Method for manufacturing a vehicle

Abstract

The invention relates to a method for manufacturing a vehicle in which, in a body-building process step (K), an auxiliary element (H) is detachably mounted to the body shell (41) instead of the B-pillar (3). At least one rear door (40) and optionally one front door (38) are held on the auxiliary element (H), so that the body shell (41) together with at least the rear door (40) is painted in a subsequent painting process step (L).

Description

[0001] The invention relates to a method for manufacturing a vehicle according to the preamble of claim 1 and a vehicle according to claim 9.

[0002] The B-pillar of a two-track vehicle extends vertically between the vehicle's roof structure and a sill at ground level. Together with the front A-pillar and the rear C-pillar, the B-pillar defines the front and rear entry points of the vehicle.

[0003] A generic process for manufacturing such a vehicle comprises the following process steps: a body-in-white process step in which a body-in-white is assembled from side panel assemblies, a floor assembly, a roof assembly, and a rear portal. The assembled body-in-white is then subjected to a subsequent painting process step, in which the body-in-white is, among other things, dip-coated using a cathodic dip coating (e-coating) process. This is followed by a vehicle assembly process step in which the vehicle interior, engine, transmission, etc., are installed.

[0004] In a conventional process sequence, the B-pillar is welded to the body shell during the body-in-white stage. This is then moved to the painting stage. In the subsequent vehicle assembly stage, the painted body shell is fed into an assembly line where, among other things, the vehicle interior, i.e., the seats and cockpit, is installed. During the installation of the interior, the B-pillar acts as an obstruction, limiting access to the body shell. Therefore, the installation of the interior is labor-intensive and ergonomically challenging for the worker. Furthermore, the possibilities for automating the assembly process are limited.

[0005] From DE 10 2019 219 129 A1, a generic method for manufacturing a motor vehicle is known. From DE 10 2019 119 393 A1, a component for a car body is known, which has a base body on which a coating is provided, at least in some areas. This coating is applied by plasma electrolytic oxidation, wherein a primer is applied to the coating, at least in some areas, and wherein the coating serves as an adhesion promoter for the primer. From DE 10 2016 113 491 A1, an armor steel component for a motor vehicle is known, comprising an armor steel molded part which has a paint coating for reducing the impact energy of a projectile, wherein the paint coating has a hardness in a range between 60 and 130. From DE 20 2005 019 619 U1, an assembly system for doors on vehicle bodies is known.

[0006] The object of the invention is to provide a method for manufacturing a vehicle in which the installation of the vehicle interior equipment can be carried out with reduced manufacturing time, reduced manufacturing effort and / or a higher degree of automation compared to the prior art.

[0007] The problem is solved by the features of claim 1 or 9. Preferred embodiments of the invention are disclosed in the dependent claims.

[0008] The invention relates to a method for manufacturing a vehicle with at least one B-pillar. This B-pillar, together with a front A-pillar and a rear C-pillar, defines a front side door opening and a rear side door opening. The method comprises a body-building process step in which a body shell is prepared. This is followed by a painting process step in which the body shell is painted. Finally, a vehicle assembly process step is carried out in which the vehicle interior, the engine, the transmission, etc., are installed in the body shell.According to the characterizing part of claim 1, the following measures are taken to simplify the installation of the vehicle interior fittings in the body-in-white during the vehicle assembly process and to reduce production time: In the body-in-white process, an auxiliary element is detachably mounted to the body-in-white in place of the B-pillar. At least one rear door and, optionally, one front door of the vehicle are held to this auxiliary element. The body-in-white, along with at least the rear door and, optionally, the front door, is painted in the painting process. By providing the auxiliary element (in place of the B-pillar), it is ensured that the body-in-white, along with the rear door and the front door, can be painted together in a single painting process.

[0009] After the painting process and before the start of the vehicle assembly process, the auxiliary element is removed from the painted body shell. This allows the front and rear side door cutouts to seamlessly merge into one another during the vehicle assembly process, forming a large side access opening. This ensures that interior components, such as seats or a cockpit, can be installed into the body shell through this side access opening without any interference.

[0010] To conclude the vehicle assembly process, the B-pillar is mounted to the painted body shell. Subsequently, the front and rear doors are hinged to the A-pillar and B-pillar, respectively, using hinge fittings.

[0011] Correct positioning of the front and rear doors during the painting process is crucial for a flawless paint finish. Therefore, the rear door can be hinged to the auxiliary element using an auxiliary hinge fitting. This auxiliary element can also include a front door attachment point where the rear of the front door can be secured. Thus, the front door is held in place by the auxiliary element during the painting process. Additionally, the front door can also be hinged to the vehicle's front A-pillar via an auxiliary hinge fitting. The auxiliary element, the rear door, and the front door can form a single assembly unit that can be robotically mounted to and removed from the body shell.

