Modular bodyshell structure for a vehicle body

Abstract

The invention relates to a bodyshell structure (1) for a vehicle body, comprising A-pillars (2) and C-pillars (4), wherein a front module (5) comprises the A-pillars (2) and a rear module (7) comprises the C-pillars (4). This structure is characterized in that the A-pillars (2) of the front module (5), together with an upper and at least one lower cross member (21, 22, 23), form a first ring structure (20), wherein the C-pillars (4) of the rear module (7), together with an upper and a lower cross member (41, 42), form a second ring structure (40).

Description

The invention relates to a modular body shell structure for a body of a vehicle. The invention also relates to a method for assembling a body shell structure of a vehicle body.The body shell of a vehicle body consists essentially of a line structure, wherein the body shell structure is assembled from individual elements such as cross members, longitudinal beams, A-pillars, B-pillars, C-pillars and the like. Subsequently, different mounting parts can be arranged and fixed in the body shell structure.If different vehicle construction rows are to be produced, different body shell structures or different bodies must be implemented. In this case, a plurality of different individual elements are necessary, which have to be mounted individually during manufacture in accordance with the respective vehicle series. This results in a high cost and time.DE 10 2010 048 350 A1 discloses a floor assembly for a plurality of construction variants of a body of a vehicle, by means of which costs and a required time outlay during assembly are to be reduced. For this purpose, a front-end module or front-end module overlapping variants and a rear-end module are provided, wherein the two modules are connected to one another via a floor arrangement. Depending on a respective structural variant of the vehicle body, different floor arrangements can be used, so that the same front modules or rear modules can always be used.The proposed modular variant disadvantageously relates only to a floor assembly, wherein a plurality of individually adapted components with high assembly effort is furthermore necessary for further individual vehicle structures or body components.The object of the present invention is now to specify a modular bodyshell structure and a method for assembling such a bodyshell structure, which overcome the aforementioned disadvantages.According to the invention, this object is achieved by a body shell structure having the features of claim 1. Advantageous embodiments and further developments are evident from the dependent claims dependent thereon. Claim 9 also specifies a method for assembling such a bodyshell structure.At least one front module and one rear module are provided in the core of the bodyshell structure according to the invention, wherein the front module comprises the A columns and the rear module comprises the C columns. The modules each form a body shell module or an assembly body shell module. According to the invention, it is the case here that the A-pillars of the front module together with an upper and at least one lower cross member form a first ring structure, and that the C-pillars of the rear module together with an upper and a lower cross member form a second ring structure.A ring structure is to be understood in particular as a closed structure which is circumferential and structurally forms a closed ring. Such a ring structure or circumferentially closed structure has a high stability. The respectively encircling, closed structure can extend in one plane or be designed as a three-dimensional structure which is arranged in two or more intersecting planes. The ring structure offers the advantage of high stability or strength even with relatively little material use. Aspects of lightweight construction can thus be ideally combined with those of the safety, in particular the safety of the passenger compartment. Each of the ring structures comprises the two columns and an upper and a lower cross member. In the region of the front module, the lower cross member can be located in the later vehicle at the bottom or also directly below the later windshield. In principle, a "double ring structure" with both lower cross members mentioned would also be conceivable.In addition, the modular construction offers further advantages, such as the ease of exchangeability of the modules, so that new vehicle variants or shapes can be easily implemented quickly. In particular, the existing manufacturing line in the bodyshell does not have to be changed for this purpose, which is a very decisive advantage.Unlike hitherto, the bodyshell after surface coating, in particular by means of cathodic dip coating (CTL), does not have to be baked as a whole by a drying / stoving furnace. This makes it possible to form the individual modules from different materials, even if these differ greatly in their thermal expansion.A further advantage is the better accessibility of the individual modules both during the pre-assembly of the modules, that is to say also during the assembly of the body shell structure.According to a particularly advantageous embodiment of the modular bodyshell structure according to the invention, a central module can furthermore be provided which comprises the B columns, wherein the B columns of the central module together with an upper and a lower cross member form a third ring structure.The above-mentioned modularity with the stable ring structure is thus extended by a central module. This too is designed to be correspondingly stable and can further reinforce the passenger compartment by the third ring structure, so that the ring structures together also form a type of roll cage, and thus contribute to the safety of the vehicle.As a result, the complete bodyshell can be of modular design, wherein individual modules can be exchanged in order to implement different vehicle variants, such as sedan or wagon and the like. This advantageously results in shorter and more cost-effective change times during the variant formation or during the implementation of new models, since in particular the entire bodyshell installation does not always have to be changed. The entire construction can be made lighter, since double structures can be omitted. Furthermore, a mixed construction can be simplified, since the