Dash panel assembly and assembling method thereof

Abstract

The invention relates to the field of vehicle bodies, in particular to a dash panel assembly and an assembling method thereof.The dash panel assembly comprises a dash panel body, and the dash panel body comprises a front baffle body, a mounting beam and a front baffle lower plate; the front baffle body is connected with the front baffle lower plate through the mounting beam; the mounting beam comprises a front baffle cross beam; a reinforcing beam is arranged in the front baffle cross beam; the front baffle plate body is connected with the front baffle plate lower plate through the front baffle plate cross beam; through cooperative use of the front baffle body, the mounting beam and the front baffle lower plate, the overall structural strength of the dash panel assembly is well guaranteed; the dash panel assembly disclosed by the invention is divided into an upper section structure and a lower section structure which are connected through the closed section profile cross beam, so that the strength is greatly improved, and the collision intrusion amount during front collision of a vehicle body is reduced; meanwhile, the front baffle body and the front baffle lower plate are stamping parts, the overall size is small, the mold opening period is short, the stamping depth is small, parts are more stable, and deformation is little.

Description

Technical Field

[0001] The present invention relates to the field of vehicle bodies, and in particular to a dash panel assembly and an assembling method thereof. Background Art

[0002] The automotive dash assembly is a key structural component located between the engine compartment and the vehicle cabin. It is designed to perform multiple functions, including isolating the engine compartment from the vehicle cabin, providing structural support, optimizing the vehicle's sound and heat insulation performance, and protecting the passenger compartment during a collision.

[0003] The traditional front panel assembly usually consists of the front panel body, reinforcement beam, installation structure, etc., but there are some technical problems, such as insufficient structural strength, heavy weight, poor sound insulation and heat insulation performance, as well as defects in collision force transmission and sealing.

[0004] In recent years, with the development of automotive technology, the performance requirements for the front panel assembly have become increasingly higher. For example, to improve the collision safety of the vehicle, it is necessary to optimize the structural strength and force transmission path of the front panel.

[0005] At the same time, in order to reduce the weight and cost of the vehicle, the development of lightweight and universal front panel assemblies has also become a research focus.

[0006] In addition, with the rapid development of the automotive industry in recent years, the requirements for lightweight automobiles are getting higher and higher, the development cycle is getting shorter and shorter, and the demand for reducing the cost and weight of stamping parts is increasing.

[0007] At present, the main structure of the front panel of mainstream cars at home and abroad is a stamped sheet metal connecting the water trough, side panel, and front floor, and is connected to the surrounding parts by spot welding. Due to the large horizontal span of the front panel body and the deep stamping and drawing depth, the parts are prone to mold problems such as deformation, cracking, and drawing marks. The intersection with surrounding parts is prone to assembly problems. At the same time, it is heavy, the development cycle is long, and the cost is high.

[0008] Although the structure disclosed in the existing patent 202310279885.2 - dash assembly and vehicle can enhance the structural strength of the dash assembly, reduce vibration response sensitivity, reduce interior noise, and improve the NVH performance of the vehicle; however, the overall size of the main body part in the patent still poses a problem of great processing difficulty.

[0009] Therefore, in order to better improve or solve at least one of the above problems, it is necessary to optimize the design of the existing front panel structure. Summary of the Invention

[0010] An object of the present invention is to provide a dash panel structure that is easy to stamp and can reduce the amount of intrusion during a vehicle body collision.

[0011] In order to achieve the above purpose, the technical solution adopted by the present invention is:

[0012] A front panel assembly includes a panel body, wherein the panel body includes a front panel body, a mounting beam, and a front panel lower plate; the front panel body is connected to the front panel lower plate via the mounting beam;

[0013] The mounting beam includes a front baffle cross beam; a reinforcement beam is provided inside the front baffle cross beam; the front baffle body is connected to the front baffle lower plate through the front baffle cross beam.

[0014] The front fender crossbeam includes a crossbeam body, an internal cavity is provided on the crossbeam body; support ribs are provided in the internal cavity; a lap slope is provided on the crossbeam body; the support ribs divide the internal cavity into a first cavity and a second cavity; the first cavity is used to insert a reinforcement beam; the first cavity is arranged close to the front cabin of the vehicle.

[0015] The crossbeam body includes a crossbeam body, and the crossbeam body includes a first plate, a second plate, a third plate and a fourth plate; the second plate and the fourth plate are distributed at intervals; the second plate and the fourth plate are connected at both ends by the first plate and the third plate respectively; and a lap slope is formed on the third plate.

[0016] The first plate and the second plate are arranged to intersect each other, and the angle between the first plate and the second plate is greater than 90 degrees; the angle between the fourth plate and the third plate is greater than 90 degrees.

[0017] The front baffle body and the front baffle lower plate are overlapped on the overlapping inclined surface of the beam body at the same time; the overlapping parts between the front baffle body and the beam body and the overlapping parts between the front baffle lower plate and the beam body are distributed at intervals.

