Vehicle body structure, vehicle and method for repairing vehicle body structure

Abstract

The invention relates to a body structure (3) for a body (2) of a vehicle (1), comprising: a first body section (10) for deformation in the event of an accident of the vehicle (1) at a first accident severity; a second body section (20) for deforming in the event of an accident of the vehicle (1) at a second accident severity greater than the first accident severity; and a third body section (30) for deformation in the event of an accident of the vehicle (1) at a third accident severity greater than the second accident severity, the second body section (20) being arranged between the first body section (10) and the third body section (30). The invention further relates to a vehicle (1) and to a method (100).

Description

Technical Field

[0001] The present invention relates to a body structure for a vehicle body, a vehicle, and a method for repairing a body structure. Background Art

[0002] It is known that body sections with different stiffnesses and / or strengths are provided in a body structure. Thereby, certain regions, for example, those located at the front (Vorderwagen), deform in an accident with a low speed, while other regions, for example, those located behind them, do not experience deformation or only experience slight deformation. Thus, the most common accidents, such as "parking lot collisions", occur at low speeds, so that at least in these cases, as large a part as possible of the vehicle structure should remain largely undamaged. Here, a clear division of the body sections enables easy replacement of the deformed body sections. Such sections for absorbing impacts are known, for example, from document US2010 / 0259033A1.

[0003] Therefore, especially in lightweight structures, known body structures are usually assembled from a large number of individual components. Here, different joining methods are used within the scope of hybrid structure joining technology. Both the component costs for many small components made of light metal and the investment costs and manufacturing costs associated with hybrid structure joining technology can be high. Therefore, it is desirable to integrate as many functions as possible in a cast component. In this regard, a major challenge is the repair concept for the vehicle body. Cast components usually have to be analyzed more complexly and repaired more difficultly for possible damages. However, when large cast components have to be completely replaced even in the case of minor accident damages to the vehicle, the minor accident damages can lead to excessive repair costs. However, with the common tools available in many motor vehicle workshops (sometimes called motor vehicle repair shops), it is very time-consuming or even infeasible to precisely locate the damages at the cast components. Sometimes called motor vehicle repair shops), it is very time-consuming or even infeasible to precisely locate the damages at the cast components. Summary of the Invention

[0004] The object of the present invention is to at least partially overcome the above-mentioned disadvantages known from the prior art. In particular, the object of the present invention is to enable simplified repair in a body structure that can be manufactured as cost-effectively as possible and / or has a low weight.

[0005] The above task is solved by a vehicle body structure with the features of claim 1, a vehicle with the features of claim 9, and a method with the features of claim 10. Other features and details of the invention result from the respective dependent claims, the description, and the drawings. Here, the features and details described in terms of the vehicle body structure according to the invention naturally also apply in terms of the vehicle according to the invention and / or the method according to the invention, and vice versa, respectively, so that with respect to the disclosure of the individual aspects of the invention, reference is always made or can be made to each other.

[0006] According to a first aspect of the invention, there is provided a vehicle body structure for a vehicle body. The vehicle body structure has a first vehicle body section, which is adapted to deform in the event of an accident of a first accident severity of the vehicle. In addition, the vehicle body structure includes a second vehicle body section, which is preferably adapted to deform only in the event of an accident of a second accident severity greater than the first accident severity of the vehicle. In addition, the vehicle body structure includes a third vehicle body section, which is preferably adapted to deform only in the event of an accident of a third accident severity greater than the second accident severity of the vehicle. The second vehicle body section is arranged between the first vehicle body section and the third vehicle body section. The third vehicle body section has a coupling device, to which the second vehicle body section is fastened as a repair section for modular replacement of the second vehicle body section after an accident of the second accident severity. In addition, the third vehicle body section (especially with the coupling device) is configured as a cast member.

[0007] The vehicle is in particular a motor vehicle, preferably in the form of an electric vehicle. The vehicle body structure can be part of the vehicle body. In addition, the vehicle body structure can define the overhang ( sometimes referred to as the external overhang) of the vehicle. For example, it can be provided that the vehicle body structure (especially the second and third vehicle body sections) is configured as a load-bearing, especially self-bearing, structure for the front end and / or the rear end (Hinterwagen) of the vehicle.

