Cooling module mounting system and assembly process

• US 6,648,089 B1
• Filed: 08/07/2001
• Issued: 11/18/2003
• Est. Priority Date: 08/07/2000
• Status: Expired due to Term

• Current Assignee: International Truck Intellectual Property Co. LLC (Volkswagen AG)
• Original Assignee: International Truck Intellectual Property Co. LLC (Volkswagen AG)
• Inventors: Kirk, Thomas E., Strauch, Eric M., Wooldridge, Scott A.
• Primary Examiner(s): Johnson, Brian L.
• Assistant Examiner(s): SHRIVER II, JAMES A
• Application Number:
  US09/923,561
• Time in Patent Office: 833 Days
• Field of Search: 180/68.4, 180/68.1, 180/68.6, 180/68.2, 180/299, 180/291, 267/140.13, 267/140.11, 165/41, 165/149, 296/187, 296/203.01, 296/203.02
• US Class Current: 180/68.4
• CPC Class Codes: B60K 11/04 Arrangement or mounting of radiators, radiator shutters, or radiator blinds B60K11/085 takes precedence
• CPC Class Codes: B62D 25/084 Radiator supports
• CPC Class Codes: F01P 2070/52 mounting heat-exchangers

Abstract

A cooling module mounting system and method of mounting the package to a vehicle is described. A chassis cross member for providing vertical support to the cooling package is sub-assembled to the cooling module separate from the vehicle where the two mounting surfaces can be held parallel to one another eliminating the possibility of unevenly preloading the isolator. Then this pre-assembled isolated system can be mounted on the truck chassis without changing the relationship of the compressed isolator when the module is bolted down during truck assembly. This system eliminates the fore aft adjustment variability allowing for more control over the static location and isolator compression of the cooling module in the truck. The stay rods used eliminate variation in the rod isolator compression during mounting. The stay rod also allows for controlled multi-axial movement with a mounting centerline perpendicular to the input loads.

Claims

1. A method for installing an engine cooling package onto a chassis for a mobile vehicle, the chassis having two generally parallel frame rails connected by rearward cross members, comprised of the steps of:

engaging a radiator to a radiator frame, along with engaging engine coolant inlet and outlet nozzles to the radiator to form a cooling package;

engaging a lower horizontal face of the cooling package to an upper horizontal face of a chassis cross member while preloading compressible isolators at the mating area between the cooling package and the chassis cross member to form a cooling module, the chassis cross member having a front face engaged to the upper horizontal face and a member right side and a member left side, the member right side and left sides having narrowed member edges, and the cooling module having mounting areas for stay rods;

engaging a frame mounted bracket to each frame rail along an assembly line;

engaging a rear stay bracket rearward of the frame mounted bracket on each frame rail along an assembly line, said stay rods containing a transition zone with a shape to set the angle of stay rods upon attachment to each rear stay bracket;

moving the cooling module to a main assembly line for chassis engagement, the chassis moving along the assembly line;

lowering the cooling module to the frame rails to engage the chassis cross member right and left sides to the frame mounted bracket on each frame rail without changing the preload of the isolators between the cooling package and the chassis cross member;

connecting the chassis cross member to the frame mounted castings through fasteners; and

engaging stay rods between the mounting areas on the cooling module and the rear stay brackets to achieve the proper angle of the cooling package relative to the frame rails.

2. The method of claim 1, wherein said stay rod transition zone for each rear stay rod is in an ‘

S’

shape to ensure stay rod angle set.

3. The method of claim 2, additionally comprising the following step after engaging the radiator to the radiator frame:

engaging a radiator overflow reservoir to the cooling package and plumbing the reservoir to the radiator prior to moving the cooling package to the assembly line.

4. A method for installing an engine cooling package onto a chassis for a mobile vehicle, the chassis having two generally parallel frame rails connected by rearward cross members. comprised of the steps of:

engaging a radiator to a radiator frame, along with engaging engine coolant inlet and outlet nozzles to the radiator;

engaging a radiator reservoir to the radiator frame and plumbing the reservoir to the radiator to form a cooling package containing the radiator, the frame, the radiator nozzles and the reservoir;

engaging a lower horizontal face of the cooling package to an upper horizontal face of a chassis cross member while preloading compressible isolators at the mating area between the cooling package and the chassis cross member to form a cooling module, the chassis cross member having a front face engaged to the upper horizontal face and a member right side and a member left side, the member right side and left sides having narrowed member edges, and the cooling module having mounting areas for stay rods;

engaging a frame mounted bracket to each frame rail along an assembly line;

engaging a rear stay bracket rearward of the frame mounted bracket on each frame rail along an assembly line, said stay rods containing a transition zone with a shape to set the angle of stay rods upon attachment to each rear stay bracket;

moving the cooling module to a main assembly line for chassis engagement, the chassis moving along the assembly line;

lowering the cooling module to the frame rails to engage the chassis cross member right and left sides to the frame mounted bracket on each frame rail without changing the preload of the isolators between the cooling package and the chassis cross member;

connecting the chassis cross member to the frame mounted castings through fasteners; and

engaging stay rods between the mounting areas on the cooling module and the rear stay brackets to achieve the proper angle of the cooling package relative to the frame rails.

