Vehicle body manufacturing process

• US 6,836,943 B2
• Filed: 07/24/2002
• Issued: 01/04/2005
• Est. Priority Date: 08/23/2001
• Status: Expired due to Fees

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: General Motors Corporation (General Motors Company)
• Inventors: Shabana, Mohsen D., Chernoff, Adrian B., Borroni-Bird, Christopher E., Vitale, Robert Louis
• Primary Examiner(s): Hong, John C.
• Application Number:
  US10/202,464
• Publication Number:
  US 20030037427A1
• Time in Patent Office: 895 Days
• Field of Search: 294/28, 294/011, 294/020.1, 294/020.3, 294/020.6, 294/020.8, 294/020.9, 294/021.1, 294/021.5, 294/69, 286/193.04, 286/10, 286/35.3, 180/89.17
• US Class Current: 29/402.08
• 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 58/40 : for controlling a combination of batteries and fuel cells
• 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: 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 7/18 : Steering knuckles; King pins
• CPC Class Codes: G06Q 30/06 : Buying, selling or leasing transactions
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells
• CPC Class Codes: Y10T 29/49716 : Converting
• CPC Class Codes: Y10T 29/49718 : Repairing
• CPC Class Codes: Y10T 29/4973 : Replacing of defective part
• CPC Class Codes: Y10T 29/49826 : Assembling or joining
• CPC Class Codes: Y10T 29/49904 : Assembling a subassembly, then assembling with a second subassembly

Abstract

A method of designing and manufacturing vehicle bodies includes establishing a common, standardized interface system for attaching vehicle bodies to vehicle chassis wherein connection components are arranged in a predetermined spatial relationship on the bodies and chassis to facilitate selective attachment of any of a plurality of different body types to the chassis. A plurality of different bodies are designed and manufactured having different body types and configured to conform to the standardized interface system for attachment to chassis which also conform to the standardized interface system. The vehicle bodies can be produced independently of the chassis. Eliminating the chassis and its hardware from the body manufacturing process can reduce current vehicle manufacturing plant sizes and system complexity. The result is an enabler to produce many vehicle bodies that can be distributed directly to dealers, customers, etc. either with or without a specified rolling platform. Smaller and customized production runs are enabled, as well as localized manufacturing plants, reduced investment costs and faster response time for order to delivery.

Claims

1. A method of designing and manufacturing vehicle bodies comprising:

establishing a common, standardized interface system for attaching vehicle bodies to vehicle chassis wherein connection components are arranged in a predetermined spatial relationship on bodies and chassis to facilitate selective attachment of any of a plurality of different body types to the chassis; and

designing and manufacturing a plurality of different bodies having different body types and configured to conform to said standardized interface system for selective attachment to chassis which also conform to said standardized interface system;

wherein said bodies are manufactured to include at least one electrical communication linkage for communicating steering, braking and propulsion control signals to a chassis, and characterized by the absence of mechanical communication linkages for communicating steering, braking and propulsion signals to a chassis.

2. The method of claim 1, wherein said different body types are of at least two body categories taken from the group consisting of sedans, pickup trucks, convertibles, coupes, vans, station wagons, sport-utility vehicles, and other types of transports.

3. The method of claim 1, further comprising, after said step of designing and manufacturing a plurality of bodies, attaching the manufactured bodies to manufactured chassis.

4. The method of claim 3, further comprising, after said attaching step, designing and manufacturing additional bodies having body types different from said attached bodies and configured to conform to said standardized interface system for selective attachment to said manufactured chassis.

5. A method of manufacturing a vehicle comprising:

designing and manufacturing a vehicle body configured to comply with a common, standardized interface system for attaching vehicle bodies to vehicle chassis wherein connection components are arranged in a predetermined spatial relationship on bodies and chassis to facilitate selective attachment of any of a plurality of different body types to the chassis without modification of the respective bodies or chassis;

wherein said body is characterized by having at least one electrical communication linkage for communicating steering, braking and propulsion control signals to a chassis, and further characterized by the absence of mechanical communication linkages for communicating steering, braking and propulsion signals to a chassis.

6. The method of claim 5, further comprising, after said step of designing and manufacturing a body, attaching the manufactured body to a manufactured chassis.

7. The method of claim 6, further comprising, after said attaching step, designing and manufacturing an additional body having a body type different from said attached body and configured to conform to said standardized interface system for selective attachment to said manufactured chassis.

8. The method of claim 7, wherein said additional body is selected from the group of body types consisting of sedans, pickup trucks, convertibles, coupes, vans, station wagons, sport-utility vehicles, and other types of transports.

9. The method of claim 5, wherein the standardized interface system includes no more that one control signal transmitting electrical connector on the body to provide communication signals to a corresponding electrical connector on a chassis.

