DE102011120232A1 - Front carriage for motor car, has lock cross beam extended as one-piece between longitudinal beams, fixed at anchor plate and embracing longitudinal beams in L-shape, and crash boxes provided with connecting plates - Google Patents

Abstract

The carriage (1) has a left longitudinal beam (5), a right longitudinal beam (7) and a lock cross beam (9) for supporting a flap (11) of a motor car (3). The lock cross beam is extended as one-piece between the longitudinal beams. The lock cross beam is fixed at an anchor plate (13) of the longitudinal beams. Crash boxes (15) are provided with connecting plates (17). The lock cross beam is connected with the connecting plates of the longitudinal beams and the anchor plate. The lock cross beam embraces the longitudinal beams in an L-shape. An independent claim is also included for a method for manufacturing a lock cross beam.

Description

The invention relates to a front end of a motor vehicle with a left side member and a right side member and a lock cross member for supporting a flap of a motor vehicle, a method for producing a lock cross member and a device according to and / or according to the method.

Forwarders of motor vehicles with lock cross members are known. These serve on the one hand for receiving forces introduced into the body, in particular spring damper forces and for supporting closing forces of the flap. In particular, when closing the flap comparatively large pulses can occur, which must be taken as non-destructively as possible over a structure of the front end. This can be done for example by means of a lock cross member in so-called hybrid design, in particular, two materials such as metal and plastic are combined. Furthermore, lock cross members are known which consist of several sheet metal parts which are welded together and / or screwed together. Closing forces of the flap are absorbed or dissipated in particular by means of specially provided braces and / or welded reinforcements. In addition, lock cross members are known which consist of several components and are mechanically connected by means of massive consoles with the rest of the front end, wherein the closing forces of the flap on the mechanical brackets on the other front end are derived. Furthermore, it is known to use specially shaped components for bodywork of motor vehicles. The US 5,882,039 discloses, for example, a front end assembly of hydroformed parts with a cross member.

The object of the invention is to provide a front end of a motor vehicle with a left side member and a right side member and a lock cross member for supporting a flap of the motor vehicle, which can be produced in a particularly simple manner and / or allows high Servicefreundlichkeit for a light source service and / / or is particularly light and / or has a minimal space requirement.

The object is achieved in a front end according to claim 1 by the characterizing part of claim 1.

Advantageously, the entire lock cross member consists of only one component and extends between the longitudinal members. Advantageously, forces introduced into the lock cross member by means of the flap can thus be diverted directly to the longitudinal members. In addition, the front end can be advantageously stiffened by means of the lock cross member. Advantageously, no further components for stiffening the lock cross member and / or for connecting the lock cross member to the side members, apart from special fasteners, such as screws, rivets and / or the like required. Advantageously, the lock cross member can thereby be designed weight and space optimized.

A preferred embodiment of the front end is designed according to claim 2. Advantageously, the lock cross member can be fixed in a simple manner to the anchor plate, in particular by means of screwing.

Another preferred embodiment of the front end is designed according to claim 3. Advantageously, no additional connecting elements are required for connecting the crash boxes with the longitudinal members and for connecting the lock cross member. Rather, with a minimum number of connecting elements, a bond between the side members, the crash boxes and the lock cross member can be made.

Another preferred embodiment of the front end is designed according to claim 4. Advantageously, the lock cross member engages around the longitudinal members vertically and in the direction of a surcharge pulse or a force which is exerted in a slamming of the flap on the lock cross member. Advantageously, the force can thus be introduced from above into the side members from above, ie in the direction of a vertical axis of the motor vehicle, from top to bottom. Advantageously, this can be saved between the longitudinal members lying space, which is needed in particular by other components of the motor vehicle, in particular a drive source and their ancillaries. Advantageously, material can also be saved in comparison with a U-shaped gripping around the side members.

Another preferred embodiment of the front end is designed according to claim 5. Advantageously, by means of hydroforming complex structured components can be produced, in particular with variable wall thicknesses and cross sections. Advantageously, such wall thicknesses and over the length of the lock cross member variable cross sections can be adapted to be absorbed by this forces and pulses.

Another preferred embodiment of the front end is designed according to claim 6. Advantageously, the at least one further component in a simple manner without further processing steps on the lock cross member even be tied to these, in particular with this riveted and / or bolted.

Another preferred embodiment of the front end is designed according to claim 7. Advantageously, closing forces can be transmitted via the hood lock between the flap and the lock cross member. By means of the holder, further components, in particular a cooler, sensor devices and / or the like can be mounted in the region of the lock cross member with the remaining front carriage. Alternatively or additionally, the further component may also have a hood buffer for cushioning the surcharge pulse of the flap. Alternatively or additionally, the receptacle may have punches and / or holes for connecting the other components.

