Vehicle assembly kits, methods for manufacturing vehicle assemblies, and methods for manufacturing vehicles.

Abstract

DEPCT66 This form of invention provides a vehicle assembly kit; this assembly kit consists of the following parts: The housing and frame structure are shaped to allow for the assembly of the frame. The frame forms a part of a vehicle;

Description

Vehicle assembly kit, vehicle assembly kit manufacturing method, and vehicle manufacturing method

[0001] The present invention relates to a vehicle assembly kit, a method for manufacturing a vehicle assembly kit, and a method for manufacturing a vehicle.

[0002] Patent Document 1 discloses an electric vehicle assembly kit.

[0003] JP 2013-249050 A

[0004] The present invention provides a vehicle that can be easily assembled.

[0005] According to one aspect of the present invention, there is provided a vehicle assembly kit, the assembly kit including a housing and a frame, the housing being configured to accommodate the frame, the frame constituting a part of the vehicle.

[0006] Such a vehicle assembly kit makes it possible to easily assemble the vehicle.

[0007] 12 is an enlarged view of the plan view of FIG. 12. FIG. 13 is an activity diagram showing a method for manufacturing the assembly kit 100. FIG. 14 is an activity diagram showing a method for manufacturing the vehicle 1. FIG. 15 is an activity diagram showing a method for manufacturing the vehicle 1. FIG. 16 is an activity diagram showing a method for manufacturing the vehicle 1. FIG. 17 is an activity diagram showing a method for manufacturing the vehicle 1. FIG. 18 is an activity diagram showing a method for manufacturing the vehicle 1.

[0008] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the accompanying drawings. Various features shown in the following embodiments can be combined with each other.

[0009] 1. Assembly Kit 100 As shown in Fig. 1, an assembly kit 100 for a vehicle 1 (see Fig. 8) according to one embodiment of the present invention contains components or modules that constitute the vehicle 1 in a housing 10. A user such as an employee or a purchaser can easily assemble the vehicle 1 using the components or modules contained in the housing 10.

[0010] The assembly kit 100 includes a housing 10 and a frame F. The housing 10 may include a first housing 10a and a second housing 10b. The first housing 10a houses a component or a module. The second housing 10b functions as a lid that covers the first housing 10a.

[0011] The components housed in the housing 10 are components for assembling the vehicle 1. The housing 10 is configured to be able to house a frame F. The frame F constitutes a part of the vehicle 1. The frame F also includes a base frame 2 and a support frame 3. The frame F is also configured to be able to mount a panel 5. In this embodiment, a roof 4 (see FIG. 8 ) is formed by a plurality of panels 5. The roof 4 covers at least a part of the passengers of the vehicle 1, and may have any shape. The panel 5 is also formed by at least a part of the housing 10.

[0012] As shown in Fig. 2, the housing 10 includes a housing section 11. The housing section 11 includes a bottom 11b and a side wall 11s, and has a space S for housing a member or a module. The housing section 11 is configured to form the space S capable of housing a frame F. The housing 10 is also configured to house a support frame 3. Here, the support frame 3 is a frame that constitutes the roof 4 of the vehicle 1. As shown in Figs. 7 and 8, in this embodiment, the panel 5 is attached to the base frame 2 via the support frame 3.

[0013] In this embodiment, the accommodation section 11 includes a first accommodation section 111 and a second accommodation section 112. The first accommodation section 111 is configured to form a space S capable of accommodating the base frame 2. Here, the base frame 2 is a frame that constitutes the base B of the vehicle. Furthermore, the second accommodation section 112 is configured to form a space S capable of accommodating the support frame 3.

[0014] A mark M corresponding to the shape of the panel 5 is formed on the storage section 11. In this embodiment, the mark M corresponding to the shape of the panel 5 is formed on at least one of the first storage section 111 and the second storage section 112. In the example of FIG. 2 , the mark M is formed on the bottom 11b of the storage section 11, but this is not limiting. For example, instead of the bottom 11b, the mark M may be formed on a part of the side wall 11s, and part of the side wall 11s may be used as the panel 5. Furthermore, instead of the storage section 11, the mark M may be formed on a part of the second storage body 10b (lid) that covers the storage section 11, and part of the lid may be used as the panel 5. Furthermore, the storage section 11 with the largest area in a plan view among the storage sections 11 may be formed with a mark M corresponding to the shape of the panel 5 with the largest area in a plan view. In this embodiment, the mark M corresponding to the floor panel 5fl (see FIG. 5 ) is formed on the first storage section 111. This is because the first housing portion 111 houses the base frame 2, and the base frame 2 is the member with the largest area in a plan view among the housing members.

