Modular vehicle architecture for assembling vehicles

Abstract

A modular vehicle architecture for efficiently assembling a vehicle. The modular vehicle architecture includes preparing multiple individual sections of the vehicle in multiple subassembly lines before forming an overall vehicle frame. The vehicle architecture further includes joining the multiple individual sections of the vehicle in a main line. The overall vehicle frame can include a front side, a rear side, an upper side, a lower side, a left side, and a right side.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. Provisional Patent Application No. 63 / 448,972, filed February 28, 2023, entitled "MODULAR VEHICLE ARCHITECTURE FOR ASSEMBLING VEHICLES," the disclosure of which is incorporated herein by reference in its entirety.

[0002] TECHNICAL FIELD This application relates to an architecture for assembling vehicles. More particularly, one or more aspects of this application relate to systems and methods for efficiently assembling vehicles in modules. Summary of the Invention

[0003] The present disclosure relates generally to a vehicle architecture for assembling a vehicle. More specifically, various embodiments of the present disclosure relate to a vehicle architecture for assembling a vehicle in sections prior to joining a body frame of the vehicle.

[0004] One aspect is directed to a method for assembling a vehicle, the method including preparing a plurality of individual sections of the vehicle in a plurality of subassembly lines prior to forming an overall vehicle frame, the method further including joining the plurality of individual sections of the vehicle in a main line, the overall vehicle frame including a front side, a rear side, an upper side, a lower side, a left side, and a right side.

[0005] Another aspect is directed to a vehicle assembly line including a plurality of subassembly lines configured to at least paint a plurality of individual sections of a vehicle, the vehicle assembly line further including a main line configured to join the plurality of individual sections of the vehicle to form an overall vehicle frame, the overall vehicle frame including a front side, a rear side, an upper side, a lower side, a left side, and a right side. [Brief explanation of the drawings]

[0006] The present disclosure will now be described with reference to the accompanying drawings, in which like reference numerals refer to like elements.

[0007] [Figure 1] 1A and 1B are side and top views of sections of a pickup truck to be joined according to one embodiment of a vehicle architecture according to the present disclosure.

[0008] [Figure 2A] FIG. 2 is a side view of a section of the pickup truck of FIG. 1 assembled in accordance with a vehicle architecture.

[0009] [Figure 2B] FIG. 2 is a top view of a section of the pickup truck of FIG. 1 assembled in accordance with a vehicle architecture.

[0010] [Figure 3A] FIG. 1 is a top perspective view of a body frame of a vehicle assembled in accordance with one embodiment of a vehicle architecture according to the present disclosure.

[0011] [Figure 3B] FIG. 3B is a top perspective view of the separate sections that make up the body frame of the vehicle of FIG. 3A.

[0012] [Figure 4] 3B is a top perspective view of the separate sections of FIG. 3B joined to form the body frame of FIG. 3A.

[0013] [Figure 5A] 1 is a flowchart of an exemplary process for manufacturing a vehicle according to the techniques described herein.

[0014] [Figure 5B] 1 is a top perspective view of one or more sections of a vehicle body frame being joined together according to one embodiment of a vehicle architecture according to the present disclosure. FIG.

[0015] [Figure 5C] FIG. 5C is a block diagram illustrating the process of the vehicle architecture of FIG. 5B.

[0016] [Figure 6A] 1 is a top perspective view of one or more sections of a vehicle body frame being joined together according to one embodiment of a vehicle architecture according to the present disclosure. FIG.

[0017] [Figure 6B] FIG. 6B is a block diagram illustrating the process of the vehicle architecture of FIG. 6A.

[0018] [Figure 7A] 1 is a top perspective view of one or more sections of a vehicle body frame being joined together according to one embodiment of a vehicle architecture according to the present disclosure. FIG.

[0019] [Figure 7B] FIG. 7B is a block diagram illustrating the process of the vehicle architecture of FIG. 7A.

[0020] [Figure 8A] FIG. 1 illustrates one embodiment of a vehicle architecture that breaks down two sides and one-half sides of the vehicle "box" from the box shape.

[0021] [Figure 8B] FIG. 1 illustrates one embodiment of a vehicle architecture that breaks down three sides of the vehicle "box" from the box-like appearance.

[0022] [Figure 8C] FIG. 1 illustrates one embodiment of a vehicle architecture that breaks down the five sides of the vehicle "box" from the box-like appearance.

