FR2767510A1 - MOUNTING METHOD AND DEVICE FOR A MOTOR VEHICLE BRAKING SYSTEM - Google Patents

Abstract

The invention relates to the assembly of automobiles, in which all the necessary pipes (9), with the groups to be connected or fixed such as an ABS unit (25), a brake pedal module (6) and a reservoir brake fluid compensation (11), are mounted together on a mechanization frame in a pre-assembly. Subsequently, the fully assembled brake system is checked for leaks and is then emptied and filled with brake fluid by means of a filling device, after which the pre-assembled and ready-to-operate installation is presented under the body of the vehicle and assembled to it at the same time as the other units pre-assembled on the mechanization frame. In this way, a production process with continuous progression is obtained. Main application: assembly lines with continuous progression.

Description

Mounting method for a vehicle braking system

  automobile The invention relates to a mounting method for a motor vehicle braking installation and for the assembly of this installation to a motor vehicle body. The invention

  also relates to a device for implementing the method.

  It is known in practice, in the automotive industry, to fix vehicle braking systems, with or without ABS, with the essential braking lines, in several phases, to the underbody of a motor vehicle body. This is done by

  generally by working above the head or on swinging swings.

  In this operation, the different brake lines, or the brake lines assembled in bundles of lines, are placed against the underbody and bolted to the various modules such as the front axle, the rear axle, the brake calipers, the cylinders brakes, ABS, crankset and the like. All of these operations must be performed

  working above the head in the main assembly line.

  Then, a brake filling device is fitted to the brake fluid compensation tank on the vehicle, then the braking system is tested, a vacuum is created and it is filled. For all these works, it is necessary to execute several phases in the main assembly line, sometimes with a considerable proportion of work to be carried out above the head, insofar as one has not planned a high degree of automation, for example thanks to swings

  oscillating to increase ergonomics.

  It is also already known in practice to bring together different brake lines on a pre-assembly line to form a bundle of pipes, then bring this bundle under a bodywork, present it to the base of the latter and put it in place. contact with it and, then, in stations of the main assembly line which are mounted downstream, to bolt the individual pipes, again by working above the head, after which these pipes are tested again, emptied and filled using a

brake filling.

  It is also known in practice to preassemble vehicle modules, or vehicle units, on mechanization frames which are arranged on forklifts, and then to fix them to the bodywork as a unit. This applies, for example, to the front axle module and the rear axle module, the bottom bracket module and similar units. Document DE 36 03 709 C2 describes a method for assembling vehicles, as well as a device for implementing the method. The document generally relates to parts pre-assembled of a running gear on a mounting frame and to an additional test of mounting and of operation of different groups before the assembly of the

complete body.

  Another document, namely DE 35 38 468 A1, describes devices and methods which are generally used in chain production, the devices (hand-held devices) moving at the same speed.

  as the chain and accompanying it.

  The object of the present invention is to develop an assembly method for a braking installation and a device for this method by means of which the complicated and painful work to be performed above the head in a continuous progression assembly process can

largely be avoided.

  According to the invention, this problem is solved by an assembly method for a braking installation of a motor vehicle and for its assembly to a motor vehicle body, in which the vehicle body is set in motion on a main belt at the rate determined by its production process, the process comprising the following stages: 1.1 all the necessary brake lines, with groups which must be connected to the brake lines or assembled there, such as an ABS unit, a pedal module brake and a brake fluid compensation tank are mounted together in a pre-assembly on a mechanization frame which moves parallel to the main strip of the production process, and in synchronism with the process, 1.2. the fully assembled braking system is then checked for leaks by means of a braking system filling device which also moves parallel to the main strip of the production process and in synchronism with the process, 1.3. the brake system is evacuated and filled with brake fluid, and 1.4. the pre-assembled and ready-to-operate braking system is presented under the vehicle body which is driven in the main belt at the rate of the production process, and it is assembled to this body, together with other units pre-assembled on the

mechanization framework.

  For the implementation of this method, the present invention further provides a device characterized by mechanization frames arranged on forklifts, and on which are arranged an assembly station for the brake lines and for the groups which must be attached to the brake lines, and an assembly station for a device for filling the brake system. Advantageously, the mechanization frame is provided with fixing members for the brake lines; in particular, preferably, at least one fixing member is arranged between the brake pedal module and the rear axle module and fixing members are arranged in the sets of brake lines which lead to the brake discs and the drums brakes. Preferably, the mechanization frame and the filling device of the braking system can be set in motion in synchronism with the

  movement of the production process.

  The method according to the invention and the device for its implementation eliminate the very painful work above the head, which was necessary until now, for fixing the brake lines to the base. On the contrary, the brake lines can be mounted, in an ergonomically advantageous position, in pre-assembly, on a mechanization frame, with a simple possibility of movement of the workers in accompaniment, in a process of

production with continuous progression.

