Method for mounting a battery unit, vehicle and production method

Abstract

The invention relates to a method (100) for mounting a battery unit (10) on a vehicle body (20) of one of several body types (2) with different passenger compartment lengths (21), wherein the battery unit (10) is suitable for mounting on each of the body types (2), the method comprising (100): providing the vehicle body (20) with a base structure (22) of a passenger compartment (23), which defines a passenger compartment length (21) which is specific to the body type (2), and has, for fastening the battery unit (10), a rear-side fastening region (26) and a front-side fastening region (27) which extends from a passenger compartment limit (25) of the passenger compartment (23) towards the rear-side fastening region (26). The invention also relates to a vehicle (1) and to a production method (200).

Description

[0001] Description

[0002] Method for assembling a battery unit, vehicle and manufacturing method

[0003] The invention relates to a method for mounting a battery unit on a vehicle body, a vehicle and a manufacturing method for manufacturing vehicles.

[0004] It is known from the prior art to mount vehicle batteries underneath the passenger compartment of a vehicle, so that a vehicle battery mounted there, with its battery housing, forms an underbody of the respective vehicle. For example, such a vehicle battery with a modular design is known from document US 2018 / 0108890 A1.

[0005] However, especially in platform-based production, it is desirable to also design the battery unit as a common component for multiple body types, especially vehicle variants with different wheelbases. At the same time, however, the space available for the battery unit beneath the passenger compartment also varies with different wheelbases.

[0006] Therefore, it is also known to mount the battery unit in a front mounting area of ​​the body and to vary the rear mounting area depending on the wheelbase. This typically involves changing the position of a rear stop of the body, against which the battery unit rests, relative to the passenger compartment.

[0007] However, with increasing complexity, batteries require additional installation space for superstructures. In particular, if a vehicle's battery is to perform additional control functions, such as battery management and / or charger functions, additional installation space is required beneath the passenger compartment. However, if the position of the rear stop varies relative to the passenger compartment, this additional installation space competes with other superstructures in the passenger compartment, such as a rear seat, which would require the body design to be significantly adapted for each body type. This, however, contradicts platform-based manufacturing.

[0008] It is an object of the present invention to at least partially remedy the above-mentioned disadvantages known from the prior art. In particular, it is an object of the present invention to improve the assembly of a battery unit for platform-based production of multiple body types with different passenger compartment lengths.

[0009] The above object is achieved by a method having the features of claim 1, a vehicle having the features of claim 9, and a manufacturing method having the features of claim 10. Further features and details of the invention emerge from the respective subclaims, the description, and the drawings. Features and details described in connection with the method according to the invention naturally also apply in connection with the vehicle according to the invention and / or the manufacturing method according to the invention, and vice versa, so that reciprocal reference is or can always be made to the individual aspects of the invention with regard to the disclosure.

[0010] According to a first aspect of the invention, a method is provided for mounting a battery unit on a vehicle body of one of several body types with different passenger compartment lengths, wherein the battery unit is suitable for, preferably selectively, mounting on each of the body types, wherein the method, in particular in the form of method steps, comprises:

[0011] Providing the vehicle body with a floor structure of a passenger compartment, which defines a passenger compartment length that is specific to the body type and has a rear fastening area and a front fastening area for fastening the battery unit, which extends from a passenger compartment boundary of the passenger compartment in the direction of the rear fastening area, in particular by producing the vehicle body,

[0012] Providing the battery unit with a battery housing and a control unit for battery management of the battery unit, wherein the battery housing has a first fastening area for fastening to the rear fastening area of ​​the vehicle body and a second fastening area for fastening to the front fastening area of ​​the vehicle body, in particular by manufacturing the battery unit as a uniform battery module for the body types, fastening the first fastening area to the rear fastening area so that the control unit has a mounting distance from the rear fastening area that is defined for all of the body types, in particular by screwing, fastening the second fastening area to the front fastening area depending on the passenger compartment length, in particular by screwing.The term "vehicle" refers, in particular, to a motor vehicle, preferably an electric vehicle. The battery unit can be configured as a high-voltage battery and / or traction battery for driving the vehicle.

[0013] The different body types can be understood, in particular, as body types for different vehicle variants and / or vehicle models. The body types can differ at least in the passenger compartment length to define common parts. Preferably, the body types can be based on a common platform. Preferably, the different body types have different wheelbases. The wheelbase can be directly, in particular proportionally, related to the passenger compartment length.