[0008] The severity of an accident can include the loads acting on the vehicle body structure caused by the accident and / or depend on the collision speed of the vehicle. The first vehicle body section, the second vehicle body section, and the third vehicle body section in particular form deformation zones (which deform depending on the severity of the accident when an accident occurs) and / or repair zones that are connected in series with each other, and when an accident occurs, the repair zones can be replaced independently depending on the severity of the accident. Preferably, when an accident of the first accident severity occurs, only or substantially only the first vehicle body section deforms, when an accident of the second accident severity occurs, only or substantially only the first vehicle body section and the second vehicle body section deform, and when an accident of the third accident severity occurs, the first vehicle body section, the second vehicle body section, and the third vehicle body section, in particular the entire vehicle body, deforms. For example, the second vehicle body section can be designed to deform only when an accident occurs at a speed of 16 km / h or higher, and this deformation is a significant damage to the second vehicle body section. The third vehicle body section can be designed to deform only when an accident occurs at a speed of 25 km / h or higher, and this deformation is a significant damage to the third vehicle body section. In particular, a clear (trennscharf, sometimes referred to as clearly distinguishable) boundary can thus be defined between the first vehicle body section and the second vehicle body section, and between the second vehicle body section and the third vehicle body section, which can in particular be utilized for modular replacement.

[0009] Due to the modular replaceability of the second vehicle body section as a repair section, the second vehicle body section can in particular be replaced by the same components. In particular, the modular replaceability of the second vehicle body section and the coupling device enable the adapter-free replacement of the second vehicle body section. Thus, the second vehicle body section and the third vehicle body section can be formed by independent vehicle body components respectively.

[0010] Two vehicle body components can be releasably fastened to each other at the coupling device, for example, by a form-fit and / or force-fit connection, preferably a threaded connection. Thereby, the replacement of the second vehicle body section can be carried out in a simple manner and / or using existing tools. The coupling device can include structural features of the third vehicle body section ( sometimes referred to as a molding). For example, the coupling device can include protrusions and / or fastening openings. Preferably, the second vehicle body section includes a mating coupling device for connection to the coupling device and / or for directly abutting at the coupling device. For this purpose, the mating coupling device can be configured to be complementary to the coupling device.

[0011] Understanding the third vehicle body section to be a cast component preferably means that the third vehicle body section is formed by an integral, i.e., in particular single, component, which is manufactured by a casting method, such as a die-casting method. For this purpose, the third vehicle body section can preferably be made of a casting material and / or be completely made of a casting material.

[0012] Within the scope of the present invention, it has been recognized that dividing the vehicle body structure into at least three zones provides an advantageous repair feasibility that is compatible with cast components. Thereby, the repair after damage detection can be achieved more easily, more quickly, more cost-effectively, and / or using existing workshop equipment. In addition, the original state produced at the workshop can be restored especially after the repair. Thereby, complex dual development of special repair solutions for additional geometries, different joining methods, and / or different collision behaviors can be avoided.

[0013] Furthermore, in the vehicle body structure according to the present invention, it can be advantageously provided that the second vehicle body section is configured as a cast component or as a steel component, and / or the second vehicle body section and / or the third vehicle body section are made of aluminum material, in particular aluminum alloy. As an alternative to the cast component or the steel component, it is also conceivable that the second vehicle body section is constructed of a different material. It is conceivable that the second vehicle body section and the third vehicle body section are manufactured in an independent casting mold or in a common casting mold. In particular, when both the second vehicle body section and the third vehicle body section are manufactured as cast components, pre-assembly for fastening the second vehicle body section to the third vehicle body section can already be carried out in the foundry. If the second vehicle body section and the third vehicle body section are transported unfastened, the packaging density can be improved during transportation due to the multiplicity of the second and third vehicle body sections, since the individual components can be nested more closely. The lightweight construction of the vehicle body structure can be achieved through the aluminum material. Preferably, the first vehicle body section and / or the second vehicle body section are manufactured by die casting of aluminum. Thereby, a suitable manufacturing feasibility can be created, which simultaneously allows complex shaping.

