Method for assembling electric motor vehicles and installation for implementing same

Abstract

The invention relates to a method and an installation for assembling electric vehicles. The method comprises the following steps: providing a front structure comprising two side members and a crossmember (22), and a piece of equipment (44) mounted close to one (14) of the side members and overhanging the crossmember (22); providing a charger (46) having a base (50) and two lateral faces, said charger comprising a connector (56) projecting from one (52) of the lateral faces; moving the charger (46) in line with the crossmember (22) into a position closer to the other side member (12) and orienting the charger (46) such that the connector (56) extends towards the above-mentioned side member (14); and bearing on the crossmember (22) so that it is possible successively to guide the charger (46) vertically towards the crossmember, to guide the charger (46) horizontally towards the aforementioned side member (14), and to guide the charger (46) vertically such that the base (50) bears on the crossmember (22).

Description

DESCRIPTION Title of the invention: Method for assembling electric motor vehicles and installation for implementing it

[0001] [The present invention relates to a method for mass assembly of electric motor vehicles and to an installation for implementing said method.

[0002] Motor vehicles have been mass-produced on assembly lines for a long time.

[0003] Thus, platforms follow one another on the same line and are successively driven from station to station to be able to assemble the different parts of the vehicle on each of the platforms until its final form. Also, productivity constraints encourage manufacturers to constantly increase production rates.

[0004] In order to assemble heavy elements weighing more than 5 kg on these platforms, grippers are generally used, for example of the "sugar tongs" type. Such a gripper has two crossed branches ending in jaws respectively and which allows an element to be suspended between the two jaws, under the effect of its own weight.

[0005] Such a device does not allow for the adjustment of all the required elements on the vehicle under construction at high speeds, because not all of them have a suitable shape. Furthermore, the precision with which certain elements must be adjusted is not compatible with this type of device.

[0006] In addition, in modern vehicles, attempts are made to reduce free spaces, so the various elements must be fitted with great precision so as not to damage those already installed.

[0007] This is particularly the case in electric motor vehicles where the aim is to compact the engine compartment located at the front of the vehicle.

[0008] It is then necessary to approach certain elements, first vertically in line with the engine compartment, then to move them in translation in a horizontal direction and finally to press them onto their support in order to secure them there.

[0009] This applies to the battery charger permanently installed in the engine compartment of electric motor vehicles.

[0010] A problem that arises and that the present invention aims to solve is to provide a method for precisely guiding the charger inside the engine compartment before fixing it, without damaging the elements already installed.

[0011] In order to solve this problem, and according to a first object, a method for mass assembly of electric motor vehicles is proposed, comprising, for each vehicle, the following steps: a front structure of a motor vehicle is provided comprising, on the one hand, two side members spaced apart from each other and a cross member connecting said two side members together, and on the other hand, equipment mounted near one of said side members overhanging said cross member; a storage battery charger is provided having a fixing base and two opposite side faces, said charger comprising a connector extending projecting from one of said side faces; said charger is brought in line with said cross member in a position offset towards the other of said side members and said charger is oriented so that said connector extends towards said one of said side members;and, one takes support against said cross member, in order to be able to successively, vertically guide said loader towards said cross member so that said base extends opposite said cross member, horizontally guide said loader towards said one of said side members, while said connection extends between said equipment and said cross member; and, vertically guide said loader towards said cross member so that said base rests on said cross member in order to be able to secure said base and said cross member.;

[0012] Thus, a characteristic of the invention lies in the support against the cross member which rigidly connects the two side members. Thanks to this support, the charger can first be guided vertically without coming into contact with other pre-installed elements. Then, the charger is guided in horizontal translation to bring it to its final position, while the connection extends under a piece of equipment of the vehicle, and in particular the brake fluid reservoir which is pre-installed. Finally, the charger is guided vertically to rest it on the cross member in its final fixing position. In this way, by guiding the charger inside the engine compartment along a vertical component, then a horizontal component and finally a vertical component, it is adjusted quickly into its terminal position where it is fixed, without damaging the elements pre-installed on the front structure.

[0013] Furthermore, the cross member is advantageously supported by two horizontal components. The support is provided by two horizontal components, both when the loader is driven vertically inside the engine compartment and when it is driven horizontally. In this way, the movement of the loader inside the engine compartment is perfectly controlled.