Another preferred embodiment of the front end is designed according to claim 8. The lock cross member extends between the ends, which advantageously have the opened U-shaped cross-section. An asymmetrical U-shaped cross-section can be understood to mean that sections of the cross-section which extend in a U-shaped manner from a base have a different length. Advantageously, the anchor plates of the longitudinal members and the connecting plates of the crash boxes engage in the asymmetrical U-shaped cross section, wherein advantageously from the side of the shorter sections of the U-shaped cross-section forth, a connection, in particular a screw connection can be made.

Another preferred embodiment of the front end is designed according to claim 9. A shaping of the ends of the lock cross member is advantageously adapted to an outer shape of the side members. These have a substantially rectangular cross-section, which is embraced by the ends advantageous L-shaped.

Another preferred embodiment of the front end is designed according to claim 10. Advantageously, the lock cross member can be made of a tube by means of hydroforming and therefore advantageously has the closed hollow cross-section, which advantageously causes a minimum weight of the lock cross member with a maximum stability. By "substantially closed" it can be understood that in some areas openings are made in the cross section, in particular punched holes and / or bores for mounting the holders.

Another preferred embodiment of the front end is designed according to claim 11. Advantageously, by means of the curved s-shaped course, the forces introduced by means of the flap into the lock cross member can be diverted particularly well.

The object is also achieved in a method for producing a lock cross member according to the preamble of claim 12 by the characterizing part of claim 12. For the manufacture of the lock cross member, essentially only the process steps of pre-bending, high-pressure forming, shear cutting and subsequent cutting to length are required. Advantageously, a weight, stiffness and space-optimized component can thus be produced in a simple manner, in particular cost-effectively.

A preferred embodiment of the method is carried out according to claim 13. Advantageously, the L-shaped ends of the lock cross member can be produced in a simple manner by means of the U-shaped cuts. The clipping plane advantageously extends through the lobes so that they are no longer part of the lock cross member after being cut to length. For this purpose, the clipping plane is located further away from ends of the tube than a crease line resulting from the folding in of the lobes. Advantageously, the lobes along with their bending line fall off after cutting.

A further preferred embodiment of the method is carried out according to claim 14. Advantageously, the punches can be installed in a simple manner by means of shear cutting in the lock cross member, which can be advantageously used in particular for connecting other components to the lock cross member.

The object is also achieved by a motor vehicle having a lock cross member described above and / or a lock cross member produced according to a method described above. This results in the advantages described above.

Further advantages, features and details will become apparent from the following description in which - where appropriate, with reference to the drawings - at least one embodiment is described in detail. Described and / or illustrated features form the subject of the invention, or independently of the claims, either alone or in any meaningful combination, and in particular can additionally also be the subject of one or more separate invention (s). The same, similar and / or functionally identical parts are provided with the same reference numerals.

Show it:

1 a three-dimensional view of a front end of a motor vehicle obliquely from above above;

2 a detailed view of the in 1 shown front wagon with a lock cross member;

3 a sectional view of the in 2 shown details along the section line III-III;

4 a pre-bent pipe;

5 a three-dimensional view of one of the in 4 shown tube produced by high pressure forming semi-finished part;

6 a cut through the in 5 illustrated semi-finished part along the section line VI-VI.

1 shows a three-dimensional view of a front end 1 of a motor vehicle 3 from diagonally up front. 2 shows a detailed view of a lock cross member 9 of in 1 shown front end. 3 shows a section through the in 2 detail shown along the line III-III. In the three-dimensional representations according to 1 and 2 is by means of an arrow 45 a direction of travel of the motor vehicle 3 located. By means of further arrows and the symbols x, y and z are a vertical axis z, a transverse axis y and a longitudinal axis x of the motor vehicle 3 located. The following is based on the 1 - 3 the front end 1 of the motor vehicle 3 explained in more detail.

The front end 1 of the motor vehicle 3 has a left side member 5 and a right side member 7 on.

The lock cross member 9 serves to support a in 2 only by the reference numeral 11 indicated flap of the motor vehicle 3 , At the flap 11 of the motor vehicle 3 it is in particular a hood. The lock cross member 9 serves in addition to a recording of closing forces to close the flap 11 also for deriving one when closing the flap 11 occurring impulse and thus to absorb the associated forces.