[0023] [Figure 8D] FIG. 1 illustrates one embodiment of a vehicle architecture that breaks down six sides of the vehicle "box" from the box-like appearance.

[0024] [Figure 9A]FIG. 10 is a close-up view of a stamped hinge pillar section having a curved inner mounting flange in accordance with the present disclosure.

[0025] [Figure 9B] FIG. 1 is a side view of a staggered bolt pattern with varying bolt positions in the horizontal (x) and vertical (y) directions according to the present disclosure.

[0026] [Figure 9C] FIG. 10 is an enlarged view of a stamped hinge pillar section having a forward flange according to the present disclosure.

[0027] [Figure 10] FIG. 1 is a top perspective view of a vehicle frame illustrating a joining technique according to the present disclosure.

[0028] [Figure 11A] 1 illustrates an example of how corners and edges between sections of a vehicle frame can be sealed in accordance with the present disclosure.

[0029] [Figure 11B] 10A-10C illustrate another example of how corners and edges between sections of a vehicle frame can be sealed in accordance with the present disclosure.

[0030] [Figure 12A] FIG. 1 is a top perspective view of one embodiment of an assembly station for joining sections of a vehicle frame according to the present disclosure.

[0031] [Figure 12B] FIG. 10 is a top perspective view of another embodiment of an assembly station for joining sections of a vehicle frame according to the present disclosure.

[0032] [Figure 13] 1A-1C are top perspective and side views of an automated assembly station for joining sections of a vehicle frame according to the present disclosure;

[0033] [Figure 14A] FIG. 1 illustrates an exemplary process by which a vehicle may be manufactured. [Figure 14B] FIG. 1 illustrates an exemplary process by which a vehicle may be manufactured. [Figure 14C] FIG. 1 illustrates an exemplary process by which a vehicle may be manufactured. DETAILED DESCRIPTION OF THE INVENTION

[0034] Generally described, vehicles are often assembled and manufactured in a specific order by first constructing the vehicle's welded frame or "box" (e.g., the body). Traditional vehicle manufacturing utilizes welding of stamped panels to construct the body. The body or "box" is then transported through an e-coat system to provide a corrosion-resistant coating and then painted. The painted body is then moved to a "general assembly" (also referred to herein as GA) shop, where the vehicle's interior and exterior components are assembled (e.g., instrument panel, seats, doors, trim, etc.). This traditional assembly process results in inefficiencies in material handling and transportation, as the entire weight / footprint of the vehicle must be transported to assemble even small parts (e.g., headlamps, thermal bars, wheels, etc.). This process also limits the ability to automate many of the manufacturing steps, as it is difficult and expensive to digitize / locate the assembly at the complete vehicle level.

[0035] One aspect of the present disclosure relates to a vehicle architecture that reduces the need for welding stamped panels. In some embodiments, no welding is used to connect major portions of the vehicle (e.g., the portions shown in FIG. 1 ). Furthermore, the vehicle architecture may avoid secondary decoration (e.g., coating / painting) at the full vehicle assembly level. In certain embodiments, the vehicle is designed to be assembled into sections or modules that can be joined in a final assembly process. In certain embodiments, this assembly can be accomplished after welding and metal surface treatment operations (e.g., e-coat, painting, etc.) have been applied, eliminating the need for traditional full-body scale body and paint shops in automotive manufacturing. In some embodiments, the assembly can include, for example, bolting or riveting operations. In some embodiments, the assembly can include stir welding operations. In some embodiments, the sections can utilize large-scale castings or smaller stamped and welded assemblies.

[0036] Another aspect of the present disclosure is that modular vehicle architectures can include assembling the vehicle body or “box” after the internal components have been assembled into individual sections or modules of the vehicle, thereby reducing the length of the GA line. In various embodiments, by “de-boxing” the assembly process, individual sub-lines can be eliminated and / or run in parallel with each other, which can increase the rate at which new factories can be ramped up (e.g., getting new factories to produce at design capacity), enable buffering of sub-assembly lines prior to GA, and reduce GA downtime. Thus, various embodiments of modular vehicle architectures can reduce the factory footprint, complexity, utility requirements, and labor required to produce a vehicle, and can also increase the overall factory equipment effectiveness (OEE).

[0037] In some embodiments, a modular vehicle architecture includes assembling separate sections or modular subcomponents before joining the vehicle body frame or box (e.g., by bolting or other techniques described herein). As illustrated in FIGS. 8A-8D, the vehicle body frame or box may be assembled in different ways to enable parallel processing of manufacturing as described herein. An exemplary embodiment of a modular vehicle architecture may include decorating (e.g., coating and / or painting) subcomponents including, for example, left and right door rings, a front underbody (FUB), a cowl, etc., before joining the vehicle body frame.

