JP2000229592A - Manufacturing method and device for automobile and automobile - Google Patents

Abstract

PROBLEM TO BE SOLVED: To dispense with a coating process until an automobile is completed in its production so as to remarkably reduce the production cost and improve the productivity by mutually relating a plurality of processes continuously by completing the production through preliminary assembling interior members such as a floor unit, body side unit and roof unit. SOLUTION: This method comprises a floor step A wherein a plurality of floor constitutional basic members made from soft metal material are combined and connected to form a floor basic member, an interior parts mounting step B wherein a floor interior member is assembled to the floor basic member to form a floor unit, a body main step C wherein a body side unit composed of a body side basic member and a body side interior member combined thereto and a roof unit composed of a roof basic member and a roof interior member assembled thereto are jointed to the floor unit to thereby form an upper body unit, a running parts mounting step D wherein an engine suspension is assembled to construct a car body, and an outer surface decorating step E.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automobile manufacturing method, an automobile manufacturing apparatus, and an automobile.

[0002]

2. Description of the Related Art As is well known, a vehicle body is formed by joining various panel members with a closed cross-section strength member such as a pillar, a side sill, a side member, a cross member, a cowl box and a roof rail. For the box type, the engine compartment and cabin, and 3
In the box type, the engine compartment is separated from the cabin and the trunk room.

[0003] Regarding any of these types of vehicle bodies, the complete book of Automotive Engineering, Vol. 19, Manufacturing Method of Automobiles, April 1980
Items on pages 178 to 179 published by Sankaido on March 20.
4 As is clear from the contents described in "Body assembly process",
The panel material is press-formed in the pressing process and then welded and joined in the body assembly process to form a white body, which is sequentially transferred to the painting process, the vehicle assembly process for assembling outfitting parts, etc., and finally various functions Parts and interior parts are assembled.

[0004]

However, in a conventional automobile manufacturing method, automation has been advanced from a pressing process to a final vehicle assembling process, and a painting process is interposed in the automation line. Process was required. That is, a step of drying the paint and a facility for changing colors are required after the paint step has been completed and before the vehicle flows to the vehicle assembling step, and the proportion of the drying step and the like has been extremely large. By the way, the space for one car is 1
In the case of the process, the conventional manufacturing method has a total of 800 to 10
About 00 steps were required. For this reason, a lot of time is required for automobile manufacturing, and the factory space is also large.

Further, in the conventional manufacturing method, an engine, interior parts, and the like are assembled in a separated closed space such as an engine compartment and a cabin.
For example, there is a problem that an operator has to go into the cabin or from the vehicle body opening where the door is attached, which requires a great deal of labor and time.

An object of the present invention is to provide a method, an apparatus, and a vehicle for manufacturing a vehicle, which can greatly reduce the number of manufacturing steps and make it easy for a worker to manufacture the vehicle.

[0007]

According to the first aspect of the present invention, a plurality of floor component base members of an automobile each formed of a light metal material are combined, and the combined floor component base members are joined to form a floor substrate. A floor step, an interior component mounting step of assembling a floor interior material to the floor base material to form a floor unit, and a body side unit assembling a body side interior material to a body side base material to constitute a side portion of the automobile; A main unit process of forming an upper body unit by joining a roof unit constituting an upper part of the automobile by assembling a roof interior material to a roof base material, and an under unit including an engine, a power train, a suspension, and the like. A running unit is assembled to the upper body unit to form a vehicle body. And running parts mounting step, on the vehicle body, it is characterized in that it comprises an outer surface decoration step of attaching an external surface covering member for decoration.

[0010] According to a second aspect of the present invention, an operator combines a plurality of floor-forming base materials of an automobile, each formed of a light metal material, on a manual conveyor, and joins the combined floor-forming base materials to form a floor base material. A floor process device, an indoor component mounting process device in which an operator accepts the floor base material on a manual conveyor and assembles a floor interior material to the floor base material to form a floor unit, and the floor unit on a manual conveyor. A body side unit that receives the floor unit and attaches a body side interior material to a body side base material to constitute a side portion of the vehicle, and a roof unit that attaches a roof interior material to a roof base material to constitute an upper portion of the automobile And an operator combined with the floor unit and on an automatic conveyor driven by driving means. An underbody unit consisting of an engine, powertrain, suspension, etc. is supplied by a supply device, and the upper body unit is assembled by lifting the upper body unit, while a body main process device that forms an upper body unit by joining it by a robot is provided. A running part mounting process device for forming a vehicle main body by using a vehicle, and an external decoration process device for receiving the vehicle main body on a manual conveyor and attaching an exterior coating member for decoration to an operator.

According to a third aspect of the present invention, there is provided a floor unit in which a floor interior material is assembled to a floor base material which is formed by combining a plurality of floor constituent base materials of an automobile each formed of a light metal material, An upper body unit in which an interior material is assembled to form a side portion of the vehicle and a roof unit in which a roof interior material is assembled to a roof base material to form an upper portion of the automobile; and an engine and a power train An underrunning unit comprising a suspension, etc., which is assembled to the upper body unit to form a vehicle body, a door unit having a vehicle body, an exterior component such as a bumper, a window shield, and a door mirror mounted on a door panel, and a decoration. With the outer surface covering member for And wherein the door.

According to a fourth aspect of the present invention, there is provided the method of manufacturing an automobile according to the first aspect, wherein the joining is performed by welding.

According to a fifth aspect of the present invention, there is provided a method of manufacturing an automobile according to the first aspect, wherein the joining is performed by bonding.

According to a sixth aspect of the present invention, in the automobile according to the first aspect, the joining is performed by rivets.

According to a seventh aspect of the present invention, in the vehicle according to the first aspect, the joining is performed by bolts.

According to an eighth aspect of the present invention, there is provided the automobile manufacturing apparatus according to the second aspect, wherein the joining is performed by welding.

According to a ninth aspect of the present invention, there is provided the automobile manufacturing apparatus according to the second aspect, wherein the joining is performed by bonding.

According to a tenth aspect of the present invention, there is provided the automobile manufacturing apparatus according to the second aspect, wherein the joining is performed with rivets.

An eleventh aspect of the present invention is the automobile manufacturing apparatus according to the second aspect, wherein the joining is performed by bolts.

According to a twelfth aspect of the present invention, in the automobile according to the third aspect, the joining is performed by welding.

According to a thirteenth aspect of the present invention, in the automobile according to the third aspect, the joining is performed by bonding.

According to a fourteenth aspect of the present invention, in the automobile according to the third aspect, the joining is performed with rivets.

According to a fifteenth aspect of the present invention, in the automobile according to the third aspect, the joining is performed by bolts.

According to a sixteenth aspect of the present invention, there is provided the first aspect of the present invention.
7. The method for manufacturing an automobile according to any one of claims 7, wherein the molding of the floor constituting base material is extrusion.

The seventeenth aspect of the present invention is the second aspect of the present invention.
12. The automobile manufacturing apparatus according to any one of the eleventh to eleventh aspects, wherein the molding of the floor constituent base material is extrusion.

[0024] The invention of claim 18 is the invention of claim 3 or 12
16. The automobile according to any one of items 15 to 15, wherein the molding of the floor constituting base material is extrusion.

The invention of claim 19 is the invention of claim 3 or 12
19. The vehicle according to any one of claims 15 to 18, wherein a fitting female portion is provided on one of the floor constituent base materials and a fitting male portion is fitted on the fitting female portion on the other. One of the male and female parts is provided with a positioning projection, and the other is provided with a positioning recess engaged with the positioning projection.

According to a twentieth aspect of the present invention, in the automobile according to the nineteenth aspect, the positioning concave / convex portion is provided on a back wall of the fitting female portion and a distal end wall of the fitting male portion, and the fitting male and female portion is provided. It is characterized in that rotation is stopped between.

According to a twenty-first aspect of the present invention, there is provided the automobile according to the twentieth aspect, wherein a clip projection for engagement is provided on both inner surfaces of the fitting female portion opposite to each other at an opening edge, and the fitting is performed. A clip concave portion is provided on both outer surfaces of the male portion to be engaged with the clip convex portion, and abuts on both outer surfaces of the mating male portion on the front end side of the clip concave portion so as to be in close contact with both inner surfaces of the fitting female portion. The surface is provided.

According to a twenty-second aspect of the present invention, there is provided the automobile according to the twenty-first aspect, wherein the clip recess is bonded to an inner surface of an opening edge of the fitting female portion on the vehicle interior side, and the female fitting is formed. The welded portion is formed by welding between the outside edge of the vehicle interior opening and the base outer surface of the fitting male portion.

According to a twenty-third aspect of the present invention, in the automobile according to the nineteenth aspect, the floor constituting base includes a front floor and a dash lower of an engine compartment skeleton, and the fitting female portion includes the dash lower. The lower is formed of a two-stage upper and lower flange extending rearward of the vehicle body, and the male fitting portion is formed at a front end of the front floor and fits between the flanges.

According to a twenty-fourth aspect of the present invention, in the automobile according to the twenty-third aspect, the concave portion is a groove-shaped portion formed in a vehicle width direction, and the convex portion is engaged with the groove-shaped portion. It is a nail-shaped part.

The invention of claim 25 is the invention of claim 23 or 24.
The vehicle according to claim 1, wherein an upper flange of the female fitting portion is thinner than a lower flange of the female fitting portion.

According to a twenty-sixth aspect of the present invention, in the automobile according to any one of the twenty-third to twenty-fifth aspects, the rear end of the lower flange of the fitting female portion is more than the rear end of the upper flange. It is characterized by projecting rearward of the vehicle body, and projecting an upper front end of the fitting male portion forward of the vehicle body from the lower front end in correspondence with the flange.

According to a twenty-seventh aspect of the present invention, in the automobile according to the third aspect, a lower positioning means for positioning between the floor unit and the body side unit is provided, and the body side unit and the roof unit are provided. And an upper positioning means for positioning between them is provided.

According to a twenty-eighth aspect of the present invention, in the automobile according to the twenty-seventh aspect, the upper and lower positioning means are constituted by pins and locate holes.

According to a twenty-ninth aspect of the present invention, in the vehicle according to the twenty-eighth aspect, the pin and the locating hole of the lower positioning means are arranged with their axes oriented in the vehicle width direction. The locating hole is arranged with its axis up and down so as to be orthogonal to the axis of the pin and the locating hole of the lower positioning means.

According to a thirtieth aspect of the present invention, in the automobile according to any one of the twenty-seventh to twenty-ninth aspects, the lower positioning means is disposed at least on the lower end of the center pillar, and the upper positioning means is disposed at least at the center. It is characterized by being arranged on the pillar upper end side and the front pillar middle section side.

According to a thirty-first aspect of the present invention, in the automobile according to the third aspect, the joint is one-way welding of a joint located outside the vehicle compartment.

According to a thirty-second aspect of the present invention, there is provided the automobile according to the third aspect, wherein the floor unit and the body side unit are joined by bonding a joint on the vehicle interior side and welding a joint on the outer side. There is a feature.

According to a thirty-third aspect of the present invention, in the automobile according to the third aspect, the outer surface covering member is formed of a resin, is connected to the vehicle body side by a clip portion, and is provided near the clip portion. A seal portion is provided between the outer surface covering member and the outer surface of the vehicle body.

[0040]

According to the first aspect of the present invention, since the painting process is not required until the automobile is completed, the manufacturing process can be greatly reduced, the automobile manufacturing time can be shortened, and the factory installation area can be reduced. Reduction can be achieved. Also, since the floor unit, body side unit, and roof unit are completed by assembling the interior materials in advance, the assembling can be performed in an open space, and the operation of the automobile can be greatly facilitated by the worker. Can be provided.

According to the second aspect of the present invention, it is possible to provide an automobile manufacturing apparatus capable of obtaining the effect of the first aspect.

According to the third aspect of the present invention, it is possible to provide an automobile which can obtain the effects of the first aspect of the present invention.

According to the fourth aspect of the present invention, in addition to the effects of the first aspect of the present invention, joining can be easily performed by welding.

According to the fifth aspect of the present invention, in addition to the effect of the first aspect of the present invention, it is possible to easily join by bonding.

According to the sixth aspect of the present invention, in addition to the effects of the first aspect of the present invention, joining can be easily performed by rivets.

According to the seventh aspect of the present invention, in addition to the effects of the first aspect of the present invention, it is possible to easily join by bolts.

According to the eighth aspect of the invention, in addition to the effect of the second aspect of the invention, it is possible to easily join by welding.

According to the ninth aspect of the present invention, in addition to the effects of the second aspect of the present invention, it is possible to easily join by bonding.

According to the tenth aspect of the present invention, in addition to the effect of the second aspect of the present invention, joining can be easily performed by using rivets.

According to the eleventh aspect of the present invention, in addition to the effect of the second aspect of the present invention, it is possible to easily join with bolts.

According to the twelfth aspect of the invention, in addition to the effects of the third aspect of the invention, joining can be easily performed by welding.

According to the thirteenth aspect, in addition to the effect of the third aspect, it is possible to easily join by bonding.

According to the fourteenth aspect of the invention, in addition to the effects of the third aspect of the invention, it is possible to easily join by rivets.

According to the fifteenth aspect, in addition to the effect of the third aspect, it is possible to easily join with bolts.

According to the sixteenth aspect, in the first or fourth aspect,
In addition to the effects of any one of the inventions of (1) to (7),
It can be easily formed by extruding a light metal material.

According to the seventeenth aspect, in the second aspect or the eighth aspect,
In addition to the effects of any one of the above-mentioned inventions, the floor constituting base material can be easily formed by extruding a light metal material.

