and bonding should be considered as "cold connection technology". Preferably, the structural modules are connected to each other inseparably, that is, the joining connection can only be achieved when the joining auxiliary device (such as rivets or adhesive) is destroyed or when the structural module is damaged. Since only cold joining methods are used to connect the structural modules to each other, the structural modules or parts of the structural modules, especially the structural components, can be provided with anti-corrosion coatings and spray paint before installation. It is no longer necessary to first manufacture the vehicle body and then guide it as a component body through the cathodic electrophoretic coating (KTL) tank and spray paint in large equipment and complex methods. Instead, the corresponding equipment can be designed to be significantly smaller, thereby saving costs and production area. In addition, the joining technology on the main belt is greatly simplified, thereby reducing complexity, and the joining technology equipment can be unified and can be used more universally. This can further reduce costs.

[0017] In one embodiment, the load-bearing vehicle structure can be formed exclusively from the structural modules, thereby further reducing the number of components to be mounted on the main belt and further simplifying the assembly method.

[0018] In a preferred design, the motor vehicle is configured so that the first structural module is used as an assembly platform (Bauplattform) for all other modules. For example, the assembly platform can have a connection surface for other structural modules. If the first structural module is used as an assembly platform, the first structural module is preferably positioned in a defined position on the mounting device. The mounting device can be a flexible receiving portion for different assembly platforms. Such a mounting device can be configured, for example, as a perforated grid workbench (Lochraster-Tisch), which can flexibly accommodate the assembly platform on all three spatial axes (X, Y, Z). Therefore, the mounting device can be quickly and flexibly adapted to assembly platforms with different geometric dimensions. The first structural module / assembly platform is oriented and fixed on the mounting device, for example. Then, the motor vehicle is assembled starting from the first structural module. Then, other structural modules are oriented and joined to the first structural module / assembly platform. If a load-bearing structure is made, other modules, such as door modules, can also be installed. For example, these modules can be positioned relative to each other by means of a gripping system guided by a robot. The assembly into a complete vehicle continues to advance with each structural module / module. Thus, starting from a first structural module / assembly platform, the bodyshell is augmented with further modules. Here, the further construction is carried out in accordance with the first structural module / assembly platform or with the existing assembly formed by the assembly platform with further structural modules. The mounting method is therefore largely independent of the geometry. This allows a single mounting device to be used universally for a variety of vehicle variants, whereby the mounting is cost-effective and at the same time flexible with regard to changes.

[0019] If the first structural module is used as an assembly platform, the structural module preferably has geometric features integrated into the component, which are arranged to realize the precise positioning of other structural modules on the assembly platform. The structural module, for example, has a mounting surface on which the structural modules are connected to each other. The geometric features integrated into the component are preferably arranged in these mounting surfaces. The geometric features integrated into the component can, for example, be configured as corresponding latches or clamping connections, etc. When assembling two structural modules, the geometric features integrated into the component preferably fit into each other and thus define the precise and correct orientation of the structural modules relative to each other. The geometric features integrated into the component can, for example, be configured in a prototyping manner (for example, by casting or injection method), in a deformation-forming manner (for example, when manufacturing a metal sheet forming component), or by mechanical processing of the structural module (for example, by milling). In addition, the use of geometric features integrated into the component is very low-cost because no separate device is required to position the structural module.

[0020] In one embodiment, it is very advantageous from an installation point of view to use an energy storage module as an assembly platform / first structural module. As a vehicle component, the energy storage module has, in particular, an energy storage, the energy of which is used to drive the motor vehicle. The energy storage is preferably a high-voltage storage, but can also be a tank for fuel, such as gasoline, diesel or hydrogen. The energy storage housing can take on additional structural tasks in the entire vehicle, especially in the case of high-voltage energy storage. The storage module is therefore designed to be particularly stable and is therefore particularly suitable as a starting point for assembling structural modules.

[0021] It is particularly preferred that the first structural module forms a floor assembly of the motor vehicle. The floor assembly can, for example, have a vehicle front end and a vehicle rear end. The floor assembly forms the lowest point of the vehicle body and, due to this spatial arrangement in the complete vehicle, is particularly suitable as a starting point for constructing the vehicle. This is especially true if the floor assembly is also designed as an energy storage module and is therefore particularly heavy. The floor assembly carries other body components and is therefore particularly suitable as an assembly platform to form the basis for constructing the complete vehicle. It is therefore particularly simple to build different vehicle models with the same floor assembly. Different vehicle models can be assembled simply and cost-effectively on the same main belt.

[0022] In one embodiment, the bulkhead module is used as a further structural module. The bulkhead module preferably includes components of the bulkhead and the instrument panel of the vehicle, such as an instrument panel support, an instrument panel cover, an air conditioning device, and the like.

