Assembly method for mounting a front end module on a front body structure of a vehicle

Abstract

Method for mounting a front end module (11) on a front body structure (10) of a vehicle, comprising: providing the front body structure (10) with two doors (12) (S10), providing the front end module (11) with at least one functional element (13) (S20), providing two fenders (14) (S30), mounting the front end module (11) on the front body structure (10) (S40), and mounting the two fenders (14) on the front body structure (10) after mounting the front end module (11) on the front body structure (S50).

Description

[0001] Assembly procedure for mounting a front-end module

[0002] to the front of a vehicle

[0003] The invention relates to a method for mounting a front-end module to the front of a vehicle.

[0004] Vehicle manufacturing involves assembling fenders, a front-end module, and a hood onto the front of the vehicle. This assembly process presents challenges regarding the accessibility of individual components due to interfering contours or undercuts, as well as time-consuming alignment procedures. These issues lead to longer assembly times and higher costs.

[0005] A method for assembling a front-end module is known from JP 4063774 B2. A device for assembling a front-end module is known from KR 20100019114 A. An assembly line for a vehicle is known from WO 12141232 A1.

[0006] In this context, it has now become apparent that there is a need to provide a method for mounting a front-end module to the front of a vehicle. In particular, there is a need to provide an improved method for mounting a front-end module to the front of a vehicle.

[0007] It is an object of the present invention to eliminate, or at least partially eliminate, the disadvantages described above in a method for mounting a front-end module to the front of a vehicle. In particular, it is an object of the present invention to provide an improved method for mounting a front-end module to the front of a vehicle.

[0008] The foregoing problem is solved by the patent claims. In particular, the problem is solved by a method for mounting a front-end module to a front section of a vehicle with the features of independent claim 1.

[0009] A first aspect of the present invention relates to a method for mounting a front-end module to the front of a vehicle, comprising: providing the front of the vehicle with two doors, providing the front-end module with at least one functional element, providing two fenders, mounting the front-end module to the front of the vehicle, and mounting the two fenders to the front of the vehicle after mounting the front-end module to the front of the vehicle.

[0010] The term "front-end module" refers in particular to an assembly designed to arrange functional elements of a vehicle front end and connect them to the front section of the vehicle. The front-end module preferably includes a module carrier on which functional elements can be arranged. The front-end module can be a single piece or multiple pieces. It can have an interface for mounting on a longitudinal member or a bulkhead of a longitudinal member of the front section. The connection between the front-end module and the front section can be in the x-direction, y-direction, and / or z-direction. The interface can be a bolted and / or welded connection. The front-end module can include a multitude of functional elements that can be pre-assembled. The front-end module represents an assembly that can be delivered to an assembly line for delivery.The frontend module can be assembled manually or automatically.

[0011] The term "front end" refers specifically to the front part of a vehicle body, extending from one end to the A-pillar. The front end may include longitudinal members for mounting a front-end module. It may also include a driver's door and / or a passenger door.

[0012] Within the scope of the invention, a functional element for a front-end module is understood to be an element configured to perform a function. The function may, for example, include a protective function, a damping function, a lighting function, and / or a covering function. The functional element may, for example, include a headlight, a bumper, or a bumper cover. The functional element may preferably be pre-assembled on the front-end module.

[0013] A fender is a structural component that is positioned above a tire or wheel arch.

[0014] The invention is based on the understanding that the front-end module is currently mounted on the front of the vehicle after the fenders have been installed. However, due to interfering geometries and undercuts, only front-end modules with a limited number of functional elements are possible. This means that the full potential of a pre-assembled front-end module cannot be utilized. Furthermore, with a conventional installation sequence of fender / hood / front-end module, there is no direct relationship between the fender and the hood and the front-end module. This results in a high degree of manual adjustment. For example, the bumper cover, radiator grille, headlights, and lighting systems must be manually and painstakingly aligned because the alignment of the fender to the front-end module and to the overall appearance of the front of the vehicle is not always possible.

[0015] The joint / flushness pattern is missing.

