Assembly system for connecting an upper body structure of a motor vehicle to a vehicle platform of the motor vehicle

Abstract

Assembly system (1) for connecting an upper body structure (11) of a motor vehicle (10) to a vehicle platform (12) of the motor vehicle (10), comprising: a hollow column element (2) which is designed to be arranged longitudinally along a vertical vehicle axis (Z); a fastening clamp (3) which is designed to laterally grip a lower end (2a) of the column element (2) and which has several fastening interfaces (3a) to fasten the fastening clamp (3) to the column element (2) at the lower end (2a); a hollow plug-in connector (4) designed to be arranged laterally along a longitudinal axis (X) of a vehicle, wherein the plug-in connector (4) defines a mounting platform (4d) having a horizontal support surface (4a) for the column element (2) to be arranged thereon at its lower end (2a) together with the fastening clip (3) and a vertical joining surface (4b) for abutting a corresponding joining surface (3b) of the fastening clip (3), wherein the fastening clip (3) has several fastening interfaces (3a) for attaching the fastening clip (3) to the plug-in connector (4) at its joining surface (3b); and a hollow side sill element (5) which is designed to be arranged longitudinally along the longitudinal axis (X) of the vehicle, wherein the side sill element (5) is designed with fastening notches (5a) which extend longitudinally along the side sill element (5) and are designed to receive complementary shaped clip arms (4c) which are formed on a bottom side (4e) of the plug-in connector (4) to fasten the plug-in connector (4) on top of the side sill element (5).

Description

Technical field

[0001] The present invention relates to a mounting system for connecting an upper body structure of a motor vehicle to a vehicle platform of the motor vehicle. Furthermore, the invention comprises a motor vehicle, in particular a purpose-built vehicle, with an upper body structure which is attached to a vehicle platform by means of such a mounting system. background

[0002] More recently, several vehicle and automotive parts manufacturers have focused on developing standardized and scalable electric vehicle (EV) platforms. These platforms are intended to serve as the foundation for future vehicles within a completely new vehicle architecture, saving development time and costs and thus bringing new electric cars to market faster. To this end, modular, electrically rollable, and road-ready platforms, also known as "skateboards," are specifically designed to be combined with body shells of varying types and shapes. In this approach, the vehicle platform represents the component common to all vehicles and can integrate the chassis, powertrain, energy storage, impact management system, and so on. The upper body structure, or "top hat," on the other hand, is offered in several variants, each designed for different purposes depending on the specific requirements of the customer.

[0003] Purpose-built vehicles (PBVs) can be designed for specific applications such as last-mile delivery or autonomous shuttles. They are tailored to specific applications from the outset and, due to standardization efforts, can be mass-produced at a much lower cost than would otherwise be possible. Purpose-built EV platforms can not only offer lower material costs but also superior performance in terms of range, acceleration, and interior space. Furthermore, developing a vehicle architecture based entirely on an EV concept, without the legacy elements of an internal combustion engine, generally results in fewer compromises and greater flexibility.

[0004] The connection between the top hat and the vehicle platform should be as flexible and simple as possible to keep manufacturing costs low. Future smart factories will have a production environment where manufacturing facilities and logistics systems largely self-organize to produce the desired products without human intervention. As a prerequisite for such automated manufacturing approaches, the assembly system should have as few mechanical connections as possible and should not require welding.

[0005] For example, US Patent 5,716,155 A describes a T-shaped connecting frame for joining vehicle frames.

[0006] In a generic manner, US 5,271,687 A discloses an assembly system for connecting an upper body structure of a motor vehicle to a vehicle platform of the motor vehicle, comprising a hollow column element configured to be arranged longitudinally along a vertical vehicle axis, a hollow side sill element configured to be arranged longitudinally along the vehicle's longitudinal axis, the side sill element having fastening notches extending longitudinally along the side sill element and receiving complementary clip arms formed on an underside of the connector to fasten the connector on top of the side sill element.