To the side members 5 . 7 is a crash box 15 tethered. The crashbox 15 has a connection plate 17 on. To connect the crashbox 15 to the side members 5 . 7 have this an anchor plate 13 on. By means of screw connections 47 are the connection plates 17 the crash boxes 15 , the anchor plates 13 and the lock cross member 9 screwed together. The screw connections 47 In particular, have a fastening screw which is connected to a weld nut. The weld nut is in particular to the anchor plates of the front side member 5 . 7 welded. Alternatively or additionally, the lock cross member 9 and the connection plates 17 the crash boxes 15 by riveting 49 connected with each other. The rivet connections 49 meet in particular the purpose of a pre-connection and can by recesses, in particular holes, the anchor plate 13 the side member 5 . 7 protrude. Advantageously, characterized from the lock cross member 9 and the 2 Crashboxen and in particular a bumper cross member 57 a pre-assembled assembly can be made.

As in 2 to recognize the lock cross member 9 Recordings 19 for attaching an in 1 shown hood lock 39 as well as two holders 41 on the lock cross member 9 on. The pictures 19 have receiving surfaces and breakthroughs in the form of punches 37 on. By means of the recordings 19 , the punching 37 as well as in this introduced Blindnietverbindungen the hood lock 39 as well as the holders 41 with the lock cross member 39 to be assembled.

As in the 1 and 2 to recognize the lock cross member 9 two ends 21 on that the anchor plates 13 the side member 5 . 7 asymmetrically U-shaped embrace and to an asymmetrical U-shaped cross-section 23 exhibit. The ends have to lateral edges of an original pipe profile of the lock cross member 9 in particular, wherein the lateral edges have a radius.

Moreover, in the 1 and 2 to realize that the lock cross member 9 in the area of its ends 21 an s-shaped course 25 having. The s-shaped course 25 is favorably designed so that from the flap 11 introduced forces particularly well on the side members 5 . 7 forwarded or can be supported on these. In addition, the lock cross member 9 tubular and has a substantially closed hollow cross section. Advantageously, characterized by means of the lock cross member 9 At a minimum weight comparatively high forces are transmitted, which also advantageous for stiffening the front end 1 , in particular for transmitting forces between the longitudinal members 5 . 7 can be exploited. The lock cross member 9 extends advantageous in one piece directly between the side rails 5 . 7 , Advantageously, the lock cross member 9 directly to the anchor plates 13 the side member 5 . 7 tethered and thus can in a single component forces to stiffen the front end 1 transferred between them.

4 shows a pre-bent tube 27 , 5 shows one out of the pipe 27 manufactured semi-finished part 51 , 6 shows a sectional view of the in 5 shown semi-finished part 51 along the section line VI-VI. The following is based on the 4 - 6 a method for producing a lock cross member 9 as in the 1 - 3 shown. explained in more detail.

For producing the lock cross member 9 First, the in 4 shown pipe 27 pre-bent. The pre-bent tube 27 is slightly open U-shaped pre-bent. This in 4 shown pre-bent pipe is in a in 4 only indicated by two lines tool 53 inserted and within the tool 53 formed by high pressure forming. It also happens inside the tool 53 a shear cutting of the already high pressure formed tube 27 , As a result of the shearing, the deformed tube shows 27 , as a semi-finished part 51 in 5 is shown, the punched 37 and essentially U-shaped cuts 29 on. As in 5 to recognize, the U-shaped cuts surround 29 cloth 31 , The rags 31 are along a crease line 43 in an interior of the hollow profile of the tube 27 folded at an obtuse angle.

6 shows a section along the in 5 represented line VI-VI by two of the fold lines 43 , two of the cuts 29 as well as two of the lobes 31 of an end 21 of the semi-finished part 51 , It can be seen that cuts on both sides 29 in the semi-finished part 51 are introduced, leaving two of the lobes 31 lie opposite each other and along the fold lines 43 worked out.

To finish the lock cross member 9 will that be in 5 shown semi-finished part 51 cut to length or cut. The cutting is done at the ends 21 along a lower clipping plane 33 and an upper clipping plane 35 , It is in 5 to recognize that the crease lines 43 the cloth 31 between the clipping planes 33 . 35 and outermost ends of the tube 27 run. In addition, it can be seen that the Beschnittebenen 33 . 35 through the rags 31 round lead. This can advantageously the lobes 31 by cutting the tube to length 27 of the semi-finished part 51 , as in 5 shown separated. This is the rag 31 no longer part of the finished lock cross member 9 which advantageously has the L-shaped ends 21 having. It is also in 6 to recognize that the opposite lobes 31 are different lengths, so that the finished lock cross member 9 the asymmetrical U-shaped cross-section 23 after cutting to length the semi-finished part 51 having.