[0016] The invention proposes pre-assembling the front-end module with at least one functional element, ideally with all possible functional elements, and mounting it on the front of the vehicle. Mounting the front-end module can include aligning it with the front of the vehicle. For example, the front-end module can be aligned centrally or flush with the two doors. The fenders are then mounted only after the front-end module has been installed. The fenders can be mounted manually, semi-automatically, or automatically under deformation to compensate for inaccuracies in the x-direction. This allows for the assembly of a fully pre-set front-end module that requires no further work. This reduces assembly time and lowers production costs. Furthermore, aligning the fender with the front-end module is simpler than the other way around due to the simpler geometry.The alignment of the front-end module can be advantageously simplified. This allows the front-end module to be equipped with fewer geometric adjustment elements, which has a positive impact on the module's provision costs. Furthermore, this can also facilitate easier disassembly of the front-end module. This has a positive effect on repair costs and disposal. Rework can also be advantageously reduced. Logistics can also be simplified. The cycle time can be reduced. The production area in body shop can be reduced, as no assembly line is required there. Material costs can also be saved. Production personnel can also be saved. Rework effort can also be reduced. Finally, logistical effort can be reduced.

[0017] According to a preferred embodiment, mounting the front-end module to the front section can include aligning the front-end module with the two doors of the front section, wherein the alignment consists of alignment in the z-direction and y-direction. The alignment can be performed using a preset device with the aid of a gauge or guides. The preset device can include a manipulator or a gripper. The alignment can be performed freely at a connection point or interface of the front-end module to the front section or to the longitudinal member of the front section. The alignment can be performed via a metrologically supported control system, for example, using reference elements on the front section and / or fit-determining components on the front section. The alignment is performed only in the z-direction and y-direction. The z-direction refers to the vertical direction and the y-direction to the horizontal or transverse direction.The x-direction refers to the longitudinal direction or direction of travel.

[0018] This method can advantageously reduce alignment effort and create an improved overall appearance in terms of joints and flushness. Furthermore, aligning the fender to the front-end module is easier than the other way around due to the simpler geometry of the fender.

[0019] Advantageously, mounting the two fenders can each involve aligning one of the two fenders to the front-end module and one of the two doors. The fender can preferably be aligned in the y-direction and / or z-direction. The alignment can involve stretching, compressing, and / or deforming the fender. The fenders can preferably be held in a defined position using a tool. The fenders can preferably be pre-positioned. The fenders can preferably be oriented. The fenders can preferably be positioned, oriented, and / or aligned at at least one geometric feature on the front-end module and at least one geometric feature on one of the two doors. The fenders can be mounted to the front of the vehicle by bolting. This can advantageously reduce the adjustment effort. The alignment can be performed manually or automatically.

[0020] Aligning the fender with the front end module and door can significantly reduce assembly effort. This has a positive impact on quality and supply costs.

[0021] According to a preferred embodiment, this can include at least one functional element of one or more of the following: bumper, headlight, bumper cover, module carrier, radiator grille, lighting system, and / or pedestrian protection. In this way, the degree of modularization can be advantageously increased and the working time in the main assembly line can be advantageously reduced. A larger assembly can thus be advantageously provided.

[0022] Advantageously, the process can further include the following steps:

[0023] Providing a front flap and

[0024] Mounting the front flap after mounting the front end module and before mounting the two fenders.

[0025] The term "front flap" refers to a hood in this case.

[0026] The front flap can preferably be picked up in a defined manner using a tool, e.g., a gripper. The front flap can preferably be pre-positioned in a defined manner using a tool. The front flap can preferably be positioned, oriented, and / or aligned at at least one geometric feature on the front-end module and at least one geometric feature on one of the two doors. The front flap can be mounted to the front section by bolting. The front flap can be installed automatically under deformation conditions, thus compensating for errors. This advantageously reduces the adjustment effort. Alignment can be performed manually or automatically.

[0027] Mounting the front flap in front of the fenders advantageously allows for easier access during assembly. This has a positive effect on manufacturing costs.

[0028] Particularly advantageous is the installation of the front flap, which may involve aligning the front flap with both doors of the front of the vehicle and the front end module.