[0023] Furthermore, in one embodiment, it can be provided that the side frame module is used as a further structural module. The side frame module has a side frame, which is formed, for example, by joining one or more sheet metal components. The side frame preferably extends from the A-pillar via the B-pillar rearward to the C-pillar or, in a motor vehicle of modular construction, to the D-pillar. An opening for a side door is preferably provided in the side frame. In one embodiment, the side frame can also have a deformation element, in particular in the area below the door opening, which is designed to cooperate with the floor assembly in order to increase stability and dissipate energy in the event of a lateral collision in order to protect the high-voltage storage device. For example, one or more interior equipment components of the vehicle, such as vehicle seat belts, inner guard plate components, vehicle locks, etc., are fixed to the side frame.

[0024] In order to assemble the structural modules, it is particularly advantageous that, in a design, the structural modules are mechanically pre-fixed and bonded to other structural modules. Mechanical pre-fixation can be achieved, for example, by a clamping connection or a bolt connection. The pre-fixation here only undertakes the task of fixing the structural modules to each other in a predetermined position until the adhesive is finally cured. However, due to the mechanical pre-fixation, further installation operations can be carried out on the vehicle before the adhesive is completely cured. Therefore, the installation steps that follow one another can be carried out without a lot of auxiliary time. In addition, the use of bonding technology as a joining method allows for greater flexibility in the selection and / or combination of materials for the individual structural modules. In addition, the joint connection can be used as a sealing device at the same time, thereby reducing the number of working steps.

[0025] By no longer assembling purely structural components to form a vehicle body, but using already pre-assembled structural modules, the number of components on the main strip can be reduced and the installation on the main strip can be greatly simplified. In this respect, it is particularly advantageous if, in a design, the hood and / or the doors are fastened to the vehicle body as pre-assembled modules. For example, when the doors are mounted on the vehicle body, they can already be equipped with windows, window lifters, locking systems and door interior trim. Likewise, other components such as sound insulation, windows and / or interior trim can already be pre-assembled on the hood.

[0026] Furthermore, a motor vehicle is proposed, which has a structure composed of a plurality of structural modules, wherein each structural module comprises at least one structural component of the vehicle body and at least one vehicle part. The structural modules are connected to each other on the structural component side only by cold joining technology.

[0027] The motor vehicle can be manufactured in particular by means of the above method. The vehicle achieves the same advantages and technical effects as those already described above with respect to the method.

[0028] Features and details described here in conjunction with the method also apply in conjunction with the motor vehicle according to the invention, and vice versa, so that reference is always made to one another with regard to the disclosure of the individual inventive aspects.

[0029] Further advantages, features and details of the invention emerge from the following description, in which exemplary embodiments of the invention are described in detail with reference to the accompanying drawings. Here, the features mentioned in the claims and in the description may be essential to the invention individually or in any combination. If the term "may" is used in this application, this relates both to technical possibilities and to practical technical realizations. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The embodiments are described below with reference to the accompanying drawings. The accompanying drawings are as follows:

[0031] Figure 1A flow chart illustrating an exemplary method for manufacturing a motor vehicle;

[0032] Figure 2 An exemplary mounting device for use in the method is shown. DETAILED DESCRIPTION

[0033] Figure 1 A method for producing a motor vehicle 1 is shown. Structural modules 10, 20, 30 are first produced before being assembled on a main strip H to form a complete vehicle 1. Each structural module 10, 20, 30 has at least one structural component 100, 110, 120, 200, 310, 320, 330 and at least one vehicle part 122, 220, 340. Figure 1 As exemplary structural components, for example, a front end 100, a rear end 110, a storage housing 120 of a high-voltage storage device, and a front wall 200 are shown. A further structural component 300 in the form of a side frame is produced as a structural assembly by joining three side frame components 310, 320, 330. In addition, further vehicle components such as a door 400 and a lid 500 are produced. If necessary or desired, the vehicle components are subjected to a corrosion protection treatment KTL and a painting L. In a first pre-assembly VM1, the structural components are pre-assembled together with at least one vehicle component 122, 220, 340 to form a structural module 10, 20, 30. For example, the storage housing 120 is pre-assembled together with a further storage component 122 to form a storage module 130, the front wall 200 is pre-assembled together with a component of the instrument panel 220 to form a front wall module 20, and the side frame 300 is pre-assembled together with the trim component 340 to form a side frame module 30. Further structural modules not shown here can also be provided. Furthermore, in the first pre-assembly VM1, the door 400 is pre-assembled with the door component 410 to form a door module 40 and the hood 500 is pre-assembled with the further component 510 to form a hood module 50. The front end 100 and the rear end 110 are then mounted on the energy storage module 130 to produce a structural module 10 in the form of a floor assembly. The floor assembly is preferably used as an assembly platform for the subsequent assembly of the complete vehicle 1. Alternatively, the energy storage module 130 can already be used as an assembly platform, in which case the front end 100 and the rear end 110 are mounted on the energy storage module 130 as structural components of a further (not shown) structural module.

