Body structure for a vehicle and method for manufacturing vehicles

Abstract

The invention relates to a body structure for the front end of a two-track vehicle, having a large cast component with at least one suspension strut mount (7), which has a suspension strut top mounting (11) on which an upper end of a suspension strut (13), in particular a strut mount (15) of the suspension strut (13), can be supported. According to the invention, the suspension strut top mounting (11) is a sheet metal insert part connected to the suspension strut mount (7), which is part of the large cast component, in a mixed construction joint, such as an adhesive joint.

Description

[0001] Description

[0002] Body structure for a vehicle and method for manufacturing vehicles

[0003] The invention relates to a body structure for the front end of a two-track vehicle according to the preamble of claim 1 and to a method for producing vehicles according to claim 10.

[0004] Manufacturing a body structure as a single large-cast component can reduce vehicle weight compared to conventional manufacturing methods, improving vehicle performance and fuel efficiency. Furthermore, the large-cast component can be structurally more stable and offer improved strength, which can lead to increased vehicle safety.

[0005] A generic body structure for the front end of a vehicle comprises a large cast component with at least one strut mount. This is formed with a strut tower on which an upper end of a strut, in particular a strut mount, can be supported.

[0006] When manufacturing vehicle models with different axle geometries, i.e., different track widths and / or different body heights, a separate casting tool must be provided for each of these vehicle models in order to cast a large cast component adapted to the desired axle geometry. This involves significant tooling and manufacturing effort.

[0007] DE 102010 013 842 A1 relates to a body structure of a motor vehicle with at least one spring strut mount. In an at least partially modular body structure, a first spring strut mount module with a specific dome design and with connecting elements of a specific connection geometry is available for connection to associated body structural elements. Furthermore, at least one further spring strut mount module with the same connection geometry but a different dome design is available for assembly according to the invention for varying the body structure with regard to the spring strut position. DE 198 47 876 A1 discloses a supporting structure for a motor vehicle body. This structure comprises a longitudinal member and a spring strut support that can be connected to the longitudinal member and includes a spring strut mount formed integrally with the longitudinal member. The spring strut support is designed as a cast part.The object of the invention is to provide a body structure for the front end of a two-track vehicle and a method for producing vehicles which can be produced with reduced tooling and manufacturing expenditure compared to the prior art.

[0008] The object is achieved by the features of claim 1 or 10. Preferred developments of the invention are disclosed in the subclaims.

[0009] The invention relates to a body structure for the front end of a two-track vehicle. The body structure is provided as a large-cast component with at least one strut mount, which has a strut tower on which an upper end of a strut can be supported, in particular via a tower bearing. According to the characterizing part of claim 1, the strut tower is not a uniform, one-piece component of the large-cast component. Rather, the strut tower is formed as a separate sheet metal insert part from the large-cast component. The sheet metal insert part can be connected to the strut mount, which is a component of the large-cast component, in a mixed-material joining connection, for example by adhesive bonding. The sheet metal insert part can be geometrically modified independently of the large-cast component in order to adapt to the axle geometry of the vehicle being manufactured. Nevertheless, the strut mount, which is a component of the large-cast component, remains unchanged.For example, for vehicle models with different axle geometries, identical large cast components but different sheet metal inserts can be kept in stock, which reduces the tooling required in the casting process as well as the manufacturing effort in the production of the vehicle models compared to the state of the art.

[0010] In a technical implementation, the strut tower can have a mounting surface to which the upper end of the strut, i.e., the strut's top mount, can be screwed, preferably in a normal orientation, i.e., perpendicular to the mounting surface. A strut bolted to the mounting surface of the strut tower in a normal orientation offers several advantages, namely easy maintenance, quick strut replacement, and increased stability due to the direct attachment to the mounting surface, which contributes to improved driving stability.

[0011] To ensure sufficient component rigidity, the strut mount can have a hollow cylindrical peripheral wall that terminates at the top in the vertical direction of the vehicle with a circumferential collar. This collar has a reduced diameter compared to the peripheral wall. The reduced-diameter, circumferential collar increases the dimensional stability of the hollow cylindrical strut mount.

[0012] The strut tower, realized as a sheet metal insert, can be manufactured cost-effectively as a cup-shaped deep-drawn part. This has a profiled base from which a circumferential side wall extends upwards. The circumferential side wall can terminate in an annular shoulder that is larger in diameter than the circumferential side wall, thus ensuring that the sheet metal insert (i.e., the strut tower) is also dimensionally stable and rigid.

[0013] In the assembled state, it is preferred if the large-diameter annular shoulder of the strut dome engages under the reduced-diameter collar of the strut mount. In this case, the collar of the strut mount forms a height stop against which the strut dome, designed as a sheet metal insert, can be brought into contact in a joining direction in the vertical direction of the vehicle, preferably in a ring-shaped, large-surface contact. Such a large-surface connection can simplify the assembly process because there is a greater tolerance for alignment errors. In addition, the large-surface connection enables efficient force transmission between the sheet metal insert and the strut mount, which is part of the large-cast component. With a view to a large-surface contact connection with as few gaps as possible, it is preferred if the annular shoulder of the strut dome and the collar of the strut mount are designed to match each other's contours.The profile base of the strut tower can provide the mounting surface for the upper end of the strut, i.e., the strut mount. Furthermore, the surrounding collar of the strut mount can define a central mounting opening through which the profile base of the strut tower can be accessed from above.

