Modular chassis with simplified body-attachment interface

• US 20030164255A1
• Filed: 12/04/2002
• Published: 09/04/2003
• Est. Priority Date: 12/07/2001
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations Incorporated (General Motors Company)
• Inventors: Shabana, Mohsen D., Chernoff, Adrian B., Borroni-Bird, Christopher E., White, Tommy E., Vitale, Robert Louis
• Granted Patent: US 7,441,615 B2
• Time in Patent Office: Days
• US Class Current: 180/54.1
• CPC Class Codes: B23P 2700/50 Other automobile vehicle parts, i.e. manufactured in assembly lines
• CPC Class Codes: B60G 13/14 having dampers accumulating utilisable energy, e.g. compressing air fluid springs with an accumulator B60G11/30
• CPC Class Codes: B60G 17/015 the regulating means comprising electric or electronic elements B60G17/002, B60G17/005 take precedence
• CPC Class Codes: B60G 17/0195 characterised by the regulation being combined with other vehicle control systems conjoint control of vehicle sub-units including control of suspension systems B60W10/22
• CPC Class Codes: B60G 2200/10 Independent suspensions
• CPC Class Codes: B60G 2200/144 with two lateral arms forming a parallelogram
• CPC Class Codes: B60G 2200/18 Multilink suspensions, e.g. elastokinematic arrangements
• CPC Class Codes: B60G 2200/44 steerable
• CPC Class Codes: B60G 2200/46 camber angle
• CPC Class Codes: B60G 2200/462 Toe-in/out
• CPC Class Codes: B60G 2202/40 Type of actuator
• CPC Class Codes: B60G 2202/42 Electric actuator
• CPC Class Codes: B60G 2204/10 Mounting of suspension elements
• CPC Class Codes: B60G 2204/11 Mounting of sensors thereon
• CPC Class Codes: B60G 2204/14 Mounting of suspension arms
• CPC Class Codes: B60G 2204/16 Mounting of vehicle body on chassis
• CPC Class Codes: B60G 2204/20 Mounting of accessories, e.g. pump, compressor
• CPC Class Codes: B60G 2204/202 of cables
• CPC Class Codes: B60G 2206/011 Modular constructions
• CPC Class Codes: B60G 2206/0114 Independent suspensions on subframes
• CPC Class Codes: B60G 2206/50 : Constructional features of wheel supports or knuckles, e.g. steering knuckles, spindle attachments
• CPC Class Codes: B60G 2206/99 : Suspension element selection procedure depending on loading or performance requirements, e.g. selection of damper, spring or bush
• CPC Class Codes: B60G 2300/45 : Rolling frame vehicles
• CPC Class Codes: B60G 2300/50 : Electric vehicles; Hybrid vehicles
• CPC Class Codes: B60G 2300/60 : Vehicles using regenerative power
• CPC Class Codes: B60G 2800/21 : Traction, slip, skid or slide control
• CPC Class Codes: B60G 2800/802 : Diagnostics
• CPC Class Codes: B60G 2800/90 : System Controller type
• CPC Class Codes: B60G 2800/91 : Suspension Control
• CPC Class Codes: B60G 2800/92 : ABS - Brake Control
• CPC Class Codes: B60G 2800/963 : Steer-by-wire
• CPC Class Codes: B60G 3/18 : with two or more pivoted arms, e.g. parallelogram
• CPC Class Codes: B60G 7/003 : of adjustable length
• CPC Class Codes: B60H 1/004 : for vehicles having a combustion engine and electric drive means, e.g. hybrid electric vehicles
• CPC Class Codes: B60K 1/00 : Arrangement or mounting of electrical propulsion units B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00; electric transmission arrangements B60K17/12; electric equipment or propulsion of electrically-propelled vehicles per se B60L; current-collectors for power supply lines of electrically-propelled vehicles B60L5/00
• CPC Class Codes: B60K 1/04 : of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 15/07 : of gas tanks
• CPC Class Codes: B60K 2001/001 : one motor mounted on a propulsion axle for rotating right and left wheels of this axle