[0014] The floor structure can be formed, in particular, by a body frame of the vehicle body. The floor structure can, for example, define a specific wheelbase of the body type to be mounted on the vehicle body. The rear fastening area is, in particular, located closer to the rear of the vehicle than the front fastening area. In particular, the rear fastening area is arranged in front of a rear axle of the vehicle. The front fastening area can be formed in a footwell of the passenger compartment. The rear fastening area preferably comprises a thrust field for transmitting force to the floor structure, in particular to a rear end of the vehicle. The thrust field can, for example, be formed by a rear stop against which the battery unit rests after being fastened to the rear fastening area.Preferably, the rear-side fastening area is defined and / or configured uniformly for all body types. The front-side fastening area can extend over a predetermined length, in particular so that the second fastening area of ​​the battery unit is fastened in a section of the front-side fastening area depending on the length of the passenger compartment.

[0015] It can be provided that a structure and / or a design of the front and rear fastening area is defined for all body types, in particular uniformly. The front fastening section can have multiple fastening sections. Depending on the length of the passenger compartment, one of the fastening sections of the front fastening section can be determined for the fastening of the second fastening section. This can, for example, only take place during assembly of the battery unit. The rear fastening area can have a distance from a rear axle of the vehicle that is defined for all body types. The passenger compartment can also be referred to as the vehicle interior. The passenger compartment boundary can be understood as a separation between the passenger compartment and an engine compartment or a trunk, in particular at the front, of the vehicle.The passenger compartment boundary can be part of the vehicle body. Preferably, the passenger compartment boundary can have a specified distance from a front axle of the vehicle for all body types.

[0016] In order to be suitable for installation on each body type, the battery unit can have a uniform battery housing which has a fixed housing length. For each body type, the battery unit can extend between the rear fastening area and a section of the front fastening area. The battery unit preferably has a plurality of battery modules which are arranged in the battery housing. Furthermore, the battery unit can have a uniform battery capacity for all body types. The control unit can preferably comprise a processor and / or microprocessor. Battery management can be understood, for example, as charging and / or discharging management. For example, the performance of the battery modules can be monitored by the battery management.The control unit can be designed as a structure on a plane of the battery housing, so that the control unit extends in the direction of the passenger compartment after the first and second fastening areas have been fastened.

[0017] It can be provided that the mounting distance is defined for all body types in the method. Preferably, the mounting distance is predefined for all body types. The rear fastening area, and in particular thus the control unit, can have a distance from a rear axle of the vehicle that is defined for all body types. The first fastening area can be fastened before the second fastening area is fastened, or the first and second fastening areas can be fastened to the floor structure at the same time. When the second fastening area is fastened depending on the passenger compartment length, a section of the front fastening area to which the second fastening area is fastened can be defined by the passenger compartment length, and the fastening of the first fastening area can be defined by the uniform design of the battery unit for all body types.

[0018] Thus, platform-based production, in which one battery type is used for all body types, can be particularly improved by specifying the rear mounting location and implementing the front mounting location based on that location. In contrast to a contrasting concept, in which the front mounting location is specified and the rear mounting location is implemented based on that location, the mounting distance of the control unit can be kept constant for all body types. This allows the positioning of the control unit in the vehicle to be independent of the footwell, particularly the legroom, within the vehicle.It has thus been recognized within the scope of the invention that the body unit can be adapted to the passenger compartment length and / or the wheelbase by simply extending the passenger compartment if the battery unit is used as a common part for the body types and the position of the control unit is fixed in the rear area.