[0014] When manufacturing vehicles, there may be a requirement to provide at least two vehicle models, each with a different axle geometry.

[0015] According to the invention, an identical large cast component but different sheet metal inserts can be installed in each of the two vehicle models. Each of these sheet metal inserts is shaped with regard to the desired axle geometry. It is preferred if the annular shoulder contours of the two differently shaped sheet metal inserts are identical to one another in order to achieve a perfect mixed construction joint with the collar of the spring strut mount. In contrast, the profile bases of the two sheet metal inserts, which form the screwing surfaces for the spring struts, can be spatially aligned differently. Depending on the installation of the first or second sheet metal insert, the spring strut can therefore be screwed to the profile base of the respective sheet metal insert at a different strut angle. In this way, the two vehicle models can each have a different body level and / or a different track width.

[0016] For example, the sheet metal insert installed in a first vehicle model may have a flat profile base, resulting in a more steeply positioned spring strut. This results in a reduced track width and / or a higher body height. Conversely, in a second vehicle model, the profile base of the bleach insert installed therein may be more steeply positioned. In this case, this results in a larger track width and / or a reduced body height compared to the first vehicle model.

[0017] In a specific embodiment, the large cast component can be formed, mirror-inverted to the vehicle's centerline longitudinal plane, with a body longitudinal member and a body cross member on each side of the vehicle. The two body longitudinal members can be connected to each other, with a spring strut mount on each side of the vehicle being integrally formed from the same material and on the respective body longitudinal member.

[0018] An embodiment of the invention is described below with reference to the attached figures.

[0019] They show:

[0020] Figures 1 to 3 each show different views illustrating the spring strut mount according to the invention.

[0021] Figure 1 shows a body structure for the front end of a two-track vehicle. The body structure is designed as a large cast component that has a body longitudinal member 1 on each side of the vehicle with reference to a vehicle center longitudinal plane. The body longitudinal member 1 merges in the vehicle longitudinal direction x towards the rear of the vehicle into a battery or vehicle floor connection 3. The two body longitudinal members 1 are connected to one another via a body cross member 5. In addition, a spring strut mount 7 is formed on each of the two body longitudinal members 1. The battery or vehicle floor connection 3, the body cross member 5 and the two spring strut mounts 7, together with the two body longitudinal members 1, are components of the large cast component, which is a mirror image of the two body longitudinal members with reference to the vehicle center longitudinal plane.

[0022] Each of the two strut mounts 7 consists of a hollow cylindrical peripheral wall 9, which terminates at the top in the vehicle's vertical direction z with a circumferential collar 10. This collar has a reduced diameter compared to the hollow cylindrical peripheral wall 9. The strut mount 7 also has a strut tower 11 designed as a sheet metal insert, on which a strut 13 can be supported via a strut bearing 15 (Figures 2 or 3). The strut tower 11 is connected to the strut mount 7 by a composite joint, such as an adhesive bond.

[0023] For a stable connection, the strut dome 11 is designed as a cup-shaped, deep-drawn part with a profiled base 17. A circumferential side wall 19 extends upwards from this. The circumferential side wall 19 terminates in an expanded annular shoulder 21. This has a larger diameter than the circumferential side wall 19 of the strut dome 11. During assembly, the strut dome 15, designed as a sheet metal insert, is guided in a joining direction in the vehicle's vertical direction z upwards through the hollow cylindrical peripheral wall 9 of the strut mount 7 until the large-diameter annular shoulder 21 of the strut dome 11 comes into annular contact with the small-diameter collar 10 of the strut mount 7. In the assembled state, the large-diameter annular shoulder 21 of the strut dome 11 therefore engages under the reduced-diameter collar 10 of the strut mount 7.The mixed construction joint thus formed between the strut dome 11 and the strut mount 7 is subjected exclusively to compressive stress, whereby a high connection strength can be achieved.

[0024] As further shown in Figure 2, the profile base 17 of the strut tower 11 provides a mounting surface to which the strut mount 15 of the strut 13 can be screwed via screw connections 16. The circumferential collar 10 of the strut mount 7 defines a central mounting opening 23 through which the profile base 17 of the strut tower 11 is accessible from above.

[0025] A core of the invention relates to a method for producing at least two vehicle models, each having different axle geometries. According to the invention, identical large cast components can be used for the two vehicle models, but with strut domes 11 specifically adapted to the respective axle geometry, as indicated in Figures 2 and 3. According to Figure 2, a first sheet metal insert 11 is installed as a strut dome in the hollow-cylindrical strut mount 7, the profile base 17 of which is aligned flat. The strut 13, which is bolted perpendicular to the profile base 17, is therefore positioned comparatively upright with a steep strut angle α, resulting in a correspondingly raised body height and a reduced track width.