[0038] According to various embodiments, the modular vehicle architecture may further include one or more major sub-assembly lines (sub-lines). In some embodiments, the individual major sub-lines may operate separately and / or in parallel with one another. In some embodiments, one or more major sub-lines may include a front underbody line, which may include, for example, a front underbody. In some embodiments, the front underbody line may also include a chassis, a thermal system, a cockpit, etc. In some embodiments, one or more major sub-lines may include a rear underbody line, which may include, for example, a rear underbody (RUB). In some embodiments, the rear underbody line may also include a chassis, a tonneau, a rear seat, etc.

[0039] The modular vehicle architecture may further include a mainline for joining assembled sections from one or more major sublines and other components of the vehicle body, such as left and right door rings. In some embodiments, the vehicle may be assembled into a complete product after the mainline.

[0040] As can be appreciated, the sub-assembly lines described above can operate using robotic technology such that the lines operate semi-autonomously or fully autonomously. For example, a control system (e.g., a processor or microcontroller) can be used to operate a manufacturing line using robotic technology, hot stamping technology (e.g., to form panels such as single or double door rings), etc. The sub-assembly line can then feed downstream into a general assembly. In some embodiments, the general assembly can utilize autonomous or semi-autonomous technology to combine inputs into the general assembly. In some embodiments, the sub-assembly line may use human personnel.

[0041] Thus, the techniques described herein improve throughput associated with vehicle manufacturing. Indeed, complex current techniques for serially manufacturing and assembling vehicle pieces to form a vehicle may be discarded in favor of increased parallelism. As described below, major vehicle sections can be quickly assembled (e.g., bolted together, e.g., using robotic techniques to achieve bolting in as little as 10 seconds, 20 seconds, etc.), and in some embodiments, major sections are assembled separately. In this way, the manufacturing line does not suffer from delays in certain steps that unnecessarily constrain the manufacturing line. Furthermore, the use of parallel processing described herein can increase the volume efficiency of the manufacturing line. For example, as illustrated at least in FIGS. 5A-7B, subassemblies can be organized to improve space utilization while also improving throughput.

[0042] As shown in FIGS. 1-2B , a modular vehicle architecture according to the present disclosure can include multiple major subassemblies or sections 102-110, each of which is assembled on a sub-line and then joined together using automated guided vehicles (AGVs). For example, the modular vehicle architecture can include a front section 102, a center section 104, a rear section 106, a left section 108, and a right section 110. In the illustrated embodiment, the center section 104 can include one or more sheets connected (e.g., bolted) to a lower portion of the subassembly 104. In some embodiments, the center section 104 can include an electric vehicle battery pack below the lower portion. In some embodiments, the electric vehicle battery pack can form the lower portion of the center section 104.

[0043] The left and right subassemblies 108-110 can represent door rings, with Figure 1 showing a double door ring. In some embodiments, the door rings may be hot stamped to allow for rapid increases in manufacturing time compared to current technology.

[0044] As shown in FIGS. 2A-2B , in some embodiments, each of the sections 102-110 can be placed on an AGV and joined together to form a vehicle body in a horizontal plane (e.g., the x-y plane with no fasteners from the bottom). For example, with respect to one example perspective, the front section 102 can be moved along the negative x-direction, the rear section 106 can be moved along the positive x-direction, the left section 108 can be moved along the negative y-direction, and the right section 110 can be moved along the positive y-direction. Thus, these sections can be moved inward toward the center section 104. Advantageously, joining these sections can avoid welding. For example, they can be bolted together to quickly form a vehicle.

[0045] 5A-7B illustrate an example technique for manufacturing example sections, which in some embodiments may be sections 102-110 shown in FIGS. 1-2B. As can be appreciated, sections 102-110 may be manufactured separately and joined together. In some embodiments, certain sections may be manufactured together and then joined. For example, FIGS. 5B-5C illustrate an example of a cabin assembly line that is installed in a front underbody (FUB) installation assembly line and a battery pack installation assembly line (e.g., with a seat on the battery pack as described above) followed by general assembly.