[0014] Furthermore, in the vehicle body structure according to the present invention, it can be advantageously provided that a longitudinal beam is provided, which is formed by at least two longitudinal beam sections, wherein the second vehicle body section and the third vehicle body section each have one of the longitudinal beam sections of the longitudinal beam, so as to form the longitudinal beam by connecting the two longitudinal beam sections of the second vehicle body section and the third vehicle body section at a connecting device. Thus, by dividing the longitudinal beam sections onto the second vehicle body section and the third vehicle body section, the longitudinal beam can be divided into two repair zones. In the event of an accident, such as a frontal collision or a rear-end collision, the longitudinal beam can be compressed and / or bent. Through the second vehicle body section, the deformation can be limited to the second vehicle body section up to a third accident severity level, so that the second vehicle body section can be replaced in a simple manner. At the same time, the longitudinal beam section of the third vehicle body section can be integrated into the cast component of the third vehicle body section, whereby in particular the number of components of the vehicle body structure can be kept small. The longitudinal beam can be disassembled in a simple manner during repair through the connecting device.

[0015] In the scope of the present invention, it is furthermore conceivable that the third body section is designed as a large casting element, in particular as a single large casting element, which has a first body side and a second body side, wherein at each of the body sides of the large casting element, the longitudinal beam is formed by at least two longitudinal beam sections each. Thus, the second body section and the third body section each have, in particular at each body side, one of the longitudinal beam sections of the longitudinal beam, in order to form the longitudinal beam of the respective body side by connecting two respective longitudinal beam sections of the second body section and the third body section at the connecting device. The large casting element can in particular be understood as a casting part that combines various functions of the body structure. For example, the third body section can include a spring leg receptacle (sometimes called a suspension strut receptacle), a wheel arch, and / or at least one further longitudinal beam section, in particular in the form of an upper longitudinal beam and / or a lower longitudinal beam. Preferably, the large casting element can be manufactured by aluminum die casting. By being designed as a large casting element, the body member can be designed to be thin-walled and / or designed in a complex shape with high quality and narrow tolerances despite high loads. Thereby, the manufacturing effort for manufacturing the body structure and / or the weight of the body structure can be reduced. The body sides can preferably correspond to the vehicle sides, in particular the left vehicle side and the right vehicle side. The longitudinal beams formed on both sides of the large casting element can be configured to be symmetric with respect to the vehicle center plane in particular. The body frame for the front end or the rear end of the vehicle can in particular be formed by the longitudinal beams on both sides. Here, the large casting element can be a member that connects the two halves of the body structure. Thereby, the number of components and thus the manufacturing complexity can be reduced. In the body structure according to the present invention, it is furthermore conceivable that the large casting element and the longitudinal beam section of the second body section are each manufactured as independent casting parts by independent and / or identical die casting methods.

[0016] Furthermore, in the body structure according to the present invention, it is conceivable that the connecting device includes flanges at each of the two body sides, and one of the longitudinal beam sections of the second body section is fastened to the flange in a form-fitting and / or force-fitting manner respectively. Preferably, the connection between the second body section and the third body section can include a threaded connection (in particular using metric screws), bonding, and / or riveting at the connecting device. Thereby, simple releasability for modular replacement of the second body section can be achieved. Here, the flange can be configured to surround the third body section and / or at the end side of the longitudinal beam section of the third body section. Preferably, the longitudinal beam section of the second body section also has a flange configured to be complementary to the flange of the third body section.

[0017] Furthermore, in the vehicle body structure according to the invention, it can be advantageously provided that the first vehicle body section, the second vehicle body section, and the third vehicle body section form a front-end structure or a rear-end structure for the vehicle body of the vehicle. By virtue of the two-piece embodiment of the longitudinal beam, large casting elements can advantageously be used for different vehicles with different wheelbases, different front overhangs, and / or different track widths. For example, the front-end structure can include an engine compartment and a wheel suspension for the front wheels. The rear-end structure can, for example, include a trunk (Kofferraum, sometimes referred to as a luggage compartment) and / or a wheel suspension for the rear wheels. The vehicle body structure can thereby form a vehicle body frame to which the wheel suspension, the engine, and / or the trunk housing can be fastened. During the operation of the vehicle, the front-end structure and the rear-end structure can be subjected to accidents of a first accident severity and / or a second accident severity multiple times, such that the current repair concept can result in high cost savings over the service life of the vehicle.

