WO2006018507A1

WO2006018507A1 - Light-duty motor vehicle

Info

Publication number: WO2006018507A1
Application number: PCT/FR2005/001872
Authority: WO
Inventors: Jacques Farge; Jean-François FICHET
Original assignee: Defi Car (Sarl)
Priority date: 2004-07-20
Filing date: 2005-07-20
Publication date: 2006-02-23
Also published as: FR2873335A1; FR2873335B1

Abstract

The invention relates to a light-duty, compact motor vehicle, that can especially transport average loads for urban use. Said vehicle is characterised by the ease of assembly thereof and the capacity thereof to undergo minor modifications of the structure thereof in order to be able to be adapted to various uses. The inventive vehicle especially comprises a driver's compartment formed by assembling a single component of elements consisting of a lightweight material, said compartment comprising a shell consisting of a composite material to which two metallic roll bars are laterally fixed.

Description

MOTORIZED LIGHT VEHICLE

The invention relates to a light and compact motorized vehicle, capable in particular of transporting medium loads in the context of a use of urban servitude, in an enterprise as well as a private context.

This vehicle is characterized by its ease of assembly and its ability to undergo minor modifications of its structure to adapt to various uses.

The invention also relates to a device and a method for mounting and assembling said vehicle.

In the automotive field, vehicles generally consist of pressed steel sheet elements assembled by welding. This solution, however, is uneconomical, excessively increases the weight of the vehicle and requires complex assembly lines.

To overcome the problem of weight, one can use lightweight materials, plastic or aluminum type, replacing the steel, especially for the inserts of the body. This solution however does not allow to lighten the entire vehicle, the remaining frame elements in particular steel. In addition, the multiplicity of materials used generates both increased complexity in the assembly process and a risk of weakening of the structure at the point of attachment of the elements together.

The object of the invention is therefore to propose a light motorized vehicle which does not have the disadvantages of the prior art described above. In particular, an object of the invention is to propose a vehicle consisting mainly of structural elements made of lightweight materials.

Patents EP 1,069,030 and FR 2,844,766 disclose such light vehicles obtained by attaching a driver's cab to a chassis. In patent EP 1.069.030, the cabin is a monolithic assembly made of a composite material, such as polyester reinforced with glass fibers, mounted to interlock and then secured on a

COPY OF COMFIRMATI ^Q fI frame consisting of a tubular metal structure. Patent FR 2,844,766 describes a vehicle whose chassis is made by bolting, without welding operation, and whose cabin consists of a tray for supporting a roll bar on which body panels are fixed.

Another object of the invention is therefore to provide a vehicle formed from a basic structure easy to assemble, distinguished from those of the prior art, and having a limited number of attachment points.

The invention also aims at providing a light motorized vehicle for carrying a large payload given its empty weight, in particular having a payload ratio on empty weight greater than or equal to 1.

Another object of the invention is also to provide a method and an assembly device adapted to this light motor vehicle, to simplify and accelerate the assembly process of said vehicle. The invention also aims at proposing a method of assembling this light motorized vehicle making it possible to obtain, by simple and rapid modifications of the assembly line, a variety of possible vehicle models, in particular with regard to the elements motorisation, transmission or bodywork of said vehicles.

In this regard, and in accordance with the invention, there is provided a light vehicle comprising a driver's cabin formed integrally by assembling lightweight material elements, said cabin being connected directly to a remarkable chassis-scale in that the driver's cabin comprises a shell of composite material on which are fixed laterally two metal hoops.

It is understood that, due to this particular structure, the vehicle will have a lighter weight, while having an easier and faster assembly because of the limited number of elements to be assembled and attachment points between these various elements. Other advantages and features will become more apparent from the following description of a possible method of construction of a vehicle according to the invention, with reference to the drawings which accompany this description and in which:

FIG. 1 is a perspective and exploded view of a light motorized vehicle according to the invention, during assembly,

- Figure 2 is a side view of the light motor vehicle of Figure 1, once the assembly is completed.

FIG. 3 is a view from above of a device for mounting a driver's cab of a light motorized vehicle according to the invention,

- Figure 4 is a side view of the mounting device of Figure 3.

Referring to Figure 1, there is shown a light motor vehicle 1 according to the invention, being assembled.

This vehicle 1 comprises a driver's cab 2, mounted at the front of a chassis structure 3, receives a powertrain 4 preferably in its rear part.

The driver's cab 2 comprises a shell 5. of composite material on which are fixed laterally two metal hoops 6.

These two arches 6 are therefore apparent and are not directly linked to the chassis 3. Their function is to reinforce the structure of the cabin 2. As will be explained later, this feature simplifies the assembly of the vehicle, while meeting the standards. applicable to vehicles.