[0007] DE 693 04 125 T2 describes a connecting piece for an intermediate frame in a motor vehicle, comprising a plurality of components in at least two dimensions, consisting of an inner panel, an outer panel located at a distance from said inner panel and substantially parallel to it, a connecting panel attached to said inner and outer panels and substantially perpendicular to said inner and outer panels to form a channel, generally having a rectangular shape, with an open end opposite said connecting panel, the channel forming an extension to accommodate one of the components;at least one extension part, which is attached to said connecting panel, said inner panel and said outer panel, and extends outwards from there to form a second extension in relation to the first extension, and which is suitable for being fitted inside another of the components to form a connection between them; wherein said extension part has two side walls and end walls to form a generally rectangular, tubular shape.

[0008] The JP H04 - 297 380 A provides a frame construction of a vehicle body in which a lower end of a front pillar extending over a vehicle is connected to a front end of a side frame in a vehicle cabin section, wherein the side frame is forked at the connecting section of the front pillar, one of the branches extends forward of the vehicle, a front suspension mounting part is formed, and both extension parts continue in the vehicle width direction by passing around the front of the vehicle, and the other branch is connected to the opposite suspension mounting part in the vehicle width direction.

[0009] US Patent 2010 / 0244497A1 further shows a first split bracket that is joined to a first tubular frame by laser welding. A second split bracket is joined to an end section of a second tubular frame by laser welding. The second tubular frame, fitted with the second split bracket, is assembled with the first tubular frame, which also fitted with the first split bracket. A second flange of the first split bracket and a second flange of the second split bracket are temporarily joined by spot welding. The second flange of the first split bracket and the second flange of the second split bracket are then permanently joined by continuous laser welding.In this way, the tubular frames can be properly joined without creating a hole in a wall of the tubular frame, thus ensuring the rigidity of the joint section of the tubular frames. Overview of the invention

[0010] It is therefore an object of the present invention to provide simple and cost-efficient solutions for joining structural body parts of purpose-built vehicles.

[0011] The problem is solved by an assembly system with the features of claim 1 and a motor vehicle with the features of claim 8. Advantageous further developments are found in the dependent claims.

[0012] According to one aspect of the invention, an assembly system for connecting an upper body structure of a motor vehicle to a vehicle platform of the motor vehicle comprises a hollow column element configured to be arranged longitudinally along a vertical vehicle axis; a fastening clamp configured to laterally engage a lower end of the column element and having multiple fastening interfaces for attaching the fastening clamp to the column element at the lower end;a hollow plug-in connector designed to be arranged laterally along a longitudinal axis of a vehicle, wherein the plug-in connector defines a mounting platform having a horizontal support surface for the column element to be arranged thereon at its lower end together with the fastening clamp and a vertical joining surface for abutting a corresponding joining surface of the fastening clamp, wherein the fastening clamp has several fastening interfaces for attaching the fastening clamp to the plug-in connector at its joining surface;and a hollow side sill element designed to be arranged longitudinally along the longitudinal axis of the vehicle, wherein the side sill element is designed with fastening notches extending longitudinally along the side sill element and designed to receive complementarily shaped clip arms formed on an underside of the plug-in connector to fasten the plug-in connector on top of the side sill element.

[0013] According to another aspect of the invention, a motor vehicle, in particular a purpose-built vehicle, comprises an upper body structure which is attached to a vehicle platform by means of a mounting system according to the invention.

[0014] One aspect of the present invention is to provide a connection between a column element and a side sill that is as simple and lightweight as possible, yet flexible, effective, and automatable. To achieve this, the present invention connects the column to the side sill by means of a positive-locking push-fit and / or snap-fit ​​connector, which can be easily attached to the side sill at any point along its length and fixed in place by snapping the clip arms into the mounting notches once the desired position is reached. The push-fit connector is provided with a suitable mounting platform that automatically ensures the alignment of the column with the push-fit connector. The column, together with the mounting clamp, simply needs to be placed onto the mounting surface of the push-fit connector so that it rests against the vertical joining surface of the push-fit connector.Then both components can be attached to each other via the mounting interfaces of the mounting clamp.

[0015] It is understood that the term "vehicle" as used herein, or any other similar term, includes motor vehicles in general, such as passenger cars, including sport utility vehicles (SUVs), buses, trucks, various commercial vehicles, and the like, as well as hybrid vehicles, electric vehicles, plug-in hybrid vehicles, hydrogen-powered vehicles, and other vehicles with alternative fuels (e.g., fuels derived from resources other than petroleum). For the purposes of this document, a hybrid vehicle is understood to be a vehicle that has two or more energy sources, for example, both gasoline-powered and electrically powered vehicles.

