Fluid-fill station for motorized vehicle wheel assembly

Abstract

A system for introducing fluids into a vehicle corner module (VCM) includes first and second fluid supply assemblies comprising vessels for coolant and brake fluids and a fluid-pumping arrangement, a vacuum pump assembly comprising a vacuum pump and fluid conveyances mediating between the vacuum pump and connection arrangements of a coolant-fluid system and a brake-fluid system, and electronic circuitry programmed to control activation of the vacuum pump to reduce a respective pressure in each of the coolant-fluid system and the brake-fluid system, and to control activation of the fluid- pumping arrangements to deliver coolant fluid and brake fluid to the coolant-fluid system and the brake-fluid system.

Description

[0001] FLUID-FILL STATION FOR MOTORIZED VEHICLE WHEEL ASSEMBLY

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to end-of-the-assembly-line preparation of independent vehicle corner modules for vehicles, and in particular to evacuation, vacuum testing and rapid filling of fluid systems.

[0004] BACKGROUND

[0005] It is typical for car manufacturing to assemble components of wheel assemblies to a car platform as part of the car assembly line. Such process includes assembly of individual sub systems like motor, powertrain, suspension, braking, steering, and electrical and control to the chassis.

[0006] Newly-conceived vehicle platforms designed for electric propulsion can include modular wheel assemblies (“vehicle corner modules, or VCMs) including such subsystem like independent suspension, drivetrain, braking and steering . The modular wheel assemblies may be assembled as a unit to a vehicle platform. Accordingly, there is a need for new assembly and preparation methods and systems for mechanizing and automating the rapid mass production of VCMs, including end-of-the-line vacuumtesting and fluid-filling.

[0007] SUMMARY

[0008] A system is disclosed, according to embodiments of the invention, for introducing fluids into a vehicle corner module (VCM). The VCM comprises (i) an electric drive unit, (ii) a control system, (iii) a coolant-fluid system comprising an internal coolant-fluid conveyance and a first connection arrangement effective to enable therethrough, when placed in fluid communication with an external source of a coolant fluid, a flow of a coolant fluid into the coolant-fluid conveyance, and (iv) a brake-fluid system comprising an internal brake-fluid conveyance and a second connection arrangement effective to enable therethrough, when placed in fluid communication with an external source of a brake fluid, a flow of a brake fluid into the brake fluid conveyance. The system comprises: (a) first and second fluid supply assemblies, each fluid supply assembly comprising one or more vessels each storing a respective one of the coolant and brake fluids or a component thereof, and a fluid-pumping arrangement having an inlet in fluid communication with each of the one or more vessels, and an outlet in at least indirect fluid communication with a respective one of the first and second connection arrangements; (b) a vacuum pump assembly comprising a vacuum pump, and first and second fluid conveyances respectively mediating between the vacuum pump and the first and second connection arrangements; and (c) electronic circuitry programmed to (i) control activation of the vacuum pump to reduce a respective pressure in each of the coolant-fluid system and the brake-fluid system, and (ii) control activation of the fluidpumping arrangements to deliver respective quantities of the coolant fluid and the brake fluid to the coolant-fluid system and the brake-fluid system.

[0009] In some embodiments, it can be that the coolant fluid comprises a mixture of components, and / or that the first fluid supply assembly comprises (i) a plurality of vessels each storing a respective component and / or (ii) at least one of a mixing tube and a mixing container, disposed downstream of the vessels and upstream of the first connection arrangement. In some embodiments,, it can be that (i) the first fluid comprises a mixture of components, (ii) one of the components comprises water, and / or (iii) the first fluid supply assembly comprises (A) a vessel storing a respective component that is not water, and / or (B) at least one of a mixing tube and a mixing container disposed downstream of the vessel and upstream of the first connection arrangement.

[0010] In some embodiments, it can be that (i) first and second fluid conveyances of the vacuum pump assembly comprise respective vacuum pressure sensors, and / or (ii) subsequent to activation of the vacuum pump, the reduced respective pressure in in each of the coolant-fluid system and the brake-fluid system is maintained for a period of time for a vacuum decay test.

[0011] In some embodiments, it can be that activating the fluid-pumping arrangement for delivering the coolant fluid is contingent upon a result of the respective vacuum decay test of the coolant-fluid system, and is not contingent upon a result of the respective vacuum decay test of the brake-fluid system. In some embodiments, it can be that activating the fluid-pumping arrangement for delivering the brake fluid is contingent upon a result of the respective vacuum decay test of the brake-fluid system, and is not contingent upon a result of the respective vacuum decay test of the coolant fluid system.

[0012] In some embodiments, the electronic circuitry can be further programmed to set or change, responsively to an identification of a VCM model, one or more of: a respective quantity of a fluid, a respective pressure of a vacuum decay test, a fluid pressure, and a location of a connection arrangement. In some embodiments, the first connection arrangement can be in fluid communication with at least one of the electric drive unit and the control system. In some embodiments, the electronic circuitry can be programmed to control the activation of the vacuum pump and of the fluid-pumping arrangements.

