Method for manufacturing an assembly and subassembly

Abstract

The invention relates to a method for manufacturing an assembly (10) wherein at least two subassemblies (11, 12) are aligned to each other by arranging the subassemblies (11, 12) each on a component (13), and to an assembly.

Description

[0001] The present invention relates to a method for manufacturing an assembly according to the preamble of claim 1, and an assembly according to the preamble of proposition 9.

[0002] In modern car body construction, various components such as longitudinal members, floor assembly, side panels, B-pillars, roof bows, etc., are traditionally assembled to form a body shell. These individual parts consist of different materials, resulting in a material mix within the body shell. When joining the components to form the body shell, they are typically aligned using fixtures such as clamping frames or jigs to ensure they are in the correct position relative to each other before being permanently joined, for example, by spot welding.

[0003] Pre-assembled large modules, such as front ends, rear ends, or underbody, cannot be hot-joined or reliably sealed. Bonding these large modules has become the established practice. Before the adhesive bond is created, the components or large modules to be bonded are typically positioned relative to each other using a separate fixture. Such fixtures for positioning the individual parts are very complex and expensive to manufacture and must meet the highest standards to ensure that the aligned components, or the subsequent body-in-white, meet tolerance specifications.

[0004] The object of the present invention is to provide an alignment concept or a method for manufacturing an assembly or an assembly which overcomes the disadvantages of the prior art.

[0005] This problem is solved by a method according to independent claim 1 and an assembly according to dependent claim 9.

[0006] Advantageous embodiments are specified in the dependent claims.

[0007] To solve this problem, the invention proposes a method for manufacturing an assembly in which at least two sub-assemblies are aligned relative to each other by arranging the sub-assemblies on a component. This offers the advantage that additional positioning aids, such as gauges, etc., can be dispensed with, resulting in a rational and efficient manufacturing process.

[0008] Furthermore, in an alignment position, each subassembly can be aligned to the component using positioning aids. Positioning aids can be, for example, centering pins or probes, which are optionally arranged on the subassembly and / or the component and engage in corresponding openings, such as holes, in the other component, i.e., the component or the subassembly. Slotted holes can also be provided to compensate for tolerances.

[0009] Furthermore, to align the individual subassemblies relative to each other, each subassembly can be aligned with the component. In other words, to align two subassemblies, the first subassembly is connected to the component in its alignment position. Then, the second subassembly is connected to the component in its alignment position. This automatically aligns the two subassemblies correctly, ensuring they are properly aligned and positioned relative to each other.

[0010] In a further step, a material-bonded connection can be made between the subassemblies. This offers the advantage that the subassemblies can be made of a wide variety of materials, which are joined via the material-bonded connection, for example, an adhesive bond.

[0011] Alternatively or additionally, a force-fit connection can be created between the subassemblies. Furthermore, this force-fit connection can also be created between the subassemblies and the component. This additional, second mechanical joining technique using fasteners, such as screws, creates handling strength for the assembly or the body-in-white particularly early in the joining process, allowing the assembly or body-in-white to be moved and repositioned immediately after joining without having to wait for the adhesive to cure.

[0012] The arrangement of mechanical fasteners should be chosen with the largest possible support bases, so that the required forces on the fasteners, such as the bolting forces, and the required size of the fasteners or the bolt size can be reduced. The greater the distance between two adjacent fasteners, the smaller the forces acting on them, and the smaller the fasteners that can be dimensioned. Furthermore, the greater the distance between two adjacent fasteners, the lower the permissible tolerances.

[0013] The frictional connection can be released after a predetermined period. This predetermined period corresponds to the time it takes for the bond to reach sufficient strength. After this period, the assembly can be repositioned without the risk of the subassemblies shifting relative to each other. If an adhesive bond is used, the predetermined period essentially corresponds to the open time of the adhesive. If the frictional connection is created using screws, for example, the fasteners or screws can be loosened and removed after the predetermined period. This offers the advantage of keeping the overall weight of the assembly, and therefore also of the body or the finished vehicle, low and preventing unnecessary increases.Secondly, the connecting elements, such as the screws, can be reused for subsequent assemblies, thus increasing the sustainability of the process.

[0014] Furthermore, the component itself can be designed as a sub-assembly. This component can therefore be assembled from other individual parts.

[0015] Furthermore, the subassembly can be designed as a large module. Large modules according to the invention can be, for example, a pre-assembled front section, a pre-assembled middle section, for example a floor assembly, and / or a pre-assembled rear section.

[0016] In another aspect, the invention relates to an assembly with at least two subassemblies that are aligned with each other, wherein the subassembly is arranged on a component.

[0017] Furthermore, in an alignment position, each subassembly can be arranged on the component using positioning aids.

[0018] Furthermore, the subassembly can be connected via a material-bonded and / or force-fit connection. Alternatively, the material-bonded and / or force-fit connection can be between the subassemblies and / or between the subassemblies and the component.