[0034] Starting from an assembly platform in the form of a structural module 10, the complete vehicle is now mounted on a main belt H. For this purpose, the structural module 10 is preferably positioned on a perforated grid table with flexible receptacles (XYZ) as a basis for all the remaining modules. Subsequently, further structural modules 20, 30 as well as door modules and cover modules 40, 50 are installed, whereby the complete vehicle 1 is increased module by module. The modules are preferably positioned with the aid of a flexible gripper having a movable end effector that can be flexibly adapted to the respective handling task. The flexible gripper can be guided, for example, by a robot.

[0035] The structural modules 10, 20, 30 are joined to one another on the structural component side only by cold joining techniques. Preferably, the structural modules 10, 20, 30 are bonded to one another, wherein they can additionally be pre-fixed, for example, by means of screws or clamping connections. Geometric features integrated into the components can be provided on the structural components 100, 110, 120, 200, 300, which enable high-precision positioning. Figure 2 A first structural module 10 is shown, which is positioned and fixed on a mounting device M. The first structural module 10 has a plurality of component-integrated geometric features 11-15, which are provided, for example, in a storage housing 120 of an energy storage module 130. For assembly, a further structural module 30 in the form of a side wall module is arranged on the first structural module 10 in a precisely positioned manner by means of corresponding component-integrated geometric features 31-35 and can be joined thereto.

[0036] To produce the complete vehicle 1, further vehicle components 60, 62, 64, 68, 70, 72 are installed, provided they have not already been installed in the module, such as lines, axles, cable harnesses, carpets, seats, center consoles and roofs. These vehicle components can be manufactured, for example, in a further pre-assembly VM2 and provided to the master strip H.

[0037] Reference numerals list

[0038] 1 Complete vehicle

[0039] 10, 20, 30 structural modules

[0040] 11-15, 31-35 Geometric features integrated into components

[0041] 40-door module

[0042] 50 cover modules

[0043] 60, 62, 64, 68, 70, 72 vehicle parts

[0044] 100, 110, 120, 200, 310, 320, 330 structural components

[0045] 122, 220, 340 vehicle parts

[0046] 130 Energy storage modules

[0047] 300 structural components

[0048] 400 doors

[0049] 500 caps

[0050] H Main Band

[0051] KTL Anti-corrosion Treatment

[0052] L spray paint

[0053] M Mounting Device

[0054] VM 1, VM2 pre-installed

Claims

1. A method for manufacturing a motor vehicle, the method comprising the following steps: A plurality of structural modules (10, 20, 30, 130) are manufactured, wherein each structural module (10, 20, 30, 130) comprises at least one structural member (100, 200, 300) of a vehicle body and at least one vehicle component (122, 220, 340), and The plurality of structural modules (10, 20, 30, 130) are assembled to produce a motor vehicle, whereby the motor vehicle is already equipped with a plurality of vehicle components when the load-bearing motor vehicle structure is completed, wherein the structural modules (10, 20, 30, 130) are joined to one another on the structural component side using only cold joining technology.

2. The method according to claim 1, wherein: The load-bearing structure of the motor vehicle (1) is assembled solely from the structural modules (10, 20, 30, 130).

3. The method according to claim 1 or 2, wherein: The motor vehicle (1) is designed such that a first structural module (10, 130) serves as an assembly platform for all further modules (20, 30).

4. A method according to any one of the preceding claims, wherein: Each of the structural modules (10, 20, 30, 130) has geometric features (11-15; 31-35) integrated into the component, and these geometric features are configured to achieve precise positioning of each of the structural modules (10, 20, 30, 130) relative to each other.

5. The method according to claim 3 or 4, wherein: The first structural module (130) forms an energy storage module of the vehicle.

6. The method according to any one of claims 3 to 5, wherein: The first structural module (10) forms a floor assembly of the vehicle.

7. The method according to any one of claims 3 to 6, wherein: The bulkhead module serves as a further structural module (20).

8. The method according to any one of claims 3 to 7, wherein: The side frame modules serve as further structural modules (30).

9. A method according to any one of the preceding claims, wherein: Each of the structural modules (10, 20, 30) is mechanically pre-fixed and adhesively bonded for connection with other structural modules (10, 20, 30).

10. A method according to any one of the preceding claims, wherein: The hood (400) and / or the door (500) are also installed as pre-installed modules (40, 50).

11. A motor vehicle, in particular manufactured by means of a method according to any one of claims 1 to 10, having a structural form assembled from a plurality of structural modules (10, 20, 30, 130), wherein: Each structural module (10, 20, 30, 130) comprises at least one structural component (100, 200, 300) of a vehicle body and at least one vehicle component (122, 220, 340), and the structural modules (10, 20, 30, 130) are connected to one another on the structural component side using only cold joining technology.

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