[0016] Advantageous designs and further developments result from the sub-requirements.

[0017] According to a further development of the invention, the column element can be formed by extrusion along its longitudinal extent.

[0018] The invention can therefore rely on a cost-effective extrusion technology to form a hollow, elongated column element by pressing the material through a die using a punch or similar device, e.g. a metal material such as aluminum or similar.

[0019] According to a further development of the invention, the fastening clamp can be formed by extrusion. The fastening clamp can have two separate clamp arms, each clamp arm being designed to grip one lateral half of the column element at its lower end.

[0020] According to a further development of the invention, the fastening interfaces of the fastening clamp can have fastening holes for receiving rivets and / or screws.

[0021] By dividing the clamp into two separate arm or shell parts, the assembly process can be kept as simple as possible. The two arms of the clamp simply need to be brought together around the lower end of the column element. The arms can then be attached to the column element using the mounting interfaces and / or an adhesive.

[0022] According to a further development of the invention, the push-on connector can be formed by extrusion along its lateral extent.

[0023] For example, blind rivet nuts and screws offer versatile solutions for fastening flexible nut / bolt threads to thin-walled metal parts, such as those used in the present invention. For this purpose, holes can be pre-drilled or punched in the fastening clip and / or other components of the present system. Blind nuts represent a very effective solution when load-bearing threads are required in thin-walled materials or profiles, as in the present case. They can be installed "blind" (from only one side) without post-processing and without damaging the pre-treated surfaces.

[0024] Especially in the fast-paced automotive industry, where components must withstand high stresses, the demands on fastening technology are high. Besides one-sided accessibility, the ease of detaching the fastener is also crucial, for example, with regard to recyclability. These complex requirements can be met by using friction and / or flow-drilling screws, which can fasten thin sheets and profiles made of steel and / or aluminum with excellent quality and without pre-drilling. Steps such as pre-drilling or pre-punching are no longer necessary. These screws penetrate the layers, extrude a short projection, form their own thread, and exert a clamping force between the layers. The increased thread engagement in the formed tension creates a high-strength screw connection without undesirable metal chipping.The screw connection is capable of transmitting both high pull-out and shear forces.

[0025] However, it is understood that other fasteners, in particular various types of rivets, bolts and / or screws, may also be used for the present purpose.

[0026] According to a further development of the invention, the push-on connector can be formed by extrusion along its lateral extent.

[0027] Extrusion can form a hollow monolithic element that not only has integrated fastening elements (such as the clamp arms in this case) but also stiffening structures such as ribs or the like, which run along the extrusion direction of the component.

[0028] According to a further development of the invention, the side sill element can be formed by extrusion along its longitudinal extent.

[0029] As with the clip arms of the plug-in connector, the fastening notches can also be easily formed into the component in a single production step by extrusion.

[0030] According to a further development of the invention, the column element, the fastening clamp, the plug-in connector and / or the side sill element can comprise aluminium.

[0031] In recent years, the automotive industry has made significant efforts to reduce vehicle weight. Faced with stricter regulations and strong consumer demand for fuel efficiency, aluminum has become the material of choice for many applications. In many cases, it has replaced high-strength steel in the body structure. The material is easy to work with, has a low density resulting in lightweight components, and is corrosion-resistant. Furthermore, aluminum is very easy to recycle. Due to its unique properties, aluminum is much easier to process than other metals. Combined with its high durability, it offers a very cost-effective solution for all types of profiles.

[0032] According to a further development of the invention, the fastening clamp can be glued to the column element.

[0033] The fastener can be attached to the mounting bracket not only using mechanical fasteners. Additionally or alternatively, the contact surfaces can be coated with a suitable adhesive to create a permanent and robust bond between the components.

[0034] According to a further development of the invention, the fastening clip can be glued to the plug-in connector at its joining surface.

