Method of assembling vehicle

Abstract

A method of assembling a vehicle, the method comprising: performing a first operation on a front vehicle structure; securing a plurality of first vehicle components to the front vehicle structure while performing the first operation on the front vehicle structure; performing a second operation on the rear vehicle structure; securing a plurality of second vehicle components to the rear vehicle structure while performing the second operation on the rear vehicle structure; and coupling the front vehicle structure and the rear vehicle structure to each other to form an intermediate vehicle structure after the first vehicle component has been secured to the front vehicle structure and the second vehicle component has been secured to the rear vehicle structure. The first operation includes continuously or intermittently rotating the front vehicle structure. The second operation includes continuously or intermittently rotating the rear vehicle structure.

Description

Technical Field

[0001] The present disclosure relates to a method for assembling a vehicle, and more particularly, to a method for assembling an electric vehicle. Background Art

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

[0003] Conventional vehicle assembly processes are typically linear processes that involve sequentially building a vehicle body structure, known as a body-in-white, then painting the body structure, and then securing vehicle components (e.g., such as a powertrain assembly, a suspension assembly, and an instrument panel assembly) to a vehicle structure (e.g., a unibody structure) as the vehicle structure moves along an assembly line. Assembly of vehicle components to the vehicle structure may be slowed due to limited access to the vehicle structure at various points along the assembly line.

[0004] The present disclosure addresses these problems associated with accessing a vehicle structure to secure vehicle components thereto as the vehicle structure moves along an assembly line. Summary of the invention

[0005] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

[0006] In one form, the present disclosure discloses a method of assembling a vehicle, the method comprising: performing a first operation on a front vehicle structure; while performing the first operation on the front vehicle structure, securing a plurality of first vehicle components to the front vehicle structure; performing a second operation on a rear vehicle structure; while performing the second operation on the rear vehicle structure, securing a plurality of second vehicle components to the rear vehicle structure; and coupling the front vehicle structure and the rear vehicle structure to each other to form an intermediate vehicle structure after the first vehicle components have been secured to the front vehicle structure and the second vehicle components have been secured to the rear vehicle structure. The first operation comprises continuously or intermittently rotating the front vehicle structure. The second operation comprises continuously or intermittently rotating the rear vehicle structure.

[0007] In a variation of the method of the above paragraph that can be implemented individually or in any combination, a plurality of first vehicle components include a front suspension assembly, an instrument panel structure, a front motor and a front subframe; a plurality of second vehicle components include a rear motor and a rear subframe; a front vehicle structure includes a left first pillar and a right first pillar; a rear vehicle structure defines a left door opening and a right door opening, and includes a left second pillar that partially defines the left door opening and a right second pillar that partially defines the right door opening, coupling the front vehicle structure and the rear vehicle structure includes fixing the left first pillar and the left second pillar to each other and fixing the right first pillar and the right second pillar to each other; painting the front vehicle structure before the first vehicle components are fixed to the front vehicle structure; painting the rear vehicle structure before the second vehicle components are fixed to the rear vehicle structure; A front vehicle structure is rotated using a first robotic platform, and a rear vehicle structure is rotated using a second robotic platform; rotating the front vehicle structure includes rotating the front vehicle structure up to 360 degrees, and rotating the rear vehicle structure includes rotating the rear vehicle structure up to 360 degrees; coupling a floor and a battery assembly to the front vehicle structure and the rear vehicle structure after the front vehicle structure and the rear vehicle structure are coupled to each other; coupling a plurality of doors to the intermediate vehicle structure after the floor and the battery assembly are coupled to the front vehicle structure and the rear vehicle structure; and securing a first vehicle component to the front vehicle structure and securing a second vehicle component to the rear vehicle structure includes simultaneously securing the first vehicle component to the front vehicle structure and securing the second vehicle component to the rear vehicle structure.

[0008] In another form, the present disclosure discloses a method of assembling a vehicle, the method comprising: performing a first operation on a front vehicle structure; while performing the first operation on the front vehicle structure, securing a plurality of first vehicle components to the front vehicle structure; performing a second operation on a rear vehicle structure; while performing the second operation on the rear vehicle structure, securing a plurality of second vehicle components to the rear vehicle structure, coupling the front vehicle structure and the rear vehicle structure to each other to form an intermediate vehicle structure after the first vehicle components have been secured to the front vehicle structure and the second vehicle components have been secured to the rear vehicle structure; and after the front vehicle structure and the rear vehicle structure are coupled to each other, coupling a floor and a battery assembly to the front vehicle structure and the rear vehicle structure. The first operation comprises continuously rotating the front vehicle structure. The front vehicle structure is allowed to rotate up to 360 degrees. The second operation comprises continuously rotating the rear vehicle structure. The rear vehicle structure is allowed to rotate up to 360 degrees.