[0014] Preferably, support is taken in two areas of said crosspiece respectively located near said two side members. In this way, the loader can be perfectly oriented in a horizontal plane as will be explained in more detail in the rest of the description.

[0015] In addition, a front structure of a motor vehicle is advantageously provided comprising a cross member having an oblong slot near said one of said side members for horizontally guiding said loader. Said oblong slot extends in a direction substantially perpendicular to the side members so as to allow horizontal guidance in this same direction. Thus, the edges of the oblong slot will be supported.

[0016] In addition, said oblong light has a general pointed shape oriented towards the spar. In this way, and as will be explained in the detailed description, the final position of the charger is adjusted more precisely during its horizontal translation.

[0017] Furthermore, a front structure of a motor vehicle is provided comprising a cross member advantageously having an orifice towards said other of said side members in order to be able to guide said charger vertically. The edge of the orifice will then be supported during vertical guidance.

[0018] Also, preferably, said base and said crosspiece are secured by means of a plurality of screwing members. Advantageously, the base has perforated peripheral ears, while the crosspiece is pre-equipped with nuts welded at the right angles to the holes. Therefore, an operator can easily insert a screw through the ears and screw them into the nuts.

[0019] According to another object of the invention, there is proposed a series assembly installation for electric motor vehicles, comprising for each vehicle: a platform for receiving a front structure of a motor vehicle comprising, on the one hand, two side members spaced apart from each other and a cross member connecting said two side members together, and on the other hand, equipment mounted near one of said side members overhanging said cross member; a gripper for gripping a storage battery charger having a fixing base and two opposite side faces, said charger comprising a connector extending projecting from one of said side faces; a robot for controlling said gripper to be able to approach said charger in line with said cross member in a position offset towards the other of said side members and to orient said charger so that said connector extends towards said one of said side members.And said control robot is adapted to carry said gripper against said cross member in order to be able to successively, vertically guide said loader towards said cross member so that said base extends opposite said cross member, horizontally guide said loader towards said one of said side members, while said connection extends between said equipment and said cross member; and, vertically guide said loader towards said cross member so that said base rests on said cross member in order to be able to secure said base and said cross member.

[0020] Thus, the robot allows, thanks to the gripper, to grasp the loader and bring it right up to the crossbar so that it can then be installed without damaging the other elements. The gripper is, for example, installed at the end of the robot's terminal arm.

[0021] Such an installation aims to implement the assembly method in accordance with the invention.

[0022] Also, said gripper comprises a frame secured to said control robot and a carriage mounted movable in translation on said frame, said carriage comprising two legs adapted to engage in said two opposite faces of said loader. The two legs can for example be driven by force towards each other against the two opposite faces of the loader to keep it in a fixed position relative to the carriage.

[0023] In addition, the chassis is equipped with an electric cylinder to be able to control the movement of the carriage on the chassis, when driving the loader in horizontal movement.

[0024] Preferably, said chassis comprises a first locating finger, while said carriage comprises a second locating finger. Thus, as will be explained below, the first locating finger is adapted to engage in the hole in the crosspiece, while the second locating finger is adapted to engage in the oblong slot.

[0025] Also, said second locating finger extends towards said one of said lateral faces while said first locating finger extends opposite towards the other of said lateral faces of said charger.

[0026] Other features and advantages of the invention will emerge from reading the description given below of a particular embodiment of the invention, given for informational purposes but not as a limitation, with reference to the appended drawings in which: [Fig. 1] is a partial schematic top view of the front frame of a motor vehicle; [Fig. 2] is a schematic front right profile view of an element of the installation according to the invention; [Fig. 3] is a schematic front right profile view of the object of [Fig. 1] and [Fig. 2] in a first phase of the method according to the invention; [Fig. 4] is a schematic front profile view of the object of [Fig. 1] and [Fig. 2] in a second phase of the method according to the invention; [Fig. 5] is a schematic front right profile view of the object of [Fig. 1] and [Fig. 2] in a third phase of the method according to the invention; [Fig. 6] is a schematic front right profile view of the object of [Fig. 1] and [Fig. 2] in a fourth phase of the method according to the invention; and, [Fig. 7] is a flowchart of the steps of the method according to the invention.

[0027] [Fig. 1] shows a front structure of a motor vehicle 10, seen from above, and it is inscribed in an orthogonal reference frame X, Y, Z, in which the X axis extends in a longitudinal front-rear direction of the motor vehicle, oriented towards the rear; the Y axis extends in a transverse direction of the vehicle, oriented from left to right when in a rolling situation; and the Z axis extends in a vertical direction, oriented away from the ground.