The shell of composite material 5 may be formed by molding in one piece or, preferably, by assembling a plurality of composite material elements fastened together by any means of assembly, in particular by gluing, screwing, riveting, crimping. The composite material used will preferably be chosen from thermoplastic polymer materials, such as, for example, the - AT -

polyethylene, polypropylene, PVC, polyamide, polycarbonate, polyurethane, PET, among resins, such as epoxy or polyester resins, and thermosetting materials. Such materials may be applied alone or mixed in a single layer, or superimposed in adjacent layers of a multilayer carrier. Reinforcing agents, of the foam type, polyurethane foam in particular, fibers, glass fibers in particular, or fillers, mineral fillers in particular, may advantageously be added to the said layer or layers to improve certain physical properties of the composite material obtained.

The hull 5 of composite material will therefore include a roof 7, a rear wall 8 having one or more projecting shapes 9 defining one or more seat back locations, a floor 10, connected to the rear wall 8 by a wall intermediate curve 11, which comprises one or more projecting shapes 12 defining one or more seat locations, two side walls 13 having openings corresponding to the location of the doors 14, said doors 14 being fixed by means of hinges 15 arranged along the metal arches 6, a front wall 16, connected to the roof 7 by two lateral uprights 17, the roof 7, the lateral uprights 17 and the front wall 16 defining an opening corresponding to the location of the windshield 18. A crossbar 19, substantially horizontal, intended in particular for the attachment of the dashboard 20 and the steering controls 21, is connected at both ends thereof s on the inner side of the side walls 13 of the shell 5.

This ^{Barre-transverse} 19 is made of a material giving it strength and appropriate rigidity. For example, it may be metal or composite material.

The driver's cab 2 rests on a frame-scale 22 at the intermediate wall 11 of the shell 5, the floor 10 being positioned below this In addition, the driver's cab 2 is attached to the ladder frame 22 only at the lower fastening points 23 of the seat belts. The chassis-scale 22 will, moreover, formed of light material, and preferably aluminum.

The chassis structure 3 comprises a front cradle 24, rear respectively 25, disposed under the frame 22 at the level of the front wheels 26, rear respectively 27 of the vehicle 1. The front cradle 24 comprises a first U-shaped vertical member 28, each leg of the U being fixed to the longitudinal members of the chassis-ladder 22, and a second element 29 in the shape of a T, said element 29 being directed towards the front and towards the bottom of the vehicle 1, each branch of the T being connected to a surface plane of the first element 28, at the hollow of the U-shape, by means of connecting elements 30, the bar of the T being terminated by a fixing plate 31, which is arranged in abutment on an end post of the chassis-scale 22, substantially in the middle, and fixed thereto by screwing, welding or riveting in particular.

Furthermore, the floor 10 of the shell 5 rests on the front cradle 24 at brackets 32 disposed at each end of the branches of the T-shaped section 29, the front wall 16 of the shell 5 being fixed on a vertical part 33 of this square.

The rear cradle 25 comprises a first vertical element 34 in the shape of a U, each leg of the U being fixed to the longitudinal members of the chassis-scale 22, a second element 35 and third element 36 substantially identical, said elements 35, 36 describing a generally U and being arranged symmetrically with respect to the median plane of the chassis-scale 22, a planar portion of each of said elements 35, 36, corresponding to the hollow of the U-shape of these elements 35, 36, being secured to a flat part of the first element 34, corresponding to the hollow of the U-shape of this first element 34, the second 35 and third 36 elements being fixed at their ends respective to the longitudinal members of the chassis-ladder 22.

The elements constituting the framework of the cradle before 24 and rear 25 will be formed of light material, including aluminum, and techniques of the type molding, wrought or mechano-welding, including extrusion.

Optionally, it is conceivable to equip the vehicle 1 with a folding lift arm 37 that can be connected to one of its free ends at the bottom of a mobile platform, a flatbed or a dumpster. This arm will allow the lifting of said platform, said tray or said bucket, so as to cause it to tilt during a loading or unloading operation. This lift arm 37 will be attached to a cross member of the ladder frame 22, preferably at the midplane of the ladder frame 22 and in the rear part of the vehicle 1, said lift arm 37 being positioned substantially under the chassis. scale 22 in its fully folded storage position. In an alternative embodiment, the lift arm may be attached to a false intermediate frame, itself attached to the frame 12.

The vehicle 1 is equipped with a motorization system, for example a powertrain 4, preferably disposed at the rear of the vehicle 1.. This powertrain 4 rests on the rear cradle 25 via shock-absorbing devices 38, of the "silent block" type, fixed on support plates 39 integral with each of the second 35 and third 36 elements of said rear cradle 25.