[0009] In a variation of the method of the above paragraphs that can be implemented individually or in any combination, the plurality of first vehicle components include a front suspension assembly, an instrument panel structure, a front motor, and a front subframe; the plurality of second vehicle components include a rear motor and a rear subframe; the front vehicle structure is painted before the first vehicle components are secured to the front vehicle structure; the rear vehicle structure is painted before the second vehicle components are secured to the rear vehicle structure; the front vehicle structure includes a left first pillar and a right first pillar; the rear vehicle structure defines a left door opening and a right door opening, and includes a portion defining the left door opening; A left second pillar defining an opening of the right door and a right second pillar partially defining the right door opening, coupling the front vehicle structure and the rear vehicle structure includes extending a first fastener and an adhesive-coated shear stud through the left first pillar and the left second pillar and extending a second fastener and an adhesive-coated shear stud through the right first pillar and the right second pillar; rotating the front vehicle structure using a first robotic platform and rotating the rear vehicle structure using a second robotic platform; and coupling a plurality of doors to the intermediate vehicle structure after the floor and the battery assembly are coupled to the front vehicle structure and the rear vehicle structure.

[0010] In yet another form, the present disclosure discloses a method of assembling a vehicle, the method comprising: performing a first operation on a front vehicle structure; while performing the first operation on the front vehicle structure, securing a plurality of first vehicle components to the front vehicle structure; performing a second operation on a rear vehicle structure; while performing the second operation on the rear vehicle structure, securing a plurality of second vehicle components to the rear vehicle structure; coupling the front vehicle structure and the rear vehicle structure to each other to form an intermediate vehicle structure after the first vehicle components have been secured to the front vehicle structure and the second vehicle components have been secured to the rear vehicle structure; after the front vehicle structure and the rear vehicle structure are coupled to each other, coupling a floor and a battery assembly to the front vehicle structure and the rear vehicle structure; and after the floor and the battery assembly are coupled to the front vehicle structure and the rear vehicle structure, coupling a plurality of vehicle doors to the intermediate vehicle structure. The first operation comprises rotating the front vehicle structure continuously or intermittently. The front vehicle structure comprises a left first pillar and a right first pillar. The second operation comprises rotating the rear vehicle structure continuously or intermittently. The rear vehicle structure defines a left door opening and a right door opening and includes a left second pillar partially defining the left door opening and a right second pillar partially defining the right door opening. Coupling the front vehicle structure and the rear vehicle structure includes fixing the left first pillar and the left second pillar to each other and fixing the right first pillar and the right second pillar to each other.

[0011] 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

[0012] 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:

[0013] Figure 1 is a perspective view of a portion of a vehicle including a front vehicle structure and a rear vehicle structure in accordance with the principles of the present disclosure;

[0014] Figure 2 yes Figure 1 a perspective view of a front vehicle structure of a vehicle with vehicle components removed from the front vehicle structure for clarity;

[0015] Figure 3 yes Figure 1 a side view of a front vehicle structure of a vehicle, wherein the vehicle component is secured to the front vehicle structure;

[0016] Figure 4 yes Figure 1 a perspective view of a front vehicle structure of a vehicle with a vehicle component secured to the front vehicle structure;

[0017] Figure 5 yes Figure 1 a perspective view of a rear vehicle structure of a vehicle with a vehicle component secured to the rear vehicle structure;

[0018] Figure 6 yes Figure 1 a side view of a rear vehicle structure of a vehicle of the type shown in FIG. 1 , wherein the vehicle component is secured to the rear vehicle structure; and

[0019] 7A to 7F According to the principles of the present disclosure Figure 1 A perspective view of a vehicle being assembled;

[0020] 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

[0021] 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.