  The postponement of the mounting and bolting of the brake lines in a pre-assembly line, in the mode according to the invention, considerably improves the quality of the bolts because in fact the bolting performed above the head so far n was not only very tiring but also led to relatively high error rates. On the contrary, thanks to the pre-assembly according to the invention, the different bolting positions on the mechanization frame are easily accessible and it is therefore thus possible to carry out the bolting reliably. This results in a lower leakage rate and, in this way, a

  higher quality and lower recovery rate.

  The fact of postponing the mounting of the brake lines and the complete production of a braking installation ready to operate in a pre-assembly line, with test, evacuation, filling and pressure test of the installation carried out at the same time, can eliminate on average 8 to 10 manufacturing phases on the main assembly line. Depending on the duration of the phases, a reduction of up to 20 minutes in the passage time of a vehicle is obtained in this way. The manufacturing time of the braking system is also reduced

  considerably thanks to better accessibility.

  Since the pre-assembly line according to the invention requires less space than the main assembly line and is therefore more economical, savings can also be made in the production means in this way. In addition, thanks to the faster assembly of the brake system, there is a need for a smaller number of assembly stations, which translates into a new economy. The continuous progression of the assembly process avoids losses of phase time (dead time) and, at the same time, we obtain that the filling installations accompany the movement in flexibility and we obtain in this way a greater security of the process, a higher quality

and higher productivity.

  Improvements and advantageous embodiments of

  the invention emerges from the embodiment described in principle below

next to the drawing.

  In this drawing, Figure 1 shows the device according to the invention in the form of a pre-assembly line with mechanization frames, seen from above; and FIG. 2 is a perspective block diagram of the elements mounted on a mechanization frame, the elements being represented in the positions they assume when they are assembled on a

  motor vehicle body.

  The pre-assembly line described below is in principle of a known construction form and mode of operation, so that only a schematic explanation will be given. A plurality of mechanization frames 1 are arranged on forklifts 2 not shown in detail, at a height of 800-900 mm, and they travel on a track

  oval manufacturing 3, used as a ground-guided transport technique.

  The forklifts 2 circulate continuously in a closed circuit. The starting point for the mounting process is at station 4, next to which a standby lift truck 2 'is also on standby if necessary - as shown in broken lines. During the course of each mechanization frame 1 arranged on a forklift 2, the

  different elements are assembled by workers.

  In the case considered, only the essential elements for the present invention are described below. Thus at station 5, a pre-assembly of a pedal module 6 is carried out. In FIG. 2, we can see more precise details on this subject and also on the subject of the assembly steps which are

  described below with reference to Figure 1.

  Then, a rear module is mounted on the mechanization frame 1 in a station 7. In another station 8, all the brake lines 9 are arranged on the mechanization frame 1 and, in a next station 10, a compensation tank brake fluid 11 is

  mounted on the mechanization frame 1.

  In a next station 12, a braking system filling device 13 is connected to the braking system which is already fully assembled at this location. Fully assembled here means that the braking lines are securely fixed to all the members which are fixed or connected to this installation, so that the brake system can be checked for leaks by the filling device 13 of the braking system. After a corresponding positive result, the braking system is evacuated in this station and then filled with brake fluid in a way which ensures the safety of the process. This means that at station 12, we already have a

  braking system fully ready for operation.

  During the following assembly steps, other elements, which are not of interest here, may possibly be pre-assembled on the mechanization frame (s) 1. This observation is valid, for example, for a tank module in a station 14. In a station 15, it is possible to carry out a visual check and, in a station 16, the forklift 2 is synchronized with the main assembly line, which runs above, on which the vehicle bodies being production are in a swing. In the main assembly line, the vehicle bodies are transported, in the direction of arrow A, above the production line 3. In a station 16, all the elements and units pre-assembled on the production line are assembled to a vehicle body. For this purpose, the mechanization frame 1 is lifted by the corresponding forklift 2 and, in this way, presented

  from bottom to top against the body of a motor vehicle.

  In a next station 18, bolting now occurs

  remaining elements and units pre-assembled on the mechanization frame 1.

  In a next station 19, the bolting of the front axle is carried out and, in a station 20, the mechanization frame 1 is separated from the body of the motor vehicle by lowering the forklift truck 2. Next, in the station 4, the pre-assembly is again carried out on the production line 3 while a vehicle body 33 fitted in this way with units and elements pre-assembled on the mechanization frame is transferred to the main assembly line in the direction of the arrow B. In the perspective representation of Figure 2, there is shown the principle of the mounting method for the braking installation of a

motor vehicle.