[0013] In some embodiments, a method of introducing respective fluids into the coolantfluid system and the brake-fluid system of the VCM using the system disclosed in any one of the foregoing embodiments can comprise: (a) at a first time, activating the vacuum pump to reduce a respective pressure in the coolant-fluid system and in the brake-fluid system; and (b) for each of the coolant-fluid system and the brake-fluid system, activating, at a second respective time, the respective fluid-pumping arrangements to deliver the respective quantity of the fluid to the corresponding fluid system. In some embodiments of the method the activating of the vacuum pump can be contingent upon receiving an input affirming that the vacuum pump is in fluid-tight communication with the first and second connection arrangements. In some embodiments, the method can additionally comprise, before each respective second time: maintaining the reduced respective pressure for a period of time to perform a vacuum decay test. In some embodiments of the method, the activating of the fluid-pumping arrangements can be contingent upon a result of the vacuum decay test.

[0014] In some embodiments, a method of introducing fluids into the VCM using the system disclosed in any one of the foregoing embodiments can comprise: (a) at a first time, activating the vacuum pump to reduce a respective pressure in the coolant-fluid system; and (b) activating, at a second time, the first fluid-pumping arrangements to deliver the respective quantity of the coolant fluid to the coolant-fluid system. In some embodiments, the method can additionally comprise: (i) reducing a respective pressure in the brake-fluid system using the vacuum pump, and / or (ii) activating the second corresponding fluid-pumping arrangement to deliver the respective quantity of the brake fluid to the brake-fluid system.

[0015] A method is disclosed, according to embodiments, for assembling a vehicle corner module (VCM). The method comprises: (a) transporting, to a fluid-fill station, a VCM sub-frame having joined thereto (i) an electric drive unit comprising an electric motor and power electronics, (ii) a brake system comprising an internal brake-fluid conveyance, (iii) a control system comprising one or more processors, and (iii) a coolantfluid system comprising an internal coolant-fluid conveyance, the fluid-fill station comprising (A) first and second fluid supply assemblies, each fluid supply assembly comprising one or more fluid-storage vessels and a fluid-pumping arrangement, (ii) a vacuum pump, and (iii) electronic circuitry programmed to regulate operation of the fluid-fill station; (b) placing both the respective fluid-pumping arrangements and the vacuum pump in respective fluid communication with each of the internal brake-fluid and coolant-fluid conveyances; (c) activating the vacuum pump to reduce a respective pressure in each of the internal brake-fluid and coolant-fluid conveyances; and (d) activating the fluid-pumping arrangements to deliver respective quantities of the brake fluid and the coolant fluid to the internal brake-fluid and coolant-fluid conveyances.

[0016] In some embodiments, all the steps of the method can be carried out robotically. In some embodiments, the method can be carried out by an automated system.

[0017] In some embodiments, the method can additionally comprise, before the transporting: joining the electric drive unit, the brake system, the control system and the coolant-fluid system to the VCM sub-frame. In some embodiments, the method can additionally comprise, before the transporting: joining a steering system and a suspension system to the VCM sub-frame. In some embodiments, the method can additionally comprise, before the activating of the fluid-pumping arrangements: maintaining the reduced respective pressure for a period of time to perform a vacuum decay test.

[0018] In some embodiments, delivering the coolant fluid to the coolant-fluid system can include mixing a plurality of components to form the delivered coolant fluid. In some embodiments, a computerized control system can be programmed to carry out the activating of the vacuum pump and the activating of the fluid-pumping arrangements according to any of the foregoing disclosed methods. In some embodiments, a computerized control system can be programmed to carry out the method of any one or more the foregoing embodiments.

[0019] BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The invention will now be described further, by way of example, with reference to the accompanying drawings, in which the dimensions of components and features shown in the figures are chosen for convenience and clarity of presentation and not necessarily to scale. In the drawings:

[0021] Fig. 1 is a schematic block diagram showing major components of a vehicle corner module (VCM), according to embodiments of the present invention.

[0022] Fig. 2 shows a schematic block diagram of a VCM during assembly mounted on a carrier, according to embodiments of the present invention.

[0023] Fig. 3 is a schematic diagram of a multi-station assembly facility, according to embodiments of the present invention.

[0024] Fig. 4A is a simplified, schematic diagram of a system for introducing fluids into a VCM, according to embodiments of the present invention.

[0025] Fig. 4B shows a detail of the vacuum pump assembly of the diagram of Fig. 4A, according to embodiments of the present invention.

[0026] Fig. 5 is a schematic block diagram of a computerized control system of the multi-station assembly facility of Fig. 3, according to embodiments of the present invention.

[0027] Figs. 6A and 6B show flowcharts of methods and method steps for introducing fluids into the coolant-fluid system and the brake-fluid system of a VCM, according to embodiments of the present invention. Figs. 7A and 7B show flowcharts of methods and method steps for introducing fluids into a VCM, according to embodiments of the present invention.

[0028] Figs. 8A, 8B, 8C and 8D show flowcharts of methods and method steps for assembling a VCM, according to embodiments of the present invention.

[0029] DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0030] The invention is herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. Throughout the drawings, like-referenced characters are generally used to designate like elements. Subscripted reference characters (e.g., 101) may be used to designate multiple separate appearances of elements of a single species, whether in a drawing or not; for example: 101 is a single appearance (out of a plurality of appearances) of element 10. Similarly, 10IA and 10IB can be two different appearances of a more general element labeled 101. The same elements can alternatively be referred to without subscript (e.g., 10 and not 10i) when not referring to a specific one of the multiple separate appearances, i.e., to the species in general.