[0035] For example, a cold-curing epoxy adhesive may be suitable for this purpose, particularly with regard to intelligent, automated production. Vehicle manufacturers are increasingly relying on adhesives as a primary joining method, moving away from conventional methods such as mechanical fastening and welding. This joining technique has proven highly effective, resulting in rigid, lightweight structures that are cost-efficient. However, the adhesives used are often still single-component, epoxy-based adhesives that require high temperatures (e.g., around 200 °C) to cure and achieve optimal performance.With the introduction of cold-curing adhesives (curing at temperatures below 100°C or even 70°C and below), the need for costly curing ovens is eliminated, resulting in direct cost savings through reduced energy consumption and a reduction in thermal deformation, making them an ideal joining technology for automated manufacturing.

[0036] According to a further development of the invention, the plug-in connector can be riveted and / or screwed to the side sill element on the clip arms.

[0037] The positive-locking snap connection between the clamp arms of the plug-in connector and the mounting notches of the side sill can thus facilitate pre-assembly of the components, while additional mechanical connecting elements can be used for a permanent connection and / or temporary fixing during further manufacturing.

[0038] According to a further development of the invention, the plug-in connector is glued to the side sill element.

[0039] As with the other components, mechanical fasteners can also be supplemented and / or replaced by adhesive bonds in this case.

[0040] The present invention will be explained in more detail below with reference to the exemplary embodiments shown in the schematic figures. Brief description of the characters

[0041] The accompanying figures are intended to provide a further understanding of the invention and form an integral part of the present invention. They illustrate embodiments of the invention and, in conjunction with the description, serve to explain the principles and concepts of the invention. Other embodiments of the invention and many of the advantages mentioned above will become apparent with regard to the following detailed description. The elements in the drawings are not necessarily shown to scale. In the figures, identical reference numerals denote identical or functionally equivalent elements, unless otherwise stated. In Fig. Figure 1 schematically shows a motor vehicle with an assembly system according to an embodiment of the invention. Fig. Figure 2 is a perspective view of a column element used in the assembly system of Fig. 1 is used. Fig. 3 is a perspective view of a mounting bracket, which is used in the mounting system of Fig. 1 is used. Fig. 4 is a cross-sectional view of a push-fit connector, which is used in the assembly system of Fig. 1 is used. Fig. 5 shows the column element made of Fig. 2 with mounted mounting bracket made of Fig. 3. Fig. 6 shows the assembly made of Fig. 5, which are on the plug-in connector Fig. 4 is mounted. Fig. Figure 7 is a cross-sectional view of the connection between the push-on connector made of Fig. 4 and a side sill element, which is part of the assembly system of Fig. 1 is used. Fig. Figure 8 shows the component groups of the Fig. 6 and Fig. 7 in a single perspective view. Detailed description of the exemplary implementations

[0042] In Fig. Figure 1 schematically shows a motor vehicle 10 with an assembly system 1 according to an embodiment of the invention.

[0043] The vehicle 10, for example, can be a purpose-built electric vehicle with a modular design based on two main components: the vehicle platform 12, or skateboard, and the upper body structure 11, or top hat. The vehicle platform 12 represents the common underpinnings of the electric vehicle, encompassing the chassis, powertrain, electric batteries, etc. The upper body structure 11, on the other hand, can be supplied in various versions to serve different purposes depending on the customer's needs (e.g., freight transport such as last-mile delivery, passenger transport such as autonomous shuttle services, buses, taxis, and so on).

[0044] In the exemplary embodiment of the Fig. 1. The vehicle platform 12 has a flat shape, while the upper superstructure 11 has a tubular shape, which is based on tubular 3D structures. As in Fig. As can be seen on the left, arc-shaped and lateral structural segments 13 are arranged one behind the other along a longitudinal vehicle axis X, which, as in Fig. 1 shown on the right, are connected to each other by longitudinal structural segments 14. Each of the lateral structural segments 13 is connected to the vehicle platform 12 on both sides of the vehicle 10 via a mounting system 1, as shown below with reference to Fig. 2 to 8 will be explained.

[0045] It goes without saying that the shape and configuration shown is merely an example. Other shapes and configurations are of course possible. The exemplary embodiment shown can offer particular advantages with regard to the automated production of various PBV hats.

[0046] The assembly system 1 comprises a hollow column element 2 according to Fig. 2, which is formed along its longitudinal extent by extrusion and is designed for arrangement in the longitudinal direction along a vertical vehicle axis Z.