[0018] A pedal reinforcement plate is provided on the front baffle body, and the pedal reinforcement plate extends to the front baffle crossbeam.

[0019] A steering gear mounting structure is provided on the enclosure body; the steering gear mounting structure comprises a mounting plate arranged on the lower plate of the front baffle; the mounting plate is overlapped on the lower plate of the front baffle.

[0020] An avoidance notch is provided on the crossbeam body; the avoidance notch is located on the side of the mounting plate close to the front baffle body.

[0021] A crossbeam sealing plate is provided on the inner wall of the avoidance gap.

[0022] An assembling method of the dash panel assembly, the assembling method comprising the following steps:

[0023] Step 1: Material preparation: prepare the front fender body, front fender crossbeam, reinforcement beam, front fender lower plate, pedal reinforcement plate and mounting plate;

[0024] Step 2: Multiple stations assemble the front fender crossbeam and reinforcement beam, the front fender body and pedal reinforcement plate, and the front fender lower plate and mounting plate; the front fender crossbeam and reinforcement beam are assembled into a reinforcement beam assembly; the front fender body and pedal reinforcement plate are assembled into a front fender body assembly; the front fender lower plate and mounting plate are assembled into a lower plate assembly;

[0025] Step 3: Connect the front fender body assembly and lower plate assembly in step 2 to the reinforcement beam assembly;

[0026] Step 4: After completing step 3, a front panel assembly is assembled. If you need to reassemble the front panel assembly, repeat steps 1-3.

[0027] The advantages of the present invention are:

[0028] The invention discloses a dash panel assembly and an assembling method thereof.

[0029] The present invention well ensures the overall structural strength of the front panel assembly through the coordinated use of the front panel body, the mounting beam and the front panel lower plate.

[0030] The front panel disclosed in the present invention is composed of an upper and lower structure, which are connected in the middle by a closed cross-section profile beam, thereby greatly improving the strength and reducing the collision intrusion amount when the vehicle body collides with the front.

[0031] At the same time, the front baffle body and the front baffle lower plate of the present invention are stamped parts, with smaller overall size, shorter mold opening cycle, smaller stamping depth, more stable parts and less deformation. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The following is a brief description of the contents and symbols in the drawings of the present invention:

[0033] Figure 1 Schematic diagram of the structure of the front panel assembly of the present invention;

[0034] Figure 2 Schematic diagram of the explosion of the front panel assembly of the present invention;

[0035] Figure 3 It is a cross-sectional view of the installation beam of the present invention;

[0036] Figure 4 It is a cross-sectional view along AA in the present invention.

[0037] Figure 5 It is a cross-sectional view along BB in the present invention.

[0038] The marks in the above figure are:

[0039] 1. Front fender body, 2. Mounting beam, 21. Front fender crossbeam, 3. Front fender lower plate, 4. Mounting plate, 5. Crossbeam cover plate, 6. Pedal reinforcement plate. DETAILED DESCRIPTION

[0040] The specific implementation of the present invention will be further explained in detail below by describing the best embodiment with reference to the accompanying drawings.

[0041] A front panel assembly includes a panel body, wherein the panel body includes a front panel body 1, a mounting beam 2 and a front panel lower plate 3; the front panel body 1 is connected to the front panel lower plate 3 through the mounting beam 2; the mounting beam 2 includes a front panel cross beam 21; a reinforcement beam 22 is provided in the front panel cross beam 21; the front panel body 1 is connected to the front panel lower plate 3 through the front panel cross beam 21; the present invention well ensures the overall structural strength of the front panel assembly through the coordinated use of the front panel body 1, the mounting beam 2 and the front panel lower plate 3.

[0042] The front panel disclosed in the present invention is composed of an upper and lower structure, which are connected in the middle by a closed cross-section profile beam, thereby greatly improving the strength and reducing the collision intrusion amount when the vehicle body collides with the front.

[0043] At the same time, the front baffle body 1 and the front baffle lower plate 3 of the present invention are stamped parts, with smaller overall size, shorter mold opening cycle, smaller stamping depth, more stable parts and less deformation.

[0044] In the present invention, the dash panel assembly mainly includes a dash panel body, which is the main structure of the dash panel assembly and the core part of the dash panel assembly.

[0045] In the present invention, the enclosure body mainly includes a front baffle body 1 , a mounting beam 2 and a front baffle lower plate 3 .

[0046] The front baffle body 1 is located at the upper part of the front panel assembly and plays a shielding and protective role.

[0047] Mounting beam 2: serves as a connecting component, used to connect the front baffle body 1 and the front baffle lower plate 3.

[0048] Front fender lower plate 3: located at the lower part of the front panel assembly, connected to the front fender body 1 through the mounting beam 2.