[0031] Some embodiments of the disclosure relate to systems for introducing fluids, specifically brake fluid and coolant fluid, into respective systems onboard a vehicle corner module (VCM). The embodiments are primarily framed in terms of a fluid-fill station in a VCM assembly facility, but are equally applicable in other contexts such as, for example, a VCM maintenance and repair facility.

[0032] A fully-assembled VCM according to embodiments includes, installed therewithin and / or integrated therewith, a plurality of systems each comprising mechanical and / or electrical components. The systems are connected either directly or indirectly to a sub-frame mountable to the reference frame of a vehicle. ‘Mountable’ means that the sub-frame includes mechanical and electrical interfaces suitable for joining the sub-frame to the vehicle, and that once mounted by connecting the sub-frame to the vehicle, the VCM is be made operational. The systems connected to the sub-frame can include any or all of, and not exhaustively: an electric drive unit (EDU), a braking system, a steering system and a suspension system; the VCM also includes a VCM control system. An EDU can include any or all of the mechanical and / or electrical components required for actuating a drivetrainto rotate the wheel of the vehicle to drive the vehicle, including, and not exhaustively: power electronics, an electric drive motor, a driveshaft turned by the motor, and gearing assemblies to transmit the rotation to the wheel including, optionally, a single-gear or multi-gear transmission. A braking system can include any or all of the mechanical and electrical components for actuating a brake assembly (e.g., brake disk, brake caliper, etc.). In embodiments, the brake system comprises a brake-fluid system which can include a brake-fluid reservoir and one or more internal conveyances for circulation of the fluid, e.g., to the brake caliper. A steering system can include any or all of the mechanical and / or electrical components required for steering, i.e., pivoting the wheel of the vehicle around a steering axis, including, and not exhaustively: a steering motor, a steering actuator, steering rods, steering system controller or control unit, steering inverter and wheel-angle sensor. A suspension system can comprise conventional components or can optionally include a controllable active suspension system. In embodiments, the VCM also includes a wheel interface or wheel hub, such that some or all of the onboard systems mediate between the sub-frame and the wheel hub.

[0033] A fully-assembled and operational VCM includes a VCM-controller which can include any or all of, and not exhaustively: one or more computer processors, one or more computer-readable storage media, communications arrangements, and a power source. In embodiments, the VCM controller is configured to control the various systems of the VCM independently and / or in response to instructions received from a central controller of the vehicle.

[0034] We now refer to the figures and in particular to Fig. 1, a schematically drawn block diagram of a fully-assembled VCM 150 according to embodiments. The VCM 150 includes a sub-frame 90, mountable to a reference frame 100, e.g., a chassis, of a vehicle and a wheel interface 170. Joined to the sub-frame 90, whether directly or indirectly, are an EDU 81, a steering system 82, a suspension system 83, and a brake system 84. A VCM controller 50 is configured to regulate the operation of some or all of the foregoing systems 81, 82, 83, 84.

[0035] Fig. 2 shows further details of the VCM, including a coolant-fluid system 75 and a brake-fluid system 74. The coolant-fluid system 75 includes a first connection arrangement 61 through which fluids can pass into and out of the coolant-fluid system 75, specifically into and out of an internal coolant-fluid conveyance 71. The fluids passing through the first connection arrangement 61 include a gas such as air, in an operating mode (a ‘vacuum mode’) in which a vacuum-pump assembly reduces the pressure in the coolant-fluid system 75, or a coolant fluid in an operating mode (a ‘filling mode’) in which a fluid supply assembly delivers a quantity of the coolant fluid to the cooling-fluid system 75. The first connection arrangement is preferably designed for a liquid-tight connection with fluid conveyances used in the filling mode, and for a gas-tight connection with fluid conveyances used in the vacuum mode. In some embodiments the same fluid conveyances are used for both the filling mode and the vacuum mode. Via the internal coolant-fluid conveyance 71, the first connection arrangement 61 is in fluid communication with client components of the coolant-fluid system 75, such as, for example (and as shown in Fig. 2), the EDU 81 and the VCM controller 50. The first connection arrangement 61 can include one or more fluid openings (ports), and if there is more than one port the multiple ports can be arranged, in some designs, so as to be connectible by a single fluid multi-connector (comprising multiple port connections) of fluid conveyances of either or both of the fluid-supply assembly and the vacuum-pump assembly. When the first connection arrangement 61 includes multiple ports, the multiple ports can be used in various ways. In a first example, it is possible to devote one port to a vacuum connection and another port to a coolant-fluid connection. In another example, one port can be used for inflow of the coolant fluid and another port can be used for outflow. In yet another example, the multiple ports can be used simultaneously in order to increase flow rates.