modules are produced individually and the entire body shell does not have to be guided through the production line during assembly. In particular, the three modules can be preassembled or upgraded separately from one another in secondary lines before assembly. As a result, a main line in assembly can be reduced. A further advantage results during recycling, since simple separation of the individual modules is made possible.Furthermore, elements can be formed on the ring structure which are oriented transversely to the encircling closed structure and thus in the longitudinal direction with respect to the vehicle. Such elements can form, for example, longitudinal member elements, on which the modules can be fixed to one another. As a result, for example, an angled encircling ring structure can be formed, which can be used in particular for the A columns and the C columns. The three ring structures can touch one another in an upper region. Specifically, the ring structure of the A column may contact the ring structure of the B column, and the ring structure of the B column may contact the ring structure of the C column. Advantageously, the ring structures can thus be fixed to one another in a readily accessible manner, whereby assembly is likewise facilitated.According to a very advantageous development of the modular bodyshell structure according to the invention, it can be provided, in particular, but not exclusively, in the case where the modules touch one another in the upper region, that the upper crossmember of the central module is designed as a removable mounting auxiliary carrier. This ensures the stability of the central module via the mounting aid carrier before the mounting and thus for the preassembly, surface coating, etc. In the later body shell structure, other elements can then assume the function, for example, as mentioned above, the upper cross members of the font and / or rear module.According to a very advantageous development of the concept, it can be provided that the ring structure is formed from a high-strength material, such as in particular from steel or aluminum alloys. Thus, the respective ring structure can be produced, for example, from a cast steel or cast aluminum. As a result, it is possible to implement, in particular, delicate columns which only form a very small visible coverage. Small cross sections can positively influence the overall appearance of the vehicle. Furthermore, design freedom results from a separation of the side wall into individual components, with lower restrictions being made possible by pressing, in particular on account of the deep drawability, press size and the like.In particular, the ring structures comprising the B columns and C columns can form a base, wherein the ring structure comprising the A columns or the front module can be embodied as a bionic casting. Thus, for example, the ring structure comprising the A-pillars can also be guided circumferentially around the windshield, wherein the windshield can be formed as far as the B-pillar.In this case, according to an advantageous configuration, it can be provided that the modules are fixed to one another in an assembled state on the ring structures. In particular, a fixing can be effected in the roof region of the later vehicle, which is easily accessible.A further advantageous embodiment can provide that the central module has a main base for the arrangement of at least one battery. The central module can thus have a battery box which is designed in particular as a load-bearing crash structure. In a further embodiment, additionally or alternatively, the B-pillar can be designed to be placed on the battery box. Furthermore, the sill may be integrated in the middle module. Advantageously, not only an efficiency in the use of the surface but also an advantage in compensating tolerances takes place, since the tolerances need not be taken into account from the entire production, but only from this subsystem.Advantageously, by the realization of a central module with a main floor and by the arrangement of at least one battery, double structures can furthermore be avoided. This likewise results in new options with respect to supplier assemblies and self-manufacturing assemblies during assembly or production.According to a very advantageous development of the concept, it can be provided that mounting parts are pre-assembled on the respective module. The mounting parts can advantageously be used when good accessibility to each module is possible by the individual modules. Thus, for example, indirect illumination, in particular transillumination of micro-perforations, attachment of sensors and / or displays and the like can be made possible, wherein the elements can be integrated directly into the outer skin. The improved accessibility makes it possible in particular to facilitate the installation of cable sets and rigid busbars. New packaging spaces can also be used. In one embodiment, for example, the vehicle seats can already be pre-assembled in the central module, wherein these can be easily inserted by a robot because of the good accessibility.The invention further relates to a method for assembling a bodyshell structure. It is proposed that at least two of the modules are connected to one another during assembly, so that a body shell structure is formed. The same features and advantages apply to the method for assembly as already described with respect to the body shell structure.In this case, according to an advantageous embodiment, it can be provided that an outer skin is mounted after the modules have been mounted. For example, the joints of the individual modules can then be covered by fitted outer skin parts. In particular, the outer skin is therefore not designed to be rigid with respect to the body shell. As a result, the outer skin can be coated independently, for example. This enables the use of different coating methods, such as anodizing, seilation and the like. A separate outer skin and the implementation of smaller individual modules also bring advantages in the implementation of surface coatings, in particular cathodic dip coating. Thus, for example, a thicker CTL coating can be made possible with a shorter heating time or cooling time in the CTL furnace. Furthermore, structures made of aluminum can be exposed to higher temperatures, whereby their final strength can be adjusted in an improved