[0018] Furthermore, in the vehicle body structure according to the invention, it can be envisaged that the third vehicle body section is configured to accommodate different implementation variants of the second vehicle body section in order to define the overhang of the vehicle. For this purpose, for example, vehicle body sections of different lengths can be fastened to the coupling device. The overhang can in particular include the vehicle body length extending beyond the vehicle's axles. For example, the engine compartment and / or the trunk of the vehicle can be defined at least in part by the overhang. In particular, by virtue of at least a two-piece embodiment of the longitudinal beam, large casting elements of the third vehicle body section can advantageously be used for different vehicles with different wheelbases, different front overhangs, and / or different track widths. Thereby, the same component range and / or modularity can be kept as constant as possible in multiple variants of the vehicle.

[0019] Furthermore, in the vehicle body structure according to the invention, it can be advantageously provided that the first vehicle body section includes a crash management system. The crash management system can, for example, include at least one crash box, preferably at least two crash boxes. For example, a crash box can be arranged at each longitudinal beam, in particular at the front side or the rear side. The second vehicle body section can include a partition for accommodating the crash management system. In addition to the crash box, the first vehicle body section can furthermore have a curved beam ( sometimes referred to as a buffer frame), or the curved beam can be arranged at the first vehicle body section such that the first vehicle body section is arranged between the curved beam and the second vehicle body section. In particular, the crash management system can be at least partially or completely constructed or made of steel, aluminum, or other materials. Thus, the crash management system can form a first deformation zone for accidents with a first accident severity. For this purpose, the crash management system can be mechanically connected in series to the second vehicle body section and the third vehicle body section. Furthermore, the crash management system can be detachably connected to the second vehicle body section. Thereby, the crash management system can also be modularly replaceable during repair.

[0020] According to another aspect of the present invention, a vehicle is provided. The vehicle has a body with at least one body structure according to the present invention.

[0021] Therefore, the vehicle according to the present invention brings the same advantages as those already described in detail with reference to the body structure according to the present invention. Preferably, the body has two body structures according to the present invention, wherein one of the body structures forms a front-end structure for the body of the vehicle, and one of the body structures forms a rear-end structure for the body of the vehicle.

[0022] According to another aspect of the present invention, a method for repairing a body structure according to the present invention is provided, in which a first body section and a second body section are deformed due to an accident with a second accident severity exceeding the first accident severity. The method particularly includes, in the form of method steps:

[0023] - Loosening the second body section from the coupling device of the third body section, in particular by releasing at least one form-fitting and / or force-fitting connection between the second body section and the third body section, wherein the third body section (30) is configured as a cast member.

[0024] - Assembling at least one replacement section at the coupling device of the third body section for modular replacement of the second body section.

[0025] - Assembling another replacement section for replacing the first body section, in particular by replacing the crash management system.

[0026] Therefore, the method according to the present invention brings the same advantages as those already described in detail with reference to the body structure according to the present invention and / or the vehicle according to the present invention. The replacement section can preferably be designed to have the same structure as the second body section. Preferably, the replacement section includes at least one longitudinal beam section, which is form-fittingly and / or force-fittingly assembled at the longitudinal beam section of the third body section. Preferably, the other replacement section can be designed to have the same structure as the first body section. Description of the Drawings

[0027] Other advantages, features, and details of the present invention result from the following description, in which embodiments of the present invention are described in detail with reference to the drawings. Here, the features mentioned in the claims and in the description can be important for the present invention individually or in any combination. Schematically:

[0028] Figure 1 A vehicle according to the present invention is shown, which has two body structures according to the present invention.

[0029] Figure 2 +3 shows one of the body structures in the form of a front-end structure.

[0030] Figure 4 shows one of the body structures in the form of a rear-end structure, and

[0031] Figure 5 shows a method for repairing a body structure according to the present invention in the form of a schematic flow chart.