[0036] The brake-fluid system 74 includes a second connection arrangement 62 through which fluids can pass into and out of the brake-fluid system 74, specifically into and out of an internal brake-fluid conveyance 72. In some designs, the brake-fluid system 74 includes a brake-fluid reservoir (not shown). The fluids passing through the second connection arrangement 62 include a gas such as air, in a vacuum mode in which a vacuum-pump assembly reduces the pressure in the brake-fluid system 74, or a brake fluid in a filling mode in which a fluid-supply assembly delivers a quantity of the brake fluid to the brake-fluid system 74. The second connection arrangement 62 is preferably designed for a liquid-tight connection with fluid conveyances used in the filling mode, and for a gas-tight connection with fluid conveyances used in the vacuum mode. In some embodiments the same fluid conveyances are used for both the filling mode and the vacuum mode. Via the internal brake-fluid conveyance 72, the second connection arrangement 62 is in fluid communication with internal client components of the brakefluid system 74, such as, for example, a brake pump and a brake caliper. The second connection arrangement 62 can include one or more fluid openings (ports), and if there is more than one port the multiple ports can be arranged in some designs so as to be connectible by a single fluid multi-connector (comprising multiple port connections) of fluid conveyances of either or both of the fluid-supply assembly and the vacuum-pump assembly. When the connection arrangement includes multiple ports, they can be used in various ways. In a first example, it is possible to devote one port to a vacuum connection and another port to a brake-fluid connection. In another example, one port can be used for inflow of the brake fluid and another port can be used for outflow. In yet another example, both ports can be used simultaneously in order to increase flow rates. The respective internal arrangements and modes of use of the multiple ports, if present, are not necessarily the same for the first and second connection arrangements 61, 62. In some embodiments, the first and second connection arrangements 61, 62 have different physical arrangements and / or mechanical designs and / or specifications.

[0037] The assembly of a VCM 150, including the installation of some or all of the systems 81, 82, 83, 84, is carried out, according to some embodiments, in an assembly facility that can be mechanized, and / or partly automated, and / or fully automated. Fig. 2 schematically illustrates a non-limiting example of carrier 200 for a delivering the VCM from station to station during assembly. In some embodiments, the assembly tasks, e.g., connecting systems and components to the sub-frame 90, take place upon the carrier 200. A non-limiting, illustrative example of such an assembly facility is shown in Fig. 3. Assembly stations 2501 through 250n are shown along a path indicated by arrow 1000. The actual path can be of any shape or length, and comprise any number of assembly stations 250. At an exemplary first (amongst those shown) assembly station 2501, exemplary assembly equipment 3001, which in some implementations can be partly or fully automated, joins a first component system 80 to the sub-frame 90 that is transported to and from the station 2501 on a VCM carrier 200. The component system 80 can comprise any of the VCM systems 81, 82, 83, 84 or the onboard VCM controller 50, or any other mechanical or electrical component of the VCM 150.

[0038] At subsequent assembly stations 2502, 250s, and all the way to station 250n, additional component systems can be added using the respective station equipment 3002, 300s and eventually 300n.

[0039] The final station shown in Fig. 3 is a fluid-fill station 260 at which a fluid-fill system 500 delivers coolant fluid and brake fluid to the coolant-fluid system 75 and the brake-fluid system 74. In the non-limiting example of Fig. 3, the fluid-fill system 500 is shown to be located at the final station of the assembly facility. In other examples, the fluid-fill system 500 may be located at an intermediate station, e.g., following the joining to the sub-frame of the EDU 81, the brake system 84, and the VCM controller 50, cited hereinabove as the three components which make up the minimum list of client components of the coolant-fluid system 75 and the brake-fluid system 74. In such examples, other component systems 80, such as a steering system 82 and suspension system 83, may be assembled to the sub-frame 90 after the fluid-fill station 260. In still other examples, the fluid-fill system 500 is a standalone system located at, for example a VCM maintenance or repair location.

[0040] Further details of the fluid-fill system 500 can be understood with reference to Figs.4 A, a schematic illustration showing a non-limiting example of a fluid-fill system 500 according to embodiments.

[0041] The fluid-fill system 500 comprises first and second fluid supply assemblies 180. Each fluid supply assembly 180 comprises one or more vessels 110 each storing a respective one of the coolant and brake fluids 21, 202 or a component 20IA, 20IB of the coolant fluid 21. A fluid-pumping arrangement 121 has an inlet in fluid communication with each of the one or more vessels 110, and an outlet in at least indirect fluid communication with a respective one of the first and second connection arrangements 61, 62. The fluid-pumping arrangements 121 can comprise respective positive-displacement pumps such as, for example, peristaltic pumps. The fluid-pumping arrangements 121, in embodiments, are in communication via respective fluid conveyances 115 disposed downstream of the vessels 110 and upstream of the fluid-pumping arrangements 121, where the terms ‘downstream’ and ‘upstream’ refer to the general direction of the flow of fluids towards the VCM 150 within the fluid-fill station 260.

[0042] In some embodiments, fluid-fill system 500 can additionally comprise respective primary sources of fluids (not shown) such as larger containers, e.g., drums) for storing respective fluids, and / or respective piping arrangements for delivering fluids to the fluidfill station 260, such as, for example, pipes in communication with the water mains. The fluid-fill system 500 can additionally comprise pumps and strainers mediating between the respective primary sources of fluids and the vessels 110.