[0046] Figure 3A shows another embodiment of a modular vehicle architecture that includes the use of main sections 302-310, including, but not limited to, a front section 302, a center section 304, a rear section 306, a left section 308, and a right section 310. In the illustrated example, the vehicle is a truck, although other vehicles may be manufactured in accordance with and fall within the scope of the present disclosure. Figure 3B shows the main sections 302-310 joined (e.g., bolted, fastened, etc., connected).

[0047] Figure 4 is a top perspective view of the separate sections of Figure 3A being joined to form the body frame of Figure 3B. After being assembled on their respective sublines, each of the sections 402-410 (e.g., sections 302-310) can be brought together to form the body in a specific sequence utilizing paths in the horizontal plane (e.g., plane xy) as well as additional paths.

[0048] As an example, the central section 404 (e.g., section 304) may be first positioned in a central position. Then, the front section 402 (e.g., section 302) may be moved from the front side in a vertical plane (e.g., plane xz) toward the central section 404 and attached. Then, the rear section 406 (e.g., section 306) may be moved from the rear side of the vertical plane toward the central section 404 and attached.

[0049] Continuing with the above example, the left section 408 (e.g., section 308) can be moved from the left side in the transverse plane (e.g., plane yz) toward the central section 404 and attached. Then, the right section 410 (e.g., section 310) can be moved from the right side in the transverse plane toward the central section 404 and attached. Finally, the top panel 412 (e.g., cowl) can be moved vertically (e.g., axis z) toward the central section 404 and attached.

[0050] The above is one example of an ordering for moving the sections to form the body, but it should be understood that a different order may be used and still fall within the scope of the disclosure herein.

[0051] 5A-7B illustrate additional embodiments of vehicle architectures that at least partially "box out" the vehicle body frame by assembling sections of the vehicle on a sub-line before joining the bodies together.

[0052] 5A is a flowchart of an example process 500 for manufacturing a vehicle according to the techniques described herein. Process 500 may be performed via a manufacturing line (e.g., a vehicle assembly line) and may use one or more assembly stations as described herein. In some embodiments, process 500 may be performed via a processor or microcontroller that automates the manufacturing line.

[0053] At block 502, individual sections or portions of a vehicle are prepared in subassembly lines. As described herein, vehicle sections can include front, rear, left, right, top, bottom, etc. sections. These portions may be prepared in individual subassembly lines, or the portions may have their own subassembly lines to parallelize production. In some embodiments, the individual sections may be decorated (e.g., painted) prior to forming the vehicle box or body. Examples of such preparation are described herein with respect to Figures 5B-7B and 14A-14C.

[0054] At block 504, the individual sections or portions thereof are joined. Individual sections can have portions joined to form the individual sections. In some embodiments, portions may be joined by bolting, and welding may not be used. Similarly, individual sections may be joined via bolting or other techniques (e.g., to form a box or body as described herein), and in some embodiments, welding may not be used for joining. Bolting may be performed from the outside in to increase throughput and ease of such bolting. Examples of such joining are described herein with respect to at least Figures 5B-7B and 14A-14C.

[0055] At block 506, the vehicle is manufactured in a general assembly (e.g., mainline). The vehicle may undergo specific finishing steps, such as the installation of exterior elements.

[0056] 5B-5C, a modular vehicle architecture according to the present disclosure may include separating a rear underbody section 514 (RUB), a front underbody section 516 (FUB), a battery pack 518, and a cowl 520 from a vehicle body frame 512. The vehicle architecture may be prepared (e.g., decorated via painting, etc.) separately on sub-lines (e.g., sub-assembly lines) before being assembled (e.g., as shown with respect to the arrows in FIG. 5B). This separation improves the efficiency of the assembly process compared to conventional assembly processes.

[0057] In some embodiments, the vehicle architecture can include joining and fastening sections (e.g., using bolts) in a particular order and orientation as shown. For example, body frame 512 can be joined with RUB 514. Then, FUB 516 can be joined. Then, battery pack 518 and cowl 520 can be joined. For example, battery pack 518 can be joined upward (e.g., in the positive z-direction) and cowl 520 can be joined downward (e.g., in the negative z-direction). Figure 5C describes the sub-lines and main lines of the vehicle architecture of Figure 5B in more detail.

[0058] 5B illustrates an exemplary process for manufacturing a vehicle. The illustrated embodiment specifically relates to manufacturing a vehicle using sections 512-520 described above with respect to FIG. 5B.