According to the eighteenth aspect, the third aspect or the first aspect is provided.
In addition to the effects of any one of the inventions 2 to 15, the floor constituting base material can be easily formed by extruding a light metal material.

According to the nineteenth aspect, the third aspect or the first aspect is provided.
In addition to the effects of any of the inventions 2 to 15, or 18,
The fitting male part is fitted to the fitting female part, and the fitting is positioned by the engagement of the positioning uneven part, so that the worker can easily form the floor base material.

According to the twentieth aspect of the present invention, in addition to the effects of the nineteenth aspect, the rotation between the fitting male and female portions is stopped by the positioning unevenness portion, and the mutual positioning of the floor constituting base materials is reliably performed. Can be formed more easily.

According to the twenty-first aspect, in addition to the effects of the twentieth aspect, by engaging the clip projections with the clip recesses, the fitting male and female parts can be reliably and easily connected. In addition, since the contact surfaces are in close contact with each other, the hermeticity between the floor constituting base materials can be improved. In addition, the engagement of the concave and convex portions of the clip ensures the close contact of the contact surface, and the sealing performance can be easily and reliably achieved.

According to the twenty-second aspect, in addition to the effect of the twenty-first aspect, the floor constituting base materials can be securely connected to each other by bonding and welding. Since the bonding is performed by using the clip concave portion, the bonding is not exposed to the vehicle interior side, and the finishing accuracy can be improved. The floor-constituting base material is an extruded product, so that the heat of welding of the floor-constituting base material on the outside of the vehicle body is prevented from being transmitted to the surface on the vehicle interior side. Materials can be assembled.

According to the twenty-third aspect, in addition to the effect of the twenty-first aspect, the fitting can be performed by moving the fitting male portion of the front floor between the upper and lower flanges of the dash lower in the front-rear direction, The front floor and the dash lower can be easily assembled. Further, the dash lower and the front floor can be easily positioned in the vertical direction. Furthermore, the engagement between the positioning projections and the positioning recesses enables positioning between the dash lower and the front floor, which facilitates assembling accuracy in the vehicle front-rear direction, and eliminates the need for mutual positioning jigs. It is possible to Further, by the engagement of the positioning concave and convex portions, the fitting between the dash lower and the front floor is hard to be disengaged even by movement in an assembly line or other vibration during transportation, and the handling is easy.

According to the twenty-fourth aspect of the present invention, in addition to the effect of the twenty-third aspect, the positioning engagement between the dash lower and the front floor is more reliably performed by the engagement between the groove-shaped portion and the claw-shaped portion. Can be.

According to the twenty-fifth aspect, the twenty-third aspect or the second aspect
In addition to the effects of the fourth aspect, while increasing the support rigidity by the lower flange, the flexibility of the upper flange reduces the insertion force of the male fitting portion of the front floor between the two flanges, thereby improving the assembling property. be able to.

According to the twenty-sixth aspect of the present invention,
In addition to the effects of any of the inventions described above, the position of the positioning uneven portion between the dash lower and the front floor can be made different between the upper and lower flanges, so that the input from the front side member is simultaneously applied to the upper and lower positioning uneven portions at the time of a frontal collision. Concentration can be suppressed, and the amount of deformation of the dash lower can be suppressed.

According to a twenty-seventh aspect of the present invention, in addition to the effects of the third aspect of the present invention, both the rigid units of the floor unit mainly composed of an extruded material and the like and the body side unit mainly composed of a casting and the like are positioned at the lower part. By performing positioning, it is possible to reliably perform temporary assembly and precision setting. In addition, the positioning between the highly rigid body side unit and the roof unit mainly made of casting by the upper positioning means makes it possible to easily perform the temporary assembly and the precision setting. Therefore, the workability of assembling the vehicle body can be improved.

According to the twenty-eighth aspect of the invention, in addition to the effects of the twenty-seventh aspect, provisional assembly and precision setting can be performed more reliably by means of pins and locate holes.

According to the twenty-ninth aspect of the present invention, in addition to the effects of the twenty-eighth aspect, the pins and locate holes of the lower positioning means are orthogonal to the pins and locate holes of the upper positioning means, so that the floor unit and the body side unit are formed. Temporarily assembling with the pin and the locating hole, and the accuracy of the mounting position between the left and right body side units with respect to the roof unit can be reliably increased. It can be done easily.

According to the invention of claim 30, in claims 27 to 29
In addition to the effects of any one of the inventions described above, both the lower positioning means and the upper positioning means can be positioned at a portion having high rigidity, and the temporary assembly and the accuracy can be more reliably performed.

According to the thirty-first aspect, in addition to the effect of the third aspect, the welding operation can be facilitated by performing the welding from outside the vehicle compartment.

According to the thirty-second aspect, in addition to the effect of any one of the third aspects, the floor unit is based on an extruded material, so that, unlike a single plate, the outside of the vehicle cabin extends to the inside. Is suppressed, and it is possible to restrict the influence of the heat of welding on the interior material and the like inside the vehicle cabin. Further, the sealing performance inside and outside the vehicle compartment can be ensured without applying the vehicle body sealing material by bonding.

According to the thirty-third aspect, in addition to the effects of the third aspect, the outer surface covering member can be easily assembled to the vehicle body side by the clip portion, and the vehicle body can be easily connected to the vehicle body by the seal portion near the clip portion. Sealing with the outer surface covering member can be easily performed. Since the outer surface covering member is formed of resin, the degree of freedom in selecting colors and shapes is wide, and it is possible to easily respond to customer needs. Further, at the time of repair or the like, only the outer surface covering member can be easily replaced, and the repairability can be improved.

[0073]

FIG. 1 is a schematic plan view of an entire factory according to an embodiment of the present invention, in which a method and an apparatus for manufacturing an automobile are realized. As shown in FIG. 1, the manufacturing apparatus is generally a floor process apparatus A, an indoor component mounting process apparatus B,
A body main process device C, a running parts mounting process device D, and an external decoration process device E are provided.

In FIG. 1, reference numeral (a) indicates an automatic process,
(B) is a manual process, (c) is a welding process, (d) is a fixed facility, (e) is a cell production, (f) is a work process, (g) is a parts yard, and (h) is a helping device. Is shown.

The floor process apparatus A realizes a floor process, and combines a plurality of floor component base materials of an automobile extruded with light metal, and welds the combined floor component substrates to form a floor substrate. Form. The floor process apparatus A includes a combination process apparatus 1 for realizing a process of combining floor constituent base materials, and a welding process apparatus 3 for realizing a welding process c. The combination process device 1 includes a floor main process device 5 and two sub process devices 7 and 9. The floor main process device 5 and the sub process devices 7 and 9 are each a work process (f) manually performed by an operator.

The indoor component mounting process apparatus B realizes an indoor component mounting process, and assembles a floor interior material with a floor base material to form a floor unit. The indoor component mounting process device B is a manual process (b), and includes a rear floor module process device 11 for realizing a rear floor module process and a rear end module process device 13 for realizing a rear end module process.

Reference numeral 13 denotes a work step (f) manually performed by an operator. In addition to the assisting device (h) and the parts (h) around the manual process (b), the dash module pallet 15, the engine room component pallet 17, the carpet pallet 19, the rear seat pallet 21, the console pallet, etc. 23, a front sheet pallet 25.

The body main process apparatus C realizes a body main process, and comprises a body side unit that forms a side portion of an automobile by assembling a body interior material with a body side base material and a roof interior material with a roof base material. The roof unit, which forms the upper part of the automobile when assembled, is welded to the floor unit to form an upper body unit.

The body main process device C includes a body side LH process device 27 and a roof process device 29 on one side of a manual process (b) and a welding process (c), and a body side RH process device 31 on the other side. I have.

The body side LH process device 27 forms a body side unit constituting a left side portion of an automobile by assembling a body side interior material with a body side base material. An interior device 33 and a body side set cart 35 are provided, and components (g) are provided on the body side pallet 37 and the like.

The body side RH process device 31 is a device for assembling a body side interior material on a body side base material to form a body side unit constituting a right side portion of an automobile. A sub-line interior device 39 and a body side set cart 41 are provided, and components (g) are provided on the body side pallet 43 and the like.

The roof process device 29 includes a setting process device 45 as a work process (f) and a roof reversing machine 47 as a fixing facility (d). Around the set process device 45, parts (g) are provided for each vehicle type. Equipped with roof parts. In the present embodiment, an S sedan pallet 49, an S setaka pallet 51, a wagon pallet 53, an SS commuter pallet 55, and an M sedan pallet 57 are provided.

In the parts storage space 103, parts related to the roof and body side having different vehicle widths are stored on pallets, and the pallets are supplied to each sub-line according to the production order.

The running parts mounting process apparatus D includes:
A running part mounting process is realized. An underrunning unit including an engine, a power train, a suspension and the like is assembled to the upper body unit to form a vehicle body. The running parts mounting process apparatus D is provided with an automatic mounting machine 59 as a fixed facility (d) for the automation step (a), and an underrunning unit URU is supplied as a part (g).

In the downstream of the running parts mounting process device D, the exterior component mounting process device F, the liquid material adding process device G, the window process device H, and the door mounting process device I are connected. Reach.

The exterior component mounting step device F realizes the exterior component mounting step, and mounts exterior components such as bumpers. In this exterior component mounting process apparatus F, the component (g) is arranged on one side of the manual process (b) on the rear bumper pallet 63 and the front bumper pallet 65, and the component (g) is placed on the other side of the manual process (b). An assisting device (h) is arranged on the end module pallet 67.

The liquid substance adding step apparatus G realizes the liquid substance adding step, and incorporates a liquid substance such as brake oil. In the liquid material adding process device G, a long life coolant supply device 67 and a gasoline supply device 69 are disposed as fixed equipment (d) on one side of a manual process (b), and a brake oil supply device 71 and a power supply are provided on the other side. A steering oil supply device 73 is provided, and other components (g) are also provided.

The window process device H is for realizing a window process, and has a window shield attached. The window process device H is used for a manual process (b).
Parts (g) are arranged on the lamp pallet 74 and the window shield panel pallet 75.

The door mounting process apparatus I implements a door mounting process, and mounts a door unit having a door mirror or the like mounted on a door panel. The door mounting process device I is provided with a door sub-RH process device 7 on one side of a manual process (b).
7 and a door sub LH process device 78 on the other side.
Equipped with an assisting device (H). The door sub RH process device 77 forms a right door unit, and the door sub LH process device 78 forms a left door unit.

The door sub RH process device 77 includes a sash module front pallet 79, a sash module pallet 81,
Door mirror pallet 83, interior module pallet 8
5. Arranged on the inner module pallet 87. The work process (f) of the door sub RH process device 78 and the arrangement of the parts (g) are the same as those of the door sub RH process device 77, although the right and left doors are different, and are denoted by the same reference numerals.

Finally, in the exterior decoration process apparatus E, a resin outer plate pallet 89 for the roof of the component (g) is arranged on one side of the manual process (b) and a resin outer plate pallet 91 for the rear fender is arranged on the other side. , Resin outer pallet 9 for front fender
3. Resin outer pallet 95 for trunk lid and resin outer pallet 97 for hood are arranged respectively.

In the vicinity of each process apparatus, necessary component storage areas 99, 101, 103, 105, 107,
109 and 111 are arranged, and parts necessary for each process are stocked.

First, in the floor process apparatus A,
A plurality of floor constituent base materials of an automobile each extruded with light metal are combined, and the combined floor constituent base materials are welded in the welding process device 3 to form a floor base material. Next, the rear floor module, the rear end module, the dash module, the engine room parts, the carpet, the rear seat, the console, and the front seat are assembled in the indoor component mounting process device B, and are transferred to the next body main process device C as a floor unit.

In the body main process device C, the body side unit provided with the interior in the body side sub line interior devices 33 and 39 is the body side set cart 3
The roof unit is provided on the left and right body side units which are supplied at 5, 41 and are assembled on the floor unit, and then inverted from the roof reversing machine 47.
In the roof reversing machine 47, a roof base material is selected according to the vehicle type in the setting process device 45, and a roof interior material is assembled and supplied to the roof reversing machine 47.

After the body side unit is assembled to the floor unit and the roof unit is further assembled, laser welding is performed in the welding process device 58.

Next, in the running parts mounting process apparatus D, an underrunning unit 61 comprising an engine, a power train, a suspension, etc.
9, the vehicle body is assembled to the upper body unit. A rear bumper, a front bumper, a front end module, and the like are attached to the vehicle body in the exterior component mounting process device F, and a liquid material such as long life coolant, gasoline, brake oil, and power steering oil is mounted in the liquid material adding process device G. Is incorporated.

In the window processing apparatus H, a window shield panel or the like is attached. Door mounting process equipment I
Then, left and right door units to which a sash module front, a sash module rear, a door mirror, an interior module, an inner module, and the like are attached to a door panel are attached.

Finally, in the exterior decoration process apparatus E, a resin outer plate for a roof, a resin outer plate for a rear fender, a resin outer plate for a front fender, a resin outer plate for a trunk lid, and a resin outer plate for a hood are attached. To the completion inspection line.

After the floor base material is formed by combining the floor constituent base materials, the seat / instrument panel, the harness, and the like are assembled into a floor unit. It is a manufacturing method, a manufacturing device, and an automobile for assembling the roof unit with the roof interior material assembled with the body side unit with the assembled interior materials, so that various interior materials can be assembled in the open space, respectively. The assembly workability can be significantly improved.

Further, since the painting process has been eliminated, it is not necessary to change the color of the painting equipment, and the vehicle assembly and the vehicle assembly are completely synchronized. It is possible to greatly reduce the number of parts to be reserved.