[0012] In its completed state, the B-pillar is attached to the vehicle's roof structure at a roof-side connection point and to the vehicle's sill at a rocker-side connection point. These roof-side and rocker-side connection points can be implemented as bolted and / or bonded joints. From a manufacturing perspective, it is simpler if the B-pillar is attached to the body shell from the outside in the vehicle's transverse direction during the vehicle assembly process. For further manufacturing simplification, it is advantageous if both the auxiliary element and the B-pillar can be attached to the body shell at identical connection points.

[0013] According to the invention, the body-in-white, assembled without the B-pillar in the body-in-white process step, is painted in the painting process step. Separately from this painting process step, a coating process step is carried out in which the B-pillar, still without any attached parts, is coated separately from the body-in-white. After this coating process step, a pre-assembly process step is performed in which various functional elements and / or a pillar trim are pre-assembled onto the B-pillar. In an alternative process configuration, the B-pillar and the body-in-white can also be painted simultaneously.

[0014] The painting process step (and possibly also the coating process step) can include a sealing layer e-coating process or an acrylic e-coating process, in which the body shell is dip-coated (UV-resistant, up to a layer thickness of 60 µm), with the color being freely selectable. Additionally, a sill-side door entry area can be coated with a clear coat or a film, especially a design film, during the painting process step.

[0015] An embodiment of the invention is described below with reference to the accompanying figures.

[0016] They show: Fig. Figures 1 to 4 each show different views, illustrating the process for manufacturing the vehicle.

[0017] In the Fig. Figure 1 shows a two-track vehicle in which a side wall assembly of a vehicle body is highlighted in a partial elevation in the vehicle's longitudinal direction x in the central vehicle area. The vehicle body has a side sill 1. A B-pillar 3 of the side wall assembly is arranged in the vehicle's longitudinal direction x between an A-pillar 5 and a C-pillar 14 and connects the sill 1 to a roof structure 7 of the vehicle body in the vehicle's vertical direction z. The B-pillar 3 serves both to stiffen the vehicle body and to accommodate attachments, such as those shown in the Fig. 2 functional elements 20, 21, 23, 24 of a safety belt system 19 shown.

[0018] In the Fig. 2 a pillar cover 17 and the functional elements of the safety belt system 19 are mounted on a sheet metal hollow beam 12 of the B-pillar 3, namely a floor-mounted belt end fitting 21, a belt deflector 24, a belt retractor 20 and a height-adjustable deflector fitting 23 for a safety belt 25.

[0019] According to the Fig. 1 The B-pillar 3 is screwed to the sill 1 at its base section 39 at a sill-side connection point S. In the same way, the B-pillar 3 is screwed to the vehicle roof structure 7 at its head section 37 at a roof-side connection point D.

[0020] The following will be based on the Fig. 3 and Fig. 4 a process chain for the production of the in the Fig. The vehicle shown in step 1 is described as follows: Accordingly, in a body construction process step K ( Fig. 3) First, a body shell 41 is provided, without the B-pillar 3. Instead of the B-pillar 3, an auxiliary element H is installed in the body shell 41. In body construction process step K, the auxiliary element H is detachably attached to the roof-side and sill-side connection points D, S, which are actually intended for attaching the B-pillar 3, using screw connections.

[0021] The auxiliary element H forms according to the Fig. 3 together with a front door 38 and a rear door 40 form a one-piece assembly, which is located in the Fig. 3, top right, shown in isolation. In the assembly, the rear door 40 is connected via an auxiliary hinge fitting 43 ( Fig. 3, below) is hinged to the auxiliary element H. Furthermore, the auxiliary element H has a front door attachment point 44 ( Fig. 3, below) on which the front door 38 is mounted. The front door 38 is furthermore in accordance with the Fig. 3 via an auxiliary hinge fitting 45 ( Fig. 3, bottom) attached to the A-pillar 5.

[0022] The body shell 41 will be produced according to the Fig. 4 together with the auxiliary element H and the front and rear doors 38, 40 are subjected to a painting process step L. In painting process step L, the body shell 41 is provided with a cathodic dip coating, among other things. Independently of this, in a separate coating process step B ( Fig. 4) The still unassembled hollow beam 12 of the B-pillar 3 is coated separately from the body-in-white 41 in a coating process step B. Coating process step B can, for example, also include an e-coating process. After coating process step B, a pre-assembly process step V is carried out in which the functional elements 20, 21, 23, 24, 25 of the seat belt system 19 and the pillar trim 17 are pre-assembled onto the hollow beam 12 of the B-pillar 3. In an alternative process configuration, the B-pillar 3 can undergo painting process step L together with the body-in-white 41.