[0015] The mark M can be any form, such as a cut that does not penetrate the storage section 11, a plurality of through holes, or coloring with paint or the like. Here, the panel 5 is a part of the storage body 10 cut out based on the mark M. In other words, the storage body 10 can be used to transport components or modules of the vehicle 1, and after the contents are removed, part of the storage body 10 can be used as the panel 5. This makes it possible to save resources used in producing the panel 5.

[0016] It is preferable that the material of the portion of the storage section 11 where the mark M is formed be a material that can be used as the panel 5. For example, polycarbonate, acrylic, or the like can be used as the material of the portion of the storage section 11 where the mark M is formed.

[0017] Returning to FIG. 1 , the contents of the assembly kit 100 will be described. In this embodiment, the assembly kit 100 includes a base frame 2 and a support frame 3. The assembly kit 100 may also include a tire 71 and a wheel 72. In this case, the housing 10 is configured to be able to house the tire 71 and the wheel 72. The assembly kit 100 may also include a handle unit 73. In this case, the housing 10 is configured to be able to house the handle unit 73. The assembly kit 100 may also include a seat 74. The assembly kit 100 may also include an electric drive unit 6. Here, the electric drive unit 6 is a unit including electric drive components. The electric drive components may include at least one of a battery, a motor, and an inverter. Here, the motor and the inverter may be disposed between the front wheels or the rear wheels to efficiently convert electric power into driving force. In this case, the electric drive components are attached to the base frame 2. In this embodiment, the electric drive components are collectively called the electric drive unit 6 and attached to the base frame 2. The base frame 2 and the electric drive unit 6 then form a base B. At this time, the assembly kit 100 includes a base B. The base B includes a base frame 2 and an electric drive component.

[0018] Furthermore, a parts set 8 may be stored in the remaining space of the housing 10. The parts set 8 is a collection of parts other than the above-mentioned members, and may include, for example, a wire harness.

[0019] The components housed in the housing 10 may be housed in the housing 10 in a manner that does not require welding when assembling the vehicle 1. Housed in the housing 10 in a pre-welded state reduces the workload at the manufacturing site. This allows even the purchaser of the vehicle 1 to easily assemble the vehicle 1.

[0020] Furthermore, since specialized knowledge and specialized equipment may be required to assemble the electric drive unit 6 and the handle unit 73, it is preferable to modularize them in advance and store them in the storage body 10.

[0021] 2. Vehicle 1 Next, vehicle 1 will be described using Figures 2 to 9. As shown in Figure 3, wheels 72 are attached to the front and rear of base frame 2. The number of wheels 72 is arbitrary, and one or more wheels 72 can be attached depending on the shape of base frame 2. Furthermore, as shown in Figure 4, tires 71 are attached to wheels 72. Furthermore, an electric drive unit 6 is disposed inside base frame 2.

[0022] As shown in Figure 5, the floor panel 5fl is attached with the electric drive unit 6 installed inside the base frame 2. The floor panel 5fl constitutes the floor portion of the passenger compartment. The floor panel 5fl may also have grooves 5g formed therein. In the example shown in Figure 5, two grooves 5g are formed in the floor panel 5fl. A support portion 75 is then attached to the front of the floor panel 5fl.

[0023] 6, a front portion 76 is disposed via the support portion 75. The handle unit 73, a display portion 77, and a light 79 are attached to the front portion 76.

[0024] The handle unit 73 is a module including a handle for the occupant to operate the vehicle 1. If the vehicle 1 is a vehicle compatible with an autonomous driving mode, it is assumed that the handle unit 73 will not be used in the autonomous driving mode, but will be used in the manual driving mode.

[0025] The display unit 77 displays images (still images and videos). The display unit 77 may display images based on a car navigation system installed in the vehicle 1, or may connect to or pair with a passenger's smart device (e.g., a multi-function information terminal such as a smartphone, a tablet terminal, a wearable terminal, or a mobile PC) and display images based on the smart device.

[0026] It is preferable to install the light 79 even when the vehicle 1 is in autonomous driving mode, in order to alert pedestrians to the presence of the vehicle 1.

[0027] As shown in FIG. 7 , a seat 74 is attached to the floor panel 5fl. In this embodiment, the seat 74 is attached to the floor panel 5fl by fitting an attachment portion 74a provided on the lower part of the seat 74 into a groove 5g. The seat 74 is configured to be movable back and forth along the groove 5g. In the example of FIG. 7 , two seats 74 are attached, but the number of seats 74 is arbitrary. For example, if the vehicle 1 is intended for passengers to ride in, one or more seats 74 are provided. On the other hand, if the vehicle 1 is driven autonomously to transport luggage, the seat 74 may not be provided.