Accordingly, the line length from the assembly of the body of the upper body unit and the like to the final assembly of the vehicle is set to 800 lines.
The number of steps can be significantly reduced from the steps to 16 steps of the present embodiment, and a very compact production line can be realized.

[0102] As a result, the time required for automobile production becomes extremely short, and as a result, the period required from ordering to delivery of a car from a customer can be greatly shortened.
By switching from conventional production to make-to-order production, the number of stocks waiting to be shipped can be significantly reduced,
Costs required for inventory management can be reduced. or,
Since the line length of automobile manufacturing can be greatly reduced, the installation area of the factory can be significantly reduced.

FIG. 2 shows the state of manufacture of each of the automobiles manufactured by the automobile manufacturing apparatus shown in FIG. FIG. 2A shows a state in which the floor process apparatus A of FIG. 1 has been completed, and the floor substrate 113 is formed through a floor process and a welding process. FIG. 2 (b)
1 shows a rear floor module processing apparatus 11 and a rear end module processing apparatus 13 in the indoor component mounting processing apparatus B of FIG. 1, and the rear floor module 115 and the rear end module The module 117 is assembled.

FIG. 2C shows a state in which the indoor component mounting process has been completed by the indoor component mounting process apparatus B, and the dash module 118, the front seats 119 and 121, the rear seat 123 and the like are assembled. FIG. 2D illustrates the body main unit C after the body side LH process and the body side RH process.
SU is assembled. FIG. 2E shows a state after the roof process of the body main process device (c), and the roof unit RU is assembled. Thereafter, laser welding is performed by the welding process device 58.

FIG. 2 (f) shows a running parts mounting process performed by the running parts mounting process apparatus D of FIG. 1, and an underrunning unit URU is assembled. The underrunning unit URU includes an engine 131 and the like.

FIG. 2 (g) shows an exterior component mounting step, a liquid substance adding step, a window step, and a door using the exterior component mounting step apparatus F, the liquid substance adding step apparatus G, the window processing apparatus H, and the door mounting step apparatus I, respectively. After the mounting process, the front end module 133, the left and right door units 13
5,137, window shield panel 139,141
And the like, and also a liquid material such as brake oil.

FIG. 2 (h) shows the external decoration process apparatus E shown in FIG.
Shows the completed state of the automobile through the exterior decoration process, and includes a roof resin panel 143, a rear fender resin panel 145, and a front fender resin panel 14.
7. The trunk lid resin panel 149 and the hood resin panel 151 are assembled.

FIG. 3 is a schematic overall perspective view of the floor process apparatus A of FIG. 1 excluding the welding process apparatus 3.
The floor main process device 5 and the sub process devices 7 and 9 are roller conveyors 153 and 155 as manual conveyors, respectively.
157. In addition, pallets 159, 161, 163, 165, 167,
169, 171 are arranged, and the load-variable table 173, 175, 177, 179, 181,
183 and 185 respectively.

Pallets 159, 161, 163, 16
5, 167, 169, 171 are the component storage areas 99, 99 of FIG.
The pallet 159 is set in the vicinity of the pallet 101, and the operator supplies and arranges each pallet 159 or the like containing each component. In this case, when pulling out a pallet of relatively heavy parts, a pallet shooter or the like in which a wheel conveyor is embedded is supplied so that the pallet can slide easily.

The pallet 159 accommodates a plurality of main floor constituent base materials 195 for each shelf.
61 has another main floor constituent base material 193, pallet 1
63 further accommodates another main floor constituting base material 191 in the same manner. On the pallet 166, a plurality of components constituting the engine compartment skeleton 187 are housed in sets on each shelf. Pallet 167,
The components of the rear floor framework 189 are accommodated in 169 and 171 respectively.

Each pallet 159, 161, 163, 16
5, 167, 169, and 171 respectively, when the parts are taken out, the parts are raised by the load-variable table, and each pallet 1
The parts can be easily taken out from the roller conveyor 153 and the like from the parts 59 and the like. When parts are no longer present on each pallet 159 or the like, the next pallet can be easily replenished from the parts storage 99 or 101 by moving the load-variable pedestal with wheels.

In the floor process apparatus A, the floor main process apparatus 5 and the sub process apparatuses 7 and 9 form a cell production line composed of U-shaped work lines, and one cell is assembled at a time. Therefore, there is no extra storage.

That is, the engine compartment skeleton 187 is assembled in the sub-process device 7. At this time, the worker manually assembles the roller conveyor 155. In the sub-step 9, the rear floor framework 189 is assembled. Also in this case, the worker manually assembles on the roller conveyor 157.

Then, on the roller conveyor 153 of the floor main process apparatus 5, the main floor constituent base materials 191, 19
3,195 and the engine compartment skeleton 1
The operator and the rear floor frame 189 are assembled by the operator.

Each of the components used in the assembly is formed by extruding a light metal material, for example, an aluminum alloy, each of which can be held by an operator, and can be easily assembled by a woman or middle-aged person. be able to.

FIGS. 4A, 6 and 7 show the main floor constituent base material 19 constituting the floor constituent base material 113, respectively.
1, 193, 195, an engine compartment frame 187, and a rear floor frame 189 are exploded perspective views showing specific structures.

First, as shown in FIG. 4A, the main floor constituent base materials 191, 193, and 195 are formed by extruding an aluminum alloy, and are respectively formed with locate holes 197, 199, and 201 for positioning. are doing. Further, grooves 20 for engaging the seat mounting bracket 203 are formed in the main floor constituent base materials 191 and 193.
5,207 are molded simultaneously.

Further, the main floor component base material 191 is provided with a fitting male part 209 at the front part and a fitting female part 21 at the rear part.
1 is provided. The main floor constituent base material 193 is provided with a fitting female portion 213 at a front portion and a fitting male portion 21 at a rear portion.
5 are provided. Furthermore, the main floor constituent base material 19
5 has a female fitting part 217 at the front and a female fitting 219 at the rear.

The main floor constituent bases 191 and 193 are connected by the fitting male and female parts 211 and 213, and the main floor constituent bases 193 and 195 are connected by the fitting male and female parts 217 and 215. The coupling structure is basically the same, and will be further described with reference to FIG. 4B, which is a cross-sectional view taken along line bb of FIG. 4A, and FIG. 5, which is an enlarged cross-sectional view.

That is, FIG. 4B, FIG. 5A to FIG.
As shown in (c), a positioning projection 223 is provided on the inner wall 221 of the fitting female part 211, and the distal end wall 22 of the fitting male part 213 is provided.
5 is provided with a positioning recess 225. The positioning uneven portions 223 and 225 are engaged with each other to stop rotation between the fitting male and female portions 211 and 213.

A clip projection 227 for engagement is projected from both inner surfaces of the fitting female portion 211 facing the opening edge, and a clip engaging with the clip projection 227 on both outer surfaces of the male fitting portion 213. A concave portion 229 is provided, and a clip concave portion 2 that engages with the clip convex portion 227 on both outer surfaces of the fitting male portion 213.
29 are provided. Furthermore, contact surfaces 231 that are in close contact with both inner surfaces of the fitting female portion 211 are provided on both outer surfaces of the fitting male portion 213 on the distal end side of the clip concave portion 229.

Then, the main floor constituent base materials 191, 1
When the worker joins 93, the adhesive 233 is inserted into the clip concave portion 229 corresponding to the vehicle interior side as shown in FIG.
Is applied, and the fitting male part 213 is fitted to the fitting female part 2 as shown in FIG.
11 from an oblique direction. As a result, FIG.
As shown in (b), the tip side of the fitting male part 213 is the fitting female part 2.
11 and then pushed further in FIG.
The fitting male and female parts 211 and 213 are fitted as shown in FIG. As a result, the positioning uneven portions 225 and 223 are engaged with each other, the rotation of the fitting male and female portions 211 and 213 is stopped, and the assembly of the main floor constituent base materials 191 and 193 is completed.

As a result, the clip recess 2 on the vehicle interior side
29 and the inner surface 23 of the opening edge of the fitting female portion 211 on the vehicle interior side.
5 are adhered by an adhesive 233, and the upper and lower contact surfaces 231 are in close contact with the upper and lower inner surfaces 235 of the fitting female portion 211 on the tip side of the clip concave portion 229. This contact surface 23
The sealing of the upper side of FIG. 5 which is the interior side of the vehicle compartment and the lower side of FIG. 5 which is the exterior side of the vehicle interior is secured by the close contact of 1, and the sealing property is further enhanced by the adhesive 233. Without using it, watertightness and airtightness inside and outside the vehicle cabin on the floor unit side can be maintained.

The main floor constituting base materials 193, 195
Can be similarly performed by the male and female fitting portions 217 and 215.

The engine compartment skeleton portion 187 as the floor constituent base material is composed of four parts as shown in FIG. 6, and includes a dash lower cross member 237, a suspension mount member 239, and left and right front side members 241. . However, in FIG. 6, the right front side member is not shown.

The dash lower cross member 237 is
The lower part has a fitting female part 243. Although the configuration of the fitting female portion 243 is slightly different in form, it is substantially the same as the fitting female portion 211 described with reference to FIGS.

The upper part of the dash lower cross member 237 has a groove 24 into which the lower end of the dash module is inserted.
5 are provided. A V-cut 247 is provided in the middle of the groove 245 in the vehicle interior in the vehicle width direction, and a front cut 249 is provided on both left and right sides. A member fitting portion 251 is provided on the front side of the dash lower cross member 237, and a through hole 253 is provided on the upper surface side of the member fitting portion 251.

The suspension mount member 239
Is formed of a vertically extruded material, and is formed into a shape that fits into the member fitting portion 251 of the dash lower cross member 237 from the front.

The front side member 241 is formed of extruded material in the front-rear direction, and has a front end to which a joint 255 made of highly ductile aluminum die-cast is joined by welding or the like. This joint part 255 is for connecting the front end module. A through hole 257 is provided on the rear end upper surface of the front side member 241. The left and right front side members 241 are
The rear end is fitted to the member fitting portion 251 on both sides of the suspension mount member 239, and the through hole 25
Temporary fixing is performed by temporary fixing bolts 259 penetrating through 3,257.

In the engine compartment skeleton 187 assembled as described above, the fitting female portion 243 is fitted to the fitting male portion 209 of the main floor constituting base material 191.
The fitting of the fitting male and female parts 243, 209 is performed as shown in FIG.
This is substantially the same as that described with reference to FIG.

The rear floor frame member 189 is formed as shown in FIG.
The six parts indicated by the symbols, namely, the rear side member front 26
1, a rear side member rear 263, a rear cross member front 265, and a rear cross member rear 267. Although the rear side members 261 have a left-right symmetric structure, they can be integrally formed by extrusion molding and cut into two to form left and right rear side member fronts.

Since the right and left rear side members 263 have the same structure, they are integrally extruded, cut, and used for the left and right sides. The rear cross member front 265 and the rear cross member 267 are formed by extruding them integrally and cutting them in the thickness direction.

The temporary assembly of the rear cross member front 265, the rear cross member rear 267, and each rear side member front 261 is performed by inserting a locating pin (not shown) through the locating hole 269.
That is, as shown in FIG. 7B, a locate hole 271 is also provided in the rear cross member front 265, and a locate pin (not shown) is inserted into both the locate holes 269 and 271 to perform temporary assembly. Rear cross member rear 2
The same applies to the temporary assembly of the rear side member front 261 and the front side 67.

The rear cross member front 265,
The rear 267 and the rear side member front 261 are connected by laser welding in a welding process described later, but the rear side member front 261 and the rear side member rear 263 are connected only by bolts and nuts. That is, in the tip of the rear side member rear 263,
Ring-shaped nut 273 having a plurality of nut portions in the circumferential direction
The front end of the rear side member rear 263 is inserted into the coupling hole 275 of the rear side member front 261, and a plurality of bolts 277 inserted from the outer surface of the rear side member front 261 are fastened to the nut 273 in the rear side member rear 263. Accordingly, the rear side member front 261 and the rear side member rear 263 are connected.

Then, FIG. 7 (a) thus connected
The front end portion of the rear floor frame member 189 of FIG.
(A) is temporarily assembled to the fitting female portion 219 at the rear end of the main floor constituent base material 195, and is transferred to a welding process described later.

As described above, since the work in the floor process is performed by fitting the extruded members of several parts of light metal such as aluminum alloy, the weight of each part is reduced to about 1/2 of steel. This makes it possible to easily perform the temporary assembling work of the floor constituting base material 113, and it is possible to greatly reduce the load on the worker. At the same time, extruded materials with lower mold costs compared to the press mold are arranged as linearly as possible,
By not adding bending or the like, it is possible to reduce the secondary processing cost of the extruded material, and to significantly reduce the die investment in addition to the conventional replacement of the pressed part with the extruded material and the casting.

Therefore, for a variety of floor-constituting base materials, the investment in the floor process is significantly reduced as compared with the related art. Further, it is possible to easily cope with a vehicle type by changing the cutting length of the extruded material constituting the floor constituting base material and the extrusion type. For this reason, in the floor process, it is possible to greatly reduce investment in production equipment and easily cope with a variety of products.

The size and weight of the extruded parts constituting the floor constituent base material are within a range that can be sufficiently performed manually (for example, the maximum length is 1400 mm, 10 kg or less), and the extruded parts are fitted to each other. Also, since the clip structure has a fitting operation force that allows manual fitting, robot equipment, assisting equipment, and the like can be significantly reduced.

FIG. 8 is an exploded perspective view of the base material constituting the main floor showing a change corresponding to each vehicle type. (A) shows a reference main floor constituent base material, (b) shows a vehicle width expansion correspondence, and (c) shows a wheelbase expansion correspondence.