[0049] In the present invention, the mounting beam 2 is a key connecting component of the dash panel assembly, and its core component is the dash panel crossbeam 21. A reinforcement beam 22 is provided inside the dash panel crossbeam 21 to enhance the structural strength of the dash panel crossbeam 21, thereby improving the stability of the entire dash panel assembly.

[0050] The front baffle body 1 is connected to the front baffle lower plate 3 via the front baffle cross beam 21 to form an integral structure.

[0051] The front panel assembly of the present invention adopts a segmented design, that is, the panel body is divided into a front panel body 1, a mounting beam 2 and a front panel lower plate 3; this design can simplify the manufacturing process, reduce the difficulty of stamping, and facilitate assembly and maintenance.

[0052] The reinforcement beam 22 is provided inside the front fender cross beam 21, which can effectively improve the bending resistance and overall strength of the cross beam, and can better withstand the impact force and reduce deformation, especially when the vehicle collides.

[0053] The front fender body 1 and the front fender lower plate 3 are connected by the mounting beam 2. This structural design ensures the integrity and stability of the front fender assembly.

[0054] In the present invention, the mounting beam 2 can be made of high-strength steel, aluminum alloy, etc.

[0055] In addition, the present invention can reduce the amount of intrusion during a collision and protect people and equipment in the vehicle during subsequent use by providing the mounting beam 2 .

[0056] The segmented design and the use of the reinforcement beam 22 can optimize the use of materials and achieve lightweighting without reducing strength.

[0057] The segmented design facilitates the implementation of manufacturing processes such as stamping and welding, and also facilitates maintenance and replacement of parts.

[0058] Furthermore, in the present invention, the front fender crossbeam 21 includes a crossbeam body, an internal cavity is provided on the crossbeam body; a supporting rib 23 is provided in the internal cavity; a lap slope 25 is provided on the crossbeam body; the supporting rib 23 divides the internal cavity into a first cavity and a second cavity; the first cavity is used to insert the reinforcement beam 22; the first cavity is arranged close to the front cabin of the vehicle; the front fender crossbeam 21 of the present invention is the core component of the mounting beam 2; its main structure includes a crossbeam body: this is the main frame of the front fender crossbeam 21, which plays the role of bearing and connection.

[0059] The interior of the crossbeam body is designed as a cavity structure, which can reduce weight while providing space for internal reinforcements.

[0060] The internal cavity is divided into two cavities by the supporting ribs 23: the first cavity is used to insert the reinforcement beam 22, the function of the reinforcement beam 22 is to enhance the structural strength of the crossbeam, especially the impact resistance during vehicle collision; the second cavity: its specific purpose is not clearly stated, but it is usually used to further optimize the structural strength or reduce weight.

[0061] Position of the first cavity: It is arranged close to the front cabin of the vehicle. This design may be to make better use of the space. At the same time, the reinforcement beam 22 is arranged in the key stress area to enhance collision safety.

[0062] The supporting ribs 23 divide the internal cavity into two independent cavities. This design can improve the stability and torsional resistance of the structure.

[0063] The supporting ribs 23 themselves also play a reinforcing role, further improving the overall strength of the beam.

[0064] The crossbeam body is provided with an overlapping inclined surface 25 : this is the part used to connect with the front baffle body 1 and the front baffle lower plate 3 .

[0065] The design of the overlapping inclined surface 25 can optimize the force distribution at the connection part, reduce stress concentration, and improve the stability and reliability of the connection.

[0066] The internal cavity design reduces the weight of the crossbeam, helping to achieve lightweight body without compromising structural strength.

[0067] The provision of the reinforcement beam 22 and the partitioned design of the supporting ribs 23 significantly enhance the impact resistance and overall strength of the crossbeam.

[0068] The design of the overlapping inclined surface 25 optimizes the stress on the connection part and further improves the structural stability.

[0069] The first cavity is arranged close to the front cabin of the vehicle, which makes rational use of the limited space. At the same time, the reinforcement beam 22 is arranged in the key stress-bearing area, thereby improving the safety performance.

[0070] The front fender crossbeam 21 of the present invention includes a crossbeam body and an insert reinforcement beam 22; such a configuration makes the front fender crossbeam 21 a split design; such a configuration facilitates the manufacture and assembly of the front fender crossbeam 21, reducing production costs and complexity.

[0071] Through the partitioning design of the internal cavity, the reinforcement of the supporting ribs 23 and the optimization of the overlapping slopes 25, the front fender crossbeam 21 significantly improves the structural strength and connection stability while ensuring lightweight.

[0072] This design is particularly suitable for modern automobile body structures and can effectively improve collision safety and manufacturing efficiency.