In the context of the present invention, it goes without saying that any type of motorization and transmission is applicable.

For fixing the front wheels 26, respectively rear 27, on the front cradle 24, respectively rear 25, bearing plates 40 projecting at each end of the branches of the first element 28 of the front cradle 24, respectively of the first element 34 of the rear cradle 25, may constitute attachment points for one of the ends of a damping device 41, of helical spring type or air spring, connected at its other end to the axis of the front wheels 24, respectively rear 25.

Referring to Figure 2, there is shown a version of the light utility type of the vehicle according to the invention, once all the constituent parts of said vehicle installed and mounted. In this version, the vehicle 1 is intended to receive a load on the rear portion of the carrier frame structure 3, including a bucket, a flat platform, a flatbed or a van. Said load can then be fixed to the frame-ladder 22 and / or the free end of the lifting arm 37 unfoldable so as to allow the load to tilt during the loading or unloading phases of the vehicle 1.

In an unrepresented version corresponding to a use of the vehicle 1 for the transport of persons, it will be possible to adapt a passenger cabin on the rear part of the carrier frame structure 3, said passenger cabin comprising a series of seats fixed on its floor and a or several free spaces constituting storage areas. In another unrepresented version corresponding to a model of a van or taxi-bush type vehicle, provision may be made for support elements or handles on the side walls or the ceiling of the passenger cabin to allow the passengers not to fall. when moving the vehicle.

Body elements 42 are fixed, in particular by gluing, around the carrier frame structure 3, to protect the internal functional elements of the vehicle 1 and to improve the external appearance of the vehicle 1 .. Inside and outside of the driver's cab 2 have been equipped with a series of accessories or functional and comfort linings. . In particular, the driver's cab 2 comprises side doors 14 equipped with an adjustable rearview mirror 43, a front bumper 44, inside which openings are provided for housing lighting elements 45 and turn signals 46, a windscreen wiper 47, a dashboard 20 fixed to the cross bar 19 and the front wall 16 grouping together all the indicators or control devices, a steering wheel direction 21, a parking brake 48, seat upholstery 49 and seat backs 50, seat belts 51, etc. Other equipment can obviously be added to the driver's cab 2 depending on the applications envisaged and the choices of end users.

Referring to Figures 3 and 4, there is shown a mounting device 100 facilitating the assembly of a driver's cab 2 of a light motor vehicle 1 according to the invention, a driver's cab 2 having been mounted on the point of being removed from the mounting device 100.

This mounting device 100 consists mainly of a fixed structure 101, on which are positioned and attach the constituent elements of the shell 5, and two foldable structures 102 connected and arranged on either side of the fixed structure 101 In particular, the folding structures 102 may be connected to the fixed structure 101 by means of hinges 103.

With reference to FIG. 3, one of the folding structures 102 has been represented in broken lines in its fully folded position, in which a pressing means 104 integral with the folding structure 102 abuts against the rear wall 8 of the shell 5 It will be possible to equip the fixed structure 101 and the folding structures 102 with complementary fastening means consisting in particular of an elastic hook 105 disposed on one of the horizontal uprights of the fixed structure 101 inserted into a locking ring 106 disposed at the end. vertical amount of each foldable structures 102.

The fixed structure 101 comprises positioning means for wedging the shell 5 of the driver's cab 2 inside the fixed structure 101.. These positioning means consist, on the one hand, of horizontal bars 107, 108 located respectively in the front and rear part of the fixed structure 101 on which rests respectively the floor 10 and the rear wall 8 of the shell 2 and, d Moreover, in the two setting means 109 adjustable by means of a screw-nut system and arranged on a horizontal bar positioned in the front portion of the fixed structure 101 facing the front wall 16 of the ^'hull 5 the driver's cabin 2 .. Similarly, there are provided other means for positioning the side arches β of the driver's cab 2 on the foldable structures 102. In the example shown, these other positioning means are elastic sleeves 110 substantially semi-cylindrical inside which are housed the side arches 6 .. On a horizontal amount of each folding structures 102, oriented substantially perpendicular In accordance with the overall plan defined by each of the folding structures 102, pressing means 104 are provided so as to apply pressure on pre-glued portions of the rear wall 8 of the shell 5 when the folding structures 102 are completely folded. These pressing means 104 will advantageously consist of a series of elastic studs regularly spaced along said horizontal upright.