That is, each of the constituent base materials 191 and 1 shown in FIG.
Assuming that the width in the vehicle width direction of 93 and 195 is L1 and the width of the component base material 193 in the longitudinal direction of the vehicle is H1, in FIG. 8B, H1 is common, and the width L2 in the vehicle body direction of each of the component base materials 191, 193 and 195 is shown. That is, the cutting length of the extruded material is increased to accommodate a vehicle having a wide vehicle width.

In the case of FIG. 8C, each of the constituent base materials 191,
Although the width in the vehicle width direction of 193 and 195 is common to L1 in (a), the width of the component base material 193 in the vehicle longitudinal direction is H1 in (a).
To H2, so as to correspond to a vehicle model having a large wheelbase. Therefore, as described above, it is extremely easy to handle a vehicle type.

The floor component base material 11 temporarily bonded in this manner.
9 is transferred from the floor main process apparatus 5 to the welding process apparatus 3 via a manual roller conveyor 279 shown in FIG.

The welding process apparatus 3 is provided with a partition wall 281 from which an operator is prohibited from entering due to safety during laser operation.
Electric shutters 283 and 284 are provided before and after the partition 281. Inside the partition 281 is an electric automatic conveyor 2
85, laser welding robot 287 and locate unit 2
89 and a work detection device 291 are provided.

The automatic conveyor 285 is provided with two left and right belts 295, 297 with respect to a base 293 containing a driving device such as a motor. The belts 295, 297 move freely with a driving roller 299 driven by the motor. It is hung between the rollers 301. The welding robot 287 is installed on one side of the electric conveyor 285.

The locate unit 289 includes three locate pins 303, 305, and 307 on each of the left and right sides. Each of the locate pins 303, 305, and 307 can be adjusted in position along the support plate 309.
Can be adapted to the position change of the locate holes 197, 199, 201.

The support plate 309 is supported by the elevating unit 311 and can be adjusted up and down. The lifting unit 311 is movably supported by left and right guide rails 312,
13 is screwed. Accordingly, the forward / backward rotation of the drive screw 313 adjusts the movement of the elevating unit 311 in the left-right direction, and the elevating unit 311 adjusts the support plate 309 up and down.
7 are fitted into the corresponding locate holes 197, 199, 201, and the positioning of the floor constituting base material 113 is performed on the automatic conveyor 285.

The work detecting device 291 can rise up from the front between the left and right belts 295 and 297 and fall forward. This work detection device 291 rises from the front,
At the same time as detecting the floor-constituting base material 113, it is positioned in the front-rear direction, and falls forward after welding is completed.

Then, the floor-constituting base material 1 is manually transferred from the floor main process apparatus 5 via the roller conveyor 279.
13 is transferred. When the floor component base member 113 is detected by the detection device or the like immediately before the opened electric shutter 283, the left and right belts 295, 2 of the automatic conveyor 285 are detected.
97 is driven and the floor constituent base material 113 handed over on the belts 295 and 297 is
Will be automatically transferred to the inside.

When the floor-forming base material 113 is detected at a predetermined position by the work detecting device 291 and is simultaneously positioned in the front-rear direction, the driving of the drive roller 299 is stopped, and the left and right belts 295 and 297 are stopped.

At the same time, locate pins 303, 305, 30
7 are located holes 197, 199, 20 of the floor base material 113 by driving the drive screw 313 and the elevating unit 311.
1 and the floor-constituting base material 113 is positioned back and forth and left and right, and the electric shutter 283 is closed.

Next, the laser welding robot 287 performs one-way welding of each part of the floor constituting base material 113, that is, laser welding. The laser welding between the main floor constituent bases 191, 193 and 195 of the floor constituent base 113 is performed from the lower surface side outside the vehicle compartment. In such a case, the locating pins 303, 305 and 307 and the work detecting device 291 are provided. Together, the floor constituent base material 113 is raised.
This can be easily performed by floating the lower surface of the. As the one-way welding, in addition to the laser welding, there are MIG welding, friction welding performed by rotating a pin, and the like.

When welding is completed, locate pin 303,
305, 307 and the work detection device 291 are lowered to the original state, and the floor constituting base material 113 is moved to the left and right belts 295,
The work detection device 291 is placed forward on the 297, and the work detecting device 291 falls forward, and the locate pins 303, 305, and 307 are separated to the left and right. As a result, the front electric shutter 285
Rises, the partition 281 is opened, and the belts 295, 29
By the drive of 7, it is transferred to the next step, the indoor component mounting step.

By the laser welding, for example, a welded portion 315 is formed between the main floor constituent base materials 191 and 193 as shown in FIG. 10, and the welding is completed. Laser welding is performed by a robot whose welding position is automatically controlled in this way, and the welding process is performed in a partition 281 where entry of an operator is prohibited due to safety during laser work.
Accidents can be prevented. Also, the welding robot 28
7 in a state in which the dimensional control between the joints is performed by the locate unit 289 linked to the floor unit 113.
Is welded. Therefore, highly accurate welding can be performed.

Next, regarding the indoor component mounting process apparatus B, first, the rear floor module process apparatus 11 is shown in FIG.
Next, FIG. 12 shows a rear end module process apparatus 13.

As shown in FIG. 11, in this apparatus 11, a pallet 321 containing a rear floor panel 319 is arranged at an end of a roller conveyor 317 which is a manual conveyor. The pallet 321 is a load-variable table 32 with wheels.
3.

[0156] Along the roller conveyor 317, a pallet 325 containing a plurality of spare tires is placed and arranged on a load-variable table 327 with wheels, and further contains a plurality of tire pans and floor carpets. A pallet 329 and a pallet 331 containing a plurality of jacks are arranged. An assisting device (h) is provided at the other end of the roller conveyor 317.

Accordingly, in the rear floor module process apparatus 11, the pallet 321 is moved from the rear floor panel 31
9 is taken out onto the roller conveyor 317, and while the operator moves it manually, tires, tire pans, floor carpets, jacks, etc. are sequentially taken out from the pallets 325, 329, 331 and assembled, and the rear floor module 115 is assembled.
And the rear floor module 115 assembled by the assisting device (h) is transferred to the main line of the indoor component mounting process apparatus B. The operation of the load-variable placing tables 323 and 327 is the same as that described with reference to FIG.

As shown in FIG. 12, the rear end module process device 13 mainly includes a roller conveyor 333 as a manual conveyor. The roller conveyor 333 has two upper and lower stages 333 according to the shape of the rear end panel 335.
a, 333b. Roller conveyor 33
A pallet 337 containing a plurality of rear end panels 335 is disposed at one end of the pallet 3.

The pallet 337 is placed on a load-variable table 339 with wheels, and the vertical position of the pallet 337 fluctuates in accordance with the component storage state as described above. In addition, the pallet 337 can be moved in the left-right direction with respect to the load-variable placing table 339, so that the rear end panel 335 can be easily taken out onto the roller conveyor 333. When the pallet 337 has no components, it is easy to move the pallet 337 by the load-variable pedestal 339 with wheels and replenish it from the component storage 99 or the like.

A pallet 341 further containing a plurality of trunk room finishers along the roller conveyor 333,
A pallet 343 containing a plurality of seal rubbers and other pallets 345 are arranged.
A helping device (h) is installed at the end of the. Each pallet 341, 343, 345 is also replenished from the parts storage 99 or the like.

Then, the rear end panel 335 is taken out from the pallet 337 onto the roller conveyor 333, and while the operator manually moves the rear end panel 335 onto the roller conveyor 333, the pallets 341, 3
Take out the trunk room finisher, seal rubber, etc. from 43 and so on and assemble them respectively. When the assembling is completed, the rear end module 117 is transferred to the main line using the assisting device (h).

In the indoor component mounting process apparatus B, as shown in FIG. 13, the rear floor module 115, the rear end module 117, and the rear floor module 113 are manually moved on the roller conveyor in the manual process (b). An operator assembles the dash module 118, the front seats 119 and 121, the rear seats and the carpet (not shown) to the floor component base 113.

The rear floor module 115 is assembled to the rear floor frame portion 189 from above, and is fixed and fixed to a predetermined location by a bolt and nut. Rear end module 1
17 is a flange portion 18 at the rear end of the rear floor frame portion 189.
9a, the rear end 117a is fastened and fixed with bolts and nuts.
5 is fastened and fixed by bolts and nuts.

The dash module 118 is provided in the groove 2 in the engine compartment skeleton of the floor constituting base member 113.
It is attached by fitting its lower edge portion 118a into 45. The center console portion 118b of the dash module 118 projects from the V cut 247 of the groove 245 toward the vehicle interior, and the dash side portion 118c projects from the front cuts 249 on both sides of the groove 245 toward the vehicle interior.

The front seats 119 and 121 are fitted with seat mounting brackets 203 in the grooves 205 and 207 of the main floor constituting base materials 191 and 193, and are fixed to the seat mounting brackets 203. The seat mounting bracket 203 is inserted so as to slide from an end opening of the groove 205 and positioned at a predetermined position. For this positioning, a jig (not shown) is used. Although the attachment of the rear seat is not shown, it can be attached by a similar method.

As described above, the operator can assemble the seats 119, 121 and the like on the floor-constituting base material 113 in an open space. Can be eliminated, and the vehicle assembling workability is significantly improved. In addition, the installation trajectory when installing from the outside of the cabin by the robot, such as seats and instrument parts, is greatly simplified because there is no restriction by the door opening and the interior space, and the degree of freedom in the mounting direction is greatly improved. Therefore, it is possible to reduce the investment in the robot and shorten the working time in the process.

The floor unit FU is transferred to the next body main process C by a manual roller conveyor by an operator.

FIG. 14 schematically shows the body main process device C, showing the main line and the body side LH process device 27. The body side RH process device 3
1 is a body side LH process apparatus 2 with a main line interposed
7 are arranged on the opposite side, have the same configuration, and are not shown.

The body side LH process device 27 includes a body side pallet 37, a roller conveyor 349 of the body sub line interior device 33, and a pallet 3 containing interior items.
51 and a body side set cart 35. The body side pallet 37 has M
A body side base material 348 such as a class sedan, a height wagon, a wagon, and an S sedan is accommodated. A roller conveyor, which is a manual conveyor, is provided on the lower surface of the body side pallet 37. This body side pallet 37
Is mounted on a lateral moving device 355, and a section required for each vehicle type is opposed to a roller conveyor 349 for mounting the next interior article, and the body side base material 348 is manually transferred.

The body side set cart 353 is a roller conveyor 359 having wheels 357.

Then, the operator slides the pallet 37 to select the body side base material 348 to be sub-assembled, and pulls out the body side base material 348 on the roller conveyor 349 for mounting the interior parts. Here, the body side base material 34
Interior parts, such as an assist grip, a seatbelt unit, and a pillar trim, attached to the interior 8 are taken out from the interior article pallet 351 and assembled.
As described above, since the interior components are assembled in the open space with respect to the body side BS, the vehicle assembling workability is significantly improved.

Thereafter, it is transferred as a body side unit BSU onto the body side set cart 35, and is temporarily connected to the floor unit FU on the roller conveyor 361 of the main line. The temporary assembly of the floor unit FU and the body side unit BSU is accurately positioned by fitting a locating pin and a locating hole described later.

In the body main process apparatus C, the left and right body side units BSU are connected like the temporary connection of the body side units BSU described above, and then the roof unit RU is connected. As described above, this roof unit RU is assembled into a roof base material by assembling a roof interior material to a roof base material for each vehicle type in the setting process device 45, and is inverted by a roof reversing machine 47 and lowered from above as shown in FIG. It is to let. That is, the roof reversing machine 47
The roof unit RU inverted in the above is moved by the overhead crane 363 to the roller conveyor 361 of the main line.
It is transported upward and temporarily assembled to the left and right body side units BSU. This assembling is also performed by using pins and locate holes described later.

Thereafter, the wafer is transferred to the welding process device 58, and laser welding is automatically performed in the partition wall as in FIG.

FIG. 15 is a perspective view showing a part of the roof processing apparatus 29 showing the supply status of the roof unit RU to the roller conveyor 361 on the main line. As shown in FIG. 15, the setting process device 4 of the roof process device 29
Reference numeral 5 denotes a work table provided with a curved manual roller conveyor 365. The roller conveyor 365 has a front end coupled to a rotating shaft 367 and a rear end movable up and down by a cylinder device 369. The setting process device 45 includes a shooter 3 having a roller conveyor 371 from the component storage space 103.
73 is extended so that a roof base material 375 according to the vehicle type can be supplied.

As described above, the pallet of the roof interior material according to the vehicle type is arranged around the setting process device 45. In FIG. 15, the pallet 53 containing the wagon interior material 376 and the M The pallet 57 containing the sedan interior material 378 is shown. These pallets 53,
Roller conveyors 377 and 379 are disposed between the roller 57 and the setting process device 45, and each interior material 376, 3
The operator can manually transfer 78 to the setting process device 45 as needed.

The roof reversing machine 47 includes a support base 3 before reversing.
81 and a reversing unit 383, and the roof reversing machine 47
An overhead crane 385 for transferring the roof unit RU is provided between the main unit and the roller conveyor 361 of the main line. The overhead crane 385 includes a rail 387 fixed to the ceiling side and a moving device 389 that automatically moves along the rail 387. The moving device 389 grasps the inverted roof unit RU and supplies the roof unit RU along the rail 387 onto the roller conveyor 361 of the main line.