[0019] Furthermore, in a method according to the invention, it can advantageously be provided that the front-side fastening region is formed by a footwell cross member of the vehicle body and / or the passenger compartment boundary is formed by a firewall. The firewall can separate the engine compartment and / or a front-side trunk of the vehicle from the passenger compartment. For this purpose, the firewall can be designed in one piece or in multiple pieces. In particular, the firewall can extend in a transverse direction of the vehicle between the engine compartment or the trunk and the passenger compartment. In the event of an accident, the firewall can protect the passenger compartment from deformation and / or penetrating parts by the firewall unit absorbing forces and / or deforming itself. The footwell cross member can extend in a longitudinal direction of the vehicle from the firewall towards the rear of the vehicle over the front-side fastening region.In a vehicle transverse direction, which is in particular perpendicular to the vehicle longitudinal direction, the footwell cross member can connect two opposite side members of the floor structure. An advantageous option for attaching the second attachment area of ​​the battery unit can be provided in the area adjacent to the bulkhead and / or on the footwell cross member. In particular, the footwell cross member can provide high strength for mounting the battery unit. Furthermore, the area adjacent to the bulkhead can be advantageous for the front-side attachment area, since additional structural components and / or footwell clearance are provided here, thus providing space for attaching the second attachment area.

[0020] Furthermore, in a method according to the invention, it can advantageously be provided that the vehicle body has a rear seat area for mounting a rear seat unit, wherein the control unit is positioned in the rear seat area by the mounting distance when mounting the battery unit on the vehicle body. The rear seat area can be provided, in particular, below the rear seat unit after the rear seat unit has been mounted. The rear seat unit can comprise one or more rear seats. In particular, the rear seat unit can be configured as a rear bench. The rear seat area can comprise a mounting structure for fastening the rear seat unit.The specified mounting distance of the control unit ensures that the control unit is positioned in the rear seat area for all body types, regardless of the passenger compartment length, if the first mounting area of ​​the battery unit is attached to the rear mounting area of ​​the body unit. The rear seat area thus forms an area where a mounting space for the control unit can be easily defined for all body types, without requiring significant variations across the different body types.

[0021] Furthermore, in a method according to the invention, it can advantageously be provided that the control unit comprises a charging module for charging the battery unit, in particular with a power converter unit. As a result, the control unit can be designed in particular as a charger for charging the battery unit and / or replace an external charger. The power converter unit can, for example, comprise a rectifier for converting an alternating current into a direct current. As a result, the vehicle can be charged, for example, from a domestic connection. The charging module, in particular with the power converter unit, requires installation space, which can be provided with little or no variation across the different body types due to the specified mounting distance for the different body types.

[0022] Furthermore, in a method according to the invention, it can advantageously be provided that the first fastening region is fastened to the rear fastening region and / or the second fastening region is fastened to the front fastening region by a screw connection. The screw connection can comprise a plurality of screws that are distributed along the rear and / or front fastening region. Furthermore, the screw connection can be carried out using self-tapping screws. Additionally or alternatively, the body unit can have threads in the front fastening region for receiving the screw connection. The screw connection can create a detachable connection in order to simplify replacement of the battery unit while the vehicle is in operation.Furthermore, the screw connection can advantageously be made from the underside of the battery unit and / or the vehicle, whereby the assembly can be carried out more conveniently and / or in a shorter time.

[0023] Preferably, in a method according to the invention, it can be provided that the front-side fastening region, the passenger compartment boundary and a stability element which connects the floor structure and the passenger compartment boundary form a space which is at least partially enclosed from the passenger compartment and for which the second fastening region and the front-side fastening region are screwed together. The stability element can, for example, be formed by a support element for supporting the front wall against the floor structure. For example, the support element can comprise a support plate and / or a rib. In the event of a vehicle accident, the support element can thus, in particular, direct forces from the passenger compartment boundary to the floor structure in order to improve the strength of the passenger compartment boundary. The at least partially enclosed space can have a triangular cross-section.A free space for the second fastening area can be created within the space. This allows the second fastening area to be shielded from the passenger compartment, so that the driver is not aware of the second fastening area or does not immediately perceive it. The stability element can, for example, be mounted on the floor structure and the passenger compartment boundary after the second fastening area has been secured to the front fastening area. This can simplify the attachment of the second fastening area.

[0024] Furthermore, in a method according to the invention, it is conceivable that the battery housing has a first housing side, on which the control unit and the first and second fastening regions extend, in particular wherein the first housing side is placed against an underside of the floor structure for fastening the first and second fastening regions. Thus, the first housing side can in particular form an upper side of the battery unit. The first and second fastening regions can run along the first housing side and / or extend on one side of the battery housing between the first housing side and a second housing side which is opposite the first housing side. The control unit can have an additional housing which is mounted on a battery housing for the battery modules, or can be integrated into the battery housing.By mounting it on the underside of the floor structure, the battery unit can be moved towards the floor structure in order to mount the battery unit on the floor structure, in particular through a cell-to-car concept.