[0028] The front structure 10 shown in [Fig. 1] comprises two substantially parallel side members spaced apart from each other, a right side member 12 and a left side member 14. It also comprises an apron 16 which separates the compartment engine 18 of the passenger compartment 20. And at the front of the apron 16, at the level of the engine compartment 18, the front structure 10 comprises a crossmember 22 which connects the two side members 12, 14 together.

[0029] The cross member 22 is relatively wide. For example, its length, extending from one side member 12 to the other 14, is between three and five times its average width. It has two opposite ends, a right end 13 and a left end 15, respectively screwed onto the side members 12, 14 so as to be perfectly secured thereto. Also, it has two opposite transverse edges, a rear edge 24 and a front edge 26. Each of these edges 24, 26 has two holes 28, 30 each equipped with a welded nut.

[0030] In addition, the crosspiece 22 has a pressed-out central zone 32. And the crosspiece 22 has a circular orifice 34 formed in the pressed-out central zone 32 towards the right end 13 and opposite, an oblong slot 36 also formed in the pressed-out central zone 32 and towards the left end 15.

[0031] The oblong light 36 extends in the longitudinal direction of the crosspiece 22; in other words, in the transverse direction of the front structure 10. And it has a widened end 38, spaced from the left end 15 of the crosspiece 22, opposite a narrow end 40 close to the left end 15. The advantage of such a shape of oblong light 36 will be explained below.

[0032] Furthermore, the front structure 10 also comprises elements of the braking device 42 installed on the bulkhead 16 near the left side member 14 and projecting into the engine compartment 18. The elements of the braking device 42 include in particular the brake fluid reservoir 44 which extends over the cross member 22 towards the left side member and also near the left end 15 of the cross member 22.

[0033] We will now refer to [Fig. 2] illustrating, from the front right profile, a battery charger 46 and a gripper 48 adapted to be moved by a robot not shown. The charger 46 has a generally parallelepiped shape and its weight is around 20 kg.

[0034] The charger 46 has a base 50 and two opposite lateral faces, a left lateral face 52 and a right lateral face 54. Also, the charger 46 has a connector 56 extending in projection from the left lateral face 52. The connection 56 allows the charger 46 to be supplied with a heat transfer fluid in order to be able to evacuate the thermal energy that it accumulates during its charging. And as will be explained in more detail below, it is precisely the protruding connection 56 which makes the mounting of the charger 46 on the front structure 10 more complex.

[0035] Furthermore, the base 50 of the magazine 46 has, in [Fig. 2], two perforated front peripheral ears 58, 60 extending in a projecting manner. Two rear ears not shown are located opposite, and they also extend in a projecting manner from the base 50.

[0036] [Fig. 2] also shows the gripper 48. It has a frame 62 which is integral with the terminal arm of the robot, and a carriage 64 mounted on the frame 62.

[0037] The frame 62 has a table 66 extending along a mean plane Pm and between two opposite ends 68, 70. The table 66 has a lower face 65 opposite an upper face 67. And the two opposite ends 68, 70 define a longitudinal direction D of the table 66.

[0038] The frame 62 also has a lateral arm 72 which extends substantially perpendicular to the table 66, at one 68 of its ends, and in line with the space located under the table 66.

[0039] Furthermore, the lateral arm 72 is equipped with a rod 74 extending in projection opposite the table 66, and which is terminated by a first locating finger 76, which extends perpendicular to the table 66. The first locating finger 76 extends below the level of the base 50 of the loader 46 relative to the level of the table 66.

[0040] The carriage 64 is slidably mounted on the lower face 65 of the table 66, and in a direction parallel to the longitudinal direction D of the table 66. To do this, the table 66 is equipped with a slide 78 oriented in the longitudinal direction D, while the carriage 64 comprises a slide 80 engaging in the slide 78.

[0041] In addition, the gripper is equipped with a recommended cylinder 82 making it possible to drive the carriage 64 in translation relative to the table 60 in a direction parallel to the longitudinal direction D of the table.