Therefore, the roof base material 375 is loaded from the shooter 373 onto the setting process device 45. in this case,
As the roof base material 375, it is assumed that a material for a wagon has been loaded. However, the roof unit RU that has already reached the side of the overhead crane 385 is for a sedan.

On the setting process device 45, a roof interior material 376 for a wagon is selected with respect to the roof substrate 375 on the back and the roof substrate 375 via the roller conveyor 377.
It is transported up and assembled by workers.

After the operation is completed, when the operator presses the start button, the cylinder device 369 is extended and the roller conveyor 3 is extended.
The rear end of 65 rises, and it becomes a forward inclined state. As a result, the roof unit RU is transferred to the pre-reversal support base 381 side, and is reversed by the reversing unit 383 in the same manner as the sedan roof unit RU already shown.

After the reversal, it is grabbed by the transfer device 389,
It moves along the rail 387 and is temporarily assembled to the wagon floor unit and the body side unit on the roller conveyor 361 of the main line.

FIG. 16 shows a positioning position and a positioning structure between the floor unit FU, the body side unit BSU, and the roof unit RU.

That is, locate holes 197 and 199 are provided in floor unit FU, and body side unit BS
The U has two pins 391 and 393. The pins 391 and 393 are formed of a steel pipe cast into a body side base material 348 formed of aluminum die casting. However, the pins 391 and 393 can also be formed integrally with the body side base material 348.

The pins 391 and 393 are located in the
7,199, the floor unit FU
And temporary connection with the body side unit BSU. Therefore, in this embodiment, the pins 391 and 393 and the locate holes 197 and 199 constitute a lower positioning means for positioning between the floor unit FU and the body side unit BSU. The pin 391 is disposed below the front pillar 395 of the body side unit BSU, and the pin 393 is provided at the lower end of the center pillar 397 at the joint between the front pillar 397 and the side sill 398. Accordingly, the lower positioning means is arranged at least on the lower end side of the center pillar 397. Also, a pin 39 as a lower positioning means is provided.
1, 393 and locate holes 197, 199 are arranged with their axes centered in the vehicle width direction orthogonal to the vehicle longitudinal direction.

Positioning and temporary assembly are also performed between the body side unit BSU and the roof unit RU by pins and locate holes. That is, the body side unit BSU has the locating holes 4 at the upper end of the front pillar 395, the upper end of the center pillar 397, and the upper end of the rear pillar 399 of the body side unit BSU.
01, 403, and 405 are provided. In the roof unit RU, pins 413, 415, and 417 are provided at the lower end of the front pillar 407, the upper end of the center pillar 409, and the upper end of the rear pillar 411, respectively.

By inserting pins 413, 415, and 417 into locate holes 401, 403, and 405, body side unit BSU and roof unit RU are inserted.
And temporary connection are performed. Therefore, locate holes 401, 403, 405 and pins 413, 415, 4
Reference numeral 17 constitutes upper positioning means for positioning the body side unit BSU and the roof unit RU.
The upper positioning means includes at least the center pillar 3
97, 409 upper end side and front pillars 407, 39
5 It is configured to be disposed on the middle part side.

In FIG. 16, the left body side unit BSU, the floor unit FU, and the roof unit R
Although only the positioning connection with U is shown, the same applies to the positioning connection with the right body side unit. And pins 413, 415 of the upper positioning means
417, the axis of the locate holes 401, 403, 405
Pin 391, 393 of lower positioning means, locate hole 1
The shafts 97 and 199 are arranged with their axes up and down so as to be orthogonal to the axes.

The pin 413 of the roof unit RU is provided at the connection between the front pillar 407 and the hood ridge 408, the pin 415 is provided at the connection between the center pillar 409 and the roof side rail 410, and the pin 417 is provided at the rear pillar 411. , The rear roof rail 412 and the roof side rail 410.

While the floor unit FU and the body side unit BSU are connected in the vehicle width direction by the lower positioning means as described above, the roof unit RU
And body side unit BSU are vertically lowered with respect to body side unit BSU previously coupled to floor unit FU, so that pins 413 and 41
5, 417 fit into the locate holes 401, 403, 405 and are joined. Thus, the body side unit BS cantilevered and combined with the floor unit FU
U upper end positioning means (pins 413, 415, 417, locate hole 4
01, 403, 405), the floor unit FU and the body side unit BSU
Will be further improved.

By positioning and temporarily holding the floor unit FU, the body side unit BSU, and the roof unit RU with the pins and the locating holes in this manner, it is possible to automatically perform the process from the temporary assembly to the accuracy setting, and to repair the vehicle body. It becomes possible to abolish fixture equipment. Furthermore,
Even if the vehicle width is different, each part has a function to automatically perform from temporary assembly to accuracy setting, so it is not necessary to equip vehicle body jig equipment for each vehicle width, so capital investment in the vehicle body joining process Can be significantly reduced.

[0191] In Fig. 16, the illustration of the interior parts mounted before the vehicle body connection is omitted.

Here, the configuration and operation of the pin and locate hole structure will be further described.

As shown in FIG. 17, when connecting the floor unit FU and the body side unit BSU, positioning is easily performed, and vehicle body accuracy is automatically obtained at the time of fitting. The inner diameter of the locate hole 199 of the floor base material 113, which is an extruded material, has a constant size due to the nature of the extruded material, and therefore is corresponded by the pin 393 on the body side unit BSU side.

The distal end of the pin 393 has a diameter 393a sufficiently small with respect to the locate hole 199 to facilitate insertion into the sleeve. At the base of the pin 393, after passing through the tapered surface 393b. If the fitting accuracy (clearance δ) and fitting length (L) are such that the vehicle body accuracy can be ensured, the perpendicularity θ between the floor and the body side, which has conventionally been obtained with a vehicle body jig, can be located at the pin 393 and the location. It can be obtained by controlling δ and L so that the fitting relationship with the hole 199, that is, θ = tan-1 (δ / L), becomes a predetermined value or less. That is, the allowable value of the positional shift amount S of the locate hole 403 on the upper end side of the body side unit BSU can be managed by the fitting length L and the clearance δ.

As shown in FIGS. 18A and 18B, the pin 393 of the lower positioning means and the locate hole 199
By dividing the connecting direction such as the pin 415 of the upper positioning means and the connecting hole of the locate hole 403 into the vehicle width direction and the vertical direction, it is possible to further improve the mounting accuracy (= square angle) of each. it can.

In addition to the portions joined by the pins and the locating holes, the aluminum die-casting parts having the closed cross-sections have the same mating surfaces on the mating surfaces of the body side unit BSU and the roof unit RU. Can be formed, and by forming a rib for suppressing local cross-sectional deformation on each of the ribs, it is possible to further secure the vehicle body rigidity with respect to the conventional vehicle body structure.

The positions of the pins and the locate holes are shown in FIG.
6, the center pillar 3 is provided between the floor unit FU and the body side unit BSU.
In the connection between the body side unit BSU and the roof unit RU, the connection between the hood ridge 408 and the front pillar 407, the center pillar 409 and the roof side rail 41
0 and a connection between the rear pillar 411, the rear roof rail 412, and the roof side rail 410.

These parts are all reinforced parts in the conventional body structure in order to ensure the collision performance and the body rigidity. In these portions, pins 391, 393, 413, 415, and 4 are firmly fixed to the body side unit BSU and the roof unit RU.
17 are locate holes 197, 19 which are also formed integrally with the floor unit FU and the body side unit BSU.
9, 401, 403, and 405 are connected with a predetermined fitting dimension.
93,413,415,417 and locate hole 197,1
The stress can be widely distributed to the entire vehicle body by being received on the entire fitting surface with 99, 401, 403, 405. Therefore, the joint efficiency can be greatly improved, and the strength and rigidity of the vehicle body can be secured without special reinforcement.

The floor unit F
When the body side unit BSU and the roof unit RU are temporarily assembled to U, the welding process device 5 of the welding process C is performed.
8, laser welding is performed. Here, similarly to the welding process of the floor unit FU, the process is performed in the partition wall in consideration of the safety of the worker, and all processes are performed by an automated robot. Therefore, the upper body unit UBU after the vehicle body is joined is transported by a roller conveyor until before the welding step (c), and is transported by a belt conveyor using power in the welding step (c).

[0200] Further, since indoor parts such as seats and instrument panels are mounted in the room of the upper body unit UBU, it is difficult to perform spot welding using a spot gun as in the past because the spot gun cannot be inserted into the vehicle interior. is there. Therefore, welding between the floor unit FU and the body side unit BSU and between the body side unit BSU and the roof unit RU are required to be welded from outside the vehicle compartment as much as possible.

In this embodiment, as is apparent from FIG. 17, since the floor base material 113 of the floor unit FU has a double floor structure, the plate 419 on the vehicle interior side and the convex on the body side unit BSU side are formed. The connection with the part 421 is also indispensable. Accordingly, the joint between the vehicle interior side plate 419 and the convex portion 421 on the body side unit BSU side is bonded with the room temperature curing adhesive 423, and the vehicle exterior side plate 425 and the body side unit Unit BSU
The joint of the outer side of the cabin with the side plate 427 is joined by laser welding 429. Due to this, there is a gap between the plates 419 and 425 inside and outside the vehicle compartment, which is an advantage of the double floor structure, and the welding heat generated when the plate 425 outside the vehicle compartment and the plate 427 on the body side unit BSU side are joined together has already been obtained. The heat conduction to the mounted interior parts can be minimized, and not only the thermal damage to the interior resin parts can be prevented, but also the vehicle interior side plate 419 and the body side unit BSU can be prevented. Adhesion between the projection 421 and the adhesive 423 enables air-tightness and water-tightness to be ensured without particularly applying a vehicle body sealing material.

The conventional body seal uses a thermosetting sealing material and is therefore cured during baking and painting of the body. However, in the production system of the present embodiment, the body painting process is not performed. Since it is omitted, an adhesive which also functions as a seal is required to be an ordinary temperature-curable adhesive, and this is used.

Each of the flange portions between the body side unit BSU and the roof unit RU is also laser welded 429 as shown in FIG. 17, for example, so as to form a closed sectional structure. This pin 415, locate hole 403
Welding 429 around upper positioning means such as
As a result, the connection between the two is also strong. or,
19 around the pin 417 and the locate hole 405.
The laser welding 429 is performed as shown in FIG. In other places, the roof unit and the body side unit BSU have their respective flange portions joined to each other by laser welding, and the roof side rails and the like form a closed cross section.

Here, in order to improve the appearance of the bonding surface between the floor unit FU and the body side unit BSU and the appearance of the welded portion between the roof unit RU and the body side unit BSU, the interior trim parts were previously removed from this portion. If the trim parts are mounted again after each joining, good appearance quality can be obtained. In this case, if the trim parts to be detached and attached are small as small as the range limited to the joint surface, the workability at the time of assembling the body parts does not hinder at all.

When the upper body unit UBU is formed through the welding step (c), it is transferred to the next running parts mounting step D. The running part mounting step D is an automation step (a) as described above,
As shown in FIG. 20, two automatic conveyors 431 and 433 are provided. The automatic conveyor 431 is arranged and extends downstream of the welding step (c) so that the pair of belts 435 are driven and controlled by a motor and a controller similarly to the automatic conveyor used in the welding step (c). Has become.

At the downstream end of the automatic conveyor 431, a transfer assisting device 437 is provided. The transfer assist device 437 is vertically movable by a cylinder device 439. The downstream automatic conveyor 433 is also the upstream automatic conveyor 4.
Similar to the motor 31, a pair of motor-driven belts 441 are provided.

The automatic loading machine 59 is provided on one side of the pair of automatic conveyors 431 and 433. The automatic mounting machine 59 includes a rail 443, and the rail 433 is supported by an elevating device 445 so as to be able to move up and down. A body transfer device 447 is supported on the rail 443 so as to be able to run freely, and the body transfer device 447 grasps the upper body unit UBU, transfers the upper body unit UBU along the rail 443, and can be separated at a predetermined position.

The supply unit 61 of the underrunning unit URU includes a pair of automatic conveyors 449 and 451 extending from the parts storage 105 and a ball roller table 45.
3. It comprises a roller conveyor 455 which is a manual conveyor and a supply trolley device 459.

The automatic conveyors 449 and 451 have a pair of belts 457 driven by a motor.
At 451, the pallet 459 on which the underrunning unit URU is mounted and the empty pallet 461 are transferred. Each pallet 459, 461 is provided with a set pin 463, respectively. The pallets 459 and 461 are provided with guide rollers 464 that rotate horizontally at four corners.

The ball roller table 453 is provided between the automatic conveyors 449 and 451. The roller conveyor 455 is moved from the ball roller table 453 to the guide rail 4.
The pallet 459 is transferred to the 56 side. The guide rail 456 is connected to the automatic conveyor 43 of the main line.
1, 433, and takes over the pallet 459 and transfers it between the automatic conveyors 431, 433. That is, the guide rail 456 includes a pair of inward channel material-shaped rails 465, and a stopper 467 is provided at an end of the guide rail 456.

Then, the upper body unit UBU on which the interior material is mounted is connected to the automatic conveyor 431 as shown in FIG.
When the upper body unit UBU reaches the transfer assisting device 437 by the sensor, this is detected by a sensor, the cylinder device 439 of the transfer assisting device 437 is raised, and the upper body unit UBU is moved.
The BU is free from the automatic conveyor 431.

Next, the rail 443 of the automatic mounting machine 59 is lowered, the body transfer device 447 grasps the upper body unit UBU, and the rail 443 is raised again by the lifting device 445. In this raised position, the body transfer device 447
Moves to the downstream side along the rail 443 and stops on the guide rail 465 in the supply device 61 of the underrunning unit URU.