[0022] refer to Figure 1 , a vehicle 10 such as an electric vehicle is provided. In the example provided, the electric vehicle is a battery electric vehicle (BEV). In other examples, the electric vehicle may be a hybrid electric vehicle (HEV), a plug-in electric vehicle (PHEV), or a fuel cell vehicle. In other examples, the vehicle 10 may be a vehicle driven by an internal combustion engine.

[0023] Additional references Figure 2 , Figure 5 and Fig. 7E , the vehicle 10 includes a front vehicle structure 12 ( Figure 2 and Fig. 7E )、rear vehicle structure 14( Figure 5 and Fig. 7E ) and floor and battery assembly 15( Fig. 7E ). The front vehicle structure 12 is positioned closer to the front of the vehicle 10 than the rear vehicle structure 14 and is coupled to the rear vehicle structure 14 as described in more detail below. In one example, the front vehicle structure 12 is manufactured using a plurality of stamped parts that are secured to each other, for example, via welding, adhesives, or fasteners. In another example, the front vehicle structure 12 is manufactured using a casting process. Figure 2 , the front vehicle structure 12 includes, among other things, a pair of hinge pillars 24a, 24b, a pair of inner longitudinal beams 26a, 26b, a pair of upper longitudinal beams 28a, 28b, and a bumper (not shown). Each inner longitudinal beam 26a, 26b extends from a lower portion of the corresponding hinge pillar 24a, 24b to the bumper. Each inner longitudinal beam 26a, 26b may also be arcuate and surrounds the front wheels 25 ( Figure 1 ) and form a part of the corresponding front wheel well. The upper longitudinal members 28a, 28b are positioned above the pair of inner longitudinal members 26a, 26b and extend from the upper portions of the corresponding hinge pillars 24a, 24b toward the front of the vehicle 10. The bumper extends in a transverse direction relative to the longitudinal direction of the vehicle 10 and is fixed to the front ends of the pair of inner longitudinal members 26a, 26b.

[0024] refer to Figure 3 and Figure 4 , a front subframe 30 is positioned below the front vehicle structure 12 and secured to a pair of inner longitudinal beams 26a, 26b of the front vehicle structure 12. The front subframe 30 may support one or more components of the vehicle 10, such as a front motor 31 ( Figure 4 ) and the front suspension component 32. The front motor 31 is composed of the floor and the battery pack 17 ( Fig. 7E ) to selectively drive a set of front wheels 25 ( Figure 1 ; only one wheel is shown). The front suspension components 32 provide a smooth ride by absorbing energy from various road bumps while traveling. The front suspension components 32 may include, for example, upper and lower control arms, springs, shock absorbers, studs, and ball joints. It should also be understood that other components may be coupled to the front vehicle structure 12, such as an instrument panel structure 35 and electronic devices (e.g., inverters, AC-DC converters, and DC-DC converters).

[0025] refer to Figure 5 and Figure 6, the rear vehicle structure 14 includes a rocker 40, a roof rail 42, and a plurality of pillars (e.g., a pair of front pillars 44a, a pair of center pillars 44b, a pair of rear pillars 44c, and a pair of hinge pillars 44d, 44e). The rocker 40 extends longitudinally in the longitudinal direction of the vehicle 10 and may be configured to mount the battery pack 17 to the rear vehicle structure 14. Each rocker 40 is made of, for example, a metal material such as aluminum, and is fixed to a corresponding side of the battery pack 17 using, for example, fasteners, adhesives, welding, or any other suitable attachment means.

[0026] Each roof rail 42 is positioned at one side of the rear vehicle structure 14 and extends in the longitudinal direction of the vehicle 10. Each roof rail 42 includes one or more structural members extending in the longitudinal direction of the vehicle 10. Each front pillar 44a extends from the corresponding roof rail 42 to the corresponding hinge pillar 44d, 44e in the longitudinal direction of the vehicle 10. Each center pillar 44b extends from the corresponding roof rail 42 to the corresponding rocker 40 in the vertical direction. Each rear pillar 44c extends from the end of the corresponding roof rail 42 toward the rear of the vehicle 10. The front pillar 44a, the center pillar 44b, the hinge pillars 44d, 44e, the rocker 40 and the roof rail 42 cooperate to define a door opening 50 in the rear vehicle structure 14. The door 51 is rotatably coupled to the rear vehicle structure 14 and / or the front vehicle structure 12 and is rotatable between a closed position in which the door 51 is disposed within the door opening 50 and an open position in which the door 51 is removed from the door opening 50 .