[0043] In the non-limiting example of Fig. 4A, the coolant fluid 21 comprises a mixture of components 20IA, 20IB, and the first fluid supply assembly 1801 comprises a plurality of vessels IIOIA, IIOIB, each storing a respective component 20i. In other example, the coolant fluid 21 either does not comprise a mixture, or the mixture is provided to the fluid-fill system 500; in such cases the fluid-fill system 500 does not include multiple vessels 110 and pumps 121. The exemplary first fluid supply assembly 1801 of Fig. 4A comprises a mixing container 130, disposed downstream of the vessels 1101 and upstream of the first connection arrangement 61. In other examples (not shown) a mixing tube is used instead of a mixing container. In embodiments, a first component 20IA comprises water and a second component 20IB comprises glycol, e.g., ethylene glycol or propylene glycol. Exemplary mixed coolant fluids 21 comprise 40-60% glycol, with the remainder water.

[0044] In the example of Fig. 4A, each of the fluid-pumping arrangements 121 of the first fluid supply assembly 1801 are in communication with a respective fluid conveyance 124 downstream of the fluid-pumping arrangements 1211 and upstream of the mixing container 130. In some embodiments, respective metering devices (not shown) are installed inline between the fluid-pumping arrangements 1211 and the mixing container 130. An additional fluid conveyance 1311 is provided downstream of the mixing container 130 and upstream of the first connection arrangement 61. In some designs, a pump (not shown) is provided downstream of the mixing container 130 and upstream of the first connection arrangement 61. The second fluid supply assembly I8O2, provided for delivering brake fluid 202 from the single vessel IIO2 to the second connection arrangement 62 via the second pumping arrangement 1212, includes fluid conveyance 1312 downstream of the fluid-pumping arrangement 1212 and upstream of the second connection arrangement 62.

[0045] In another example (not illustrated) of a first fluid supply assembly I8O1, a single vessel 1101 holds the coolant fluid 21, which may be mixed coolant fluid, such that no mixing container is required. In such an example, a single pump 121i is provided, and a fluid conveyance 1311 is provided downstream of the pump 121i and upstream of the first connection arrangement 61.

[0046] The fluid-fill system 500 of Fig. 4A additionally comprises a vacuum pump assembly 140 comprising a vacuum pump 145, and first and second fluid conveyances 148 respectively mediating between the vacuum pump 145 and the first and second connection arrangements 61, 62. In some embodiments, as shown in Fig. 4B, the vacuum pump assembly 140 can include respective manual or automatic vacuum pressure sensors 144 arranged to monitor pressures in the first and second fluid conveyances 148. The pressure sensors 144 can be used, for example, to monitor pressures after partial evacuation of the coolant-fluid system 75 and / or the brake-fluid system 74. In some embodiments, manual and / or automatic valves (not shown) can be provided in the first and second fluid conveyances 148 of the vacuum pump assembly 140, so as to partially evacuate and / or or maintain reduced pressure in the coolant-fluid system 75 and the brake-fluid system 74 separately.

[0047] Referring again to Fig. 4A, electronic circuitry, e.g., a control system 40 of the fluid-fill system 500, is programmed to control activation of the vacuum pump 145 to reduce a respective pressure in each of the coolant-fluid system 75 and the brake-fluid system 74, and to control activation of the fluid-pumping arrangements 121, to deliver predetermined quantities of the coolant fluid 21 and the brake fluid 202 to the coolantfluid system 75 and the brake-fluid system 74. The level of mechanization and automation in a fluid-fill station 260 can vary according to implementation strategy. As illustrated schematically in Fig. 4A, robotic equipment 310 can be made available for semi-automated or fully automated operation of the fluid-fill system 500. Vision systems 320 and / or an image-processing in the control system 40 can be provided as necessary for such operation. Some or all of the robotic elements of the fluid-fill station equipment 310 can be configured for automatic or semi-automatic adaption to one or more parameters of a VCM 150, including, for example and without limitation, VCM size, internal arrangement of VCM components, placement of connection arrangements 61, 62, and specifications of the internal fluid conveyances 71, 72 such as volume and / or pressure. ‘Adaptation’ of the equipment 310 in this context can mean, and not exhaustively: changing an operational parameter, changing placement of a fluid conveyance 131, reconfiguring a port connection, and changing a mixture ratio of coolant-fluid components 201. In some embodiments, a VCM 150 is identified, e.g., by imaging equipment 320, by another sensor such as an RF receiver or barcode reader, or by transferring information after establishing communications between, e.g., the VCM controller 150 and the control system 40 of the fluid-fill system 500 or station 260.

[0048] We now refer to Fig. 5. The control system 40 (or, equivalently, ‘electronic circuitry’) comprises computing equipment and ancillary equipment configured for monitoring, controlling, regulating and / or actuating one or more components, systems or sub-systems of the fluid-fill system 500. Depending on location customization, the control system can include any or all of (and not exhaustively): one or more computer processors 55, a computer-readable storage media 58, 59, a communications module 57. The computer-readable program storage media 58, 59 can include transient and / or transient storage, and can include one or more storage units, all in accordance with desired functionality and design choices. Some or all of the computer-readable program storage media 58, 59 can be cloud-based. In embodiments, the program storage 58 can be used for storing program instructions in firmware and / or software, for execution by the one or more processors 55; operating data and / or maintenance data relating to the VCMs 150 being handled and / or any one or more of its sub-systems and their components can be stored in the data storage module 59. The communications module 57 is configured to establish communications links with fluid-supply assemblies 180 and vacuum pumping assemblies 140 via communications arrangements 91, with an external, e.g., assembly facility computer via communications arrangements 94, with sensors, e.g., vision sensors 320 via communications arrangements 92, to assembly systems such as mechanical or robotic equipment 310 via communications arrangements 93, and to the VCM 150 view communications arrangements 95. The communication link to the VCM 150 can be to the VCM controller 50. In some embodiments, not all of the illustrated components of the control system 40 are provided. In some embodiments, not all of the communications arrangements are provided.