[0073] Furthermore, in the present invention, the crossbeam body includes a crossbeam body, which includes a first plate 211, a second plate 212, a third plate 213, and a fourth plate 214; the second plate 212 and the fourth plate 214 are spaced apart; the second plate 212 and the fourth plate 214 are connected at both ends by the first plate 211 and the third plate 213, respectively; the third plate 213 is formed with a lap bevel 25; the crossbeam body is the core frame of the front fender crossbeam 21, and is composed of the following four main plates: the second plate 212 and the fourth plate 214 are spaced apart and not directly connected; the first plate 211 and the third plate 213 are connected at both ends of the second plate 212 and the fourth plate 214, respectively, to form a closed frame.

[0074] This connection method is similar to a "frame structure", in which four plates are connected to each other to form a stable beam body.

[0075] The overlapping bevel 25 is located on the third plate body 213 and is used for overlapping connection with the front baffle body 1 and the front baffle lower plate 3; the design of the overlapping bevel 25 can optimize the force distribution of the connection part, reduce stress concentration, and improve the stability and reliability of the connection.

[0076] The present invention forms a stable frame structure by interconnecting four plates, which can effectively disperse and bear various loads.

[0077] Compared to solid structures, this frame design can significantly reduce weight while maintaining sufficient strength.

[0078] The design of the overlapping inclined surface 25 allows the front baffle body 1 and the front baffle lower plate 3 to be connected to the crossbeam body at a certain angle. This angle connection can better disperse stress and reduce deformation of the connection part.

[0079] The design of the overlapping bevel 25 facilitates assembly operation and improves production efficiency.

[0080] The second plate 212 and the fourth plate 214 are spaced apart from each other: This design may be intended to form a cavity inside for arranging the reinforcing beam 22 or other reinforcement members while maintaining the lightweight of the structure.

[0081] By arranging reinforcement members (such as the reinforcement beam 22) at key positions, the local strength of the beam can be significantly improved without increasing excessive weight.

[0082] Furthermore, in the present invention, the first plate 211 and the second plate 212 are arranged to intersect, and the angle between the first plate 211 and the second plate 212 is greater than 90 degrees; the angle between the fourth plate 214 and the third plate 213 is greater than 90 degrees; through the obtuse angle design between the first plate 211 and the second plate 212, and the fourth plate 214 and the third plate 213, the crossbeam body is significantly optimized in terms of structural stability, stress distribution and space utilization; this design not only improves the overall strength and reliability of the front panel assembly, but also provides important support for the lightweight and safety of the automobile body.

[0083] The design with an angle greater than 90 degrees can significantly improve the torsional resistance and overall stability of the beam body.

[0084] This angle setting makes the connection between the plates more stable and can better disperse and withstand loads in various directions.

[0085] Through the above-mentioned angle design, stress can be distributed more evenly on each plate, reducing the risk of local stress concentration, thereby improving the durability and reliability of the structure.

[0086] The design of an angle greater than 90 degrees enables the beam body to better adapt to complex working conditions, such as the stress conditions of the vehicle during collision, bumps or torsion.

[0087] Since the third plate body 213 is provided with a lap bevel 25, the obtuse angle design between the first plate body 211 and the second plate body 212 can better connect with the front baffle body 1 and the front baffle lower plate 3; this angle setting can optimize the force distribution of the connection part, reduce stress concentration, and improve the stability and reliability of the connection.

[0088] Furthermore, in the present invention, the front baffle body 1 and the front baffle lower plate 3 are simultaneously overlapped on the overlapping inclined surface 25 on the beam body; the overlapping part between the front baffle body 1 and the beam body and the overlapping part between the front baffle lower plate 3 and the beam body are distributed at intervals; the present invention is based on this design, the front baffle body 1 and the front baffle lower plate 3 are simultaneously overlapped on the overlapping inclined surface 25 of the beam body; the overlapping parts are distributed at intervals, and this design can effectively disperse the welding stress, avoid stress concentration, and thus improve the strength and stability of the welded joint.

[0089] In addition, the front fender body 1 assembly and the front fender lower body are both connected to the front panel mounting beam 2 assembly by MIG welding.

[0090] MIG welding (Metal Inert Gas Welding) is a highly efficient welding method suitable for welding thin plates and complex structures.

[0091] It can reduce the heat affected zone and welding deformation through continuous wire feeding and inert gas protection.

[0092] In order to eliminate the effects of welding heat, thermal deformation and interference between welds, the welding surface width of the front panel mounting beam 2 assembly must be larger than the two sheet metal overlap surfaces and the weld width; the reserved space in the middle must be more than 60mm. This design can effectively avoid the superposition of heat-affected zones during welding and reduce welding deformation.

[0093] By controlling welding parameters (such as current, voltage and welding speed) and selecting appropriate welding materials, the heat affected zone of welding can be effectively reduced; during the welding process, the use of preheating and post-heat treatment can further reduce the welding residual stress and improve the performance of the welded joint.

[0094] When using MIG welding, the welding deformation is smaller due to its lower heat input.

[0095] Welding deformation can be further reduced by optimizing the welding sequence and adopting measures such as tracking cooling during welding.