In 5 it can be seen that the lock cross member 9 the punches 37 for the recordings 19 and at the ends 21 for fixing to the anchor plates 13 having.

Alternatively or additionally, the high pressure forming under heat, so with a preheated tool 53 and a preheated tube 27 occur.

Advantageously, legal requirements for CO ₂ emissions due to a reduction in weight can be better met. Advantageously, by means of the lock cross member 9 higher structural requirements for the front end 1 , in particular with regard to a pedestrian protection and a flexural rigidity of a body of the motor vehicle 3 be fulfilled. Advantageously, the lock cross member 9 in a simple manner, in particular cost, can be produced.

The lock cross member 9 is produced by means of the hydroforming process and integrates otherwise required supports in a component, can advantageously otherwise required, in particular approximately vertical struts to the front side members 5 . 7 a front longitudinal frame, in particular the side members 5 . 7 , the bodywork of the motor vehicle 3 eliminates and advantageous yet forces when closing the door 11 by means of the lock cross member 9 be supported. Advantageously, due to the omission of lateral wheel struts a pedestrian protection of the motor vehicle 3 be improved and a bulb service to headlights of the motor vehicle 3 be improved. Advantageously, the holder 41 be positioned freely, in particular to meet pedestrian protection. Advantageously, further can of spring struts of the motor vehicle 3 in strut receptacles 55 the body or in the front 1 the body introduced spring damper forces in addition by means of the lock cross member 9 are received, so that a connection rigidity is increased.

The lock cross member 9 is in particular made of an extruded or roll-formed light metal tube, in particular pipe 27 , manufactured. The pipe 27 can have round, oval, square, rectangular or polygonal cross-sections. To fulfill the support function, the pipe becomes 27 prebent in a Vorbiegeoperation, wherein a tube blank in approximately a contour of the finished shape of the lock cross member 9 what is brought in 5 can be seen. The preformed tube 27 In particular, it is heated and in a tool which is also heated in particular 53 by introducing internal pressure into, in 5 shown, brought finished shape. In this case, all functional surfaces, in particular the images are advantageous 19 , for fixing the holders 41 , the hood castle 39 and in particular further attachments and all necessary holes, in particular the punches 37 , into the semi-finished component 51 brought in. In a connection area to the side rails 5 . 7 , at the ends 21 and the anchor plates attachable thereto 13 , is in the form of the cut 29 in the pipe 27 on a front and a back a later Fertigbeschnitt the L-shaped ends 21 introduced corresponding recess. In the case of high pressure forming, the die cuts become advantageous 37 as well as the cuts 29 so in the pipe 27 introduced that so-called punched slugs, in particular along the fold lines 43 , on the semi-finished part 51 remain. This can advantageously damage the tool 53 safely avoided. Advantageously, the cloths allow 31 that from the cuts 29 be demarcated, it by the subsequent trimming operation or trimming, the lock cross member 9 finish. The cutting or trimming takes place along the Beschnittebenen 33 . 35 , in the 5 can be seen. By this type of cutting or trimming the connection area or the ends 21 that the body structure of the motor vehicle 3 , in particular the longitudinal members 5 . 7 is assigned or is assignable, it is possible that the lateral edges of the tube, which in the sectional view of 3 can be seen, remain preserved, which advantageously has an inherent rigidity of the lock cross member 9 improved.

Another advantage results from the fact that the lock cross member thus produced 9 Part of the front car 1 , in particular a front module with pre-assembled components, in particular the holders 41 and the hood lock 39 is. The continuous edges of the pipe 27 then completed lock cross member 9 allow a simple way of suspending a front module produced in this way, the lock cross member 9 has, at the anchor plates 13 the side member 5 . 7 , Advantageously, such a simplification of the assembly can be achieved, in particular due to the asymmetrical U-shaped cross-section 23 in which the anchor plates 13 intervention. Advantageously, the lock cross member 9 a high intrinsic stiffness at a significantly reduced weight, in particular reduced by about 50%, in particular, a reduced number of components over known embodiments can be achieved. The front module has in particular the bumper cross member 57 , the crashboxes 15 as well as the lock cross member 9 , especially including hood lock 39 and holder 41 , on.

In summary, there is a weight reduction of the entire motor vehicle 3 compared to conventional sheet metal structures with different struts, in particular by reducing lengths of required connecting flanges. Advantageously, a maximum profile structure of the lock cross member 9 and thus a maximum load capacity or a maximum load torque of the profile cross section of the lock cross member 9 be achieved. Compared with so-called hybrid designs, cost reduction and / or reduction of components and / or ease of repair are advantageous.