[0029] The front flap can preferably be aligned with at least one geometric feature on the front end module and at least one geometric feature on one of the two doors.

[0030] Such alignment can be easily automated. This type of alignment is simpler than aligning the front-end module to the front panel. This has a positive impact on quality and process costs. According to a preferred embodiment, the method can further comprise the following steps:

[0031] Providing at least one small part, wherein the at least one small part may comprise at least one or more of the following components: retaining element, deformation element and / or front flap hinge, and

[0032] Mounting the at least one small part on the front of the vehicle after mounting the front end module, wherein the mounting of the at least one small part may include aligning the at least one small part on the front end module and on at least one of the two doors.

[0033] The small parts are used, among other things, for mounting the front hood and fenders to the front of the vehicle. These small parts can preferably be picked up, pre-positioned, and / or aligned using a defined tool. The alignment of the small parts can preferably be achieved using at least one geometric feature of the front-end module and / or at least one geometric feature of one of the two doors. This enables a simple and automatable alignment process, which can have a positive impact on quality and production costs. This also reduces the adjustment effort required for the fender and / or the front hood.

[0034] Alternatively, at least one small part, including the fender and / or hood, can be pre-assembled and then mounted to the front of the vehicle as a separate assembly. This can have a positive impact on assembly time.

[0035] Alternatively, the front-end module, fender, at least one small part, and / or the front flap can be rigidly installed according to pre-settings without measuring equipment. This can have a positive impact on assembly time.

[0036] All disclosures and embodiments described herein relate to the method described above. Advantageously, the advantages offered by one embodiment and example also apply to all other embodiments and examples, and vice versa.

[0037] Further advantages, features, and details of the invention will become apparent from the following description, in which several exemplary embodiments of the invention are described in detail with reference to the drawings. The features mentioned in the claims and in the description can each be essential to the invention individually or in any combination. The drawings schematically show:

[0038] Figure 1 shows a front section,

[0039] Figure 2 shows a frontend module,

[0040] Figure 3: fender and hood,

[0041] Figure 4 shows a method according to the invention for mounting a front-end module to the front of a vehicle,

[0042] Figure 5 shows a schematic assembly sequence,

[0043] Figure 6 shows another schematic assembly sequence and

[0044] Figure 7 shows another schematic assembly sequence.

[0045] Fig. 1 shows the front section 10 of a vehicle. Doors 12 are mounted on the front section 10. Small parts 16 for mounting the front hood 15 and fenders 14 are mounted on the longitudinal members 17 of the front section 10.

[0046] Fig. 2 shows a front-end module 11. The front-end module 11 comprises a multitude of functional elements 13. In this case, a radiator guard 18, two main headlights 19 and a bumper cover 20 are already pre-assembled in the front-end module 11.

[0047] Fig. 3 shows two fenders 14 and a front flap 15.

[0048] Fig. 4 shows a method according to the invention for mounting a front-end module 11 to a front section 10 of a vehicle. The method comprises several steps:

[0049] Step S10 includes providing the front section 10 with two doors 12.

[0050] Step S20 includes providing the front-end module 11 with at least one functional element 13. The functional element 13 can be, for example, a main headlight 19, a bumper cover 20, or a radiator grille 18. Step S30 includes providing two fenders 14.

[0051] Step S40 includes mounting the front end module 11 to the front body 10. Mounting the front end module 11 to the front body 10 may include aligning the front end module 11 to the two doors 12 of the front body 10, wherein the alignment consists of alignment in the z-direction and y-direction.

[0052] Step S50 involves mounting the two fenders 14 to the front end 10 after mounting the front end module 11 to the front end. Mounting the two fenders 14 may each involve aligning one of the two fenders 14 to the front end module 11 and one of the two doors 12.

[0053] Preferably, the method may further include, as a step S60, the provision of a front flap.

[0054] Preferably, the method can further comprise step S70 of mounting the front flap 15 after mounting the front-end module 11 and before mounting the two fenders 14. Mounting the front flap 15 can preferably include aligning the front flap 15 with both doors 12 of the front section 10 and the front-end module 11.