[0026] Conversely, in Figure 3, a second sheet metal insert 11 is installed in the hollow cylindrical strut mount 7, the profile base 17 of which is oriented more steeply than in Figure 2. The strut 13, which is bolted perpendicular to the profile base 17, is therefore positioned with a comparatively flat strut angle ß, resulting in a correspondingly reduced body height and an increased track width.

[0027] As can be further seen from Figures 2 and 3, the annular shoulders 21 of the two differently designed strut domes 11 and the associated collar 10 of the strut mount 7 are contour-matched to each other in order to achieve the largest possible contact area. Furthermore, Figures 2 and 3 show that the annular shoulder contours of the two sheet metal inserts 11 are structurally identical, while only the profile bases 17 of the two sheet metal inserts 11 are spatially aligned differently.

[0028] List of reference symbols

[0029] 1 body longitudinal member

[0030] 3 Battery or vehicle connection

[0031] 5 body cross members

[0032] 7 Suspension strut mount

[0033] 9 hollow cylindrical peripheral wall

[0034] 10 collars

[0035] 11 Suspension strut tower

[0036] 13 shock absorber

[0037] 15 strut mounts

[0038] 16 screw connection

[0039] 17 profile floor

[0040] 19 surrounding side wall

[0041] 21 Ring shoulder

[0042] 23 central mounting opening a, ß strut angles

Claims

Patent claims 1. Body structure for the front end of a two-track vehicle, with a large cast component with at least one spring strut mount (7) which has a spring strut dome (11) on which an upper end of a spring strut (13), in particular a dome bearing (15) of the spring strut (13), can be supported, characterized in that the spring strut dome (11) is a sheet metal insert which is connected in a mixed construction connection, for example an adhesive connection, to the spring strut mount (7), which is a component of the large cast component.

2. Body structure according to claim 1, characterized in that the spring strut dome (11) has a screwing surface to which the upper end of the spring strut (13) can be screwed, in particular in an orientation normal, that is to say perpendicular, to the screwing surface.

3. Body structure according to claim 1 or 2, characterized in that the spring strut mount (7) consists of a hollow cylindrical peripheral wall (9) which terminates upwards in the vehicle vertical direction (z) with a circumferential collar (10) which is of reduced diameter compared to the hollow cylindrical peripheral wall (9).

4. Body structure according to one of the preceding claims, characterized in that the spring strut dome (11) is a cup-shaped deep-drawn part which has a profiled base (17) from which a circumferential side wall (19) is raised, which ends with an annular shoulder (21) which is larger in diameter than the circumferential side wall (19), and in particular that the profiled base (17) forms the screw-on surface for the spring strut (13).

5. Body structure according to claim 4, characterized in that in the assembled state the large-diameter annular shoulder (21) of the spring strut dome (11) engages under the reduced-diameter collar (10) of the spring strut mount (7), and in particular the collar (10) of the spring strut mount (7) forms a vertical runout against which the spring strut dome (11) designed as a sheet metal insert can be brought into preferably annular contact in a joining direction in the vehicle vertical direction (z) towards the top of the vehicle, and / or in that the mixed construction joining connection between the reduced-diameter collar (10) of the spring strut mount (9) and the large-diameter annular shoulder (21) of the spring strut dome (11) is essentially subjected to compressive stress in the installed position.

6. Body structure according to claim 5, characterized in that the annular shoulder (21) of the spring strut dome (11) and the collar (10) of the spring strut mount (7) are contour-matched to one another in order to provide a large-area contact.

7. Body structure according to one of claims 4 to 6, characterized in that the circumferential collar (10) of the spring strut mount (7) defines a central assembly opening (23) through which the profile base (17) of the spring strut dome (11) is accessible from above.

8. Body structure according to one of the preceding claims, characterized in that in order to provide vehicles with different axle geometries, at least a first sheet metal insert part (11) and a second sheet metal insert part (11) can be kept in stock, which have different component geometries, and in that in particular the annular shoulder contours of the two sheet metal insert parts (11) are of identical construction, while the profile bases (17) of the two sheet metal insert parts (11) are spatially differently aligned, so that in particular depending on the installation of the first or the second sheet metal insert part (11), the spring strut (13) can be screwed at different spring strut angles (α, β) to the profile base (17) of the respective sheet metal insert part (11), whereby in particular vehicles with varying body levels and / or varying track widths can be produced.

9. Body structure according to one of the preceding claims, characterized in that the large cast component is formed mirror-inverted with respect to the vehicle center longitudinal plane on each vehicle side with a body longitudinal member (1) and in particular with a body cross member (5) which connects the two body longitudinal members (1) to one another, and / or that the spring strut mount (7) is formed of the same material and in one piece on the respective body longitudinal member (1).

10. A method for producing vehicles with different axle geometries, wherein the vehicles each have a body structure according to one of the preceding claims.

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