[0027] Each hinge pillar 44d, 44e extends in the vertical direction from the end of the corresponding front pillar 44a to the end of the corresponding rocker 40. In the example shown, the hinge pillar 44d is fixed to the hinge pillar 24a of the front vehicle structure 12 using a left attachment structure (not shown) and a left interface block 16, and the hinge pillar 44e is fixed to the hinge pillar 24b of the front vehicle structure 12 using a right attachment structure (not shown) and a right interface block (not shown). In this way, the intermediate vehicle structure 90 ( Fig.7D ). An example of such an attachment structure and interface block is disclosed in U.S. patent application Ser. No. 18 / 495,075, entitled “VEHICLE HAVING FRONT AND REAR VEHICLESTRUCTURES,” which is filed concurrently with and commonly owned with the present application, and the contents of which are incorporated herein by reference in their entirety.

[0028] Continue to refer Figure 5 and Figure 6, the rear subframe 81 is fixed to the rear vehicle structure 14 and can support one or more components of the vehicle 10, such as the rear motor 71 which can also be coupled to the rear vehicle structure 14. The rear motor 71 is powered by the battery pack 17 to selectively drive the rear wheels 25 of a set of rear wheels. It should also be understood that other components can be coupled to the rear vehicle structure 14, such as the vehicle floor 69 ( Fig. 7E ), rear suspension components (not specifically shown), and a battery pack 17. The vehicle floor 69 can support one or more vehicle seats 72 or multiple rows of seats. The rear suspension components provide a smooth ride by absorbing energy from various road bumps while driving. The rear suspension components may include, for example, upper and lower control arms, springs, shock absorbers, studs, and ball joints. The battery pack 17 may be rechargeable and may include a lithium-ion battery or any other suitable power storage unit. The battery pack 17 may be disposed at various locations on the rear vehicle structure 14 and may be mounted to the various locations. In this way, the battery pack 17 is supported by the rear vehicle structure 14 and is away from the passenger compartment (not shown) and cargo compartment (not shown) of the vehicle 10, and therefore, does not occupy space that could otherwise be used for passengers or cargo. One example of such a battery pack is disclosed in U.S. Patent Application No. 17 / 980,208, entitled “STRUCTURAL ASSEMBLY FOR BATTERY STRUCTURE OF ELECTRIC VEHICLE,” which is commonly owned with the present application and is incorporated herein by reference in its entirety.

[0029] refer to 7A to 7F , the method of assembling the vehicle 10 will be described in detail. First, as Fig. 7A As shown, one or more stations 88 are provided for painting individual or separate parts of the vehicle 10. That is, for example, the front vehicle structure 12, the rear vehicle structure 14, the fender 96, and the door 51 of the vehicle 10 are painted and treated when they are not coupled together. It should be understood that the front vehicle structure 12 is painted before the vehicle parts are fixed thereto, and the rear vehicle structure 14 is painted before the vehicle parts are fixed thereto. Next, as shown in FIG. Figure 7BAs shown, the front vehicle structure 12 is rotated. In the example shown, the front vehicle structure 12 is disposed on a robot platform 84a configured to rotate. The platform 84a can be rotated manually or automatically using a controller (not shown). In some forms, the front vehicle structure 12 can be supported by a robot arm or any other suitable device that allows the front vehicle structure 12 to rotate or is connected to the robot arm or any other suitable device. It should be understood that the robot platform 84a can be configured to rotate the front vehicle structure 12 360 degrees. When the front vehicle structure 12 is on the robot platform 84a, vehicle components (e.g., such as the front subframe 30, the front motor 31, the front suspension components 32, the dashboard structure 35, and the electronic device) are fixed to the front vehicle structure 12. In one example, the front vehicle structure 12 can be rotated on the robot platform 84a and can be stopped at a predetermined angle orientation so that different vehicle components can be fixed to the front vehicle structure. For example, the front vehicle structure 12 can be stopped at one angular orientation, where a component (e.g., the front subframe 30) can be secured to the front vehicle structure at a station (not shown), and then rotated and stopped at another angular orientation, where another component (e.g., the front motor 31) can be secured to the front vehicle structure. This rotation can occur while the robotic platform 84a is at one station or before, after, or also while translating, so that another component (e.g., the front motor 31) is secured at another station (not shown) along the assembly line. In another example, when the front vehicle structure 12 is continuously rotated on the robotic platform 84a, vehicle components can be secured to the front vehicle structure 12 at various stations. In one form, the robotic platform 84a can be large enough so that an operator (not shown) can stand on or near the robotic platform 84a to attach components while the robotic platform 84a is stationary or while the robotic platform is rotating and / or translating.