[0055] Preferably, the method can further comprise step S80 of providing small parts 16. The small parts can, for example, include a retaining element, a deformation element, or a front flap hinge. Preferably, the small parts 16 are mounted in front of the fenders 14.

[0056] Preferably, the method can further comprise step S90 of mounting the small parts 16 onto the front section 10 after mounting the front-end module 11. Preferably, the mounting of the small parts 16 can comprise aligning the small parts 16 onto the front-end module 11 and at least one of the two doors 12.

[0057] Fig. 5 shows a schematic assembly sequence for a front-end module 11 onto a front section 10. First, the front section 10 with doors 12 is provided. Then, the front-end module 11 is aligned and mounted on the doors 12. Next, the small parts 16 are aligned and mounted on the front-end module 11 and the doors 12. Following this, the front flap 15 is aligned and mounted on the front-end module 11 and the doors 12. Finally, the fenders 14 are aligned and mounted on the front-end module 11 and the doors 12.

[0058] Fig. 6 shows a schematic assembly sequence for a front-end module 11 on a front section 10. In contrast to Fig. 5, the fenders 14 are first aligned and mounted on the front-end module 11 and the doors 12. Subsequently, the front flap 15 is aligned and mounted on the front-end module 11 and the doors 12.

[0059] Fig. 7 shows a schematic assembly sequence for a front-end module 11 on a front section 10. In contrast to Fig. 7, the small parts 16 are first aligned and mounted on the front-end module 11 and the doors 12. Then the front-end module 11 is aligned and mounted on the doors 12. Alternatively, the assembly sequence of the fender 14 and the front flap 15 could also be reversed here. Reference numeral list

[0060] 10 Front end

[0061] 11 Frontend module

[0062] 12 doors

[0063] 13 Functional element

[0064] 14 fenders

[0065] 15 Front flap

[0066] 16 small parts

[0067] 17 longitudinal beams

[0068] 18 Radiator guards

[0069] 19 main headlights

[0070] 20 Bumper cover

[0071] S10 Provide front section

[0072] S20 Deploy Frontend Module

[0073] S30 Providing two fenders

[0074] S40 Mount Front End Module

[0075] S50 Mounting Fenders

[0076] S60 Provide front flap

[0077] S70 Mount Front Flap

[0078] S80 Provide small parts

[0079] S90 Mounting Small Parts

Claims

Patent claims 1. Method for mounting a front-end module (11) to a front section (10) of a vehicle, comprising: Providing the front section (10) with two doors (12) (S10), Provisioning the frontend module (11) with at least one Functional element (13) (S20), Providing two fenders (14) (S30), Mounting the front end module (11) to the front body (10) (S40) and mounting the two fenders (14) to the front body (10) after mounting the front end module (11) to the front body (S50).

2. Method according to claim 1, wherein mounting the front end module (11) to the front carriage (10) includes aligning the front end module (11) to the two doors (12) of the front carriage (10), wherein the alignment consists of alignment in the z-direction and y-direction.

3. Method according to claim 1 or 2, the assembly of the two fenders (14) each includes aligning one of the two fenders (14) to the front end module (11) and one of the two doors (12).

4. Method according to any of the preceding claims, wherein at least one functional element (13) comprises one or more of the following: bumper, main headlight (19), bumper cover (20), module carrier, radiator guard (18), lighting system and / or pedestrian protection.

5. Method according to any one of the preceding claims, further comprising: Providing a front flap (15) (S60) and Mounting the front flap (15) after mounting the front end module (11) and before mounting the two fenders (14) (S70).

6. The method of claim 5, wherein mounting the front flap (15) comprises aligning the front flap (15) with both doors (12) of the front body (10) and the front end module (11).

7. The method of any one of the preceding claims, further comprising: providing at least one small part (16) (S80), wherein the at least one small part comprises at least one or more of the following: retaining element, deformation element and / or front flap hinge, and Mounting at least one small part (16) on the front carriage (10) after mounting the front end module (11) (S90), wherein the assembly of the at least one small part (16) includes aligning the at least one small part (16) on the front end module (11) and on at least one of the two doors (12).

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