[0032] In the following description of some embodiments of the present invention, the same reference numerals are used for the same technical features in different embodiments. Detailed Description

[0033] Figure 1 shows a part of a vehicle 1 according to the present invention with a body 2, which body includes two body structures 3 according to the present invention. One of the two body structures 3 includes a front-end structure 3.1 for the body 2, which is presented in more detail in Figure 2 and Figure 3 Another of the two body structures 3 includes a rear-end structure 3.2, which is shown in more detail in Figure 4 .

[0034] As Figure 2 shows, the body structure 3 in the form of a front-end structure 3.1 includes: a first body section 10, which is adapted to deform in the event of an accident of the vehicle 1 with a first accident severity; a second body section 20, which is adapted to deform in the event of an accident of the vehicle 1 with a second accident severity greater than the first accident severity; and a third body section 30, which is adapted to deform in the event of an accident of the vehicle 1 with a third accident severity greater than the second accident severity. The different accident severities are visualized (visualisieren, sometimes called made intuitive) by hatched areas. Here, the second body section 20 is arranged between the first body section 10 and the third body section 30, in particular such that the first, second and third body sections 10, 20, 30 are mechanically connected in series. Thus, the first, second and third body sections 10, 20, 30 form three independent, separable damage zones, which need to be repaired depending on the accident severity.

[0035] The first body section 10 includes a crash management system 11, 12, which preferably deforms in the event of an accident at a speed of up to (bis zu, sometimes called not exceeding) 16 km / h. For this purpose, the crash management system particularly has a crash box 12 and / or a bending beam 11. In the event of an accident of the first accident severity, the second and third body sections 20, 30 can remain at least substantially or completely undeformed, in particular due to their stiffness and / or strength, so that the second and third body sections 20, 30 do not need to be replaced after an accident of the first accident severity.

[0036] For simple replacement to be possible, at least the third vehicle body section 30 has a coupling device 31 to which the second vehicle body section 20 is fastened as a repair section for modular replacement of the second vehicle body section 20 after an accident of second accident severity.

[0037] As can be seen from Figure 3 it, the third vehicle body section 30 is designed as a cast component in the form of a large cast element 32 with a first vehicle body side 30.1 and a second vehicle body side 30.2. Furthermore, at the large cast element 32, at each of the vehicle body sides 30.1, 30.2, a longitudinal beam 35 is formed by at least two longitudinal beam sections 21, 34 each. Therein, the second and third vehicle body sections 20, 30 each have one of the longitudinal beam sections 21, 34 of each longitudinal beam 35, so that the longitudinal beam 35 is formed by connecting the two longitudinal beam sections 21, 34 of the second and third vehicle body sections 20, 30 at the coupling device 31. Preferably, the second vehicle body section 20 is also constructed as a cast part or alternatively as a steel member. In particular, for a lightweight design of the vehicle body structure 3, the second and third vehicle body sections 20, 30 are preferably made of aluminum material. For example, the second and third vehicle body sections 20, 30 can be manufactured together or independently of each other by an aluminum die-casting method.

[0038] The third vehicle body section 30 can in particular be configured to accommodate different implementation variants of the second vehicle body section 20 in order to define the overhang of the vehicle 1. Thereby, the large cast element of the third vehicle body section 30 can be used across variants. The coupling device 31 can, for example, include flanges 33 at each of the two vehicle body sides 30.1, 30.2, to which one of the longitudinal beam sections 21 of the second vehicle body section 20 is respectively form-fittingly / or force-fittingly fastened.

[0039] Thus, as presented by the schematic process in Figure 5 it, the method 100 according to the invention for repairing the vehicle body structure 3 can be implemented in a simple manner. Herein, first, the loosening 101 of the second vehicle body section 20 from the coupling device 31 of the third vehicle body section 30 is achieved. The first vehicle body section 10 can be loosened from the vehicle body structure 3 in advance or simultaneously with the second vehicle body section 20. Thereafter, the assembly 102 of at least one replacement section is carried out for modular replacement of the second vehicle body section 20 at the coupling device 31 of the third vehicle body section 30. Herein, the replacement section preferably has the same structure as the longitudinal beam section 21 of the second vehicle body section 20. Further, the assembly 103 of another replacement section, in particular in the form of structurally identical crash management systems 11, 12, is achieved for replacing the first vehicle body section 10.