Advantageously, the lock cross member 9 with only one material as a one-piece component between the longitudinal members 5 . 7 be provided. Advantageously results in a reduction of complexity in terms of materials used and number of parts. In addition, advantageously results in a higher structural strength of the front end 1 , Advantageously, due to the elimination of the struts for supporting the lock cross member 9 on the side rails 5 . 7 a requirement for pedestrian protection and requirements for a lighting service can be better met. Advantageously, additional dynamic forces occurring in a driving operation by means of the lock cross member 9 be supported.

LIST OF REFERENCE NUMBERS

1

front end

3

motor vehicle

5

left side member

7

Right side member

9

Castle crossmember

11

flap

13

anchor plate

15

crash box

17

connecting plate

19

admission

21

The End

23

cross-section

25

course

27

pipe

29

cut

31

cloth

33

lower clipping plane

35

upper landing level

37

punching

39

Haubenschloss

41

holder

43

fold line

45

arrow

47

screw

49

riveted joints

51

Semi-finished part

53

Tool

55

MacPherson strut

57

Bumper crossmember

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• US 5882039 [0002]

Claims (15)

Front end ( 1 ) of a motor vehicle ( 3 ) with a left side member ( 5 ) and a right side member ( 7 ) and a lock cross member ( 9 ) for supporting a dome ( 11 ) of the motor vehicle ( 3 ), characterized in that the lock cross member ( 9 ) in one piece between the longitudinal members ( 5 . 7 ). Front end according to the preceding claim, characterized in that each of the longitudinal members ( 5 . 7 ) each an anchor plate ( 13 ), wherein the lock cross member ( 9 ) on the anchor plates ( 13 ) is fixed. Front end according to one of the preceding claims, characterized in that the front end ( 1 ) per longitudinal beam ( 5 . 7 ) a crash box ( 15 ) with a connection plate ( 17 ), wherein the lock cross member ( 9 ) on both sides with the respective connecting plates ( 17 ) the side members ( 5 . 7 ) and anchor plates ( 13 ) of crash boxes ( 15 ) connected is. Front end according to one of the preceding claims, characterized in that the lock cross member ( 9 ) the side members ( 5 . 7 ) in each case engages in an L-shape. Front end according to one of the preceding claims, characterized in that the lock cross member ( 9 ) is made by hydroforming. Front end according to one of the preceding claims, characterized in that the lock cross member ( 9 ) at least one recording ( 19 ) for at least one further component ( 39 . 41 ) of the front car ( 1 ) having. Front end according to the preceding claim, characterized in that the further component is a hood lock ( 39 ) for locking the flap ( 11 ) and / or a holder ( 41 ). Front end according to one of the preceding claims, characterized in that the lock cross member ( 9 ) two ends ( 21 ), which on the side members ( 5 . 7 ) are tethered or attachable, the ends ( 21 ) an asymmetrical U-shaped cross section ( 23 ) exhibit. Front end according to the preceding claim, characterized in that the ends ( 21 ) for L-shaped gripping around the side members ( 5 . 7 ) Are L-shaped. Front body according to one of the preceding two claims, characterized in that the lock cross member ( 9 ) between the ends ( 21 ) has a substantially closed and hollow cross-section. Front end according to one of the preceding claims, characterized in that the lock cross member ( 9 ) at the ends ( 21 ) one on the longitudinal members ( 5 . 7 ) tapering S-shaped curved course ( 25 ) having. Method for producing a lock cross member ( 9 ), in particular a lock cross member ( 9 ) according to one of the preceding claims, characterized by: - pre-bending a tube ( 27 ), - high-pressure forming of the pre-bent tube ( 27 ), Shear cutting of the high-pressure-formed tube ( 27 ), - cutting of the tube ( 27 ) and thereby finishing the lock cross member ( 9 ). Method according to the preceding claim, characterized by: introduction of two U-shaped sections ( 29 ) in the pipe ( 27 ) by shearing, - folding in by the U-shaped cuts ( 29 ) delimited, lobes ( 31 ), - cutting of the tube ( 27 ) along one of the lobes ( 31 ) passing through level ( 33 . 35 ). Method according to one of the preceding two claims, characterized by: inserting punches ( 37 ) in the pipe ( 27 ) by shear cutting. Motor vehicle ( 3 ) with a front end ( 1 ) according to one of the preceding claims 1-11 and / or produced by a method according to one of the preceding three claims.

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