On the other hand, the underrunning unit URU
Is transported from the parts storage 105 of FIG. The underrunning unit URU is composed of an engine, a power train, a suspension, a fuel system, and the like, and constitutes a traveling drive system. In the parts storage 105, a pallet 459 selected from pallets equipped with several types of underrunning units URU is transferred according to the production order, and one of the automatic conveyors 44 is transferred.
9 as shown in FIG. Automatic conveyor 4
The pallet 459 is moved from the end of the
3 automatically transferred. Next, the operator slides the pallet 459 on the ball roller table 453 and transfers the pallet 459 to the guide rail 465 via the roller conveyor 455.

Further, the operator moves the pallet 459 along the guide rail 465 to the automatic conveyor 4 of the main line.
31 and 433. This position is determined by the stopper 467. When the pallet 459 moves along the guide rail 465, the pallet 45
The guide rollers 464 at the four corners of No. 9 can smoothly move.

Thus, the underrunning unit U
When the RU is positioned between the automatic conveyors 431 and 433 on the main line, the rail 443 of the automatic mounting machine 59 is lowered, and the upper body unit UBU is automatically mounted on the underrunning unit URU.

[0216] Then, the operator carries out the work of fastening the joint between the upper body unit UBU and the underrunning unit URU, and the work of fastening the two is performed. Therefore, in this step, the underrunning unit URU
And the upper body unit UBU can be connected at the same height level as the vehicle main body MB, so that difficult work such as upward work is eliminated, and workability is significantly improved.

When the joining operation is completed, the rail 443 is raised again by the drive of the lifting / lowering device 445, and the body transfer device 447 moves further downstream at the raised position, and the vehicle main body MB is placed on the downstream automatic conveyor 433. When it reaches,
The rail 443 is lowered again by the driving of the lifting / lowering device 445, and the vehicle main body MB is placed on the automatic conveyor 443. At this time, the body transfer device 447 releases the vehicle main body MB, and the body transfer device 447 returns to the original position on the upstream side with the elevation of the rail 443 by the elevating device 445 again.

The vehicle main body MB is transported by the automatic conveyor 443 to a next step, an exterior component mounting step. The empty pallet 459 is returned to the original position along the guide rail 465, and is handed over to the automatic conveyor 451 via the roller conveyor 455 and the ball roller table 453 by a manual operation of an operator.

The pallet 459 is returned to the parts storage 105 again by the automatic conveyor 451, the next underrunning unit URU is selected, and is supplied again to the main line side as described above.

Next, in the exterior component mounting step, the rear bumper, the front bumper, and the front end module are first mounted while transferring the vehicle main body MB on a roller conveyor which is a manual conveyor in the manual step (b). The front-end module is a module component having a radiator, a condenser, a headlamp, and mounting these, and having a mounting portion to the vehicle main body MB.
The operator couples the front end module to the vehicle main body MB while transferring the vehicle to the vehicle main body MB. Since the rear bumper and the front bumper are relatively light, the operator holds the rear bumper and the front bumper as they are
To join.

[0220] After this exterior component mounting step, a liquid substance adding step is performed, and the operator places the vehicle body M on a manual roller conveyor.
B is transferred to the liquid substance adding process apparatus G. In the liquid material addition process apparatus G, long life coolant, gasoline, brake oil, and power steering oil are respectively injected. The vehicle main body MB into which the fats and oils have been injected is transferred to the next window process by an operator via a manual roller conveyor.

The window process apparatus H is also a manual process (b), in which lamps installed on the rear end panel are combined, and front and rear window shield panels are mounted. After mounting the window shield panel, it is moved on the roller conveyor for the door mounting process.

In the door mounting process apparatus I, the left and right doors pre-assembled are mounted on the vehicle main body MB.
In the conventional vehicle, the door panel body was attached to the white body and painted together, and then removed, the parts were assembled to the door, and the troublesome work of assembling the door to the vehicle body MB again was performed. Since the painting process is omitted, such a troublesome operation is unnecessary. In the present embodiment, the left and right doors are assembled in advance as a unit, and this is directly assembled to the vehicle body MB. Therefore, the assembling work of the vehicle can be remarkably facilitated as compared with the related art.

Here, the assembly of the door will be described with reference to FIG. FIG. 21 shows a door sub RH process device 77. The device 77 and the door sub LH process device 78 have substantially the same configuration although there are left and right differences. That is, the sash module pallet 469, the inner module pallet 471, the interior module pallet 473, the door mirror unit pallet 4
75 are arranged to assemble the door unit according to the cell production system.

The Sash Module Palette 469
Is mounted on a load-variable table 477 with wheels,
Regardless of the number of sash modules 479 for the pallet 469, the pallet 469 is always
It is maintained at the same height level as that of No. 7, making the work easy.

Then, the worker transfers the door sash module 479 from the pallet 469 onto the roller conveyor 467 by using the assisting device (h), and moves the door sash module 479 on the roller conveyor 467 while moving the inner sash module 479 on the roller conveyor 467. Module 481, interior module 48
3. Assemble the door mirror unit 485 sequentially to complete the door unit. The completed left and right door units are supplied to the main line by the operator's hand,
It is assembled by a worker's hand on the vehicle main body MB of the main line.

Next, the vehicle main body MB is sent to the exterior decoration process. In the exterior decoration process apparatus E, the worker moves the vehicle main body MB on the roller conveyor in the manual process (b), while the roof resin panel 143, the rear fender resin panel 145, and the front fender resin panel 14 are moved.
7. The trunk lid resin panel 149 and the hood resin panel 151 are sequentially assembled. These resin panels 14
Since 3, 145, 147, 149, and 151 are colored components, the component storage 111 is required as a temporary storage for considerable components according to the color variation.

Each of the pallets 89, 91, 93, 95, and 97 supplied to the main line side is sorted in advance in the parts storage 111 in the order of production, and is mounted on the vehicle main body MB manually.

FIG. 22 shows the mounting position of each resin panel. In FIG. 22, the vehicle main body MB is partially omitted. In contrast to the vehicle body MB, the roof resin panel 143 is attached to the roof opening 49 of the vehicle body MB.
1,493. The rear fender resin panel 145 is mounted on the outer surface of the rear fender 497 of the vehicle body MB. The front fender resin panel 147 is mounted outside the hood ridge 408 of the vehicle body MB.

[0230] The trunk lid resin panel 149 is mounted on the trunk lid inner 503, and is attached to the vehicle main body MB together with the trunk lid inner 503. The trunk lid inner 503 is formed by aluminum die casting.

The hood resin panel 151 is mounted on the hood inner 507 and is mounted together with the hood inner 507 on the engine room of the vehicle body MB. The hood inner 507 is formed by, for example, aluminum die casting.

Although not shown in FIG. 1, the door resin panels 509 and 511 are assembled to the front door unit 513 and the rear door unit 515, respectively.

The details of the connection structure of each resin panel are as follows.
23, 24, and 25.

FIG. 23 shows the roof resin panel 143.
The structure to be assembled to the roof opening 491 is shown. The roof resin panel 143 is integrally provided with a clip portion 143a, which is engaged with a fitting hole 491a provided at an edge of the roof opening 491. The edge portion 491b provided with the fitting hole 491a is formed to be slightly thicker, and the tip thereof is in contact with the inner surface of the roof resin panel 143.

The periphery of the edge portion 491b of the roof opening 491 is one step lower than the roof side rail 410, and the convex portion 143b of the peripheral portion of the roof resin panel 143 comes into contact therewith. I have. On the outer peripheral edge of the roof resin panel 143, a convex portion 143c for weather strip engagement is provided over the entire periphery. Then, the convex portion 143b of the roof resin panel 143 is formed.
A sealing material 517 as a seal portion is filled between the roof opening 491 and the opening edge 491b.

As described above, by providing the sealing material 517 near the clip portion 487a, the sealing material 5 is provided.
17 can be reliably maintained, and airtightness and watertightness inside and outside the vehicle cabin can be reliably maintained. And
Roof side rail 410 and roof resin panel 14
A weatherstrip 519 as a seal portion is provided in the gap between the first and third seals 3 to ensure improved appearance and further sealability.

The front fender resin panel 14
7 is connected to the hood ridge 408 by a bolt nut 519 as shown in FIG. The bolt and nut 519 are subjected to a dacro treatment for rust prevention.
The front fender resin panel 147 is provided with a curved resin hinge 147a.
The difference in the coefficient of thermal expansion between the front panel 8 and the front fender resin panel 147 is absorbed.

The rear fender resin panel 145
Is attached to the wheel house opening edge 521 of the body side unit BSU with a separate resin clip 523. Rear fender resin panel 495
Also, a resin hinge 145a for absorbing a difference in thermal expansion is provided.

Thus, the resin panels 143, 145, 1
47, 149, and 151 are attached to the vehicle body as appropriate using an integrated clip or a separate bolt and nut, a resin clip, or the like. Therefore, FIGS.
The panels 143, 147, and 145 described in are not limited to the respective mounting structures, but can be appropriately selected and combined.

In other panels not described with reference to FIGS. 23 to 25, the connection structure can be appropriately selected.

Thus, the colored resin panels 143, 143
By designing the outer surface of the vehicle body by using 145, 147, 149, and 151 and using the vehicle body color, it is possible to respond to the needs of various customers by separating the vehicle design from the investment in the vehicle production line and to respond to various needs. The investment in plate shaping can be significantly reduced. At the same time, mounting the resin panel on the vehicle body in the final process of vehicle assembly makes it possible to significantly reduce damage in the factory, improving the appearance quality and significantly reducing the cost required for repairing the damage. can do.

Further, a resin panel 143,1 for exterior decoration is provided.
By making 45, 147, 149, and 151 consumables,
This resin panel 14 reduces the appearance and appearance of the vehicle.
By replacing only 3, 145, 147, 149 and 151, it is possible to refresh including colors and shapes, and it is possible to extend the life of the skeleton that is the base of the vehicle by responding to customer needs. it can.

That is, the parts can be replaced only for the parts that the customer feels necessary, and as a result, the amount of waste can be reduced. Further, in order to prolong the life of a skeleton serving as a base of a vehicle, it is extremely effective to use a material having high corrosion resistance, such as aluminum, with respect to a conventional steel car body from the viewpoint of preventing perforation and rusting of a structure.

As described above, in the embodiment of the present invention, the painting process is abolished, and a light alloy such as aluminum having excellent corrosion resistance is used as a structural material of the vehicle body. . That is, as shown in FIG. 2 of JP-A-8-244572, the coating process of an automobile generally includes chemical conversion, electrodeposition coating, intermediate coating, and top coating, and chemical conversion and electrodeposition coating are mainly performed. Rust prevention and middle / overcoating are mainly used for design and aesthetics.

On the other hand, when a light alloy such as aluminum is used as a structural material, an oxide film having good corrosion resistance is naturally formed in the atmosphere in the air, and has excellent corrosion resistance for self-defense. Therefore, if the electrodeposition coating on the steel body comes off due to contact with stone splashes or obstacles, the rust prevention performance will be significantly reduced, whereas in the case of light alloys such as aluminum, an oxide film will be repeatedly formed. And the rust prevention performance is remarkably superior to the steel body. As a result, as in the present embodiment, the painting process can be abolished, and the time required for automobile production can be significantly shortened, thereby enabling order-made production.

Further, the production line can be significantly shortened, and the installation area of the factory can be greatly reduced. Further, by using a light alloy such as aluminum having excellent corrosion resistance as a structural material of the vehicle body and eliminating the painting process after the vehicle body is assembled, the vehicle body assembly line and the vehicle assembly line can be integrated.

That is, after assembling the floor unit of the vehicle body, parts such as seats, instrument panels, harnesses, etc., which are heavy and difficult to work in, are mounted, and thereafter, body side units in which interior parts such as door trims and roof linings are pre-assembled are provided. By joining the roof unit to the floor unit, it becomes possible to eliminate the work of assembling heavy objects under a bad working posture, which has conventionally been performed in a narrow cabin, and the vehicle assembling work is significantly improved.

In addition, since the painting process is abolished, it is not necessary to change the color of the painting equipment, and the assembly of the vehicle and the vehicle assembly are completely synchronized. The number of parts can be greatly reduced. Therefore, a very compact production line in which the line length from the conventional body assembly to the vehicle assembly is significantly reduced can be realized.

As a result, it is possible to greatly shorten the time required from ordering to delivery of a car from a customer.
The number of vehicles waiting to be shipped can also be significantly reduced,
Costs required for inventory management can be reduced.

In the joining step of the floor unit, the body side unit and the roof unit, each has a pin having a positioning / temporary holding function and a locate hole structure.
By fitting and fastening the pin and the locating hole, it is possible to automatically perform from the temporary assembly to the accuracy setting, and as a result, it becomes possible to abolish the body jig equipment at the time of so-called body coupling. .

The floor unit is constructed by fitting several extruded members and using aluminum or the like as a structural material, so that the weight of each part can be reduced to about half that of steel. The load on the operator in the sub-assembly process can be significantly reduced.

At the same time, the extruded material whose mold cost is lower than that of the press die is arranged as linearly as possible, and the bending process is not added. Together with the replacement with extruded materials and castings, it is possible to significantly reduce mold investment.

In addition, the resin panels and the like colored on the outer panel of the vehicle body are fastened to the vehicle body with bolts and clips in the final production process, so as to correspond to the molding and the vehicle color, thereby enabling the vehicle design to meet various customer needs. Can be dealt with separately from the investment in the vehicle manufacturing line, so that the investment in various external plate modeling can be reduced.