[0096] Furthermore, in the present invention, a pedal reinforcement plate 6 is provided on the front fender body 1, and the pedal reinforcement plate 6 extends to the front fender cross beam 21; the extension of the pedal reinforcement plate 6 of the present invention: a pedal reinforcement plate 6 is provided on the front fender body 1, and the reinforcement plate extends to the front fender cross beam 21; this design increases the continuity of the structure, thereby better transferring the load of the pedal area to the cross beam, thereby improving the strength and stability of the overall structure.

[0097] The pedal reinforcement plate 6 is usually formed by integrally stamping a steel plate of equal wall thickness, and comprises two functional plates: a clutch pedal bracket reinforcement plate and a brake pedal bracket reinforcement plate.

[0098] The pedal reinforcement plate 6 is fixed to the front baffle body 1 by welding to ensure the firmness of the connection.

[0099] The provision of the pedal reinforcement plate 6 significantly improves the dynamic stiffness of the pedal installation area, effectively reduces the vibration of the pedal during use, and improves driving safety and comfort.

[0100] By increasing the structural rigidity of the pedal area, the pedal reinforcement plate 6 can also improve the sound insulation and vibration reduction performance of the front panel, and reduce the amount of engine compartment noise transmitted into the passenger compartment.

[0101] Without increasing the thickness and weight of the reinforcement plate, the pedal reinforcement plate 6 achieves improved strength by optimizing the structural design (such as setting ribs), avoiding the increase in vehicle body weight and cost caused by using thicker materials.

[0102] Design of pedal mounting holes: The pedal reinforcement plate 6 is provided with pedal bracket mounting holes corresponding to the front baffle body 1 for fixing the brake pedal and the clutch pedal.

[0103] U-shaped ribs are set on the periphery of the pedal installation area to further enhance the dynamic stiffness of this area; this design not only improves the fatigue resistance of the pedal, but also optimizes space utilization.

[0104] Furthermore, in the present invention, a steering gear mounting structure is provided on the enclosure body; the steering gear mounting structure includes a mounting plate 4 arranged on the front fender lower plate 3; the mounting plate 4 is overlapped on the front fender lower plate 3; the mounting plate 4 is overlapped on the front fender lower plate 3 for fixing the steering gear.

[0105] The mounting plate 4 is fixed to the front baffle lower plate 3 by overlapping. This design can effectively improve the stability and reliability of the connection.

[0106] Overlap structures are usually fixed by welding or bolting.

[0107] The main function of the mounting plate 4 is to provide a stable supporting platform for the steering gear, thereby ensuring the stability and reliability of the steering gear during vehicle driving.

[0108] By combining the mounting plate 4 with the front fender lower plate 3 , the mounting position of the steering gear can be optimized and interference with other components can be reduced.

[0109] By arranging the mounting plate 4 on the front fender lower plate 3, the weight and load of the steering gear can be evenly distributed on the front fender structure, thereby improving the stability of the entire steering system.

[0110] The design of the mounting plate 4 makes the installation and removal of the steering gear more convenient, thus reducing maintenance time.

[0111] Furthermore, in the present invention, an avoidance gap 24 is provided on the crossbeam body; the avoidance gap 24 is located on the side of the mounting plate 4 close to the front baffle body 1; the avoidance gap 24 provided on the crossbeam body in the present invention is located on the side of the mounting plate 4 close to the front baffle body 1; the main purpose of this design is to provide space for the steering gear mounting plate 4 or other related components to avoid structural interference.

[0112] The provision of the avoidance notch 24 can ensure that there is sufficient space for the steering gear mounting plate 4 during installation and use, while not affecting the overall structural strength of the crossbeam body.

[0113] The design of the avoidance gap 24 is usually combined with a reinforcement member or a reinforcement structure to compensate for the strength loss caused by the gap. For example, by installing an avoidance reinforcement member in the avoidance area, the strength and stability of the beam body at the avoidance gap 24 are ensured.

[0114] The avoidance gap 24 is not only used for installing the steering gear, but also can be used for arranging other components (such as the transmission shaft, wiring harness, etc.), thereby optimizing the space layout in the engine compartment.

[0115] In some designs, the avoidance notch 24 may be combined with crushing feature ribs or reinforcing ribs to further improve the energy absorption capability of the cross beam in a collision.

[0116] The design of the avoidance notch 24 can be realized by a simple stamping or cutting process, which reduces the manufacturing cost and improves the assembly accuracy.

[0117] Furthermore, a crossbeam sealing plate 5 is provided on the inner wall of the avoidance gap 24 described in the present invention; the setting of the crossbeam sealing plate 5 of the present invention is that a crossbeam sealing plate 5 is installed on the inner wall of the avoidance gap 24, and is fixed on both sides of the gap by welding to seal the gap and ensure the integrity and sealing of the structure; after the sealing is completed, PVC sealant is usually applied for sealing to enhance the waterproof and anti-corrosion properties.