[0025] Furthermore, in a method according to the invention, it can advantageously be provided that the second fastening region for fastening to the front fastening region is extended by a structural spacer element depending on the passenger compartment length. The structural spacer element can additionally be arranged on the battery housing in order to enable the fastening of the second fastening region in the front fastening region of the body unit. In this case, the spacer element can be designed purely structurally, i.e. in particular without an additional battery module. As a result, the battery unit can continue to be used as a self-contained unit. At the same time, the distance of the second fastening region from the first fastening region can be increased, whereby the front fastening region is reduced and / or the second fastening region for all body units is at a constant distance from the passenger compartment boundary, i.e.In particular, it can be mounted in a constant section of the front mounting area. This can reduce variation between body types.

[0026] According to a further aspect of the invention, a vehicle is provided. The vehicle comprises a vehicle body and a battery unit, which are assembled by a method according to the invention.

[0027] Thus, a vehicle according to the invention offers the same advantages as those already described in detail with reference to a method according to the invention. The body unit is designed, in particular, as one of at least two different body types on which the battery unit can be mounted.

[0028] According to a further aspect of the invention, a manufacturing method is provided for producing vehicles of at least two different body types, which differ at least in the length of the passenger compartment. The manufacturing method comprises, in particular in the form of method steps:

[0029] Manufacturing a vehicle having a vehicle body of a first body type of the body types, wherein a battery unit suitable for mounting on each of the body types is mounted on the vehicle body of the first body type by a method according to the invention, Manufacturing a vehicle having a vehicle body of a second body type of the body types, wherein another battery unit suitable for mounting on each of the body types is mounted on the vehicle body of the second body type by a method according to the invention.

[0030] Thus, a manufacturing method according to the invention brings with it the same advantages as have already been described in detail with reference to a method according to the invention and / or a vehicle according to the invention. Preferably, in the manufacturing method, a plurality of vehicles with body units of the first body type and a plurality of vehicles with body units of the second body type are produced, in particular in series. In particular, the methods for assembling the vehicle bodies with the first and second body types can be identical or at least substantially identical. The first body type and the second body type have, in particular, a different passenger compartment length and preferably a different wheelbase. The first and second body types can be based on a uniform platform.Further advantages, features, and details of the invention will become apparent from the following description, in which exemplary embodiments of the invention are described in detail with reference to the drawings. The features mentioned in the claims and in the description may be essential to the invention individually or in any combination. They show schematically:

[0031] Figure 1 shows a manufacturing method according to the invention for the production of vehicles,

[0032] Figure 2 shows a method for assembling a battery unit on a vehicle body for manufacturing one of the vehicles,

[0033] Figure 3 the battery unit in perspective view,

[0034] Figure 4 shows a screw connection of the battery unit to vehicle bodies of different body types,

[0035] Figure 5 shows a passenger compartment of a vehicle according to the invention and the battery unit,

[0036] Figure 6 shows a structural spacer element for extending a second fastening area of ​​the battery unit.

[0037] In the following description of some embodiments of the invention, the same reference numerals are used for the same technical features even in different embodiments.

[0038] Figure 1 shows a manufacturing method 200 for producing vehicles 1 with at least two different body types 2.1, 2.2, which have different passenger compartment lengths 21, as shown in Figure 4. In particular, each of the body types 2.1, 2.2 has a wheelbase specific to the respective body type 2.1, 2.2. In this case, a battery unit 10, as shown, for example, in Figure 3, with a control unit 12 for battery management of the battery unit 10 is used as an assembly in the form of a common part. The control unit 12 comprises, in particular, a charging module 16 for charging the battery unit 10 with a power converter unit 17. In the manufacturing method 200, therefore, one of the vehicles 1 is first manufactured with a vehicle body 20 of a first body type 2.1 of the body types 2.1, 2.2. In this case, such a battery unit 10, which is designed for mounting on each of the body types 2.1, 2.2 is mounted on the vehicle body 20 of the first body type 2.1 by a method 100 for mounting a battery unit 10 on a vehicle body 20. Subsequently, a further vehicle 1 is manufactured with a vehicle body 20 of a second body type 2.2 of the body types 2.1, 2.2. During the manufacture of the further vehicle 1, a different, in particular structurally identical, battery unit 10 is mounted on the vehicle body 20 of the second body type 2.2 by a further, in particular identical, method 100.