[0042] Also, the carriage 64, opposite the table 66, is equipped with two opposite legs, a right leg 84 and a left leg 86. These two legs 84, 86 respectively engage in the two opposite lateral faces 54, 52 of the loader 46 in order to keep it in a fixed position relative to the carriage 64. The loader 46 of generally parallelepipedal shape itself defines a mean plane which is substantially parallel to the mean plane Pm defined by the table 66.

[0043] It will be observed that the left leg 86 extends perpendicularly to the carriage 64, by a second locating finger 88 which extends below the level of the base 50 of the loader 46. In other words, the second locating finger 88 extends opposite the table 66 relative to the carriage 64. It will be observed, however, that the second locating finger 88 extends at a lower level than that of the first locating finger 76.

[0044] Furthermore, it will be observed that, in [Fig. 2], the carriage 64 is in a position close to the lateral arm 72.

[0045] We will now describe with reference to [Fig. 3], [Fig. 4], [Fig. 5], [Fig. 6] and with the support of the flowchart of [Fig. 7], the steps of implementation of the gripper 48 and the front structure 10 to install the loader 46 in the latter.

[0046] Thus, after the steps of developing the front structure 10 and loading the loader 46 onto the gripper 48, as illustrated in [Fig. 2], according to a first assembly step 90, the loader 46 is approached, using the robot, overhanging the cross member 22 in a position offset towards the right side member 12 and the loader 46 is oriented so that the connection extends towards the left side member 14. Thus, during this approach, it will be observed that the rectilinear travel of the connection 56 which projects from the left lateral face 52 of the loader 46, extends next to the brake fluid reservoir 44, without interfering with it.

[0047] And from this position, in a first pressing step 92, the first locating finger 76 is engaged through the orifice 34 as illustrated in [Fig. 3], while the second locating finger 88 is adjusted to the right of the widened end 38 of the oblong slot 36.

[0048] According to a second support step 94, the gripper 48 is further driven vertically towards the crosspiece 22 according to the arrow F so as to engage the second locating finger 88 through the widened end 38 of the oblong slot 36. The engagement of the second locating finger 88 is facilitated, precisely thanks to the widened end 38 which allows a greater degree of freedom in the approach. During this second support step 94, the first locating finger 76 is guided laterally by the edges of the orifice 34, then the second locating finger 88 penetrates through the widened end 38, the edge of which also contributes to the lateral guidance of the gripper 48 as illustrated in [Fig. 4]. Consequently, the gripper 48 is guided vertically in translation relative to the crosspiece 22. Consequently, the loader 46, integral with the gripper 48, is itself guided in vertical translation through the engine compartment 18.

[0049] Also, the gripper 48 is stopped in its vertical travel by the robot, when the base 50 of the loader 46 comes to extend at a distance from the crosspiece 22 of, for example, between 4 mm and 8 mm.

[0050] Then, according to a third support step 96, the actuator 82 is actuated and therefore the carriage 64 is driven in translation in a direction opposite to the lateral arm 72. Consequently, the first locating finger 76 remains engaged in the orifice 34, while the second locating finger 88 is guided precisely in the oblong slot 36 against these two opposite edges which converge towards each other up to the narrow end 40.

[0051] As a result, the loader 46 is itself guided precisely in horizontal translation towards the left side member 14, parallel to the cross member 22, until the second locating finger 88 comes into abutment in the edge of the oblong slot 36 at the level of the narrow end 40 as illustrated in [Fig. 5]. The connector 56 is then driven into movement under the brake fluid reservoir 44, between the latter and the cross member 22. The cylinder 82 then ceases to be activated.

[0052] The relative position of the second locating finger 88 with respect to the magazine 46 and the length of the oblong slot 36 are then predetermined so that the two perforated front peripheral ears 58, 60, and respectively the two rear peripheral ears, not shown, extend respectively in line with the two times two holes 30, 28 of the front 26 and rear 24 edges.

[0053] Finally, in a fourth support step 98, the gripper 48 is driven in vertical translation by means of the robot towards the crosspiece 22, precisely so as to press the loader 46 on the latter. The loader 46 is thus driven vertically along a stroke of a few millimeters, for example 5 mm.

[0054] The two perforated front peripheral ears 58, 60, and respectively the two rear peripheral ears, not shown, come respectively opposite the two times two holes 30, 28, as illustrated in [Fig. 6],

[0055] According to a second assembly step 100, four screws are then engaged and screwed through the two times two ears 58, 60 of the base 40 of the charger 46 and the two times two corresponding holes 30, 28, so as to secure the charger 46 with the crosspiece 22.