manner. Furthermore, a more homogeneous adhesive curing and / or the use of energy-efficient paint systems can be implemented, with a reduced system size. Furthermore, different surfaces or materials, such as in particular also stainless steel, can be used.Thus, dividing the assembly of the body shell structure and the subsequent attachment of the outer skin allows new materials and / or surfaces to be used in the outer skin, since the material does not pass through the surface.The subsequent installation of the outer skin also makes it possible to use construction spaces in the bodyshell structure which, in the case of a conventional construction, would be accessible only with very great effort or not at all.Finally, the effort involved in coating the modules can thus also be reduced, which is sufficient if they are provided with a cathodic dip coating. This saves effort and costs.Further advantageous embodiments of the modular bodyshell structure according to the invention and of the method also result from the exemplary embodiment which is illustrated in more detail below with reference to the figures. The following are shown: FIG. 1 shows different assembly steps of an embodiment of a body shell structure; FIG. 2 shows a schematic illustration of an assembly of a vehicle body; and FIG. 3 shows an exemplary center module with mounting parts.In the illustration of FIG. 1, different assembly steps of an embodiment of a modular body shell structure 1 are shown. The terms of the longitudinal direction L and the transverse direction Q, which apply according to the usual definition, are drawn in FIG. 1 a). The height direction, not shown, perpendicular thereto correspondingly defines the terms top and bottom, which are to be understood in each case with reference to this height direction. The body shell structure 1 has a front module 5, a middle module 6 and a rear module 7. The two A columns 2 are integrated into the front module 5, the two B columns 3 are integrated into the middle module 6, and the two C columns 4 are integrated into the rear module 7. They each form with upper and lower cross members 21, 22; 31, 32; 41, 42 a first, second and third ring structure 20, 30, 40 respectively. This means that the A-pillars 2, B-pillars 3 and C-pillars 4 with the corresponding cross members 21, 22; 31, 32; 41, 42 are each designed as a circumferential construction and thus form a type of ring.An alternative of the front module 5 is indicated in FIG. 1 b). There, instead of or in addition to the lower cross member 22 arranged in the floor area, a lower cross member 23 is shown below the later windshield with a dot-dash line.In this case, two or, as shown in FIG. 1 a), three independent modules 5, 6, 7 can be implemented, wherein in principle, more than three modules 5, 6, 7 would of course also be conceivable. The individual modules 5, 6, 7 can be manufactured independently of one another. This can be done in several outlines of the production, wherein here also pre-assembly of the modules 5, 6, 7 with mounting parts 8, as shown for example in FIG. 3, can already be done. The pre-assembled modules 5, 6, 7 can then be supplied to the assembly of the body shell structure 1 in a finished and tested manner. This can lead to a reduction in the main line of production. The production, pre-assembly and testing could of course also be completely removed from the market, for example to (different) suppliers.The vehicle can then be assembled geometrically in the body shell assembly, wherein the door openings, roof openings can be influenced by the positions of the ring structures. The respective ring structure 20, 30, 40 can be embodied in a plane, such as, for example, the third ring structure 30 of the B column 3 shown, or protrude out of the plane and can be embodied as a spatial ring structure 20, 40, as is illustrated in the region of the A columns 2 or C columns 4. Thus, in particular, the ring structures 20, 40 or the ring structures 30 can also be used to implement longitudinal carrier elements 10 in order to connect the ring structures to one another.During assembly, the three modules 5, 6, 7 can be fixed to one another, as shown in FIGS. 1 b) and c). In this case, the rear module 7 in FIG. 1 b) has two longitudinal member elements 10 which can be connected to the B-pillars 3 of the central module 6. In FIG. 1 c), the first ring structure 20 is per se designed in such a way that longitudinal elements are formed quasi in the first ring structure 20 itself. This is implemented in particular as a spatial structure by the circumferential arrangement of the first ring structure 20 formed out of the plane. This is also substantially embodied in the case of the second ring structure 40 in the rear module 7, although not with an extent in the longitudinal direction L that is as large as in the first ring structure 20.A further variant of the body shell structure 1 can be seen in FIG. 2. The same components are provided with the same reference numerals, so that they need not be discussed in detail here. In contrast to FIG. 1, an outer skin 9 made of a plurality of parts is shown here. This can then be arranged after the modules 5, 6, 7 have been mounted, and in particular can cover the fixing points of the modules.FIG. 3 shows an exemplary central module 6 with mounting parts 8. The mounting parts 8 can be built-in parts such as seats and the like. Furthermore, indirect lighting, sensors and / or displays can be easily preassembled. In particular, the modular construction enables new packaging spaces to be used.The inventive bodyshell structure 1 or the method can accordingly implement a lower variant complexity, wherein the variant formation is implemented in particular only by mounting different modules 5, 6, 7. Thus, by using different rear modules 7, for example, a combi or a sedan can be implemented, while the same designs are used for modules 5 and 6. The central module 6 can be equipped in particular with a battery, wherein accessibility can be improved when the battery is used. The ring structures 20, 30, 40 allow a delicate design to be implemented, which allows a luxurious appearance of the vehicle and a wide variety of designs. In particular, the door openings can be enlarged, and entry during use of the vehicle can be simplified.References included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedDE 10 2010 048 350 A1