[0047] The mounting system 1 further comprises a fastening clamp 3, as shown in Fig. Figure 3 shows a clamping bracket 3, which is designed to laterally grip a lower end 2a of the column element 2. The clamping bracket 3 is a two-part component with two separate clamping arms 6, each clamping arm 6 being designed to grip a lateral half of the column element 2 at its lower end 2a. Both clamping arms 6 can also be manufactured by extrusion, e.g., together in a single manufacturing step.

[0048] The fastening clamp 3 has several fastening interfaces 3a for attaching the fastening clamp 3 to the column element 3 at its lower end 2a. In the illustrated exemplary embodiment, each fastening interface 3a is designed as a pre-formed fastening hole for receiving mechanical fasteners, e.g., blind rivets or similar.

[0049] Fig. Figure 5 shows the column element 2 after the fastening clamp 3 has been attached to its lower end 2a (see also Fig. 6) In this exemplary case, the fastening clamp 3 is attached to the column element 2 by eight mechanical connecting elements.

[0050] The connection between the column element 2 and the fastening clamp 3 can be reinforced by coating the joining surfaces of one or both components with a suitable adhesive, e.g. a cold-curing epoxy adhesive, before the two components are brought into contact with each other and the connection is fixed using the mechanical fasteners.

[0051] The assembly system 1 further comprises a hollow push-fit connector 4, which is in Fig. Figure 4 shows a cross-sectional view. The push-fit connector 4 is extruded along its lateral extent and designed for lateral arrangement along the vehicle's longitudinal axis X. The push-fit connector 4 defines a mounting platform 4d on its upper side, which has a horizontal support surface 4a for the column element 2, which is to be arranged on it at its lower end 2a together with the mounting bracket 3, and a vertical joining surface 4b for abutting a corresponding joining surface 3b of the mounting bracket 3. The mounting bracket 3 has several fastening interfaces 3a on its joining surface 3b for attaching the mounting bracket 3 to the push-fit connector 4, which in this case are also designed as fastening holes. For this purpose, the push-fit connector 4 can also be provided with pre-drilled and / or pre-punched fastening holes (not shown in the figures).

[0052] Fig. Figure 6 shows the assembled structure consisting of column element 2, mounting bracket 3, and push-fit connector 4. As can be seen here, the mounting bracket 3 is attached to the push-fit connector 4 by means of four mechanical connecting elements. In this case as well, the connection can be reinforced by using a suitable adhesive on some or all of the contact surfaces.

[0053] In Fig. 7 and Fig. 8 The mounting system 1 further comprises a hollow side sill element 5, which is formed along its longitudinal extent by extrusion. The side sill element 5 is designed to be arranged longitudinally along the vehicle's longitudinal axis X. It is provided with fastening notches 5a extending longitudinally along the side sill element 5, which are designed to receive complementarily shaped clip arms 4c formed on an underside 4e of the plug-in connector 4 in order to fasten the plug-in connector 4 to the upper side of the side sill element 5.

[0054] As from Fig.As can be seen in Figure 8, the extruded profiles used in the present system 1 can be provided with stiffening structures, e.g., ribs, to achieve an optimal strength-to-weight ratio. In the embodiment shown, both the side sill element 5 and the plug-in connector 4 are provided with ribs on the inside that run along the longitudinal axis X of the vehicle.

[0055] The push-fit connector 4 simply needs to be placed onto the side sill element 5 and pressed downwards to engage the clip arms 4c in the mounting notches 5a. After this pre-assembly, the push-fit connector 4 can still be moved along the longitudinal axis X by shifting and / or offsetting the two components relative to each other along the mounting notches 5a. Once a suitable mounting position is reached, the push-fit connector 4 can be permanently fastened to the side sill element 5 using mechanical fasteners, e.g., self-drilling screws.

[0056] In this case, too, an adhesive can be applied to the underside 4e of the snap-on connector 4 to further reinforce the connection with the side sill element 5. In this case, the adhesive must be applied before the connector 4 is snapped onto the side sill element 5. However, it can also be cured after the connector 4 has been attached to the side sill element 5 using the mechanical fasteners. The mechanical fasteners can only secure the exact position of the connector 4 while the adhesive cures and can then be removed. In this case, the adhesive can ensure the permanent bond between the two components.

[0057] The assembly system 1 described here is highly efficient yet cost-effective and compatible with automated manufacturing in a smart factory environment (without paint shop and welding shop). System 1 offers simple assembly based on few parts, using an interlocking snap connection for pre-assembly and a cold-curing adhesive for a permanent bond.