In addition, by mounting the resin panel on the vehicle body in the final step of the vehicle assembly, it is possible to significantly reduce the damage in the factory, and to improve the appearance quality and to repair the damage. Cost can be reduced.

Further, by using the outer panel resin panel as a consumable item, it is possible to refresh the color and the shape of the vehicle by replacing only the panel with respect to the deterioration of the appearance and appearance of the vehicle. By responding to the needs, it is possible to extend the life of the skeleton serving as the base of the vehicle.
That is, it is possible to replace only parts that the customer feels necessary, thereby reducing the amount of waste.

In order to prolong the life of the skeleton serving as the base of the vehicle, it is effective to use a material having high corrosion resistance, such as aluminum, with respect to the conventional steel car body from the viewpoint of preventing perforated rust of the structure.

26 to 32 show an embodiment according to a modification of the floor constituting base material, FIG. 26 is an exploded perspective view, and FIG. 27 is a sectional view showing an exploded state of a main part. The components corresponding to those of the above-described embodiment are denoted by the same reference numerals, and the description thereof will not be repeated.

On the other hand, in the present embodiment, as shown in FIG. 26 and FIG. 27, the floor constituting base material 113 is formed of the front floor 601 and the dash lower 603 of the engine compartment frame.
And The dash lower 603 is mounted on the reinforcement 605.

The front floor 601 is formed of an extruded material of a light metal such as an aluminum alloy or a magnesium alloy, and the longitudinal direction of the vehicle body is the extruding direction.
The front floor 601 includes a tunnel portion 607 having a closed cross-sectional structure, left and right flat portions 609, and left and right side sill portions 611. And this front floor 60
The dash lower 603 is joined to the front end of the dash lower 603. Therefore, particularly the flat portion 6 of the front floor 601
The front end of 09 is a fitting male part 613.

The dash lower 603 is formed of an extruded material of a light metal such as an aluminum alloy or a magnesium alloy similarly to the front floor 601, and its extruding direction is the vehicle width direction. The dash lower 603 includes a tunnel corresponding part 615 for joining the tunnel part 607 of the front floor 601 and a fitting female part 617 for joining the male fitting part 613.

The relationship between the male fitting portion 613 and the female fitting portion 617 is shown in FIG. 27 which shows a cross section taken along line XXVII-XXVII in FIG.
It is as shown in the sectional view of FIG. A front end 613a of the fitting male portion 613 is formed so as to have an upper portion projecting forward from a lower portion in accordance with the inclination of the dash lower 603, and an upper front end 625a of the fitting male portion 613 has a lower front end 625.
It protrudes forward from the vehicle body beyond b. Also, the fitting male part 613
Are provided with groove-shaped portions 619a and 619b formed as upper and lower concave portions in the vehicle width direction. The upper groove-shaped portion 619a is located on the front side of the lower groove-shaped portion 619b.

The female female part 617 of the dash lower 603 is fitted.
Are upper and lower two-stage flanges 621a extending rearward of the vehicle body.
621b. The upper flange 621a of the fitting female portion 617 is formed to be thinner than the lower flange 621b. In the present embodiment, the upper flange 621a is formed similarly to the thickness of the general portion of the dash lower 603, and the lower flange 621b is formed thicker than the general portion. Rear end 6 of lower flange 621b
23b protrudes rearward of the vehicle body from the rear end 623a of the upper flange 621a.

On the lower surface of the upper flange 621a and the upper surface of the lower flange 621b, claw-shaped portions 627a and 627b are provided as projections, respectively. The positional relationship between the upper and lower claw-shaped portions 627a and 627b
21a, 621b are the same as the rear ends 623a, 623b, and the upper claw-shaped portion 627a is
It is obliquely offset so as to be located on the front side of 27b.

The reinforcement 605 is made of a light metal casting, such as an aluminum alloy or a magnesium alloy. The dash lower 603 is mounted on the reinforcement 605 and joined by, for example, laser welding. ing. In addition,
The bonding between the dash lower 603 and the reinforcement 605 can also be performed by bonding, rivet fastening, bolt nut fastening, or the like.

The front floor 601 is joined to the dash lower 603 by fitting the fitting male portion 613 between the upper and lower flanges 621a and 621b of the fitting female portion 617. In this fitting, the upper flange 621a is formed to be thinner than the lower flange 621b, so that it is relatively easily bent, and the fitting male portion 613 is fitted between the flanges 621a and 621b. When doing so, the upper flange 621a can be positively elastically deformed, and the insertion force at the time of fitting can be reduced.

At this time, for example, as shown in FIG. 28, by setting the dash lower receiving portion 629, the lower surface of the lower flange 621b is supported, and the elastic deformation of the lower flange 621b is further suppressed to thereby suppress the upper flange 621a. By elastically deforming only the fitting male part 613 between the flanges 621a and 621b, it is possible to further reduce the insertion force.

At the time of this fitting, the lower flange 62
Since the rear end 623b of 1b protrudes rearward from the rear end 623a of the upper flange 621a, the visibility of the lower flange 621b and the claw-shaped portion 627b can be improved, and the fitting at the time of assembly is performed. The guide performance of the fitting male part 613 with respect to the female part 617 can be improved, and the assemblability can be greatly improved.

When the fitting male part 613 fits between the flanges 621a and 621b, the upper and lower grooved parts 619a and 619
The upper and lower claw-shaped portions 617a and 617b are engaged with b. Thus, positioning between the dash lower 603 and the front floor 601 can be performed, and assembling accuracy in the vehicle front-rear direction is easily ensured, and a positioning jig is not required. Further, since the fitting male portion 613 is configured to fit between the upper and lower flanges 621a and 621b, the positioning in the vertical direction can be performed reliably. Further, after the fitting male portion 613 is fitted between the upper and lower flanges 621a and 621b, the claw-shaped portions 627a,
Since b is engaged with the groove-shaped portions 619a and 619b, the fitting between the front floor 601 and the dash lower 603 is difficult to be disengaged, and it is reliably transported to the welding process apparatus 3 while maintaining the positional accuracy of both. can do. Therefore, the dash lower 603 and the front floor 601 can be directly joined by laser welding or the like,
In this case, a positioning jig such as a clamp is unnecessary.

In the event of a frontal collision of the vehicle, when there is an input from a front side member (not shown), the upper and lower groove-shaped portions 619a, 619b and the claw-shaped portion 62 are provided as in the above embodiment.
7a and 627b are shifted back and forth, the dash lower 6
03 can be suppressed. This will be described with reference to FIG.

FIG. 29A shows a case where the upper and lower claw-shaped portions 627a and 627b of the above embodiment are shifted back and forth.
(B) shows a case where they are vertically aligned. First,
As shown in FIG. 29B, when the load F is input by a frontal collision, the load is concentrated on the lower claw-shaped portion 627b and the groove-shaped portion 619b near the closed cross-sectional structure of the dash lower 603, and the claw shape is reduced. The dash lower 603 tends to rotate around the portion 627b and the groove-shaped portion 619b, and the upper side of the male fitting portion 613 of the front floor 601 is largely collapsed, and the displacement L2 of the dash lower 603 increases.

On the other hand, as shown in FIG. 29A, upper and lower claw-shaped portions 627a and 627b and groove-shaped portions 619a and 619a are formed.
When 19b has a distance of S before and after, the lower claw-shaped portion 627b and the groove-shaped portion 619b are also dashed lower 603.
The structure is separated from the closed cross section of the front floor 60. When the load F is input, the concentration of the load on the lower claw-shaped portion 627b side is suppressed, and the input F causes the front floor 60 to be closed.
The front end of the first male fitting portion 613 is entirely crushed and deformed in the vertical direction, and the displacement of the dash lower 603 is also L1, which can be greatly reduced as compared with the above L2.

FIGS. 30 to 32 further show a guide structure when the dash lower 603 and the front floor 601 are joined.

FIG. 30 is a perspective view showing a substantially right half of the reinforcement 605, and FIG. 31 is a XXXI-XX of FIG.
FIG. 32 is a cross-sectional view taken along arrow XI-XXXII of FIG. 30, respectively.

First, as shown in FIG. 30, a boss 633 protrudes from the tunnel engaging portion 631 of the reinforcement 605. The boss 633 is fitted in a notch 635 provided at the tip of the tunnel 607 of the front floor 601. The notch 635 is provided at the tip of the ceiling portion of the tunnel portion 607, has a front end opened and has a predetermined length rearward,
For example, it is cut out to a length slightly longer than the boss 633.

On the left and right sides of the reinforcement 605 in the vehicle width direction, vertical ribs 637 are provided to protrude toward the rear of the vehicle body with a space inside the vertical wall 635 at the outermost end in the vehicle width direction. ing. And the vertical wall 635 and the rib 6
37 and the side sill 611 of the front floor 601
The front ends are fitted and joined. These connections are performed by laser welding in a welding process apparatus, but may be performed by bonding, rib fastening, bolt fastening, or the like.

The dash lower 603 is mounted on the reinforcement 605 in advance and connected. When the fitting male part 613 is inserted between the upper and lower flanges 621a and 621b at the time of joining the reinforcement 603 and the front floor 601 as described above, the boss 633 of the reinforcement 605 is attached to the front floor 60.
1 is engaged with the notch 635 at the front end of the tunnel portion 607, and the tip of the side sill 611 is
5 is engaged between the vertical wall 635 and the rib 637, and the fitting male part 613 is guided by the two to form the flange 621.
a, 621b.

Under the guide, the male fitting portion 613 is inserted between the flanges 621a and 621b by inserting the claw-shaped portions 627a and 627a into the groove-shaped portions 619a and 619b.
627b is engaged. Therefore, the joining between the front floor 601 and the dash lower 603 can be performed extremely easily. Since the engine compartment frame and the front floor 601 are large in both weight and size and are difficult to carry by hand,
The transport is performed by using a transport device such as a trolley, and the joining structure as described above facilitates the transport operation between the engine compartment skeleton portion and the front floor 601 and also facilitates the joining operation between the two. Can be.

In the above embodiment, as shown in FIG. 29B, the rear ends 623 of the upper and lower flanges 621a and 621b are provided.
Although the case where the rearward protruding positions of a and 623b are the same has been described as a comparative example, this case can also be adopted as one of the embodiments.

In the above embodiment, the upper flange 6
Although 21a is formed thin and the lower flange 621b is formed thick, both may be formed to have the same thickness. In this case, both flanges 621a and 621b can be made thicker or thinner.

FIGS. 33A and 33B show an embodiment in which the claw-shaped portion is modified. FIG. 33A is a sectional view of an exploded state, and FIG. The components corresponding to those in the above embodiment are denoted by the same reference numerals, and the description thereof will not be repeated. As shown in FIG. 33, in this embodiment, the claw-shaped portion 639
a, 639b are formed in a wedge shape inclined toward the back side in the fitting direction.

According to the present embodiment, the claw-shaped portions 639a,
Since the male part 639b is inclined in the fitting direction, when the male part 613 of the front floor 601 is fitted between the upper and lower flanges 621a, 621b, the claw-shaped parts 639a, 639 are formed.
It can suppress that b becomes resistance of fitting, and can reduce insertion force. After the fitting, the claw-shaped portions 639a, 63
9b can also be engaged so as to fit into the groove portions 619a, 619b, and the positioning accuracy can be further improved.

FIG. 34 is a cross-sectional view of an embodiment showing a modification of the joint between the dash lower 603 and the front floor 601. The components corresponding to those in the above embodiment are denoted by the same reference numerals and will not be described.

On the other hand, in the present embodiment, after the fitting male portion 613 of the front floor 601 is fitted to the upper and lower flanges 621a, 621b, the rivets 641a, 641
b. Rivets 641a, 641b
Are provided at predetermined intervals in the vehicle width direction, for example. Even in such a joint structure, the upper and lower rivets 641a,
Since the front side members 641b are offset in front and rear, for example, even when a load is input from the front side member as described above at the time of a frontal collision, the load is prevented from being concentrated on the lower rivet 641b. The operation described in (2) can be similarly maintained. The rivets 641a and 641b can be replaced with bolts and nuts.

FIGS. 35A and 35B show still another embodiment in which the joining structure is modified, wherein FIG. 35A is a sectional view and FIG. 35B is a sectional view of a main part. The components corresponding to those in the above embodiment are denoted by the same reference numerals and will not be described.

In this embodiment, the joint structure on either side of the upper and lower flanges 621a and 621b has the same structure.
The essential part of (a) is shown enlarged in (b), and the enlarged illustration of the joining structure on the lower flange 621b side is omitted.

As shown in FIGS. 35 (a) and (b), the male fitting portion 613 of the front floor 601 has a groove-shaped portion 619a.
Groove 64 along the groove portions 619a, 619b behind the
3a and 643b are provided. Grooves 643a, 64
3b is similarly formed continuously along the groove portions 619a and 619b. However, the grooves 643a and 643b may have a concave shape continuously provided at predetermined intervals. The ends 623a and 623b of the upper and lower flanges 621a and 621b face the grooves 643a and 643b.

The upper and lower flanges 621a, 621
After the fitting male part 613 of the front floor 601 is fitted to the front end 601b, the adhesive 645a and 645b are filled to form the rear ends 6 of the flanges 621a and 621b as shown in FIG.
23a, 623b and the grooves 643a, 643b are adhered, and the rear end of the groove-shaped portion 619a and the claw-shaped portion 619 are bonded.
27a is bonded to the rear end. The bonding between the front floor 601 and the dash lower 603 can also be performed by such bonding.

In the embodiments shown in FIGS. 1 to 25 as well, the bonding between the floor-constituting base materials and the bonding between the body side unit, the roof side unit and the floor unit may be performed by bonding other than laser welding. It is also possible to use joining, fastening with rivets or bolts and nuts.
Further, the floor unit FU and the like are not limited to those formed of an extruded material, and a honeycomb material or the like can be used.