[0004]

Claims

Modular body shell structure (1) for a vehicle body, comprising A-pillars (2) and C-pillars (4), wherein a front module (5) comprises the A-pillars (2) and a rear module (7) comprises the C-pillars (4), characterized in that the A-pillars (2) of the front module (5) together with an upper and at least one lower cross member (21, 22, 23) form a first ring structure (20), wherein the C-pillars (4) of the rear module (7) together with an upper and a lower cross member (41, 42) form a second ring structure (40).Modular bodyshell structure (1) according to Claim 1, characterized in that a central module (6) is furthermore provided, which comprises B columns (3), the B columns (3) of the central module (6) forming a third ring structure (30) together with an upper and a lower cross member (31, 32).Modular bodyshell structure (1) according to Claim 2, characterized in that the upper cross member (31) of the central module (6) is designed as a removable mounting auxiliary member.Modular bodyshell structure (1) according to Claim 1, 2 or 3, characterized in that the ring structures (20, 20, 40) are formed from high-strength materials.Modular bodyshell structure (1) according to one of Claims 1 to 4, characterized in that the at least two modules (5, 6, 7) are connected to one another in an assembled state on the ring structures (20, 30, 40).Modular bodyshell structure (1) according to one of Claims 2 to 5, characterized in that the central module (6) has a main floor comprising the lower crossmember (32).Modular bodyshell structure (1) according to Claim 6, characterized in that the main floor is designed to accommodate a traction battery.Modular bodyshell structure (1) according to one of Claims 1 to 7, characterized in that mounting parts (8) are pre-assembled and tested on the respective module (5, 6, 7).Method for mounting a modular bodyshell structure (1) according to one of Claims 1 to 8, characterized in that at least two of the modules (5, 6, 7) are connected to one another during mounting to form the bodyshell structure (1).Method according to claim 9, characterised in that at least two of the modules (5, 6, 7) are connected to one another in the region of their respective ring structure (20, 30, 40) during assembly.Method according to claim 9 or 10, characterised in that an outer skin (9) is applied to the body shell structure (1) after the body shell structure (1) has been mounted thereon.

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