[0049] Referring now to Fig. 6A, a method is disclosed for introducing respective fluids 21, 202 into the coolant-fluid system 75 and the brake-fluid system 74 of a VCM 150 using the system 500 of any one of the disclosed embodiments. As illustrated by the flow chart in Fig. 6A, the method comprises at least the two steps SOI, S02:

[0050] Step SOI includes activating the vacuum pump 145 to reduce a respective pressure in each of the coolant-fluid system 75 and in the brake-fluid system 74. In some embodiments, the activating of the vacuum pump 145 is contingent upon receiving an input, e.g., by the control system 40 or by an operator, affirming that the vacuum pump 145 is in fluid-tight communication with the first and second connection arrangements 61, 62.

[0051] Step S02 includes activating the respective fluid-pumping arrangements 121 for each of the coolant-fluid system 75 and the brake-fluid system 74 to deliver respective quantities of the fluids 21, 202, to the corresponding fluid system 75, 74.

[0052] According to the method, Step SOI is carried out at a first time, and Step S02 is carried out at a second respective time, later than the first time. In other words, for each of the respective fluid systems 75, 74, the lowering of pressure by the vacuum pump 145 precedes the delivery of the liquid by the fluid-supply assembly 180.

[0053] In some embodiments, as illustrated by the flow chart in Fig. 6B, the method additionally comprises Step S03.

[0054] Step S03 includes: maintaining the reduced respective pressure for a period of time to perform a vacuum decay test, i.e., in each of the coolant-fluid system 75 and the brake-fluid system 74. Step S03, when carried out, is carried out after the beginning of Step SOI and before the commencement of Step S02 for each of the respective fluid systems 75, 74. In some embodiments, carrying out Step S02, i.e., activating the fluidpumping arrangements 121, is contingent upon a result of the vacuum decay test of Step S03.

[0055] Referring now to Fig. 7A, a method is disclosed for introducing respective fluids 21, 2(h into the VCM 150 using the system 500 of any one of the disclosed embodiments. As illustrated by the flow chart in Fig. 7A, the method comprises at least the two steps Sil, S12:

[0056] Step Sil includes activating the vacuum pump 145 to reduce a pressure in the coolant-fluid system 75.

[0057] Step S12 includes activating the fluid-pumping arrangements 1211 for the coolantfluid system 75 to deliver a specified quantity of the coolant fluid 21 to the coolant-fluid system 75.

[0058] According to the method, Step Sil is carried out at a first time, and Step S12 is carried out at a second respective time, later than the first time. In other words, the lowering of pressure by the vacuum pump 145 precedes the delivery of the coolant fluid 21 by the fluid-supply assembly 1801.

[0059] In some embodiments, as illustrated by the flow chart in Fig. 7B, the method additionally comprises Steps S13 and S14.

[0060] Step S13 includes reducing a pressure in the brake-fluid system 74 using the vacuum pump 145.

[0061] Step S14 includes activating the fluid-pumping arrangement 1212 for the brakefluid system 74 to deliver a specified quantity of the brake fluid 202 to the brake-fluid system 74.

[0062] In some embodiments, Step S13 is carried out at a first time, and Step S14 is carried out at a second respective time, later than the first time. These first and second times are not necessarily the first and second times of Steps Sil and S12. Steps S13 and S14 can be carried out independently of Steps Sil and S12, or can be carried out in parallel but without interdependence; in other words, carrying out Step S14 depends on completing Step S13 but does not depend on completing Step Sil, and carrying out Step S12 depends on completing Step Sil but does not depend on carrying out Step S13.

[0063] Referring now to Fig. 8A, a method is disclosed for assembling a VCM 150. As illustrated by the flow chart in Fig. 8A, the method comprises at least the four steps S21, S22, S23 and S24.

[0064] Step S21 includes transporting a VCM sub-frame 90 to a fluid-fill station 260. Joined to the sub-frame 90 are an electric drive unit 81 comprising an electric motor and power electronics, a brake system 84 comprising an internal brake-fluid conveyance 72, a VCM control system 50 comprising one or more processors, and a coolant-fluid system 75 comprising an internal coolant-fluid conveyance 71, the fluid-fill station 260 comprising first and second fluid supply assemblies 180, each fluid supply assembly 180 comprising one or more fluid-storage vessels 110 and a fluid-pumping arrangement, a vacuum pump 145, and electronic circuitry 40 programmed to regulate operation of the fluid-fill system 500.

[0065] Step S22 includes placing both the respective fluid-pumping arrangements 121 and the vacuum pump 145 in respective fluid communication with each of the internal brake-fluid and coolant-fluid conveyances 72, 71.

[0066] Step S23 includes activating the vacuum pump 145 to reduce a respective pressure in each of the internal brake-fluid and coolant-fluid conveyances 72, 71. In some embodiments, activation of the vacuum pump 145 is performed by the control system 40 of the fluid-fill system 500.