[Brief description of the drawings]

FIG. 1 is a process of manufacturing an automobile according to an embodiment of the present invention;
It is a schematic plan view of the factory which shows the substantially whole manufacturing process apparatus.

FIG. 2 shows a completed state of each step, (a) a state where a welding step is completed, (b) a state where a rear floor module and a rear end module are attached, (c) a state where a floor step is completed, and (d) a body side. (E) with roof unit attached, (f) with roof unit attached
Is a state in which the upper body unit is mounted on the running unit, (g) is a state in which the exterior component mounting step, liquid substance adding step, window step, and door mounting step are completed, and (h) is a state in which the outer surface decoration step is completed. It is a schematic plan view.

FIG. 3 is a schematic enlarged perspective view of a main part of a floor process apparatus A.

4A and 4B show a main floor constituent base material, wherein FIG. 4A is an exploded perspective view, and FIG. 4B is a cross-sectional view taken along line bb of FIG.

FIG. 5 shows a bonding state of a main floor constituent base material,
(A) is an enlarged cross-sectional view after the start of connection, (b) during connection, and (c) after completion of connection.

FIG. 6 is an exploded perspective view of an engine compartment skeleton.

FIGS. 7A and 7B show a rear floor frame portion, and FIG.
(B) is a partially exploded perspective view.

8 (a) is an exploded perspective view of a reference dimension, FIG. 8 (b) is an exploded perspective view corresponding to an expanded vehicle width, and FIG. 8 (c) is an exploded perspective view corresponding to an enlarged wheel base. It is.

FIG. 9 is a schematic enlarged perspective view of a welding process apparatus.

FIG. 10 is an enlarged sectional view showing a state after welding of a main floor constituent base material.

FIG. 11 is an enlarged perspective view showing a rear floor module process device.

FIG. 12 is an enlarged perspective view showing a rear end module process device.

FIG. 13 is an enlarged exploded perspective view showing an assembled state of the floor unit.

FIG. 14 is an enlarged perspective view showing an assembled state of the upper body unit.

FIG. 15 is a perspective view showing a part of the roof processing apparatus.

FIG. 16 is an exploded perspective view showing the connection between the floor unit, the body side unit, and the roof unit.

FIG. 17 is an enlarged sectional view of a main part showing the connection between the floor unit and the body side unit.

FIGS. 18A and 18B show the connection of the floor unit, the body side unit, and the roof unit, wherein FIG. 18A is a cross-sectional view before the roof unit is mounted, and FIG. 18B is a cross-sectional view after the roof unit is mounted.

FIG. 19 is a fragmentary cross-sectional view for explaining welding of the roof unit and the body side unit.

FIG. 20 is a perspective view showing a running unit mounting process apparatus.

FIG. 21 is a perspective view showing a door sub RH process device.

FIG. 22 is an exploded perspective view showing attachment of a resin panel.

FIG. 23 is a cross-sectional view of a main part showing a mounting mode of the roof resin panel.

FIG. 24 is a cross-sectional view of a main part showing a mounting mode of a resin panel for a front fender.

FIG. 25 is a cross-sectional view of a main part showing a mounting form of a resin panel for a rear fender.

FIG. 26 is an exploded perspective view of an embodiment according to a modification of the floor constituting base material.

FIG. 27 is a sectional view showing an exploded state of the dash lower and the front floor.

FIG. 28 is a cross-sectional view illustrating assembling.

29 (a) is a cross-sectional view in which the lower flange protrudes rearward relative to the upper flange, and FIG. 29 (b) is the same position where the rear ends of the upper and lower flanges project at the same position. FIG.

FIG. 30 is a perspective view showing a substantially right half of a reinforcement.

FIG. 31 is a sectional view taken along the line XXXI-XXXI of FIG. 30;

32 is a sectional view taken along the line XXXII-XXXII in FIG. 30.

FIG. 33 is a cross-sectional view of a state where a front floor and a dash lower are disassembled in an embodiment showing a modified example of a claw-shaped portion.

FIG. 34 is a cross-sectional view showing an embodiment according to a modification of the joining structure.

35A and 35B show an embodiment according to another modified example of the joining structure, in which FIG. 35A is a cross-sectional view, and FIG.

[Explanation of symbols]

FU Floor unit BSU Body side unit UBU Upper body unit URU Underrunning unit MB Vehicle body A Floor process device B Indoor component mounting process device C Body main process device D Running part mounting process device E Exterior decoration process device 113 Floor base material 143a Clip Part 197, 199, 201 Locate hole 211 Fitting female part 213 Fitting male part 221 Back wall 223 Positioning convex part 225 Positioning concave part 227 Clip convex part 229 Clip concave part 231 Contact surface 233 Adhesive 235 Inner surface of fitting female part 315 Welding 348 Body side base material 375 Roof base material 423 Adhesion 429 Welding 391,393 Pin (lower positioning means) 197,199 Locate hole (lower positioning means) 413,415,417 pin (upper) Positioning means) 401, 403, 405 Locate holes (upper positioning means) 395, 407 Front pillar 397, 409 Center pillar 517 Seal part 523 Clip 601 Front floor (floor constituent base material) 603 Dash lower (floor constituent base material, engine compartment) Skeleton fitting part 613 fitting male part 617 fitting female part 619a, 619b groove-shaped part 621a, 621b flange 623a, 623b end part 627a, 627b, 639a, 639b nail-shaped part 641a, 641b rivet 645a, 645b adhesive

 ────────────────────────────────────────────────── ─── Continued on the front page (72) Koji Sato, inventor Nissan Motor Co., Ltd., 2 Takaracho, Kanagawa-ku, Yokohama, Kanagawa Prefecture (72) Inventor Koichi Ohira 2 Takaracho, Kanagawa-ku, Yokohama, Kanagawa, Nissan Motor Co., Ltd. 72) Inventor Masami Tashiro 2 Takaracho, Kanagawa-ku, Yokohama, Kanagawa Prefecture Inside Nissan Motor Co., Ltd. (72) Inventor Takashi Matsuoka 2 Takaracho, Kanagawa-ku, Yokohama City, Kanagawa Prefecture 2 Nissan Motor Co., Ltd. (72) Inventor Takamitsu Tajima, Kanagawa Prefecture Nissan Motor Co., Ltd. (72) Inventor Kenji Kanamori 2 Takaracho, Kanagawa-ku, Yokohama Nissan Motor Co., Ltd.

Claims (33)

[Claims] 1. A floor step of combining a plurality of floor constituent base materials of an automobile, each formed of a light metal material, and joining the combined floor constituent base members to form a floor base material; An interior component mounting step of assembling a material into a floor unit, and a body side unit assembling a side portion of the automobile by assembling a body side interior material with a body side base material.
A body main process in which a roof unit forming the upper part of the automobile by assembling a roof interior material with a roof base material is joined to the floor unit to form an upper body unit; and an under part comprising an engine, a power train, a suspension, etc. Manufacturing a vehicle, comprising: a running part mounting step of assembling a running unit to the upper body unit to form a vehicle body; and an outer decoration step of attaching a decorative outer covering member to the vehicle body. Method. 2. A floor process apparatus comprising: an operator combining a plurality of floor constituent base materials of an automobile, each formed of a light metal material, on a manual conveyor, and joining the combined floor constituent base members to form a floor base material; An interior component mounting process apparatus that accepts the floor base material on a manual conveyor and allows a worker to assemble a floor interior material with the floor base material to form a floor unit; and that the floor unit accepts the floor unit on a manual conveyor. A body side unit forming a side portion of the vehicle by attaching a body side interior material to a body side base material; and a roof unit forming an upper portion of the vehicle by attaching a roof interior material to a roof base material. The operator assembles with the unit, receives it on the automatic conveyor driven by the driving means, and A main body process device that forms an upper body unit by joining together with an underrunning unit that includes an engine, a powertrain, a suspension, and the like, and a vehicle that combines the two by assembling the upper body unit by lifting the upper body unit Manufacturing of an automobile, comprising: a running part mounting process device forming a main body; and an external decoration process device that accepts the vehicle main body on a manual conveyor and mounts an external coating member for decoration by an operator. apparatus. 3. A floor unit in which a floor interior material is assembled to a floor substrate joined by combining a plurality of floor constituent substrates of an automobile each formed of a light metal material, and a body side interior material is assembled to a body side substrate. An upper body unit in which a body side unit constituting the side portion of the automobile, a roof interior material assembled to a roof base material and a roof unit constituting the upper part of the automobile are joined, and an engine, a power train, a suspension and the like. An underrunning unit that is assembled to the upper body unit to form a vehicle body; an exterior component such as a bumper; a window shield; a door unit having a door mirror or the like attached to a door panel; and an exterior covering member for decoration It is characterized by having assembled Dosha. 4. The method for manufacturing an automobile according to claim 1, wherein the joining is performed by welding. 5. The method for manufacturing an automobile according to claim 1, wherein the joining is performed by bonding. 6. The method for manufacturing an automobile according to claim 1, wherein the joining is performed with rivets. 7. The method for manufacturing an automobile according to claim 1, wherein the joining is performed with bolts. 8. The automobile manufacturing apparatus according to claim 2, wherein the joining is performed by welding. 9. The automobile manufacturing apparatus according to claim 2, wherein the joining is performed by bonding. 10. The automobile manufacturing apparatus according to claim 2, wherein the joining is performed with rivets. 11. The automobile manufacturing apparatus according to claim 2, wherein the joining is performed by bolts. 12. The vehicle according to claim 3, wherein the joining is performed by welding. 13. The vehicle according to claim 3, wherein the joining is performed by bonding. 14. The vehicle according to claim 3, wherein the joining is performed with rivets. 15. The vehicle according to claim 3, wherein the joining is performed by bolts. 16. The method for manufacturing an automobile according to claim 1, wherein the molding of the floor constituting base is extrusion. 17. The automobile manufacturing apparatus according to claim 2, wherein the molding of the floor constituting base material is extrusion. 18. The vehicle according to claim 3, wherein the molding of the floor constituent base material is extrusion. 19. The automobile according to claim 3, or any one of claims 12 to 15, and 18, wherein one of the floor constituent base members is fitted to the female part, and the other is fitted to the female part. An automobile comprising: a male fitting portion; a positioning convex portion provided on one of the male and female fitting portions; and a positioning concave portion engaging with the positioning convex portion on the other. 20. The automobile according to claim 19, wherein the positioning uneven portion is provided on a back wall of the fitting female portion and a distal end wall of the fitting male portion to stop rotation between the fitting female and male portions. An automobile characterized by performing. 21. The automobile according to claim 20, wherein engagement clip projections are protruded on opposite inner surfaces of an opening edge of the fitting female portion, and both outer surfaces of the fitting male portion. A clip concave portion that engages with the clip convex portion, and contact surfaces that are in close contact with both inner surfaces of the female fitting portion are provided on both outer surfaces of the male fitting portion closer to the distal end side than the clip concave portion. An automobile characterized by the following. 22. The automobile according to claim 21, wherein the clip concave portion is bonded to an inner surface of an inner edge of an opening inside the vehicle interior of the fitting female portion, and a vehicle exterior of the fitting female portion. An automobile wherein an opening edge portion and a base outer surface of the fitting male portion are welded. 23. The vehicle according to claim 19, wherein the floor component base includes a front floor and a dash lower of an engine compartment frame portion, and the fitting female portion is provided on the dash lower on a vehicle body rear side. The vehicle is characterized in that the fitting male portion is formed at a front end of the front floor and fitted between the flanges. 24. The automobile according to claim 23, wherein the concave portion is a groove-shaped portion formed in a vehicle width direction, and the convex portion is a claw-shaped portion engaging with the groove-shaped portion. An automobile characterized by the following. 25. The vehicle according to claim 23, wherein an upper flange of the fitting female portion is thinner than a lower flange of the fitting female portion. 26. The vehicle according to claim 23, wherein a rear end of the lower flange of the fitting female portion projects rearward of the vehicle body from a rear end of the upper flange. An automobile, wherein an upper front end of the male fitting portion is made to protrude forward of the vehicle body more in correspondence with the flange than a lower front end thereof. 27. The vehicle according to claim 3, wherein: between the floor unit and the body side unit
An automobile, comprising: lower positioning means for positioning between the two; and upper positioning means for positioning between the body side unit and the roof unit. 28. The vehicle according to claim 27, wherein said upper and lower positioning means are constituted by pins and locate holes. 29. The vehicle according to claim 28, wherein the pin and the locating hole of the lower positioning means are arranged with their axes oriented in the vehicle width direction, and the pin and the locating hole of the upper positioning means are A motor vehicle characterized in that the lower positioning means is vertically oriented so as to be perpendicular to the axes of the pins and the locate holes of the lower positioning means. 30. The vehicle according to claim 27, wherein said lower positioning means is disposed at least at a lower end of a center pillar, and said upper positioning means is at least at an upper end of a center pillar. An automobile, which is arranged in the middle of a front pillar. 31. The vehicle according to claim 3, wherein the joining is one-way welding of a seam located outside a vehicle cabin. 32. The automobile according to claim 3, wherein the joint between the floor unit and the body side unit is bonding of a joint on the vehicle interior side and welding of a joint on the outer side. Car. 33. The vehicle according to claim 3, wherein the outer surface covering member is formed of a resin, and is connected to the vehicle body side with a clip portion, and near the clip portion, the outer surface covering member and the vehicle. An automobile, wherein a seal portion is provided between the outer surface of the vehicle and the main body.