[0118] In the present invention, the dash panel mounting beam 2 assembly mainly includes the following components:

[0119] The front fender cross member 21 serves as a main load-bearing component and provides structural support.

[0120] Reinforcement beam 22: used to enhance the strength of the crossbeam and compensate for the strength loss caused by the avoidance gap 24.

[0121] Mounting plate 4: used to fix the steering gear to ensure its stability and reliability.

[0122] Crossbeam sealing plate 5: used to seal the avoidance gap 24 to ensure the sealing of the structure.

[0123] The front fender cross beam 21 and the reinforcement beam 22 are made of high-strength 6 series aluminum alloy, which has good strength, corrosion resistance and formability.

[0124] Molding process: adopt extrusion molding process, through high temperature extrusion and rapid cooling, to obtain high-strength and high-precision profiles.

[0125] The reinforcement beam 22 is fixed to the interior of the front baffle cross beam 21 by means of blind rivets. This connection method is simple and reliable and is suitable for occasions where space on one side is limited.

[0126] The steering gear mounting plate 4 and the sealing plate are fixed by welding to ensure the connection strength.

[0127] 6 series aluminum alloy has a low density while maintaining high strength, which helps to achieve lightweight body.

[0128] 6 series aluminum alloy can realize the molding of complex multi-cavity structures.

[0129] An assembling method of the dash panel assembly, the assembling method comprising the following steps:

[0130] Step 1: Material preparation: prepare the front fender body 1, the front fender cross beam 21, the reinforcement beam 22, the front fender lower plate 3, the pedal reinforcement plate 6 and the mounting plate 4;

[0131] Step 2: Multi-station assembly of the front fender crossbeam 21 and the reinforcement beam 22, the front fender body 1 and the pedal reinforcement plate 6, and the front fender lower plate 3 and the mounting plate 4; the front fender crossbeam 21 and the reinforcement beam 22 are assembled into a reinforcement beam assembly; the front fender body 1 and the pedal reinforcement plate 6 are assembled into a front fender body 1 assembly; the front fender lower plate 3 and the mounting plate 4 are assembled into a lower plate assembly;

[0132] Step 3: Connect the front baffle body 1 assembly and the lower plate assembly in step 2 to the reinforcement beam assembly;

[0133] Step 4: After completing step 3, a front panel assembly is assembled. If you need to reassemble the front panel assembly, repeat steps 1-3.

[0134] Based on the above assembly method, the front panel assembly can be assembled and assembled.

[0135] Step 1: Material preparation;

[0136] The front fender body 1 , the front fender cross beam 21 , the reinforcement beam 22 , the front fender lower plate 3 , the pedal reinforcement plate 6 and the mounting plate 4 .

[0137] Step 2: Multi-station assembly

[0138] Reinforcement beam assembly: The front fender crossbeam 21 and the reinforcement beam 22 are assembled together to form a reinforcement beam assembly. The reinforcement beam 22 is usually fixed inside the crossbeam by welding or riveting to enhance structural strength.

[0139] Assembly of the front fender body 1: Assemble the front fender body 1 with the pedal reinforcement plate 6. The pedal reinforcement plate 6 is fixed to the front fender body 1 by welding or bolting to ensure the strength and stability of the pedal area.

[0140] Lower plate assembly: Assemble the front fender lower plate 3 and the mounting plate 4. The mounting plate 4 is usually fixed to the front fender lower plate 3 by welding and is used to install the steering gear or other components.

[0141] Modular design: By pre-assembling components into assemblies, production efficiency can be improved and the complexity of the assembly process can be reduced.

[0142] Multi-station operation: This design allows multiple components to be assembled simultaneously at different stations, further improving production efficiency.

[0143] Step 3: Assembly Connection

[0144] Connect the front fender body 1 assembly and the lower plate assembly assembled in step 2 to the reinforcement beam assembly. The connection method usually includes welding, riveting or bolting, depending on the design requirements.

[0145] After the connection is completed, a complete front panel assembly is formed.

[0146] By connecting the various assemblies together to form a complete front panel assembly, the integrity and stability of the structure are ensured.

[0147] During the connection process, each assembly can be fine-tuned to ensure assembly accuracy.

[0148] Step 4: Repeat the assembly

[0149] If the front panel assembly needs to be reassembled, just repeat steps 1-3; this modular and standardized assembly method is particularly suitable for large-scale production and can significantly improve production efficiency and product quality.

[0150] Multi-station operation and modular design significantly improve production efficiency and reduce assembly time.

[0151] Standardized assembly processes facilitate automated production, further increasing production speed.

[0152] Modular design and standardized processes ensure the quality of each component and assembly, thereby improving the reliability of the entire front panel assembly.

[0153] Through pre-assembly and connection operations, errors and defects in the assembly process are reduced.