[0040] Figure 4The body structure 3 is shown in the form of a rear end structure 3.2. Here, the rear end structure 3.2 is structurally constructed similarly to the front end structure 3.1 described above.

[0041] The above explanation of the embodiment only describes the present invention within the scope of examples. Of course, as long as it is technically meaningful, the various features of the embodiment can be freely combined with each other without departing from the scope of the present invention.

[0042] List of reference numerals

[0043] 1 Vehicle

[0044] 2 Body

[0045] 3 Body structure

[0046] 3.1 Front end structure

[0047] 3.2 Rear end structure

[0048] 10 First body section

[0049] 11 Bending beam

[0050] 12 Crash box

[0051] 20 Second body section

[0052] 21 Longitudinal beam element

[0053] 30 Third body section

[0054] 30.1 First body side

[0055] 30.2 Second body side

[0056] 31 Connecting device

[0057] 32 Large casting element

[0058] 33 Flange

Claims

1. A body structure (3) for a body (2) of a vehicle (1), comprising a first body section (10) configured to deform when the vehicle (1) is involved in an accident with a first severity level of the accident, a second body section (20) configured to deform when the vehicle (1) is involved in an accident with a second severity level of the accident greater than the first severity level of the accident, and a third body section (30) configured to deform when the vehicle (1) is involved in an accident with a third severity level of the accident greater than the second severity level of the accident, wherein the second body section (20) is arranged between the first body section (10) and the third body section (30), wherein the third body section (30) has a coupling device (31), and the second body section (20) is fastened as a repair section at the coupling device (31) for modular replacement of the second body section (20) after an accident with the second severity level of the accident, wherein the third body section (30) is configured as a cast member.

2. The body structure (3) according to claim 1, characterized in that the second body section (20) is configured as a cast member or as a steel member and / or the third body section (30) is made of aluminum material.

3. The body structure (3) according to claim 1 or 2, characterized in that a longitudinal beam (35) is provided, which is formed by at least two longitudinal beam sections (21, 34), wherein the second body section (20) and the third body section (30) each have one of the longitudinal beam sections (21, 34) of the longitudinal beam (35), so as to form the longitudinal beam (35) by connecting the two longitudinal beam sections (21, 34) of the second body section (20) and the third body section (30) at the coupling device (31).

4. The body structure (3) according to any one of the preceding claims, characterized in that the third body section (30) is designed as a large cast element (32) with a first body side (30.1) and a second body side (30.2), wherein at each of the body sides (30.1) of the large cast element (32), the longitudinal beam (35) is formed by at least two longitudinal beam sections (21, 34) respectively.

5. The body structure (3) according to claim 4, characterized in that the coupling device (31) includes a flange (33) at each of the two body sides (30.1, 30.2), and one of the longitudinal beam sections (21) of the second body section (20) is fastened to the flange (33) in a form - fit and / or force - fit manner respectively.

6. The body structure (3) according to any one of the preceding claims, characterized in that the first body section (10), the second body section (20) and the third body section (30) form a front - end structure (3.1) or a rear - end structure (3.2) for the body (2) of the vehicle (1).

7. The body structure (3) according to any one of the preceding claims, characterized in that The third vehicle body section (30) is configured to accommodate different implementation variants of the second vehicle body section (20) in order to define the overhang of the vehicle (1).

8. The vehicle body structure (3) according to any one of the preceding claims, characterized in that the first vehicle body section (10) includes a crash management system (11, 12).

9. A vehicle (1) having a vehicle body (2) with at least one vehicle body structure (3) according to any one of the preceding claims.

10. A method (100) for repairing a vehicle body structure (3) according to any one of claims 1 to 8, in which the first vehicle body section (10) and the second vehicle body section (20) are deformed due to an accident with a second accident severity exceeding the first accident severity, the method comprising:[[]]END]] - loosening (101) the second vehicle body section (20) from the coupling device (31) of the third vehicle body section (30), wherein the third vehicle body section (30) is configured as a cast member, - fitting (102) at least one replacement section at the coupling device (31) of the third vehicle body section (30) in order to modularly replace the second vehicle body section (20), - fitting (103) another replacement section in order to replace the first vehicle body section (10).

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