5. A method for installing an engine cooling package onto a chassis for a mobile vehicle, the chassis having two generally parallel frame rails connected by rearward cross members, comprised of the steps of:

engaging a radiator to a radiator frame to form a cooling package;

engaging a lower horizontal face of the cooling package to an upper horizontal face of a chassis cross member while preloading compressible isolators at the mating area between the cooling package and the chassis cross member to form a cooling module, the chassis cross member having a front face engaged to the upper horizontal face and a member right side and a member left side, and the cooling module having mounting areas for stay rods;

engaging a front mounting bracket to each frame rail along an assembly line;

engaging a rear stay bracket rearward of the frame mounted bracket on each frame rail along an assembly line, said stay rods containing a transition zone with a shape to set the angle of stay rods upon attachment to each rear stay bracket;

moving the cooling module to a main assembly line for chassis engagement, the chassis moving along the assembly line;

lowering the cooling module to the frame rails to engage the chassis cross member right and left sides to the front mounting bracket on each frame rail without changing the preload of the isolators between the cooling package and the chassis cross member;

connecting the chassis cross member to the front mounting bracket through fasteners; and

engaging stay rods between the mounting areas on the cooling module and the rear stay brackets to achieve the proper angle of the cooling package relative to the frame rails.

6. A mobile vehicle chassis manufactured by the steps comprised of:

engaging two generally parallel frame rails through rearward cross members;

engaging a radiator to a radiator frame, along with engaging engine coolant inlet and outlet nozzles to said radiator to form a cooling package;

engaging a lower horizontal face of said cooling package to an upper horizontal face of a chassis cross member while preloading compressible isolators at the mating area between said cooling package and said chassis cross member to form a cooling module, said chassis cross member having a front face engaged to said upper horizontal face and a member right side and a member left side, said member right side and left sides having narrowed member edges, and said cooling module having mounting areas for stay rods;

engaging a frame mounted bracket to each frame rail along an assembly line;

engaging a rear stay bracket rearward of said frame mounted bracket on each frame rail along an assembly line, said stay rods containing a transition zone with a shape to set a mounting angle of stay rods upon attachment to each rear stay bracket;

moving said cooling module to a main assembly line for chassis engagement, said chassis moving along the assembly line;

lowering said cooling module to said frame rails to engage said chassis cross member right and left sides to said frame mounted bracket on each frame rail without changing said preload of said isolators between said cooling package and said chassis cross member;

connecting said chassis cross member to the frame mounted brackets through fasteners; and

engaging stay rods between said mounting areas on said cooling module and said rear stay brackets to achieve the proper angle of said cooling package relative to said frame rails.

7. The vehicle of claim 6, wherein said or stay rod transition zone for each rear stay rod is in an ‘

S’

shape to ensure stay rod angle set.

8. The vehicle of claim 7, wherein:

a radiator overflow reservoir is engaged to said cooling package and plumbing said reservoir to said radiator prior to moving said cooling package to said assembly line.

9. A mobile vehicle chassis manufactured by the steps comprised of:

engaging two generally parallel frame rails through rearward cross members;

engaging a radiator to a radiator frame, along with engaging engine coolant inlet and outlet nozzles to said radiator;

engaging a radiator reservoir to said radiator frame and plumbing said reservoir to said radiator to form a cooling package containing said radiator, said frame, said radiator nozzles and said reservoir;

engaging a lower horizontal face of said cooling package to an upper horizontal face of a chassis cross member while preloading compressible isolators at said mating area between said cooling package and said chassis cross member to form a cooling module, said chassis cross member having a front face engaged to said upper horizontal face and a member right side and a member left side, said member right side and left sides having narrowed member edges, and said cooling module having mounting areas for stay rods;

engaging a frame mounted bracket to each frame rail along an assembly line;

engaging a rear stay bracket rearward of said frame mounted bracket on each frame rail along an assembly line, said stay rods containing a transition zone with a shape to set said angle of stay rods upon attachment to each rear stay bracket;

moving said cooling module to a main assembly line for chassis engagement, said chassis moving along said assembly line;

lowering said cooling module to said frame rails to engage said chassis cross member right and left sides to said frame mounted bracket on each frame rail without changing said preload of said isolators between said cooling package and said chassis cross member;

connecting said chassis cross member to said frame mounted bracket through fasteners; and

engaging stay rods between said mounting areas on said cooling module and said rear stay brackets to achieve said proper angle of said cooling package relative to said frame rails.

10. A mobile vehicle chassis manufactured by the steps comprised of:

engaging two generally parallel frame rails through rearward cross members;

engaging a radiator to a radiator frame to form a cooling package;

engaging a lower horizontal face of said cooling package to an upper horizontal face of a chassis cross member while preloading compressible isolators at said mating area between said cooling package and said chassis cross member to form a cooling module, said chassis cross member having a front face engaged to said upper horizontal face and a member right side and a member left side, and said cooling module having mounting areas for stay rods;

engaging a front mounting bracket to each frame rail along an assembly line;

engaging a rear stay bracket rearward of said frame mounted bracket on each frame rail along an assembly line, said stay rods containing a transition zone with a shape to set said angle of stay rods upon attachment to each rear stay bracket;

moving said cooling module to a main assembly line for chassis engagement, said chassis moving along said assembly line;

lowering said cooling module to said frame rails to engage said chassis cross member right and left sides to said front mounting bracket on each frame rail without changing said preload of said isolators between said cooling package and said chassis cross member;

connecting said chassis cross member to said front mounting bracket through fasteners; and

engaging stay rods between said mounting areas on said cooling module and said rear stay brackets to achieve said proper angle of said cooling package relative to said frame rails.