[0059] In FIG. 5B , block 522 relates to the portion of the manufacturing line where external installation is performed. Examples of external installation relate to the cabin 512 and can include installation of a lift gate, fascia, roof, etc. Cabin assembly line 524 can represent a sub-assembly line related to the cabin 512. RUB line 526 can represent a sub-assembly line associated with RUB 516. As depicted in FIG. 5B , RUB 516 may be joined (e.g., joined, attached, etc. as described herein) with the cabin 512. Thus, sub-assembly line 526 can feed into cabin assembly line 524 such that the output of line 524 represents the joined cabin 512 and RUB 516 (e.g., also with external installation).

[0060] Block 530 relates to the attachment of a FUB to the output of line 524, where FUB 514 is assembled in subassembly line 528. Subassembly line 528 therefore outputs a FUB for mating with cabin 512. Block 532 receives the output of block 530, and block 532 attaches battery pack 518 to cabin 512. Block 532 receives the completed battery pack, optionally with a seat attached, from block 534.

[0061] Thus, the output of block 532 represents a cabin with attached FUB 514, RUB 516, and battery pack 518, optionally with seats. Block 536 represents a main line (e.g., a typical assembly line), where additional manufacturing steps are performed on a substantially completed body or box of the vehicle. For example, block 538 may include fixtures such as doors, hood, front fascia, etc.

[0062] 5B-5C thus illustrate an exemplary technique for constraining a manufacturing line by forming a vehicle body or box through separate blocks. Each of the blocks can represent a separate operation that reinforces parallel downstream operations. In this manner, main sections of a vehicle can be manufactured substantially separately and then rapidly joined to form the vehicle body or box. As described herein, in some embodiments, the main sections may be attached by bolting the sections together. For example, one or more robots can be used to fire fasteners (e.g., automated bolt inclusion and fastening) into holes (e.g., bolt holes, threaded holes) to join the sections.

[0063] 6A-6B illustrate another embodiment of a vehicle architecture according to the present disclosure in which the vehicle body frame can be partially "boxed out." The vehicle architecture can be prepared (e.g., painted) separately on a sub-line prior to the assembly step shown in FIG. 6A to improve process efficiency compared to conventional assembly processes.

[0064] In the illustrated embodiment, the partial body frames (e.g., excluding the front underbody 610, battery pack 612, and cowl 614) can be joined together after each sub-line. For example, the partial body frame can include a joined left side 602, a joined right side 604, a RUB 606 (e.g., with a toeboard), and an upper support bar 608. In this example, the RUB 606 can be joined (e.g., bolted) in the x-direction, and the sides can be bolted in the y-direction. Subsequently, the FUB 610 can be joined to the partial body frame (e.g., bolted in the positive x-direction). The battery pack 612 and cowl 614 can then be joined to form a body or box as described herein. For example, the battery pack 612 can be joined in the positive z-direction, and the cowl 614 can be joined in the negative z-direction. The vehicle architecture can include joining and fastening (e.g., using bolts) the sections 602-614 in a specific order and orientation as shown in FIG. 6A . FIG. 6B explains this process in more detail. As can be appreciated, the above directions can be adjusted and still fall within the scope of the present disclosure.

[0065] Figure 6B illustrates an exemplary process for manufacturing a vehicle. The illustrated embodiment specifically relates to manufacturing a vehicle using sections 602-614 described above with respect to Figure 6A.

[0066] In block 620, sub-assembly lines manufacture vehicle body sides. For example, block 620 can output a left side 602 and a right side 604. In some embodiments, block 620 may be separated into two sub-assembly lines, with each line manufacturing one side. In some embodiments, left side 602 and right side 604 may be single or double door rings to which door panels are attached.

[0067] At block 622, a subassembly line may manufacture RUB 606. At block 624, rear cargo may be manufactured based on the output from block 622. The rear cargo may represent additional elements that may be included at the rear of the vehicle and that may be joined with RUB 606.

[0068] At block 626, assembly 626 may be performed using the outputs of sub-assembly lines 620 and 624. Assembly is shown in FIG. 6A at the left-most position of the diagram. For example, assembly may include joining the rear cargo (e.g., FUB) to the sides 602-604. As another example, assembly may include preparation for joining (e.g., loading the rear cargo, sides, and pallets). At block 628, the cabin is joined or otherwise assembled, and exterior elements are installed 630. Exemplary exterior elements may include a lift gate, fascia, roof, cant rails, etc.