[0028] A support frame 3 is attached to the base frame 2. The support frame 3 is configured by connecting a plurality of frame parts 3a via joints 3b. The shape and size of the support frame 3 are arbitrary.

[0029] As shown in Figures 8 and 9, a panel 5 is attached to the frame F. In this embodiment, the panel 5 is attached to the base frame 2 via the support frame 3. The support frame 3 and the panel 5 form a roof 4. The panel 5 may include a front panel 5fr, a roof panel 5r, a rear panel 5b, a side panel 5s, and a floor panel 5fl. The roof 4 may be formed by the roof panel 5r, the rear panel 5b, and the side panel 5s. The shape, number, and type of the panel 5 are arbitrary. If the vehicle 1 is a vehicle compatible with an autonomous driving mode, the front panel 5fr may obstruct the view of the occupants. On the other hand, if the vehicle 1 is not a vehicle compatible with an autonomous driving mode, the panel 5 is attached so that the view of the occupants is not obstructed by the front panel 5fr. In the example of Figure 8, the front panel 5fr is formed of a transparent material. If the vehicle 1 is a vehicle compatible with an autonomous driving mode, the front panel 5fr may be formed of a non-transparent material, and the panel 5 may be attached so that the view of the occupants is obstructed by the front panel 5fr.

[0030] A mirror 78 may also be attached to the side panel 5s. Here, the mirror 78 is not essential when the vehicle 1 is in the autonomous driving mode. Even when the vehicle 1 is in the manual driving mode, the mirror 78 is not essential if an image captured by a camera capable of capturing an image of the rear is displayed on the display unit 77. Therefore, although it is preferable that the mirror 78 be detachably attached to the side panel 5s, the mirror 78 does not have to be attached at all.

[0031] 10 , the assembly kit 100 may be configured so that (area S1 of the first storage section 111 in a plan view) / (area S2 of the panel 5 in a plan view defined by the mark M)<3. This allows at least one-third of the bottom 11b constituting the first storage section 111 to be reused as the panel 5. Here, the value of S1 / S2 is 1 to less than 3, specifically, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or less than 3, and may be within a range between any two of the numerical values ​​exemplified here.

[0032] The size of the panel 5 that can be cut out from the housing 10 is arbitrary, but the following configurations can be adopted. (1) A portion of the panel 5 (e.g., floor panel 5fl) is cut out from the first housing section 111, and a portion of the panel 5 (e.g., front panel 5fr, roof panel 5r, side panel 5s, rear panel 5b) is cut out from the second housing section 112 and other housing sections 11. Note that if it is not possible to cut out all of the panels 5 used for one vehicle 1 from the housing 10, the remaining panels 5 may be stored in a housing dedicated to panels and transported. (2) A housing 10 that can store multiple base frames 2 is prepared, and configured so that the panels 5 used for one vehicle 1 can be cut out from one housing 10. (3) Although the packing rate of the housing 10 is reduced, one housing 10 can store one vehicle's worth of base frames 2, and one housing 10 can be configured so that the panels 5 used for one vehicle 1 can be cut out from one housing 10.

[0033] In this way, in either embodiment, at least a portion of the container 10 used when transporting the components of the vehicle 1 can be used as the panel 5, thereby saving resources compared to when the components of the vehicle 1 and the panel 5 are transported separately.

[0034] 11 is an example of a six-sided view of the housing 10. The dashed lines in the plan view represent the mark M (see FIG. 10). The vertical length D1, horizontal length D2, and height D3 of the housing 10 are arbitrary, but can be set to the following ranges, for example: D1: 300 mm to 5,000 mm D2: 500 mm to 15,000 mm D3: 100 mm to 2,000 mm

[0035] Furthermore, the thickness t1 of the outer wall of the housing 10 and the thickness t2 of the wall separating the chambers may be the same or different. Furthermore, the lengths d1 to d3 of the chambers may be designed as appropriate.

[0036] In the example of FIG. 11, the values ​​are as follows, but are not limited to these: D1: 1,900 mm D2: 3,600 mm D3: 650 mm d1: 1,045 mm d2: 705 mm d3: 1,425 mm d4: 1,050 mm d5: 925 mm t1: 50 mm t2: 50 mm

[0037] In particular, the mark M shown in the plan view (see FIG. 10) is a distinctive feature of the design.