[0067] Step S24 includes activating the fluid-pumping arrangements 121 to deliver respective quantities of the brake fluid 202 and the coolant fluid 21 to the internal brakefluid and coolant- fluid conveyances 72, 71. In some embodiments, delivering the coolant fluid 21 to the coolant-fluid system 75 includes mixing a plurality of components 20i to form the delivered coolant fluid 21. In some embodiments, activation of the fluidpumping arrangements 121 is performed by the control system 40 of the fluid-fill system 500.

[0068] In some embodiments, any or all of Steps S21, S22, S23 and S24 can be performed robotically and / or by semi-automated or automated systems. For example, a carrier 200 used to transport the assembled or partly-assembled VCM 150 and the associated systems 80 to the fluid-fill station 260 can be robotic and / or automated. Similarly, fluid-fill equipment 310 can be used to mechanize and / or automate Step S02. In an example, the activation circuits and / or valves of the vacuum pump 145 and / or the fluid pumps 121 can, in an example, be controlled automatically by the control system 40 of the fluid-fill system 500.

[0069] In some embodiments, as illustrated in Fig. 8B, the method can additionally comprise Step S25.

[0070] Step S25 includes joining the electric drive unit 81, the brake system 84, the VCM control system 50, and the coolant-fluid system 75 to the VCM sub-frame 90. If Step S25 is performed, it can be carried out at one or more other locations other than at the fluidfill station 260, e.g., at one or more assembly stations 250 preceding the fluid-fill station 260 on the path 1000, and thus it is carried out before Step S21, i.e., before the transporting of the partly-assembled or fully-assembled VCM 150 to the fluid-fill station 260.

[0071] In some embodiments, as illustrated in Fig. 8C, the method can additionally comprise Step S26.

[0072] Step S26 includes joining a steering system 82 and a suspension system 83 to the VCM sub-frame 90. In some embodiments, Step S26, if performed, is carried out before Step S21, i.e., before the transporting to the fluid-fill station 260. In some embodiments, Step S26, if performed, is carried out after Step S24, i.e., after completion of the fluid filling.

[0073] In some embodiments, as illustrated in Fig. 8D, the method can additionally comprise Step S27.

[0074] Step S27 includes maintaining the reduced respective pressure for a period of time to perform a vacuum decay test. Step S27, if performed, is carried out before Step S24, i.e., before the coolant fluid 21 and brake fluid 202 are delivered.

[0075] Any of the methods and / or method steps disclosed herein can be combined in any way suitable, and any such combination is within the scope of the disclosed embodiments. Any of the methods and / or method steps disclosed herein can be carried out by (or in response to an instruction by) the control system 40 of the fluid-fill system

[0076] 500.

[0077] The present invention has been described using detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the present invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the present invention that are described and embodiments of the present invention comprising different combinations of features noted in the described embodiments will occur to persons skilled in the art to which the invention pertains.

Claims

CLAIMS1. A system for introducing fluids into a vehicle corner module (VCM), the VCM comprising an electric drive unit, a control system, a coolant-fluid system comprising an internal coolant-fluid conveyance and a first connection arrangement effective to enable therethrough, when placed in fluid communication with an external source of a coolant fluid, a flow of a coolant fluid into the coolant-fluid conveyance, and a brake-fluid system comprising an internal brake-fluid conveyance and a second connection arrangement effective to enable therethrough, when placed in fluid communication with an external source of a brake fluid, a flow of a brake fluid into the brake fluid conveyance, the system comprising: a. first and second fluid supply assemblies, each fluid supply assembly comprising one or more vessels each storing a respective one of the coolant and brake fluids or a component thereof, and a fluid-pumping arrangement having an inlet in fluid communication with each of the one or more vessels, and an outlet in at least indirect fluid communication with a respective one of the first and second connection arrangements; b. a vacuum pump assembly comprising a vacuum pump, and first and second fluid conveyances respectively mediating between the vacuum pump and the first and second connection arrangements; and c. electronic circuitry programmed to (i) control activation of the vacuum pump to reduce a respective pressure in each of the coolant-fluid system and the brake-fluid system, and (ii) control activation of the fluid-pumping arrangements to deliver respective quantities of the coolant fluid and the brake fluid to the coolant-fluid system and the brake-fluid system.

2. The system of claim 1, wherein the coolant fluid comprises a mixture of components, and the first fluid supply assembly comprises (i) a plurality of vessels each storing a respective component and (ii) at least one of a mixing tubeand a mixing container, disposed downstream of the vessels and upstream of the first connection arrangement.

3. The system of claim 1, wherein (i) the first fluid comprises a mixture of components, (ii) one of the components comprises water, and (iii) the first fluid supply assembly comprises (A) a vessel storing a respective component that is not water, and (B) at least one of a mixing tube and a mixing container disposed downstream of the vessel and upstream of the first connection arrangement.

4. The system of any one of the preceding claims, wherein (i) first and second fluid conveyances of the vacuum pump assembly comprise respective vacuum pressure sensors, and (ii) subsequent to activation of the vacuum pump, the reduced respective pressure in in each of the coolant-fluid system and the brake-fluid system is maintained for a period of time for a vacuum decay test.