[0030] like Figure 7CAs shown, the rear vehicle structure 14 is also rotated. In the example shown, the rear vehicle structure 14 is disposed on a robot platform 84b configured to rotate. The robot platform 84b can be rotated manually or automatically using a controller (not shown). In some forms, the rear vehicle structure 14 can be supported by a robot arm or any other suitable device that allows the rear vehicle structure 14 to rotate or is connected to the robot arm or any other suitable device. It should be understood that the robot platform 84b can be configured to rotate the rear vehicle structure 14 360 degrees. For example, vehicle components such as the rear motor 71, the rear subframe 81, and the rear suspension components are fixed to the rear vehicle structure 14. In one example, the rear vehicle structure 14 can be rotated on the robot platform 84b and can be stopped at a predetermined angle orientation so that the vehicle components can be fixed to the rear vehicle structure. That is, the rear vehicle structure 14 can stop at one angular orientation, where a first component (e.g., rear subframe 81) can be fixed to the rear vehicle structure at a station, and then rotate and stop at another angular orientation, where another component (e.g., rear motor 71) can be fixed to the rear vehicle structure. This rotation can occur when the robot platform 84b is at one station or before, after, or also during translation, so that another component (e.g., rear motor 71) is fixed at another station along the assembly line. In another example, when the rear vehicle structure 14 is continuously rotated on the robot platform 84b, vehicle components can be fixed to the rear vehicle structure 14 at various stations. In one form, the robot platform 84b can be large enough so that an operator (not shown) can stand on or near the robot platform to attach components when the robot platform 84b is stationary or when the robot platform rotates and / or translates. The robot platform 84b can be on an assembly line separate from the robot platform 84a. The vehicle components may be secured to the front vehicle structure 12 at the same time (ie, simultaneously) as the vehicle components are secured to the rear vehicle structure 14 , thereby reducing assembly time of the vehicle 10 .

[0031] Next, if Fig.7DAs shown, after vehicle components have been secured to the front vehicle structure 12 and vehicle components have been secured to the rear vehicle structure 14, the front vehicle structure 12 and the rear vehicle structure 14 are coupled to one another to form the intermediate vehicle structure 90. That is, the hinge pillar 44d of the rear vehicle structure 14 is coupled to the hinge pillar 24a of the front vehicle structure 12, and the hinge pillar 44e of the rear vehicle structure 14 is coupled to the hinge pillar 24b of the front vehicle structure 12. One example of coupling the front vehicle structure 12 and the rear vehicle structure 14 to one another is disclosed in U.S. Patent Application No. 18 / 495,075, entitled “VEHICLE HAVING FRONT AND REAR VEHICLE STRUCTURES,” which was filed concurrently with and commonly owned with the present application, and the contents of which are incorporated herein by reference in their entirety.

[0032] Next, if Fig. 7E As shown, the floor and battery assembly 15 is coupled to the front vehicle structure 12 and the rear vehicle structure 14 after the front vehicle structure 12 and the rear vehicle structure 14 have been coupled to each other. That is, the floor and battery assembly 15 is inserted from the bottom of the intermediate vehicle structure 90 and coupled to the intermediate vehicle structure 90. Components such as the seat 72 may be optionally attached to the floor 69 before coupling the floor and battery assembly 15 to the intermediate vehicle structure 90, so that these components attached to the floor 69 are inserted from the bottom of the intermediate vehicle structure 90.

[0033] Next, if Figure 7F As shown, the door 51 and the guard panel 96 are coupled to the intermediate vehicle structure 90 after the floor and battery assembly 15 are coupled to the intermediate vehicle structure 90. In some forms, the guard panel 96 is coupled to the intermediate vehicle structure 90 before or at the same time as the floor and battery assembly 15 are coupled to the intermediate vehicle structure 90. It should be understood that any remaining components of the vehicle 10 (such as wheels, a vehicle trunk, a vehicle hood, or additional electronics, for example) may be coupled to the vehicle 10 before the vehicle 10 is removed from the assembly line.