[0039] According to Figure 2, the method 100 for mounting the battery unit 10 on the vehicle body 20 of the first body type 2.1 comprises providing 101 the vehicle body 20 of the first body type 2.1 with a floor structure 22 of a passenger compartment 23. The manufactured vehicle 1 is shown with the floor structure 22 and the passenger compartment 23 in Figure 5. The floor structure 22 defines the passenger compartment length 21, which is specific to the body type 2.1, 2.2, for example in that the wheelbase of the vehicle body 20 is defined by the floor structure 22. The vehicle body 20 further has a rear seat area 28 for mounting a rear seat unit 30. The floor structure 22 further forms a rear fastening area 26 and a front fastening area 27 for fastening the battery unit 10. The rear fastening area 26 is arranged in a rear of the vehicle 1.The front fastening area 27 extends from a passenger compartment boundary 25 of the passenger compartment 23 in the direction of the rear fastening area 26. The front fastening area 27 is formed by a footwell cross member 22.1 of the vehicle body 20 and / or the passenger compartment boundary 25 is formed by a bulkhead which delimits the passenger compartment 23 from a front end of the vehicle.

[0040] Furthermore, in the method 100, the battery unit 10 is provided 102 with a battery housing 11 and the control unit 12 for battery management. As shown in particular in Figures 3 and 5, the battery housing 11 has a first fastening region 13 for fastening to the rear fastening region 26 of the vehicle body 20 and a second fastening region 14 for fastening to the front fastening region 27 of the vehicle body 20. For this purpose, the battery housing 11 comprises a first housing side 11.1, on which the control unit 12 and the first and second fastening regions 13, 14 extend.

[0041] The assembly of the battery housing 11 comprises, as shown in Figures 4 and 5, fastening 103 of the first fastening region 13 to the rear fastening region 26, so that the control unit 12 has a mounting distance 15 from the rear fastening region 26, which is defined for all of the body types 2.1, 2.2. In particular, the method 100 subsequently comprises fastening 104 of the second fastening region 14 to the front fastening region 27. For this purpose, the first

[0042] - IQ - Housing side 11.1 is placed on an underside of the floor structure 22 and the control unit 12 is positioned by the mounting distance 15 when mounting the battery unit 10 on the vehicle body 20 in the rear seat area 28.

[0043] As shown in Figure 4, the first fastening area 13 is fastened to the rear fastening area 26 and the second fastening area 14 is fastened to the front fastening area 27 by a screw connection. The fastening 104 of the second fastening area 14 to the front fastening area 27 takes place depending on the passenger compartment length 21. For this purpose, the footwell cross member 22.1 in the front fastening area 27 forms a space 27.1 that is at least partially closed off from the passenger compartment 23 with a stability element 29 that connects the floor structure 22 and the passenger compartment boundary 25. The second fastening area 14 and the front fastening area 27 are screwed together for this space 27. It is conceivable that the stability element 29 is installed later. The screw connection is therefore subsequently located in the at least partially closed off space 27.1.Due to the fixed mounting distance 15, a section of the front fastening area 27, in which the screw connection takes place, varies. As a result, the surrounding parts remain at least substantially unaffected by the passenger compartment length 21, so that variation of the body types 2.1 and 2.2 can be reduced.

[0044] In addition or alternatively to the variation of the section of the front-side fastening area 27 in which the screw connection takes place according to Figure 4, the second fastening area 14 for fastening 104 to the front-side fastening area 27 can be extended by a structural spacer element 18 depending on the passenger compartment length 21, as shown in Figure 6. The spacer element 18 can be inexpensive and, for example, can be screwed to the battery housing 11.

[0045] Subsequently, the process 100 is carried out in the manufacturing process 200 for the second body type 2.2 with the identical battery unit 10.

[0046] The above explanation of the embodiments describes the present invention exclusively by way of example. Of course, individual features of the embodiments can be freely combined with one another, provided they are technically feasible, without departing from the scope of the present invention.