[0023] Following this, a vehicle assembly process step FM ( Fig.4) is carried out. Before the vehicle assembly process step FM is performed, the auxiliary element H, including the front and rear doors 38, 40, is removed from the painted body shell 41. The front and rear side door cutouts of the body shell 41 thus merge seamlessly into one another, forming a large lateral access opening. This allows the vehicle interior, i.e., vehicle seats or a cockpit, to be installed into the body shell 41 without any interference. To conclude the vehicle assembly process step FM, the still separate B-pillar 3 is mounted to the painted body shell 41. The B-pillar 3 is attached to the roof-side and sill-side connection points D, S from the outside of the vehicle in the transverse direction y using screw connections. Afterwards, the front and rear doors 38, 40 can be hinged to the A-pillar 5 and the B-pillar 3, respectively, via hinge fittings. Reference symbol list 1 sill 3 B-pillar 5 A-pillar 7 Roof structure 9 inner sheet metal part 11 Sheet metal outer part 12 hollow beams 14 C-pillar 17 pillar trim 19 Seat belt system 20 belt retractor 21 End fitting 23 height-adjustable deflection fittings 24 belt guides 25 Seatbelt 37 Head section 38 Front door 39 foot section 40 rear door 41 Body shell 43 Auxiliary hinge fitting 44 Front door connection point 45 Auxiliary hinge fitting K Bodywork process step L Painting process step FM vehicle assembly process step B Coating process step V Pre-assembly process step H Auxiliary element D roof-side connection point S sill-side connection point

Claims

[1] Method for manufacturing a vehicle with at least one B-pillar (3) which together with a vehicle front A-pillar (5) and a vehicle rear C-pillar (14) define a front side door opening and a rear side door opening, the method comprising the following process steps: - a body construction process step (K) in which a body shell (41) is provided, - a painting process step (L) in which the body shell (41) is painted, and - a vehicle assembly process step (FM), characterized by , that in the body construction process step (K) an auxiliary element (H) is detachably mounted to the body shell (41) instead of the B-pillar (3), and that at least one rear door (40) is held on the auxiliary element (H), so that the body shell (41) together with at least the rear door (40) is painted in the painting process step (L), and that the auxiliary element (H) is removed from the painted body shell (41) after the painting process step (L) and before the vehicle assembly process step (FM), so that in the vehicle assembly process step (FM) the front and rear side door cutouts merge seamlessly into one another to form an access opening, in order to insert a vehicle interior fitting into the body shell (41) without interference contours. [2] Method according to claim 1, characterized by , that at the conclusion of the vehicle assembly process step (FM) the B-pillar (3) is mounted to the painted body shell (41), and that subsequently the front and / or rear doors are hinged to the A-pillar (5) and B-pillar (3) via hinge fittings. [3] Method according to any one of the preceding claims, characterized by, that the rear door (40) can be hinged to the auxiliary element (H) via an auxiliary hinge fitting (43), and / or that the auxiliary element (H) and the rear door (40) form a one-piece assembly that can be mounted to or removed from the body shell (41). [4] Method according to any one of the preceding claims, characterized by , that the auxiliary element (H) and the B-pillar (3) can each be attached to the body shell (41) at identical attachment points (D, S), and / or that the attachment points (D, S) are realized as screw points and / or as adhesive points, and / or that the B-pillar (3) is joined to the body shell (41) from the outside of the vehicle in the transverse direction (y) of the vehicle. [5] Method according to any one of the preceding claims, characterized by, that the process includes a coating process step (B) separate from the painting process step (L), in which the B-pillar (3), which is not yet fitted with attachments, is coated with paint separately from the body shell (41), or that in an alternative process configuration the B-pillar (3) goes through the painting process step L together with the body shell (41), and / or that after the coating process step (B) a pre-assembly process step (V) takes place, in which functional elements and / or a pillar cover (17) are pre-assembled onto the B-pillar (3). [6] Method according to any one of the preceding claims, characterized by , that the painting process step (L) includes a thick-film e-coating process or an acrylate e-coating process in which the body shell (41) is dip-coated. [7] Method according to any one of the preceding claims, characterized by, that a sill-side door entry area is coated with a clear coat or a film during the painting process step. [8] Method according to any one of the preceding claims, characterized by , that the auxiliary element (H) has a front door attachment point (44) for holding the rear of the front door, and that a front door (38) is not only held on the auxiliary element (H) during the painting process step (L), but is also hinged to the A-pillar (5) via an auxiliary hinge fitting (45). [9] Vehicle with a B-pillar (3) which is connected to a roof structure (7) of the vehicle at a roof-side connection point (D) and to the sill at a sill-side connection point (S), wherein the vehicle is manufactured in a method according to one of the preceding claims.

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