[0038] 12 is another example of a six-sided view of the container 10. As shown in FIG.

[0039] 3. Manufacturing Method of Assembly Kit 100 The assembly kit 100 is manufactured at a manufacturing site such as a factory. As shown in Fig. 14 , among the components of the vehicle 1, those that require welding are welded (A11). Then, the welded components (e.g., the base frame 2) are housed in the housing 10 (A12). If necessary, the housing 10 may be packed in a packaging material (A13).

[0040] In other words, the manufacturing method includes a housing step. In the housing step, the frame F is housed in the housing body 10. Here, the housing body 10 is configured to be able to house the frame F. In particular, the housing body 10 may be configured to be able to house the base frame 2. The base frame 2 is a frame that constitutes the base B of the vehicle 1, and is configured to be able to mount the panel 5. The panel 5 is formed by a part of the housing body 10. Furthermore, the manufacturing method may include a packaging step. In the packaging step, the housing body 10 is packaged.

[0041] The manufactured assembly kit 100 may be transported to a base other than the manufacturing base of the assembly kit 100 or to an overseas base. Also, the assembly kit 100 may be transported to the purchaser of the vehicle 1.

[0042] 4. Manufacturing Method of Vehicle 1 The manufacturing method of the vehicle, in which the vehicle 1 is manufactured using the assembly kit 100 at a location where the delivered assembly kit 100 is received, includes a first removal step, a second removal step, and an installation step.

[0043] 15 , in a first removal step, a frame F is removed from the housing 10 (A21). In a second removal step, a panel 5 formed by a part of the housing 10 is removed (A22). Then, in an attachment step, the panel 5 is attached to the frame F (A23).

[0044] Furthermore, a coating step may be included as necessary. In the coating step, the panel 5 is coated (A24). This can improve the strength of the panel 5 or the appearance of the surface of the panel 5. In particular, if the first storage section 111 of the storage body 10 is damaged during transportation of the assembly kit 100, it is preferable to coat the panel 5 during the manufacture of the vehicle 1. Note that if the vehicle 1 is manufactured in an ordinary home, the panel 5 can be coated with varnish or the like.

[0045] The above-described manufacturing method makes it possible to provide a vehicle 1 that is easy to assemble while saving resources.

[0046] 5. Others The above-described embodiments can also be implemented in the following ways: - The portion of the housing 10 that cannot be reused as a panel 5 is used as a material for biomass power generation. - If it is desired to reduce the volume of the housing 10, the tires 71 are not housed in the housing 10, but are transported in a housing specifically for the tires 71. - It is preferable that highly specialized work such as incorporating the electric drive unit 6 into the base frame 2 and assembling the handle unit 73 be completed during the manufacture of the assembly kit 100, but these work may be left to the manufacturing site in consideration of the level of the manufacturing site.

[0047] Furthermore, the present invention may be provided in the following aspects. The assembly kit, wherein the frame is configured to allow a panel to be attached, and the panel is formed by at least a part of the housing. The assembly kit, wherein the housing includes a storage section, the storage section is configured to form a space capable of storing the frame, and a mark corresponding to the shape of the panel is formed on the storage section. The assembly kit, wherein the panel is formed by cutting out a part of the housing based on the mark. The assembly kit, wherein the frame includes a support frame, the housing is configured to be able to store the support frame, the support frame is a frame that forms a roof for the vehicle, and the panel is attached to the frame via the support frame. the frame comprises a base frame, the base frame being a frame that constitutes a base of the vehicle, the accommodating body comprising a accommodating section, the accommodating section comprising a first accommodating section and a second accommodating section, the first accommodating section being configured to form a space capable of accommodating the base frame, the second accommodating section being configured to form a space capable of accommodating the support frame, and at least one of the first accommodating section and the second accommodating section being formed with a mark corresponding to the shape of the panel. The assembly kit is configured so that (area S1 of the first accommodating section in a plan view) / (area S2 of the panel in a plan view defined by the mark) < 3 ... frame comprises a base frame, the base frame being a frame that constitutes a part of the vehicle and comprising a base, the base comprising the base frame and electric drive components, the electric drive components including at least one of a battery, a motor, and an inverter, and the electric drive components are attached to the base frame. The assembly kit includes a tire and a wheel, the housing being configured to be able to accommodate the tire and the wheel. The assembly kit includes a handle unit, the housing being configured to be able to accommodate the handle unit.

[0010] In the assembly kit, the components accommodated in the container are components for assembling the vehicle, and are accommodated in the container in a manner that does not require welding when assembling the vehicle.