[0034] The vehicle 10 of the present disclosure provides that the front vehicle structure 12 and the rear vehicle structure 14 are fixed to each other at the hinge pillars 24a, 24b, 44e, 44f after each vehicle structure 12, 14 has been built. That is, the front vehicle structure 12 can be approached from multiple sides and areas (including from the rear of the front vehicle structure 12) to fix one or more vehicle components to the front vehicle structure during the assembly process. Similarly, the rear vehicle structure 14 can be approached from multiple sides and areas (including from the front of the rear vehicle structure 14) to fix one or more vehicle components to the rear vehicle structure during the assembly process. After the front vehicle structure 12 and the rear vehicle structure 14 have been built, the front vehicle structure 12 and the rear vehicle structure 14 are conveniently fixed to each other, and then the remaining components (e.g., the floor and battery assembly 15, the door 51, the guard plate 96) are fixed to the front vehicle structure 12 and the rear vehicle structure 14. In this way, the assembly process of the vehicle 10 is enhanced.

[0035] 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.

[0036] 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."

[0037] In this application, the terms "controller" and / or "module" may refer to, be part of, or include: an application-specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinatorial logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality (e.g., an operational amplifier circuit integrator as part of a heat flux data module); or a combination of some or all of the above, such as in a system on a chip.

[0038] The term memory is a subset of the term computer-readable medium. The term computer-readable medium as used herein does not encompass transient electrical or electromagnetic signals propagated through a medium (such as on a carrier wave); therefore, the term computer-readable medium may be considered to be tangible and non-transitory. Non-limiting examples of non-transitory tangible computer-readable media are non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or mask read-only circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), magnetic storage media (such as analog or digital tape or hard drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0039] The apparatus and methods described in this application may be implemented partially or completely by a special-purpose computer, which is created by configuring a general-purpose computer to perform one or more specific functions embodied in a computer program. The functional blocks, flow chart components, and other elements described above are used as software specifications, which can be translated into a computer program by routine work of a technician or programmer.

[0040] The description of the present disclosure is merely exemplary in nature, and thus, 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.

[0041] According to the present invention, a method for assembling a vehicle includes: performing a first operation on a front vehicle structure, the first operation including continuously rotating the front vehicle structure, the front vehicle structure being allowed to rotate up to 360 degrees; while performing the first operation on the front vehicle structure, fixing a plurality of first vehicle components to the front vehicle structure; performing a second operation on a rear vehicle structure, the second operation including continuously rotating the rear vehicle structure, the rear vehicle structure being allowed to rotate up to 360 degrees; while performing the second operation on the rear vehicle structure, fixing a plurality of second vehicle components to the rear vehicle structure; coupling the front vehicle structure and the rear vehicle structure to each other to form an intermediate vehicle structure after the first vehicle components have been fixed to the front vehicle structure and the second vehicle components have been fixed to the rear vehicle structure; and coupling a floor and a battery assembly to the front vehicle structure and the rear vehicle structure after the front vehicle structure and the rear vehicle structure are coupled to each other.

[0042] In one aspect of the present invention, the plurality of first vehicle components includes a front suspension assembly, an instrument panel structure, a front motor, and a front subframe.

[0043] In one aspect of the present invention, the plurality of second vehicle components includes a rear motor and a rear subframe.

[0044] In one aspect of the present invention, the plurality of second vehicle components includes a rear motor and a rear subframe.

[0045] In one aspect of the invention, the method includes painting a front vehicle structure before a first vehicle component is secured to the front vehicle structure; and painting a rear vehicle structure before a second vehicle component is secured to the rear vehicle structure.

[0046] In one aspect of the present invention, a front vehicle structure includes a left first pillar and a right first pillar; and a rear vehicle structure defines a left door opening and a right door opening, and includes a left second pillar that partially defines the left door opening and a right second pillar that partially defines the right door opening, wherein coupling the front vehicle structure and the rear vehicle structure includes extending a plurality of first fasteners through the left first pillar and the left second pillar and extending a plurality of second fasteners through the right first pillar and the right second pillar.

[0047] In one aspect of the invention, a first robotic platform is used to rotate the front vehicle structure, and a second robotic platform is used to rotate the rear vehicle structure.