[0069] The output of block 628 may be provided to block 632 where the FUB is joined or otherwise attached. For example, block 632 may receive the FUB from a FUB subassembly line 634. In block 636, the battery pack is attached to the vehicle being manufactured. In some embodiments, the battery pack may form the bottom or floor of the vehicle so that seats can be joined (e.g., bolted) to the battery pack. These seats may be joined to the battery pack in block 638.

[0070] Block 640 represents the main line where the body or box is substantially completed. Exterior installation 642 can be performed, with exemplary exterior installation including installation of doors, hood, front fascia, etc.

[0071] As an example, Figures 6A-6B include additional blocks (e.g., subassembly lines) compared to Figures 5B-5C. For example, the car body can be seen as being further disassembled (e.g., separated) from the box shape compared to Figures 5B-5C.

[0072] 7A-7B illustrate another embodiment of a vehicle architecture according to the present disclosure in which the vehicle body frame can be completely "unboxed." The vehicle architecture can be prepared (e.g., painted) separately at a sub-line prior to assembly to improve process efficiency. In some embodiments, as shown in FIG. 7A, at least the front underbody (FUB) 702 and rear underbody (RUB) 704 can be loaded onto a geopallet at the end of the sub-line. Similarly, the vehicle architecture can include joining and fastening sections (e.g., using bolts) in a specific order and orientation, as shown in FIG. 7A.

[0073] For example, FUB 702 and RUB 704 may be placed on a pallet as described above. The sides 706 may then be joined (e.g., bolted) in the y direction. The cowl 708 having a header and roof bow may then be joined (e.g., fastened or bolted) in the negative z direction. The battery pack 710 may be joined in the positive z direction. As can be appreciated, the above directions can be adjusted and still fall within the scope of the disclosure herein.

[0074] 7B illustrates an exemplary process for manufacturing a vehicle. The illustrated embodiment specifically relates to manufacturing a vehicle using sections 702-710 described above with respect to FIG. 6A.

[0075] At block 720, the vehicle sides are manufactured through one or more subassembly lines. For example, single or double door rings may be manufactured. In this example, the single or double door rings may be manufactured with holes or other attachment points. At block 722, RUBs are manufactured through the subassembly lines and then delivered to rear cargo 724. As described above, the rear cargo can complete the RUB assembly. Similarly, at block 726, FUBs are manufactured.

[0076] At block 728, assembly is performed. For example, the vehicle side, RUB, and FUB are joined together. Advantageously, the joining may be performed manually or via a robot, and the joining (e.g., bolting) is performed from the outside to the inside of the vehicle.

[0077] At block 730, the vehicle with frame is received and the battery pack is attached. In some embodiments, the battery pack can represent the floor of the vehicle so that seats can be bonded to the battery pack. At block 732, the body or box is substantially completed. In this embodiment, all exterior installation 734 is performed. Examples of exterior installation include installation of the lift gate, front fascia, rear fascia, cant rails, doors, hood, etc.

[0078] Various embodiments according to the present disclosure can include different levels of "boxing-out" as shown in Figures 8A-8D, where different numbers of sides or "faces" are assembled or "boxed-out" separately before joining all sides of the vehicle body frame.

[0079] For example, Figure 8A illustrates a vehicle architecture that may have two and a half "faces" of a vehicle overall frame or "box" that are separately prepared (e.g., painted) at sub-lines before being joined to the overall vehicle frame. The middle portion shows the different sections without interior components (e.g., vehicle seats) for illustrative purposes, and the right portion shows the separately prepared sections at sub-lines that are shown with non-structural components (e.g., vehicle seats) attached. Thus, Figure 8A may be related to Figures 5B-5C.

[0080] Similarly, FIG. 8B illustrates another embodiment of a vehicle architecture in which three sides of the vehicle's overall frame can be "boxed out" and separately prepared on sub-lines before joining to the overall frame. FIG. 8C illustrates another embodiment of a vehicle architecture in which five sides of the vehicle's overall frame can be "boxed out" and separately prepared on sub-lines before joining to the overall frame. FIG. 8D illustrates another embodiment of a vehicle architecture in which all six sides of the vehicle's overall frame can be "boxed out" and separately prepared on sub-lines before joining to the overall frame. Thus, FIG. 8D can be related to FIGS. 6A-7B.

[0081] For the joining and / or fastening sections, bolts can be used in some embodiments. Figure 9A shows a stamped hinge pillar section with a curved inner mounting flange to minimize the depth of the features in the mating cast component. Figure 9B shows a staggered bolt pattern (e.g., in a side view) with bolt positions that vary in the longitudinal (x) and vertical (z) directions and are located in the lateral (y) direction to increase the vertical (z) moment capacity of the hinge pillar joint. Figure 9C shows a stamped hinge pillar section with the flange moved inward to reduce the depth of the cast feature.