• CPC Class Codes: B60K 2001/005 : the electric storage means
• CPC Class Codes: B60K 7/0007 : the motor being electric
• CPC Class Codes: B60L 50/66 : Arrangements of batteries
• CPC Class Codes: B60N 2/14 : rotatable, e.g. to permit easy access B60N2/10 , B60N2/2869 take precedence
• CPC Class Codes: B60N 2/90 : Details or parts not otherwise provided for
• CPC Class Codes: B60T 1/065 : employing disc B60T1/062 takes precedence
• CPC Class Codes: B60T 1/10 : by utilising wheel movement for accumulating energy, e.g. driving air compressors
• CPC Class Codes: B60T 13/66 : Electrical control in fluid-pressure brake systems
• CPC Class Codes: B60T 13/662 : characterised by specified functions of the control system components
• CPC Class Codes: B60T 13/74 : with electrical assistance or drive
• CPC Class Codes: B60T 2270/82 : Brake-by-Wire, EHB
• CPC Class Codes: B60T 7/00 : Brake-action initiating means
• CPC Class Codes: B60T 7/042 : by electrical means, e.g. using travel or force sensors
• CPC Class Codes: B60T 8/00 : Arrangements for adjusting wheel-braking force to meet varying vehicular or ground-surface conditions, e.g. limiting or varying distribution of braking force by changing number of effective brake cylinders in power brake systems B60T17/10
• CPC Class Codes: B60W 10/18 : including control of braking systems
• CPC Class Codes: B60W 10/20 : including control of steering systems
• CPC Class Codes: B60W 10/22 : including control of suspension systems
• CPC Class Codes: B60W 10/28 : including control of fuel cells
• CPC Class Codes: B60W 2520/10 : Longitudinal speed
• CPC Class Codes: B60W 2520/105 : Longitudinal acceleration
• CPC Class Codes: B60W 2520/125 : Lateral acceleration
• CPC Class Codes: B60W 2520/14 : Yaw
• CPC Class Codes: B60W 2520/28 : Wheel speed
• CPC Class Codes: B60W 2540/18 : Steering angle
• CPC Class Codes: B60W 30/18 : Propelling the vehicle
• CPC Class Codes: B62D 21/00 : Understructures, i.e. chassis frame on which a vehicle body may be mounted combined frame and vehicle body B62D23/00 ; characterised by the material thereof B62D29/00
• CPC Class Codes: B62D 21/07 : wide-hipped frame type, i.e. a wide box-shaped mid portion with narrower sections extending from said mid portion in both fore and aft directions
• CPC Class Codes: B62D 21/10 : in which the main member is plate-like
• CPC Class Codes: B62D 24/02 : Vehicle body, not intended to move relatively to the vehicle frame, and mounted on vibration absorbing mountings, e.g. rubber pads
• CPC Class Codes: B62D 29/008 : predominantly of light alloys, e.g. extruded
• CPC Class Codes: B62D 35/02 : Streamlining the undersurfaces B62D35/005, B62D35/007, B62D35/008 take precedence
• CPC Class Codes: B62D 5/00 : Power-assisted or power-driven steering for non-deflectable wheels B62D11/00; fluid-pressure servomotors in general F15B
• CPC Class Codes: B62D 63/025 : Modular vehicles superstructures for busses having modular sections B62D31/025
• CPC Class Codes: B62D 65/04 : Joining preassembled modular units composed of sub-units performing diverse functions, e.g. engine and bonnet B62D65/06 - B62D65/16 take precedence
• CPC Class Codes: B62D 65/18 : Transportation, conveyor or haulage systems specially adapted for motor vehicle or trailer assembly lines conveyors and haulage in general B65G
• CPC Class Codes: B62D 7/18 : Steering knuckles; King pins
• CPC Class Codes: G06Q 30/06 : Buying, selling or leasing transactions
• CPC Class Codes: H01M 2250/20 : Fuel cells in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/88 : Optimized components or subsystems, e.g. lighting, actively controlled glasses
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