[0019] The method and device according to the invention offer the advantage of introducing a novel alignment concept in which the large modules front end, center floor, and rear end can be positioned relative to each other in the component side frame by means of geometric features such as positioning aids or recesses in the form of elongated holes or circular bores. This allows for the particularly advantageous production of car bodies or body-in-whites, with the assembly then forming the car body. In car body construction, the side frame provides the essential basis for the overall vehicle. With the vehicle alignment concept according to the invention, using component-integrated features or positioning aids, the manufacturing process for car bodies is simplified, and the investment required for equipment such as clamping frames and the like is reduced.

[0020] The invention will now be explained in more detail with reference to the figures. Fig. Figure 1 shows a perspective side view of an assembly. Fig. Figure 2 shows a perspective side view of an alternative embodiment of an assembly.

[0021] In Fig. Figure 1 shows a tolerance and alignment concept for large modules. Assembly 10 comprises a first subassembly 11, shown here as an example of a large module front section. A further subassembly 12 is shown as a second subassembly, figuratively represented as a large module center section or large module base assembly. A third subassembly 14 is shown as an example of a large module rear section. Each of the subassemblies 11, 12, 14 is connected to a component 13, shown here as an example of a side frame assembly, via positioning aids 20, 21. The positioning aids can be, for example, positioning pins or positioning studs, which are arranged, for example, on the large module front section 11 and engage in openings or holes 20 or elongated holes 21 provided in component 13 or in the side frame. Of course, the positioning studs and pins can also be provided on the side frame 13 and engage in openings 20 or 21.21 penetrate the large module front carriage.

[0022] The positioning aids 20 are so-called full fixtures. Full fixtures fix the subassemblies 11, 12, 14 in the vehicle longitudinal direction x and in the vehicle vertical direction z relative to the component 13. The positioning aids 21, shown as elongated holes 21, fix subassemblies 11, 12, 14 in the vehicle longitudinal direction x or in the vehicle vertical direction z relative to the component 13. This allows freedom of movement and thus tolerance compensation in the unfixed direction, i.e., in the vehicle vertical direction y or vehicle longitudinal direction x. At least two positioning aids are required per subassembly 11, 12, 14 to prevent rotation about the vehicle transverse axis y.

[0023] Connecting elements for creating a force-fit connection are not shown in the figures. Preferably, however, the connecting elements are arranged in the subassemblies 11, 12, 14 or the side frame 13 at locations with high strength values. Such locations would be, for example, in the large-module front end, the lower area of ​​the bulkhead and the area where the strut mount of the front suspension is supported. In the side frame 13, connecting elements are preferably arranged in the front footwell area, in the overlap area of ​​the A-pillar with the large-module front end 11, or in the area of ​​a B-pillar (not shown in the figures).

[0024] An adhesive gap K1 is shown between the first subassembly 11 and the second subassembly 12. A second adhesive gap K2 is shown between the second subassembly 12 and the third subassembly 13. Besides creating a material-bonded connection between the respective subassemblies 11 and 12 or 12 and 14, the adhesive gaps also compensate for tolerances. Furthermore, the adhesive can also be used to fill cavities and thus seal the subassemblies 11, 12, 14, and component 13, protecting the subassemblies 11, 12, 14, component 13, and ultimately the assembly 10 from corrosion. This eliminates the need for polyvinyl chloride (PVC) as a sealant.

[0025] Fig. Figure 2 shows an alternative embodiment of the assembly made of Fig. 1, where identical reference numerals denote the same components. The ones in the Fig. The assembly shown in Figure 2, assembly 10, differs from the one shown in Figure 2. Fig. 1 shown assembly by the shape of the large module rear structure 14, which is arranged at least partially above the large module floor group 12.

Claims

[1] Method for manufacturing an assembly (10) wherein at least two subassemblies (11, 12) are aligned to each other by arranging the subassemblies (11, 12) on a component (13) each. [2] Method according to claim 1, characterized by , that in an alignment position each subassembly (11, 12) is aligned to the component (13) via positioning aids (14). [3] Method according to claim 2, characterized by , that in order to transfer the individual subassemblies to each other into an alignment position, each subassembly (11, 12) is aligned with the component (13). [4] Method according to any one of the preceding claims, characterized by the step: Creating a material-bonded connection between the subassemblies (11, 12). [5] Method according to any one of the preceding claims, characterized by the step: Creating a force-fit connection between the subassemblies (11, 12). [6] Method according to any one of the preceding claims, characterized by , that the component (13) is a subassembly. [7] Method according to any one of the preceding claims, characterized by , that that the sub-assembly is a large module. [8] Method according to any one of the preceding claims, characterized by , that the first sub-assembly (11) is a front section, the second sub-assembly (12) is a floor assembly and the component (13) is a side frame. [9] Assembly (10) comprising at least two subassemblies (11, 12) which are aligned with each other, wherein the subassemblies (11, 12) are each arranged on a component (13). [10] Assembly according to claim 9, characterized by , that in an alignment position each subassembly (11, 12) is arranged on the component (13) via positioning aids (14). [11] Assembly according to claim 10, characterized by, that the subassemblies (11, 12) are connected via a material-bonded and / or force-bonded connection.

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