[0011] A manufacturing method for a vehicle assembly kit, comprising: a housing step, in which a frame is accommodated in a container, the container being configured to be able to accommodate the frame, the frame being a frame that constitutes a part of the vehicle.

[0012] The manufacturing method also comprises: a packaging step, in which the container is packaged.

[0013] A manufacturing method for a vehicle, comprising: a first removal step, a second removal step, and an attachment step, in which the frame is removed from the container, the container being configured to be able to accommodate the frame, the frame being a frame that constitutes a part of the vehicle and configured to be able to attach a panel, the second removal step removing a panel formed by a part of the container, and the attachment step attaching the panel to the frame.

[0014] The manufacturing method also comprises: a coating step, in which the panel is coated in the coating step. Of course, this is not limited to the above.

[0048] Finally, while various embodiments of the present invention have been described, these are presented by way of example only and are not intended to limit the scope of the invention. The novel embodiments may be embodied in various other forms, and various omissions, substitutions, and modifications may be made without departing from the spirit of the invention. Such embodiments and modifications are intended to be included within the scope and spirit of the invention, as well as within the scope of the inventions and their equivalents as defined in the accompanying claims.

[0049] 1: Vehicle 2: Base frame 3: Support frame 3a: Frame part 3b: Joint 4: Shed 5: Panel 5b: Rear panel 5fl: Floor panel 5fr: Front panel 5g: Groove 5r: Roof panel 5s: Side panel 6: Electric drive unit 8: Parts set 10: Container 10a: First container 10b: Second container 11: Container section 11b: Bottom 11s: Side wall 71: Tire 72: Wheel 73: Handle unit 74: Seat 74a: Mounting section 75: Support section 76: Front section 77: Display section 78: Mirror 79: Light 100: Assembly kit 111: First container 112: Second container B: Base D3: Height F: Frame M: Mark S: Space S1: Area S2: Area t1: Thickness t2: Thickness

Claims

DEPCT661. The vehicle assembly consists of: a container and a frame; where the container is shaped to accommodate the frame, and the frame shaped the vehicle section.

2. The assembly pursuant to Reputation 1, where: the frame is shaped to allow panels to be installed into it, and the panels are constructed by at least a portion of the container.

3. The assembly pursuant to Reputation 2, where: the container consists of a packing section shaped to create a space that accommodates the frame, and markings corresponding to the shape of the panels are constructed in the packing section.

4. The assembly pursuant to Reputation 3, where: panels are obtained by cutting out a portion of the container based on markings.

5. The assembly pursuant to any one of Reputations 2 through 4, where: the frame consists of a support structure; the container is shaped to accommodate the support structure; the support structure is the frame that shaped the vehicle roof, and the panels are installed onto the frame via the support structure.6.The assembly pursuant to claim 5, where: the frame consists of a base frame that forms the form of the vehicle's base; the container consists of a first container formed to create a space where the base frame can be assembled and a second container formed to create a space where the support frame can be assembled; and markings corresponding to the panel shapes are made in at least one of the first and second containers.

7. The assembly pursuant to claim 6, is formed in such a way that: (Area S1 in the planar view of the first container) / (Area S2 in the planar view of the panel as defined by the markings) < 3.

8. Any assembly pursuant to claims 1 through 7, where: the frame consists of a base frame that forms the form of the vehicle's base; and the assembly consists of a base comprising the base frame and the electric drive component; the electric drive component comprises at least one battery, motor, and inverter; and the electric drive component is mounted to the base frame.9.

10. An assembly under any of the claims 1 through 8 consists of: tires and wheels, where the container is shaped to assemble the tires and wheels.

11. An assembly under any of the claims 1 through 9 consists of: steering units, where the container is shaped to assemble the steering units.

12. An assembly under any of the claims 1 through 10, where: parts assembled in the container are components for vehicle assembly and are assembled in the container in a way that does not require welding when assembling the vehicle.

13. The manufacturing method of a vehicle assembly consists of: the assembly step of assembling the frame in a container, where the container is shaped to assemble the frame and the frame is the frame that forms the vehicle parts.

14. The manufacturing method under claim 12 consists of: the packaging step of packaging the container.The manufacturing method of the vehicle consists of: the first removal step of removing the frame from the vehicle, where the container is shaped to assemble the frame and the frame is shaped to form the vehicle section and is shaped to allow the panels to be installed; the second removal step of removing the panels created by the container section; and the installation step of installing the panels onto the frame.

15. The manufacturing method according to claim 14 consists of: the coating step of coating the panels;

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