A chassis having systems responsive to a nonmechanical control signals and a simplified body-attachment interface includes preassembled modules to enhance ease and simplicity of chassis assembly. The chassis is preferably configured to minimize the possibility of a preassembled module being incorrectly positioned within the chassis. Methods for advantageously employing preassembled modules to assemble vehicle chassis are also provided.

Claims

1. A vehicle chassis comprising:

a structural frame;

vehicular systems mounted with respect to the structural frame, the vehicular systems including a suspension system, a steering system, a braking system, an energy conversion system, and an energy storage system operatively connected to the energy conversion system;

at least three wheels rotatably mounted with respect to the suspension system; and

a plurality of preassembled modules having vehicular components at least partially forming at least one of the suspension system, the steering system, the braking system, the energy conversion system, and the energy storage system;

wherein the steering system, braking system, and energy conversion system are responsive to nonmechanical control signals and operatively connected to at least one of the wheels.

2. The vehicle chassis of claim 1, wherein each of the plurality of preassembled modules is characterized by a module interface having at least one locking or fastening element, and said vehicle chassis further comprising a plurality of frame interfaces mounted with respect to the structural frame, each of the plurality of frame interfaces having at least one complementary locking or fastening element engageable with the at least one locking or fastening element in the module interface of one of the plurality of preassembled modules;

wherein the module interface of each of the plurality of preassembled modules is operatively engaged with one of the plurality of frame interfaces such that each of the plurality of preassembled modules is mounted with respect to the structural frame.

3. The vehicle chassis of claim 2, wherein the preassembled modules have module interfaces different from one another;

and wherein each of the plurality of frame interfaces is engageable with the module interface of only one of the plurality of preassembled modules to prevent errors in assembly.

4. The vehicle chassis of claim 3, wherein the module interface of each of the plurality of preassembled modules includes at least two locking or fastening elements;

wherein the at least two locking or fastening elements are in a predetermined spatial relationship with one another;

wherein the predetermined spatial relationship of the at least two locking or fastening elements is different for each of the plurality of preassembled modules; and

wherein each of the plurality of frame interfaces has at least two complementary locking or fastening elements in the same predetermined spatial relationship as the locking or fastening elements of one of the plurality of preassembled modules.

5. The vehicle chassis of claim 1, wherein each of the plurality of modules has a size and geometrical shape, and said chassis further comprising at least one locating member mounted with respect to the structural frame and forming a plurality of cavities, each of the plurality of cavities having a size and geometrical shape sufficient to locate with respect to the structural frame, and at least partially contain, one of the plurality of modules.

6. The vehicle chassis of claim 5, wherein said at least one locating member is a rigid sheet having formations that define the plurality of cavities.

7. The vehicle chassis of claim 1, wherein the energy conversion system includes a fuel cell.

8. The vehicle chassis of claim 1, wherein one of the plurality of modules is selected from an inventory of modules;

and wherein the inventory includes a first version and a second version of modules;

wherein the vehicular components of the first version and the vehicular components of the second version are configured to perform a common vehicular function; and

wherein the first version differs from the second version in the configuration of the vehicular componentry.

9. The vehicle chassis of claim 1, wherein one of the modules is configured to store hydrogen gas.

10. A method of assembling vehicle chassis, the method comprising:

maintaining an inventory of preassembled modules, the preassembled modules each having vehicular componentry and a module interface engageable with a complementary interface, the module interface of each of the preassembled modules having a common module interface configuration; and

assembling a first vehicle chassis having a first length, width, and height, the first vehicle chassis having

a first structural frame;

a first steering system;

a first braking system;

a first energy conversion system;

a first energy storage system operatively connected to the first energy conversion system;

a first suspension system mounted with respect to the first structural frame;

a first set of at least three wheels rotatably mounted with respect to the first suspension system;

a first structural frame interface complementary to the module interfaces of the preassembled modules in the inventory; and

a first module selected from the inventory having componentry that at least partially forms at least one of the first steering system, first braking system, first suspension system, first energy conversion system, and first energy storage system;

the module interface of the first module engaged with the first structural frame interface such that the first module is mounted with respect to the first structural frame;

wherein the first steering system, first braking system, and first energy conversion system are mounted with respect to the first structural frame, responsive to nonmechanical control signals, and operatively connected to at least one wheel.