  For reasons of clarity of the drawing, the mechanization frame 1 and the forklift 2 are not shown in FIG. 2. Only the various supports are shown which receive the elements to be assembled, which

  are arranged on the mechanization frame 1 or integral with the latter.

  This is how, for example, the brake pedal module 6, which is arranged

  in the central position, is placed on supports 21 of the mechanization frame.

  In addition to the brake pedal module 6, a front axle, which is not further shown in this figure, is put in place. A rear axle module, which is lying or placed on module supports 22

  rear, only a brake drum 23 has been shown for the rear left.

  A support 24 is used for an ABS hydraulic unit or an ABS unit 25, supports 26 are used to receive the front axle module not shown. A module 27 is provided for the brake fluid compensation reservoir 11. From the front axle module, no drawing has been made on the

  Figure 2 as a brake disc 18 for the front left.

  To ensure exact centering of the pre-assembled units at the time of their assembly to the vehicle body in station 17, there is provided for each, on the mechanization frame, a locating pin 18 for the body in the rear region and another locating pin 29 for the bodywork in the front region. The two locating pins 28 and 29 ensure precise positioning in the directions

- XetY.

  As explained above with reference to FIG. 1, first place the pedal module 6 in station 5 then the front axle module and, in station 7, the rear module. In station 8, the various braking lines 9 are then mounted between the

  different groups and connected to these groups with a pressure-tight seal.

  Thus, for example, the brake lines 9 are connected to the pedal module 6, to the ABS hydraulic group 5, to the brake drums 23, to the brake discs 28 and to the reservoir 11 for compensating the brake fluid. After the assembly of the brake fluid compensation reservoir 11 in the station 10, as described above with reference to FIG. 1, the test, the evacuation and the filling of the entire braking installation in station 12, by means of the device 13 for filling the braking installation. To this end, the device 13 for filling the braking system is connected to the reservoir 11 for compensating the brake fluid. After filling the braking system, the reservoir 11 for compensating the

  braking is closed by means of a cover in a known manner.

  As a general rule, the brake lines 9 are sufficiently solid to be able to be laid in free range between the different groups. Simply, an assembly member 30, having the shape of a clamp, can be provided only between the front axle module and the rear axle module, this member being fixed to the frame of

  mechanization and thus maintaining the brake line 19 at this location.

  In addition, the ABS cable bundles, which lead to the brake drums 23 and to the brake discs 28, can also be fitted with an assembly member 31. The other assembly elements shown in FIG. 2 are used only to position the brake lines 9 gathered in bundles. Screw pins 32, which are only shown schematically in Figure 2, are provided at stations 17, 18 and 19

  to bolt the pre-assembled elements to the vehicle body.

  The forklifts 2, with the mechanization frames 1 mounted on them, and the device 13 for filling the braking system, are driven on the production line 3 in a movement synchronized for the process with the movement of the production process. or from

main assembly line.

Claims (6)

  1. Assembly method for a braking installation of a motor vehicle and for its assembly to a motor vehicle body, in which the vehicle body is set in motion on a main strip at the rate determined by its production process, the process comprising the following steps: 1.1 all the necessary brake lines (9), with groups which must be connected to or assembled with the brake lines (9), such as an ABS unit (25), a pedal module brake (6) and a reservoir (11) for compensating the brake fluid, are mounted together in a pre-assembly on a mechanization frame (1) which moves parallel to the main strip of the production process, and in synchronism with the process, 1.2. then, the fully assembled braking system is subjected to a leak test by means of a device (13) for filling the braking system which also moves parallel to the main strip of the production process and synchronism with the process, 1.3. the brake system is evacuated and filled with brake fluid, and 1.4. the pre-assembled and ready-to-operate braking system is presented under the vehicle body which is driven in the main belt at the rate of the production process, and it is assembled to this body, together with other units pre-assembled on the mechanization frame (1).   2. Device for implementing the method according to claim 1, characterized by mechanization frames (1) disposed on forklifts, and on which are arranged an assembly station (8) for the brake lines (9) and for groups (6, 11, 25) which must be fixed to the brake lines (9), and an assembly station (12) for a device   (13) filling the brake system.   3. Device according to claim 2, characterized in that the mechanization frame (1) is provided with members   fixing (30, 31) for the brake lines (9).   4. Device according to claim 3, characterized in that at least one fixing member (30) is arranged   between the brake pedal module (6) and the rear axle module.   5. Device according to claim 3 or 4, characterized in that fixing members (31) are arranged in the sets of brake lines   which lead to the brake discs (28) and the brake drums (23).   6. Device according to one of claims 2 to 5,   characterized in that the mechanization frame (1) and the device (13) for filling the braking system can be set in motion in synchronism with the movement of the production process.