10. A method of designing and manufacturing vehicles comprising:

predefining a vehicle body-chassis interface system wherein mechanical and electrical connection components are required to be in predetermined spatial positions relative to each other in a body-attachment interface on a chassis and in corresponding predetermined spatial positions relative to each other in a corresponding chassis-attachment interface on any body to be attached to the chassis, thereby enabling a chassis design to receive any of a large number of different body types complying with said predefined body-chassis interface system; and

after said predefining step, designing and manufacturing vehicle bodies conforming to said predefined vehicle body-chassis interface system, wherein different types of said bodies are manufactured at different locations to accommodate local market demands.

11. The method of claim 10, wherein said step of designing and manufacturing different types of vehicle bodies at different locations further comprises using local materials to manufacture said bodies.

12. The method of claim 10, wherein said vehicle bodies comprise different types of bodies selected from the group consisting of sedans, pickup trucks, convertibles, coupes, vans, station wagons, sport-utility vehicles, and other types of transports.

13. The method of claim 12, wherein said vehicle bodies comprise at least two body styles selected from said group.

14. The method of claim 10, further comprising attaching one of said bodies to a chassis and, thereafter, designing and manufacturing different bodies having different body types than said one of the bodies and configured to conform to said predefined body-chassis interface system.

15. The method of claim 10, wherein said bodies are manufactured to include at least one electrical communication linkage (electrical connector) for communicating steering, braking and propulsion control signals to a chassis, and characterized by the absence of mechanical communication linkages for communicating steering, braking and propulsion signals to a chassis.

16. The method of claim 10, wherein said chassis design includes a family of chassis complying with the standardized interface system.

17. A method of designing and manufacturing vehicle bodies comprising:

designing and manufacturing vehicle bodies conforming to a predefined vehicle body-chassis interface system wherein mechanical and electrical connection components are required to be in predetermined spatial positions relative to each other in a body-attachment interface on a chassis and in complementary predetermined spatial positions relative to each other in a corresponding chassis-attachment interface on any body to be attached to the chassis, thereby enabling a variety of different body types to be attached to the chassis; and

wherein said vehicle bodies are designed and manufactured independently of any vehicle chassis to which the bodies may be attached.

18. The method of claim 17, wherein said vehicle bodies comprise different types of bodies selected from the group consisting of sedans, pickup trucks, convertibles, coupes, vans, station wagons, sport-utility vehicles, and other types of transports.

19. The method of claim 18, wherein said vehicle bodies comprise at least three body types selected from said group.

20. The method of claim 19, further comprising, after said step of designing and manufacturing said vehicle bodies, subsequently designing and manufacturing different bodies having different body types than said designed and manufactured bodies and configured to conform to said predefined body-chassis interface system.

21. The method of claim 17, wherein said bodies are manufactured to include at least one electrical communication linkage (electrical connector) for communicating steering, braking and propulsion control signals to a chassis, and characterized by the absence of mechanical communication linkages for communicating steering, braking and propulsion signals to a chassis.

22. The method of claim 17, wherein said predefined vehicle body-chassis interface system includes no more than one control signal transmitting electrical connector on said bodies to provide communication signals to a corresponding electrical connector on a chassis.

23. The method of claim 17, wherein each of said bodies is manufactured to include:

a floor configured to extend substantially the entire length of a chassis to which the respective body will be attached;

a seat assembly supported by the floor; and

a driver interface supported with respect to the floor adjacent the seat assembly to communicate vehicle control signals to a chassis from a seated driver.

24. The method of claim 23, wherein each of said bodies is manufactured to further comprise an enclosure connected to the floor for sheltering occupants within the body, wherein the enclosure is connected to opposing ends of the floor such that the enclosure extends substantially the entire length of the floor so that substantially the entire length of the floor is accessible and usable space for occupants.

25. The method of claim 17, wherein each of said bodies are manufactured to include:

an enclosure configured to shelter a vehicle occupant; and

a driver communication interface positioned within the enclosure to communicate vehicle control signals to a chassis from a vehicle driver.

26. The method of claim 25, wherein each of said bodies is manufactured to include a single umbilical electrical connector through which all electrical communication signals pass from the body to a corresponding single electrical connector on the chassis.

27. The method of claim 25, wherein each of said bodies is manufactured to include a substantially flat floor supporting the enclosure, and at least one seat supported on the floor.

28. The method of claim 25, wherein each of said bodies is manufactured to include a drive-by-wire control input device, and wherein the body is further characterized by the absence of a mechanical steering linkage, such as a steering column.

29. The method of claim 25, wherein the enclosure is selected from the body-style group consisting of sedans, pickup trucks, convertibles, coupes, vans, station wagons, sport-utility vehicles, and other types of transports.

30. A method of manufacturing and selling vehicles comprising:

designing and manufacturing a vehicle body configured to comply with a common, standardized interface system for attaching vehicle bodies to vehicle chassis wherein connection components are arranged in a predetermined spatial relationship on bodies and chassis to facilitate selective attachment of any of a plurality of different body types to the chassis without modification of the respective bodies or chassis, wherein said body is designed in accordance with a perceived local market demand;

purchasing a manufactured chassis complying with said common, standardized interface system;

attaching the body to the chassis to form a vehicle; and

granting possession of the vehicle to a customer in a financial transaction.