[0154] Standardized processes and modular design reduce production costs and minimize material waste.

[0155] Multi-station operation improves equipment utilization and further reduces production costs.

[0156] In the present invention, the reinforcement beam 22 is fixed inside the front fender cross beam 21 by means of blind rivets.

[0157] The position of the reinforcement beam 22 should be accurately positioned according to the design requirements to ensure that it can effectively enhance the strength of the crossbeam, especially the structural strength after avoiding the steering system.

[0158] Check whether the connection between the two is firm and whether the rivets are evenly distributed and not loose.

[0159] Assembly of steering gear mounting plate 4

[0160] Weld the steering gear mounting plate 4 to the bottom of the front fender crossbeam 21, ensuring that the welding position is accurate and the weld is uniform and free of defects.

[0161] Check the welding quality to ensure the connection strength between the steering gear mounting plate 4 and the crossbeam.

[0162] Assembly of the front fender crossbeam 21 sealing plate; welding the front fender crossbeam 21 sealing plate on both sides of the avoidance gap 24 of the steering gear mounting plate 4; inspect the welding parts to ensure that they are tightly sealed.

[0163] PVC sealant is applied to the surface of the avoidance gap 24 after welding to perform sealing treatment to prevent moisture or impurities from entering.

[0164] The front fender body 1 is connected to the brake pedal bracket reinforcement plate; 33 SPR rivets are used to connect the brake pedal bracket reinforcement plate to the front fender body 1.

[0165] During the riveting process, ensure that the rivets are evenly distributed and the riveting quality meets the requirements.

[0166] A local closed structure is formed between two sheets of metal through the features of surface and ribs to enhance the structural strength.

[0167] Installation of reinforcement plates: Add reinforcement plates to stress-bearing parts and fix them by SPR riveting or welding to ensure that the strength of the stress-bearing parts is enhanced.

[0168] Weld the front fender body 1 , the front fender lower plate 3 and the front panel mounting beam 2 .

[0169] Clean the welding surfaces of the front baffle body 1 and the front baffle lower plate 3 to remove surface impurities and oxide layers.

[0170] Use MIG welding technology to weld the front fender body 1 and the front panel mounting beam 2. The welding surface width must be greater than the width of the two sheet metal overlap surfaces, and the reserved space in the middle of the weld width must reach more than 60mm to eliminate the influence of welding heat, thermal deformation and interference between welds.

[0171] Weld the front baffle lower plate 3 and the mounting beam 2; clean the welding surface of the front baffle lower plate 3 and the mounting beam 2, and also use MIG welding technology for welding. The welding surface width and reserved space requirements are the same as those of the front baffle body 1.

[0172] Inspection and adjustment: Check the entire front panel assembly to ensure that all parts are firmly connected and the welding and riveting quality meet the requirements. Specific embodiment 1:

[0174] The present invention discloses a front fender assembly; it mainly includes a front fender body 1, a mounting beam 2 and a front fender lower plate 3; the front fender body 1 is connected to the front fender lower plate 3 through the mounting beam 2; the mounting beam 2 includes a front fender cross beam 21; a reinforcement beam 22 is provided in the front fender cross beam 21; the front fender body 1 is connected to the front fender lower plate 3 through the front fender cross beam 21.

[0175] The front fender body 1 and the front fender lower plate 3 of the present invention are equivalent to a two-stage structure. The front fender assembly disclosed in the present invention is divided into two sections, connected in the middle by a closed-section crossbeam. This significantly improves strength and reduces collision intrusion during a frontal collision. Furthermore, the stamped parts are smaller in size, the mold opening cycle is shorter, the stamping depth is smaller, and the parts are more stable and less deformed.

[0176] The present invention divides the front panel assembly into two unconnected stamped parts during the design stage, namely the front panel body 1 and the front panel lower plate 3, which are connected in the middle by a profile mounting beam 2. The material of both parts is changed from steel to aluminum, and MIG welding is adopted to form the front panel assembly structure.

[0177] The front panel assembly is connected to adjacent parts on the left and right, and overlapped with the water trough assembly and the front fender lower crossbeam assembly at the top and bottom. The connection method is also MIG welding.

[0178] The front baffle assembly disclosed in the present invention is composed of a front baffle body 1, a mounting beam 2 and a front baffle lower plate 3, and is connected by MIG welding.

[0179] The front baffle body 1 and the front baffle lower plate 3 are both welded to the same surface of the mounting beam 2 by MIG welding. In order to eliminate the influence of welding heat, thermal deformation and interference between welds, the width of the welding surface of the mounting beam 2 needs to be greater than the two sheet metal joint interfaces, the weld width, and the space reserved in the middle must reach more than 60mm.

[0180] The front fender body 1 and the pedal reinforcement plate 6 are connected by 33 SPR rivets. The strength of the stress-bearing parts is enhanced by adding reinforcement features at local positions. Except for the connection part, the two sheet metals form a local closed structure through the features of surface and ribs, such as Figure 4 AA.