[0058] In the preceding detailed description, various features have been summarized in one or more examples to improve the clarity of the presentation. However, it should be clear that the above description is merely illustrative and not limiting. It serves to cover all alternatives, modifications, and equivalents. Many other examples will be immediately clear to the person skilled in the art based on their technical knowledge, given the description above. The exemplary embodiments were selected and described to demonstrate the principles underlying the invention and its practical applications, thus enabling those skilled in the art to optimally modify and utilize the invention and its various embodiments with regard to their intended purpose. Reference symbol list 1 Mounting system 2 column elements 2a lower end 3 Mounting bracket 3a Mounting interface 3b Joining surface of the clamp 4 push-on connectors 4a Support surface 4b vertical joining surface 4c Cliparm 4D assembly platform 4e Underside 5 side sill element 5a Mounting notch 6 clamp arm 10 motor vehicle 11 upper body structure 12 vehicle platforms 13 lateral structural segment 14 longitudinal structural segment X Vehicle longitudinal axis Y vehicle transverse axis Z vertical vehicle axis

Claims

[1] Assembly system (1) for connecting an upper body structure (11) of a motor vehicle (10) to a vehicle platform (12) of the motor vehicle (10), comprising: a hollow column element (2) which is designed to be arranged longitudinally along a vertical vehicle axis (Z); a fastening clamp (3) which is designed to laterally grip a lower end (2a) of the column element (2) and which has several fastening interfaces (3a) to fasten the fastening clamp (3) to the column element (2) at the lower end (2a); a hollow plug-in connector (4) designed to be arranged laterally along a longitudinal axis (X) of a vehicle, wherein the plug-in connector (4) defines a mounting platform (4d) having a horizontal support surface (4a) for the column element (2) to be arranged thereon at its lower end (2a) together with the fastening clip (3) and a vertical joining surface (4b) for abutting a corresponding joining surface (3b) of the fastening clip (3), wherein the fastening clip (3) has several fastening interfaces (3a) for attaching the fastening clip (3) to the plug-in connector (4) at its joining surface (3b); and a hollow side sill element (5) which is designed to be arranged longitudinally along the longitudinal axis (X) of the vehicle, wherein the side sill element (5) is designed with fastening notches (5a) which extend longitudinally along the side sill element (5) and are designed to receive complementary shaped clip arms (4c) which are formed on a bottom side (4e) of the plug-in connector (4) to fasten the plug-in connector (4) on top of the side sill element (5). [2] Assembly system (1) according to claim 1, wherein the column element (2) is formed by extrusion along its longitudinal extent. [3] Mounting system (1) according to claim 1 or 2, wherein the fastening clamp (3) is formed by extrusion and has two separate clamp arms (6), each clamp arm (6) being designed to engage one lateral half of the column element (2) at its lower end (2a). [4] Mounting system (1) according to any one of claims 1 to 3, wherein the fastening interfaces (3a) of the fastening clamp (3) have fastening holes for receiving rivets and / or screws. [5] Assembly system (1) according to any one of claims 1 to 4, wherein the plug-in connector (4) is formed by extrusion along its lateral extent. [6] Assembly system (1) according to any one of claims 1 to 5, wherein the side sill element (5) is formed by extrusion along its longitudinal extent. [7] Mounting system (1) according to any one of claims 1 to 6, wherein at least one of the column element (2), fastening clamp (3), plug connector (4) and side sill element (5) comprises aluminium. [8] Motor vehicle (10) with an upper body structure (11) which is attached to a vehicle platform (12) by a mounting system (1) according to any one of claims 1 to 7. [9] Motor vehicle (10) according to claim 8, wherein the fastening clip (3) is glued to the column element (2). [10] Motor vehicle (10) according to claim 8 or 9, wherein the fastening clip (3) is glued to its joining surface (3b) on the plug connector (4). [11] Motor vehicle (10) according to one of claims 8 to 10, wherein the plug-in connector (4) is riveted and / or screwed to the clip arms (4c) with the side sill element (5). [12] Motor vehicle (10) according to one of claims 8 to 11, wherein the plug connector (4) is glued to the side sill element (5).

Images