[0048] In one aspect of the invention, the method includes coupling a plurality of doors to a mid-vehicle structure after coupling a floor and a battery assembly to a front vehicle structure and a rear vehicle structure.

[0049] According to the present invention, a method for assembling an electric vehicle includes: performing a first operation on a front vehicle structure, the first operation including continuously or intermittently rotating the front vehicle structure, the front vehicle structure including a left first pillar and a right first pillar; while performing the first operation on the front vehicle structure, fixing a plurality of first vehicle components to the front vehicle structure; performing a second operation on a rear vehicle structure, the second operation including continuously or intermittently rotating the rear vehicle structure, the rear vehicle structure defining a left door opening and a right door opening, and including a left second pillar partially defining the left door opening and a right second pillar partially defining the right door opening; while performing the second operation on the rear vehicle structure, A plurality of second vehicle components are secured to the rear vehicle structure; after the first vehicle components have been secured to the front vehicle structure and the second vehicle components have been secured to the rear vehicle structure, the front vehicle structure and the rear vehicle structure are coupled to each other to form an intermediate vehicle structure, wherein coupling the front vehicle structure and the rear vehicle structure includes securing a left first pillar and a left second pillar to each other and securing a right first pillar and a right second pillar to each other; after the front vehicle structure and the rear vehicle structure are coupled to each other, a floor and a battery assembly are coupled to the front vehicle structure and the rear vehicle structure; and after the floor and the battery assembly are coupled to the front vehicle structure and the rear vehicle structure, a plurality of vehicle doors are coupled to the intermediate vehicle structure.

Claims

1. A method of assembling a vehicle, the method comprising: performing a first operation on a front vehicle structure, the first operation comprising continuously or intermittently rotating the front vehicle structure; securing a plurality of first vehicle components to the front vehicle structure while performing the first operation on the front vehicle structure; performing a second operation on the rear vehicle structure, the second operation comprising continuously or intermittently rotating the rear vehicle structure; securing a second plurality of vehicle components to the rear vehicle structure while performing the second operation on the rear vehicle structure; as well as After the first vehicle component has been secured to the front vehicle structure and the second vehicle component has been secured to the rear vehicle structure, the front vehicle structure and the rear vehicle structure are coupled to one another to form an intermediate vehicle structure.

2. The method of claim 1, wherein the plurality of first vehicle components include a front suspension assembly, an instrument panel structure, a front motor, and a front subframe.

3. The method of claim 1 or 2, wherein the plurality of second vehicle components includes a rear motor and a rear subframe.

4. The method of claim 1, wherein: The front vehicle structure includes a left first pillar and a right first pillar; and The rear vehicle structure defines a left door opening and a right door opening and includes a left second pillar that partially defines the left door opening and a right second pillar that partially defines the right door opening.

5. The method of claim 4, wherein coupling the front vehicle structure and the rear vehicle structure includes securing the left first pillar and the left second pillar to each other and securing the right first pillar and the right second pillar to each other.

6. The method of claim 4, wherein coupling the front vehicle structure and the rear vehicle structure includes extending a plurality of first fasteners through the left first pillar and the left second pillar and extending a plurality of second fasteners through the right first pillar and the right second pillar.

7. The method of claim 1, further comprising: painting the front vehicle structure before the first vehicle component is secured to the front vehicle structure; as well as The rear vehicle structure is painted before the second vehicle component is secured to the rear vehicle structure.

8. The method of claim 1, wherein the front vehicle structure is rotated using a first robotic platform and the rear vehicle structure is rotated using a second robotic platform.

9. The method of claim 1, wherein rotating the front vehicle structure comprises rotating the front vehicle structure up to 360 degrees, and rotating the rear vehicle structure comprises rotating the rear vehicle structure up to 360 degrees.

10. The method of claim 1, further comprising coupling a floor and a battery assembly to the front vehicle structure and the rear vehicle structure after the front vehicle structure and the rear vehicle structure are coupled to each other.

11. The method of claim 10, further comprising coupling a plurality of doors to the intermediate vehicle structure after the floor and battery assembly are coupled to the front vehicle structure and the rear vehicle structure.

12. The method of claim 1, wherein securing the first vehicle component to the front vehicle structure and securing the second vehicle component to the rear vehicle structure comprises simultaneously securing the first vehicle component to the front vehicle structure and securing the second vehicle component to the rear vehicle structure.

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