[0082] FIG. 10 illustrates a joining technique that can be used to join surfaces of a vehicle body frame. For example, FIG. 10 illustrates the use of multiple bolts to join sections of the vehicle body. In this example, the bolts may be applied by humans or robots. The joining technique may include forcing a tool toward the outside of the vehicle with a clear line of sight, so that the vehicle can be framed in a substantially typical assembly context.

[0083] Vehicle architectures according to the present disclosure can also include sealing techniques that can be used at different corner and edge locations between surfaces of a vehicle's body frame, as shown in FIGS. 11A-11B. In some embodiments, as shown in FIG. 11A, sealing techniques according to the present disclosure can include using baffles 1102 to fill voids that occur between mating surfaces. To eliminate the need for a skiving operation, material 1104 can be tailored to fill the gap without creating pinholes. In some embodiments, for example, a heat-activated expansion material can be employed that over-expands to fill the gap, followed by application of urethane or another pumpable material 1106-1108 to create the adjacent joint.

[0084] 11B, in other embodiments, sealing techniques according to the present disclosure can also include dispensing a urethane 1110 or other pumpable, uncured bead across the two joining sections to ensure extrusion occurs at the edges. The sealing technique can further include attaching a mating piece to the top of the joint that also has dispensed uncured, pumpable material 1112.

[0085] Various embodiments of the modular vehicle architecture disclosed herein may relate to different types of vehicles. For example, certain figures show sedans, while other figures show pickup trucks. Those skilled in the art will appreciate that various modular vehicle architectures according to the present disclosure may be applied to various types of vehicles, such as sedans, pickup trucks, sport utility vehicles (SUVs), boats, airplanes, etc.

[0086] 12A-12B and 13 show examples of assembled or joined sections of a vehicle. For example, FIG. 13 shows automated assembly via a frame station where sections may be joined in different directions. In the example shown, a side section 1302 may be joined in a particular direction, while another section 1304 may be joined in a different direction (e.g., in the negative z direction).

[0087] 14A-14C illustrate an exemplary process by which a vehicle may be manufactured. In FIG. 14A, certain main sections are shown as being manufactured or produced. In this example, the sections include a front section 1402 (e.g., FUB), a rear section 1404 (RUB), and a side section 1406. In FIG. 14A, each section is shown as traversing manufacturing steps including raw material, die-casting, blanking, stamping, machining, joining, decorating (e.g., e-coating, powder coating), sealing, and firing. The output of this part therefore represents a section that can then be joined as described herein. In some embodiments, separate sub-assembly lines can be used to manufacture the pieces.

[0088] FIG. 14B illustrates the main sections of FIG. 1, such as the front, center, rear, and sides (e.g., left and right). Specifically, the figure describes exemplary steps for positioning each section and then assembling them into the vehicle. As described herein, this can be performed using separate subassemblies.

[0089] FIG. 14C shows finishing the vehicle by adding windows, exterior elements, lights, wheels, etc.

[0090] The foregoing disclosure is not intended to limit the disclosure to the precise form or particular field of use disclosed. Accordingly, various alternative embodiments and / or modifications to the disclosure, whether expressly described or implied herein, are contemplated as possible in light of the present disclosure. While embodiments of the present disclosure have been described in this manner, those skilled in the art will recognize that changes can be made in form and detail without departing from the scope of the present disclosure. Accordingly, the present disclosure is limited only by the claims.

[0091] In the foregoing specification, the present disclosure has been described with reference to specific embodiments. However, as those skilled in the art will understand, the various embodiments disclosed herein can be modified or otherwise embodied in various other ways without departing from the spirit and scope of the present disclosure. Accordingly, this description is to be considered illustrative and is for the purpose of teaching those skilled in the art how to make and use various embodiments of the disclosed systems and processes. It should be understood that the forms of the disclosure shown and described herein are to be construed as representative embodiments. Equivalent elements, materials, processes, or steps may be substituted for those typically shown and described herein. Furthermore, certain features of the present disclosure can be utilized independently of the use of other features, all of which will become apparent to those skilled in the art after having the benefit of this description of the present disclosure. The terms "including," "comprising," "incorporating," "consisting of," "have," "is," and the like, used to describe and claim the present disclosure, are intended to be construed in a non-exclusive manner, i.e., allowing for the presence of items, components, or elements not expressly described. References to the singular are also to be construed as relating to the plural.