5. The system of claim 4, wherein activating the fluid-pumping arrangement for delivering the coolant fluid is contingent upon a result of the respective vacuum decay test of the coolant-fluid system, and is not contingent upon a result of the respective vacuum decay test of the brake-fluid system.

6. The system of claim 4, wherein activating the fluid-pumping arrangement for delivering the brake fluid is contingent upon a result of the respective vacuum decay test of the brake-fluid system, and is not contingent upon a result of the respective vacuum decay test of the coolant fluid system.

7. The system of any one of the preceding claims, wherein the electronic circuitry is further programmed to set or change, responsively to an identification of a VCM model, one or more of: a respective quantity of a fluid, a respective pressure of a vacuum decay test, a fluid pressure, and a location of a connection arrangement.

8. The system of any one of the preceding claims, wherein the first connection arrangement is in fluid communication with at least one of the electric drive unit and the control system.

9. The system of any one of the preceding claims, wherein the electronic circuitry is programmed to control the activation of the vacuum pump and of the fluidpumping arrangements.

10. A method of introducing respective fluids into the coolant-fluid system and the brake-fluid system of the VCM using the system of any one of claims 1 to 9, the method comprising: a. at a first time, activating the vacuum pump to reduce a respective pressure in the coolant-fluid system and in the brake-fluid system; and b. for each of the coolant-fluid system and the brake-fluid system, activating, at a second respective time, the respective fluid-pumping arrangements to deliver the respective quantity of the fluid to the corresponding fluid system.

11. The method of claim 10, wherein the activating of the vacuum pump is contingent upon receiving an input affirming that the vacuum pump is in fluid-tight communication with the first and second connection arrangements.

12. The method of claim 11, additionally comprising, before each respective second time: maintaining the reduced respective pressure for a period of time to perform a vacuum decay test.

13. The method of claim 12, wherein the activating of the fluid-pumping arrangements is contingent upon a result of the vacuum decay test.

14. The method of any one of claims 10 to 13, additionally including, before the activating of the vacuum pump and of the respective fluid-pumping arrangements, adapting the system to one or more parameters of the VCM.

15. The method of claim 14, wherein the adapting is carried out automatically or semi-automatically.

16. The method of either one of claims 14 or 15, wherein the adapting is in response to detecting the one or more parameters of the VCM.

17. The method of either one of claims 14 or 15, wherein the adapting is in response to receiving information from the control system of the VCM.

18. The method of any one of claims 14 to 17, wherein the adapting comprises at least one of changing an operational parameter, changing placement of a fluidconveyance, reconfiguring a port connection, and changing a mixture ratio of coolant-fluid components.

19. A method of introducing fluids into the VCM using the system of any one of claims 1 to 9, the method comprising: a. at a first time, activating the vacuum pump to reduce a pressure in the coolant-fluid system; and b. activating, at a second time, the first fluid-pumping arrangements to deliver the quantity of the coolant fluid to the coolant-fluid system.

20. The method of claim 19, additionally comprising: i. reducing a pressure in the brake-fluid system using the vacuum pump, and ii. activating the second corresponding fluid-pumping arrangement to deliver the quantity of the brake fluid to the brake-fluid system.

21. A method of assembling a vehicle corner module (VCM), the method comprising: a. transporting, to a fluid-fill station, a VCM sub-frame having joined thereto (i) an electric drive unit comprising an electric motor and power electronics, (ii) a brake system comprising an internal brake-fluid conveyance, (iii) a control system comprising one or more processors, and (iii) a coolant-fluid system comprising an internal coolant-fluid conveyance, the fluid-fill station comprising (A) first and second fluid supply assemblies, each fluid supply assembly comprising one or more fluid-storage vessels and a fluid-pumping arrangement, (ii) a vacuum pump, and (iii) electronic circuitry programmed to regulate operation of the fluid-fill station; b. placing both the respective fluid-pumping arrangements and the vacuum pump in respective fluid communication with each of the internal brakefluid and coolant-fluid conveyances;c. activating the vacuum pump to reduce a respective pressure in each of the internal brake-fluid and coolant-fluid conveyances; and d. activating the fluid-pumping arrangements to deliver respective quantities of the brake fluid and the coolant fluid to the internal brake-fluid and coolant-fluid conveyances.

22. The method of claim 21, wherein all the steps of the method are carried out robotically.

23. The method of claim 22, wherein the method is carried out by an automated system.

24. The method of any one of claims 21 to 23, additionally comprising before the transporting: joining the electric drive unit, the brake system, the control system and the coolant-fluid system to the VCM sub-frame.

25. The method of claim 24, additionally comprising: joining a steering system and a suspension system to the VCM sub-frame.

26. The method of any one of claims 21 to 25, additionally comprising, before the activating of the fluid-pumping arrangements: maintaining the reduced respective pressure for a period of time to perform a vacuum decay test.

27. The method of any one of claims 21 to 26, wherein delivering the coolant fluid to the coolant-fluid system includes mixing a plurality of components to form the delivered coolant fluid.

28. A computerized control system, programmed to carry out the activating of the vacuum pump and the activating of the fluid-pumping arrangements according to the method of any one of claims 21 to 27.

29. A computerized control system, programmed to carry out the method of any one of claims 21 to 27.

Images