[0056] Then in a third assembly step 102, the separation of the two legs 84, 86 is controlled so as to release the loader 46 from the carriage 64. Then, the gripper 48 is driven in translation in a vertical direction opposite the loader 46, by means of the robot, so as to release the crosspiece 22 from the two locating fingers 76, 88.

[0057] The gripper 48 can then be driven to a new loader for the next vehicle in the production line.

Claims

CLAIMS

1. [Method for mass assembly of electric motor vehicles characterized in that it comprises, for each vehicle, the following steps: - a front structure (10) of a motor vehicle is provided comprising, on the one hand, two side members (12, 14) spaced apart from each other and a cross member (22) connecting said two side members together, and on the other hand, equipment (42, 44) mounted near one (14) of said side members overhanging said cross member (22); - a storage battery charger (46) is provided having a fixing base (50) and two opposite side faces (52, 54), said charger comprising a connector (56) extending projecting from one (52) of said side faces; - said loader (46) is brought in line with said crosspiece (22) in a position offset towards the other (12) of said side members and said loader (46) is oriented so that said connection (56) extends towards said one of said side members (14); and, - one presses against said crosspiece (22), in order to be able to successively, vertically guide said loader (46) towards said crosspiece (22) so that said base (50) extends opposite said crosspiece, horizontally guide said loader (46) towards said one of said side members (14), while said connection (56) extends between said equipment (42, 44) and said crosspiece (22); and, vertically guide said loader (46) towards said crosspiece (22) so that said base (50) presses against said crosspiece (22) in order to be able to secure said base and said crosspiece.

2. Assembly method according to claim 1, characterized in that one presses against said crosspiece (22) along two horizontal components.

3. Assembly method according to claim 1 or 2, characterized in that support is taken in two zones of said crosspiece (22) respectively located near said two side members (12, 14).

4. Assembly method according to any one of claims 1 to 3, characterized in that a front structure (10) of a motor vehicle is provided comprising a cross member (22) having an oblong slot (36) near said one of said side members (14) to horizontally guide said loader (46).

5. Assembly method according to any one of claims 1 to 4, characterized in that a front structure (10) of a motor vehicle is provided comprising a cross member (22) having an orifice (34) towards said other of said side members (12) in order to be able to vertically guide said loader (46).

6. Assembly method according to any one of claims 1 to 5, characterized in that said base (50) and said crosspiece (22) are secured by means of a plurality of screwing members.

7. Installation for the series assembly of electric motor vehicles, characterized in that it comprises for each vehicle: - a platform for receiving a front structure (10) of a motor vehicle comprising, on the one hand, two side members (12, 14) spaced apart from each other and a cross member (22) connecting said two side members together, and on the other hand, equipment (42, 44) mounted near one (14) of said side members overhanging said cross member (22); - a gripper (48) for gripping a storage battery charger (46) having a fixing base (50) and two opposite side faces (52, 54), said charger (46) comprising a connector (56) extending projecting from one (52) of said side faces; - a robot for controlling said gripper (48) to be able to approach said loader (46) in line with said crosspiece (22) in a position offset towards the other of said longitudinal members (12) and to orient said loader so that said connection (56) extends towards said one of said longitudinal members (14); and in that said control robot is adapted to carry said gripper (48) against said crosspiece (22) to be able successively to vertically guide said loader (46) towards said crosspiece (22) so that said base (50) extends opposite said crosspiece (22), horizontally guide said loader (46) towards said one of said longitudinal members (14), while said connection (56) extends between said equipment (44) and said crosspiece (22); and, vertically guiding said charger (46) towards said crosspiece (22) so that said base (50) rests on said crosspiece (22) to be able to secure said base and said crosspiece.

8. Assembly installation according to claim 7, characterized in that said gripper (48) comprises a chassis (62) secured to said control robot and a carriage (64) mounted movable in translation on said chassis, said carriage (64) comprising two legs (84, 86) adapted to engage in said two opposite faces (52, 54) of said loader (46).

9. Assembly installation according to claim 8, characterized in that said chassis (62) comprises a first locating finger (76), while said carriage (64) comprises a second locating finger (88).

10. Assembly installation according to claim 9, characterized in that said second locating finger (88) extends towards said one of said lateral faces (52) while said first locating finger (76) extends opposite towards the other (54) of said lateral faces of said loader (46).

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