[0047] Vehicle first body type second body type

[0048] Battery unit Battery housing first housing side Control unit first fastening area second fastening area Mounting distance Charging module

[0049] Converter unit spacer element

[0050] Vehicle body Passenger compartment lengths Floor structure Footwell cross member Passenger compartment Passenger compartment boundary Rear attachment area Front attachment area Enclosed space Rear seat area Stability element Rear seat unit

[0051] Proceedings

[0052] Providing 20 Providing 10 Attaching 13 Attaching 14

[0053] Manufacturing processes

Claims

Claims 1. A method (100) for mounting a battery unit (10) on a vehicle body (20) of one of several body types (2.1, 2.2) with different passenger compartment lengths (21), wherein the battery unit (10) is suitable for mounting on each of the body types (2.1, 2.2), the method (100) comprising: Providing (101) the vehicle body (20) with a floor structure (22) of a passenger compartment (23) having a passenger compartment length (21) which is suitable for the body type (2.1, 2.2) is specific, defined and has a rear fastening region (26) and a front fastening region (27) for fastening the battery unit (10), which extends from a passenger compartment boundary (25) of the passenger compartment (23) in the direction of the rear fastening region (26), providing (102) the battery unit (10) with a battery housing (11) and a control unit (12) for battery management of the battery unit (10), wherein the battery housing (11) has a first fastening region (13) for fastening to the rear fastening region (26) of the vehicle body (20) and a second fastening region (14) for fastening to the front fastening region (27) of the vehicle body (20), fastening (103) the first fastening region (13) to the rear fastening region (26), so that the control unit (12) has a control unit which is suitable for all of the body types (2.1, 2.2) has a specified mounting distance (15) to the rear fastening area (26). Fastening (104) the second fastening area (14) to the front fastening area (27) depending on the passenger compartment length (21).

2. Method (100) according to claim 1, characterized in that the front fastening region (27) is formed by a footwell cross member (22.1) of the vehicle body (20) and / or the passenger compartment boundary (25) is formed by an end wall.

3. Method (100) according to claim 1 or 2, characterized in that the vehicle body (20) has a rear seat area (28) for mounting a rear seat unit (30), wherein the control unit (12) is defined by the mounting distance (15) is positioned in the rear seat area (28) when mounting the battery unit (10) on the vehicle body (20).

4. Method (100) according to one of the preceding claims, characterized in that the control unit (12) comprises a charging module (16) for charging the battery unit (10) with a power converter unit (17).

5. Method (100) according to one of the preceding claims, characterized in that the first fastening region (13) is fastened to the rear fastening region (26) and the second fastening region (14) is fastened to the front fastening region (27) by a screw connection.

6. Method (100) according to claim 5, characterized in that by the front fastening area (27), the passenger compartment boundary (25) and a stability element (29) which connects the floor structure (22) and the passenger compartment boundary (25), a space (27.1) which is at least partially closed off from the passenger compartment (23) is formed, for which the screw connection of the second fastening area (14) and the front fastening area (27) takes place.

7. Method (100) according to one of the preceding claims, characterized in that the battery housing (11) has a first housing side (11.1) on which the control unit (12) and the first and second fastening areas (13, 14) extend, wherein the first housing side (11.1) is placed on an underside of the floor structure (22) for fastening the first and second fastening areas (13, 14).

8. Method (100) according to one of the preceding claims, characterized in that the second fastening region (14) for fastening to the front fastening region (27) is extended by a structural spacer element (18) depending on the passenger compartment length (21).

9. Vehicle (1) comprising a vehicle body (20) and a battery unit (10) assembled by a method (100) according to any one of the preceding claims.

10. Manufacturing method (200) for manufacturing vehicles (1) of at least two different body types (2.1, 2.2) which differ at least in a passenger compartment length (21), comprising: Manufacturing a vehicle (1) with a vehicle body (20) of a first body type (2.1) of the body types (2.1, 2.2), wherein a battery unit (10) suitable for mounting on each of the body types (2.1, 2.2) is mounted on the vehicle body (20) of the first body type (2.1) by a method (100) according to one of claims 1 to 8, Manufacturing a vehicle (1) having a vehicle body (20) of a second body type (2.2) of the body types (2.1, 2.2), wherein a different battery unit (10) suitable for mounting on each of the body types (2.1, 2.2) is mounted on the vehicle body (20) of the second body type (2.2) by a method (100) according to one of claims 1 to 8.

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