11. The method of claim 10, wherein the inventory contains a first version and a second version of preassembled modules, wherein the vehicular componentry of the first version and the vehicular componentry of the second version are configured to perform a common vehicular function;

wherein the preassembled modules of the first version and the preassembled modules of the second version have substantially identical module interfaces;

wherein the vehicular componentry of the first version has a different configuration from the vehicular componentry of the second version; and

wherein the method further comprises;

assembling a second vehicle chassis having

a second structural frame;

a second steering system;

a second braking system;

a second energy conversion system;

a second energy storage system operatively connected to the second energy conversion system;

a second suspension system mounted with respect to the second structural frame;

a second set of at least three wheels rotatably mounted with respect to the second suspension system;

a second structural frame interface complementary to the module interfaces of the preassembled modules in the inventory; and

a second module having componentry that at least partially forms at least one of the second steering system, second braking system, second suspension system, second energy conversion system, and second energy storage system;

the second module being a different version from the first module;

the module interface of the second module engaged with the second structural frame interface such that the second module is mounted with respect to the second structural frame;

wherein the second steering system, second braking system, and second energy conversion system are mounted with respect to the second structural frame, responsive to nonmechanical control signals, and operatively connected to at least one wheel.

12. The method of claim 10, further comprising assembling a second chassis having a second length, second width, and second height, and being differently dimensioned from the first chassis such that at least one of the second length, the second width, and the second height is different from the first length, the first width, and the first height, respectively;

the second chassis including

a second structural frame;

a second steering system;

a second braking system;

a second energy conversion system;

a second energy storage system operatively connected to the second energy conversion system;

a second suspension system mounted with respect to the second structural frame;

a second set of at least three wheels rotatably mounted with respect to the second suspension system;

a second structural frame interface complementary to the module interfaces of the preassembled modules in the inventory; and

a second module selected from the inventory having componentry that at least partially forms at least one of the second steering system, second braking system, second suspension system, second energy conversion system, and second energy storage system;

the module interface of the second module engaged with the second structural frame interface such that the second module is mounted with respect to the second frame;

wherein the second steering system, second braking system, and second energy conversion system are mounted with respect to the second structural frame, responsive to nonmechanical control signals, and operatively connected to at least one wheel.

13. A method of assembling vehicle chassis, the method comprising:

maintaining an inventory of preassembled modules each having vehicular componentry and a module interface with a plurality of locking or fastening elements, the inventory including a plurality of preassembled modules having module interface configurations different from one another; and

assembling a first chassis having a first length, a first width, and a first height, the first chassis including

a first structural frame;

a plurality of fastening or locking elements mounted with respect to the first structural frame, the plurality of fastening or locking elements defining a first set of frame interfaces having a predetermined spatial relationship with one another, each of the frame interfaces being configured to engage only one of the module interface configurations in the inventory, at least two of the frame interfaces of the first set having frame interface configurations different from one another;

a first by-wire steering system mounted with respect to the first structural frame;

a first by-wire braking system mounted with respect to the first structural frame;

a first by-wire energy conversion system mounted with respect to the first structural frame;

a first energy storage system operatively connected to the first energy conversion system;

a first suspension system mounted with respect to the first structural frame;

a first set of at least three wheels mounted with respect to the first suspension system; and

a first set of preassembled modules selected from the inventory, each of the preassembled modules of the first set at least partially forming at least one of the first steering system, first braking system, first energy conversion system, first energy storage system, and first suspension system;

the module interface of each of the first set of preassembled modules engaged with one of the first set of frame interfaces such that the first set of preassembled modules is mounted with respect to the first structural frame.

14. The method of claim 13, further comprising:

assembling a second chassis having

a second structural frame;

a plurality of fastening or locking elements mounted with respect to the second structural frame, the plurality of fastening or locking elements defining a second set of frame interfaces substantially identical to the first set of frame interfaces and having a predetermined spatial relationship substantially identical to the predetermined spatial relationship of the first set of frame interfaces;

a second by-wire steering system mounted with respect to the second structural frame;

a second by-wire braking system mounted with respect to the second structural frame;

a second by-wire energy conversion system mounted with respect to the second structural frame;

a second energy storage system operatively connected to the second energy conversion system;

a second suspension system mounted with respect to the second structural frame;

a second set of at least three wheels mounted with respect to the second suspension system; and

a second set of preassembled modules selected from the inventory, each of the preassembled modules of the second set at least partially forming one of the second steering system, second braking system, second energy conversion system, second energy storage system, and second suspension system;

the module interface of each of the second set of preassembled modules engaged with one of the second set of frame interfaces such that the second set of preassembled modules is mounted with respect to the second structural frame;

wherein the second chassis has a second length, a second width, and a second height, and wherein the second chassis is differently dimensioned from the first chassis such that at least one of the second length, the second width, and the second height is different from the first length, the first width, and the first height, respectively.