[0181] The front baffle body 1 and the front baffle lower plate 3 are both stamped from 5 series aluminum plates, which are light in weight. Figure 4 As shown in the cross section BB, the front baffle body 1 and the front baffle bottom have a small stamping depth, and the forming difficulty is small.

[0182] The mounting beam 2 includes a front baffle cross beam 21 , a reinforcement beam 22 , a mounting plate 4 and a cross beam cover plate 5 .

[0183] The front fender crossbeam 21 is partially avoided due to the need to avoid the steering system. The crossbeam structure here is cut off and the strength is reduced. A reinforcement beam 22 is added to strengthen it. Figure 3 Cross section (C) schematic.

[0184] The reinforcement beam 22 is fixed to the inside of the front fender crossbeam 21 by means of blind rivets; the steering gear mounting plate 4 is welded below, and crossbeam sealing plates 5 are welded on both sides of the avoidance gap 24 to seal it, and then PVC sealant is applied for sealing.

[0185] The cross section of the front baffle beam 21 and the reinforcement beam 22 are both closed sections. Figure 3 As shown, the material is high-strength 6 series aluminum, extruded, the mounting holes and cutting edges are machined, with high precision, the error is less than 0.1mm, and the product performance is stable.

[0186] Obviously, the specific implementation of the present invention is not limited to the above-mentioned methods. As long as various non-substantial improvements are made using the method concept and technical solution of the present invention, they are all within the scope of protection of the present invention.

Claims

1. A front panel assembly, characterized in that: The enclosure body includes a front baffle body, a mounting beam, and a front baffle lower plate; the front baffle body is connected to the front baffle lower plate through the mounting beam; The mounting beam includes a front baffle cross beam; a reinforcement beam is provided inside the front baffle cross beam; the front baffle body is connected to the front baffle lower plate through the front baffle cross beam.

2. The dash panel assembly according to claim 1, characterized in that: The front fender crossbeam includes a crossbeam body, an internal cavity is provided on the crossbeam body; support ribs are provided in the internal cavity; a lap slope is provided on the crossbeam body; the support ribs divide the internal cavity into a first cavity and a second cavity; the first cavity is used to insert a reinforcement beam; the first cavity is arranged close to the front cabin of the vehicle.

3. A dash panel assembly according to any one of claims 1-2, characterized in that: The crossbeam body includes a crossbeam body, and the crossbeam body includes a first plate, a second plate, a third plate and a fourth plate; the second plate and the fourth plate are distributed at intervals; the second plate and the fourth plate are connected at both ends by the first plate and the third plate respectively; and a lap slope is formed on the third plate.

4. The dash panel assembly according to claim 3, characterized in that: The first plate and the second plate are arranged to intersect each other, and the angle between the first plate and the second plate is greater than 90 degrees; the angle between the fourth plate and the third plate is greater than 90 degrees.

5. The dash panel assembly according to claim 3, characterized in that: The front baffle body and the front baffle lower plate are overlapped on the overlapping inclined surface of the beam body at the same time; the overlapping parts between the front baffle body and the beam body and the overlapping parts between the front baffle lower plate and the beam body are distributed at intervals.

6. The dash panel assembly according to claim 1, characterized in that: A pedal reinforcement plate is provided on the front baffle body, and the pedal reinforcement plate extends to the front baffle crossbeam.

7. The dash panel assembly according to claim 1, characterized in that: The said enclosure body is provided with a steering gear mounting structure; the said steering gear mounting structure comprises a mounting plate provided on the lower plate of the front baffle; The mounting plate is overlapped on the lower plate of the front baffle.

8. The dash panel assembly according to claim 7, characterized in that: An avoidance notch is provided on the crossbeam body; the avoidance notch is located on the side of the mounting plate close to the front baffle body.

9. The dash panel assembly according to claim 8, characterized in that: A crossbeam sealing plate is provided on the inner wall of the avoidance gap.

10. An assembling method of a dash panel assembly according to any one of claims 1 to 9, characterized in that: The assembly method comprises the following steps: Step 1: Material preparation: prepare the front fender body, front fender crossbeam, reinforcement beam, front fender lower plate, pedal reinforcement plate and mounting plate; Step 2: Multiple stations assemble the front fender crossbeam and reinforcement beam, the front fender body and pedal reinforcement plate, and the front fender lower plate and mounting plate; the front fender crossbeam and reinforcement beam are assembled into a reinforcement beam assembly; the front fender body and pedal reinforcement plate are assembled into a front fender body assembly; the front fender lower plate and mounting plate are assembled into a lower plate assembly; Step 3: Connect the front fender body assembly and lower plate assembly in step 2 to the reinforcement beam assembly; Step 4: After completing step 3, a front panel assembly is assembled. If you need to reassemble the front panel assembly, repeat steps 1-3.

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