[0092] Furthermore, the various embodiments disclosed herein should be construed in an exemplary and explanatory sense and in no way as limiting the present disclosure. All joining references (e.g., attached, secured, coupled, connected, etc.) are used solely to aid the reader's understanding of the present disclosure and do not create any limitations with respect to the position, orientation, or use of the systems and / or methods disclosed herein, among other things. Accordingly, any joining reference should be interpreted broadly. Furthermore, such joining references do not necessarily imply that two elements are directly connected to one another. Furthermore, without limitation, all numerical terms such as "first," "second," "third," "primary," "secondary," "main," or any other conventional and / or numerical terminology should also be construed solely as identifiers to aid the reader's understanding of the various elements, embodiments, variations, and / or modifications of the present disclosure, and in particular do not create any limitations with respect to the order or preference of any element, embodiment, variation, and / or modification relative to or over another element, embodiment, variation, and / or modification.

[0093] It will also be understood that one or more of the elements shown in the drawings / figures may also be implemented in a more separate or integrated manner, or may even be removed or rendered inoperable in certain cases, as may be useful depending on the particular application.

Claims

1. 1. A method for assembling a vehicle, comprising: preparing a plurality of individual sections of the vehicle in a plurality of subassembly lines prior to forming an overall frame of the vehicle; joining the individual sections of the vehicle within a main line; The method, wherein the overall vehicle frame includes a front side, a rear side, an upper side, a lower side, a left side, and a right side.

2. The method of claim 1 , wherein the joining step does not include welding the sections together.

3. The method of claim 1 , wherein the joining step includes bolting at least a subset of the sections together simultaneously.

4. Joining the individual sections comprises: joining the left side, the right side, the top side, and the rear side to form a cabin of the vehicle; then joining the front side to the cabin; and then joining the battery pack.

5. The method of claim 4 , wherein the battery pack has a sheet attached to the battery pack.

6. The method of claim 4 , wherein the main line installs an exterior element, the exterior element including one or more of a door, a hood, and a front fascia.

7. Joining the individual sections comprises: joining the left side, the right side, the top side, and the rear side to form a cabin of the vehicle; then joining the front side to the cabin; and then joining the battery pack.

8. Joining the individual sections comprises: loading the front section and the rear section onto a movable pallet; then joining the left and right sides to the front and rear sections to form a cabin of the vehicle; and then joining the upper section and battery pack to the cabin.

9. The method of claim 8 , wherein exterior installation is performed after joining, the exterior installation including one or more of a lift gate, a fascia, a roof, a cant rail, one or more doors, and a hood installation.

10. The method of claim 1 , wherein each individual section is decorated before joining.

11. A vehicle assembly line, a plurality of subassembly lines configured to at least decorate a plurality of individual sections of the vehicle; a main line configured to join a plurality of individual sections of the vehicle to form an overall frame of the vehicle; The overall frame of the vehicle includes a front side, a rear side, an upper side, a lower side, a left side, and a right side. Vehicle assembly line.

12. 12. The vehicle assembly line of claim 11, wherein joining does not include welding the sections together.

13. 12. The vehicle assembly line of claim 11, wherein joining comprises bolting at least a subset of the sections together simultaneously.

14. Joining the individual sections joining the left side, the right side, the top side, and the rear side to form a cabin of the vehicle; then joining the front side to the cabin; and then joining the battery packs.

15. 15. The vehicle assembly line of claim 14, wherein the battery pack has a seat attached to the battery pack.

16. 15. The vehicle assembly line of claim 14, wherein the main line installs exterior elements, the exterior elements including one or more of doors, a hood, and a front fascia.

17. Joining the individual sections joining the left side, the right side, the top side, and the rear side to form a cabin of the vehicle; then joining the front side to the cabin; and then joining the battery packs.

18. Joining the individual sections loading the front section and the rear section onto a movable pallet; then joining the left and right sides to the front and rear sections to form a cabin of the vehicle; and then joining the upper section and battery pack to the cabin.

19. 20. The vehicle assembly line of claim 18, wherein external installation is performed after bonding, the external installation including one or more of the installation of a lift gate, a fascia, a roof, a cant rail, one or more doors, and a hood.

20. 12. The vehicle assembly line of claim 11, wherein each individual section is decorated before joining.

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