31. The method of claim 30, further comprising, after said attaching step, designing and manufacturing an additional body having a body type different from said attached body and configured to conform to said standardized interface system for selective attachment to said manufactured chassis.

32. The method of claim 31, wherein said additional body is selected from the group of body types consisting of sedans, pickup trucks, convertibles, coupes, vans, station wagons, sport-utility vehicles, and other types of transports.

33. The method of claim 30, wherein said body is characterized by having at least one electrical communication linkage (electrical connector) for communicating steering, braking and propulsion control signals to a chassis, and further characterized by the absence of mechanical communication linkages for communicating steering, braking and propulsion signals to the chassis.

34. The method of claim 30, wherein the standardized interface system includes no more that one control signal transmitting electrical connector on the body to provide communication signals to a corresponding coupling on the chassis.

35. The method of claim 30, wherein said body is manufactured to include:

a floor configured to extend substantially the entire length of the chassis to which the respective body will be attached;

a seat assembly supported by the floor; and

a driver interface supported with respect to the floor adjacent the seat assembly to communicate vehicle control signals to the chassis from a seated driver.

36. The method of claim 35, wherein said body is manufactured to further comprise an enclosure connected to the floor for sheltering occupants within the body, wherein the enclosure is connected to opposing ends of the floor such that the enclosure extends substantially the entire length of the floor so that substantially the entire length of the floor is accessible and usable space for occupants.

37. The method of claim 30, wherein said body is manufactured to include:

an enclosure configured to shelter a vehicle occupant; and

a driver communication interface positioned within the enclosure to communicate vehicle control signals electronically to a chassis from a vehicle driver.

38. The method of claim 37, wherein said body is manufactured to include a single umbilical electrical connector through which all electrical communication signals pass from the body to a corresponding single electrical connector on the chassis.

39. The method of claim 37, wherein said body is manufactured to include a substantially flat floor supporting the enclosure, and at least one seat supported on the floor.

40. The method of claim 37, wherein said body is manufactured to include a drive-by-wire control input device, and wherein the body is further characterized by the absence of a mechanical steering linkage, such as a steering column.

41. The method of claim 37, wherein the enclosure is selected from the body-style group consisting of sedans, pickup trucks, convertibles, coupes, vans, station wagons, and sport-utility vehicles.

42. A method of manufacturing and dealing vehicle bodies comprising:

designing and manufacturing a vehicle-body configured to comply with a common, standardized interface system for attaching vehicle bodies to vehicle chassis wherein connection components are arranged in a predetermined spatial relationship on bodies and chassis to facilitate selective attachment of any of a plurality of different body types to the chassis without modification of the respective bodies or chassis;

granting possession of the body to a customer in a financial transaction; and

attaching the body to the customer'"'"'s chassis which complies with said common, standardized interface system;

wherein said body is manufactured to include a floor configured to extend substantially the entire length of the chassis to which the respective body will be attached.

43. The method of claim 42, further comprising, after said attaching step, designing and manufacturing an additional body having a body type different from said attached body and configured to conform to said standardized interface system for selective attachment to said manufactured chassis.

44. The method of claim 43, wherein said additional body is selected from the group of body types consisting of sedans, pickup trucks, convertibles, coupes, vans, station wagons, sport-utility vehicles, and other types of transports.

45. The method of claim 42, wherein said body is characterized by having at least one electrical communication linkage (electrical connector) for communicating steering, braking and propulsion control signals to a chassis, and further characterized by the absence of mechanical communication linkages for communicating steering, braking and propulsion signals to the chassis.

46. The method of claim 42, wherein the standardized interface system includes no more that one control signal transmitting electrical connector on the body to provide communication signals to a corresponding coupling on the chassis.

47. The method of claim 42, wherein said body is manufactured to include:

a seat assembly supported by the floor; and

a driver interface supported with respect to the floor adjacent the seat assembly to communicate vehicle control signals to the chassis from a seated driver.

48. The method of claim 42, wherein said body is manufactured to further comprise an enclosure connected to the floor for sheltering occupants within the body, wherein the enclosure is connected to opposing ends of the floor such that the enclosure extends substantially the entire length of the floor so that substantially the entire length of the floor is accessible and usable space for occupants.

49. The method of claim 42, wherein said body is manufactured to include:

an enclosure configured to shelter a vehicle occupant; and

a driver communication interface positioned within the enclosure to communicate vehicle control signals electronically to a chassis from a vehicle driver.

50. The method of claim 49, wherein said body is manufactured to include a single umbilical electrical connector through which all electrical communication signals pass from the body to a corresponding single electrical connector on the chassis.

51. The method of claim 49, wherein said body is manufactured to include a drive-by-wire control input device, and wherein the body is further characterized by the absence of a mechanical steering linkage, such as a steering column.

52. The method of claim 49, wherein the enclosure is selected from the body-style group consisting of sedans, pickup trucks, convertibles, coupes, vans, station wagons, and sport-utility vehicles.