The method of assembling the driver's cab 2 implementing said mounting device comprises the following steps: positioning and staking a first composite material element defining the front wall, the floor, the seats and the rear wall; base of the hull of the light motorized vehicle, on the positioning means of the fixed structure of the mounting device mentioned above,

- we glue some parts of this first element to be covered by corresponding parts of a second element and a third composite material element, the second element defining the upper rear wall and the roof of the hull and the third element defining the lateral uprights arranged on either side of the windshield, - the second and third elements are assembled on the first element, we have the metal hoops of the driver's cab on the positioning means of the folding structures of the mounting device, - the folding structures are positioned in their fully folded position,

the metal hoops are fixed on the shell, in particular by bonding, riveting or bolting,

the windshield is glued into the opening defined by the lateral uprights, the front wall and the roof of the hull,

a rear window is optionally glued into an opening in the rear wall of the shell,

- One possibly fixes a transversal bar on the lateral uprights of the hull, intended in particular for the subsequent fixing of the dashboard and steering controls.

In the context of the invention, this method of assembly of the driver's cab 2 is also part of an innovative manufacturing process to lead to the light motor vehicle 1 described above.

This method has the particular feature of being carried out without the aid of conveying devices during the movements of the vehicle 1 between each assembly station. This result results, on the one hand, by the low weight of the vehicle 1 allowing its manual movement by one or more persons normally constituted, and, on the other hand, by the preliminary stages of the method itself consisting in mounting means of ground connection, wheel type, on a carrier frame structure 3, thus facilitating the movement of the vehicle 1 during assembly to the following positions.

The assembly process of the light motor vehicle is based on a linear main assembly line, along which parallel manufacturing islands are arranged to provide intermediate subassemblies to the vehicle being mounted on the main assembly line. This arrangement makes it possible in particular to easily adapt the assembly line according to the vehicle models to be produced. and it is therefore perfectly conceivable to continuously produce several models of light motor vehicle on the same main assembly line, without loss of time and without substantial modification of the overall process of assembly of the light motor vehicle.

This assembly method comprises in particular the following steps: - the carrier frame structure is assembled,

- we pre-assemble a powertrain,

the powertrain is fixed on the carrier frame structure,

the driver's cab is pre-assembled in accordance with the assembly method mentioned above, the driver's cab is fixed on the carrier chassis structure,

internal and external cladding elements are fixed on the carrier structure and on the driver's cab,

- The general operation of the entire vehicle is checked. The vehicle according to the invention, as described above, can thus be the subject of numerous applications and variants. In particular, the vehicle can be easily modified to adapt all existing or future transmission and propulsion means and any type of bodywork imaginable. Other equipment may also be provided extra without departing from the general scope of the invention. It is also conceivable to propose other possible configurations of the driver's cabin, in particular a driver's cabin having a raised floor relative to the curved intermediate wall or a wall rear disposed obliquely to the vertical.

Claims

1 - light motor vehicle (1), comprising a driver's cab (2) formed in one piece by assembling light material elements, said cabin (2) being connected directly to a ladder frame (3) characterized in that that the driver's cab (2) comprises a shell (5) of composite material on which are fixed laterally two metal hoops (6).

2 - light motor vehicle (1) according to the preceding claim, characterized in that the shell (5) is formed of an assembly in one piece of several panels of composite material fixed together by gluing.

3 - light motor vehicle (1) according to any one of the preceding claims, characterized in that the driver's cab (5) is fixed on the ladder frame (22) at the lower attachment points (23) of the seat belts. security (52).

4 - light motor vehicle (1) according to any one of the preceding claims, characterized in that it comprises a front cradle (24) disposed under the chassis-scale (22) at the front wheels (26) of the vehicle ( 1), said front cradle (24) having a first U-shaped vertical member (28), each leg of the U being attached to the frame-ladder side members (22), and a second T-shaped member (29), said element (29) being directed towards the front of the vehicle (1) and downwards, each branch of the T being connected to a planar surface of the first element (28), at the level of the hollow of the U-shape, by means of connecting elements (30), the T bar being terminated by a fixing plate (31), which is fixed on an end upright of the chassis-ladder (22), substantially in its middle.

5 - light motor vehicle (1) according to the preceding claim, characterized in that the floor (10) of the shell (5) rests on the front cradle (24) at brackets (32) arranged at each end of the branches of the T-shaped element (29), the front wall (16) of the shell (5) being fixed on vertical portions (33) of these brackets (32).

6 - light motor vehicle (1) according to any one of the preceding claims, characterized in that it comprises a rear cradle (25) fixed under the chassis-scale (22) at the rear wheels (27) of the vehicle ( 1), said rear cradle (25) having a first U-shaped vertical member (34), each leg of the U being attached to the chassis-ladder side members (22), a second (35) and third (36) substantially identical, said elements (35,36) describing a generally U-shaped shape and being arranged symmetrically with respect to the median plane of the ladder frame (22), a planar portion of each of said second and third elements (35,36), corresponding to the hollow of the U-shape of these second and third elements (35,36), being secured to a flat portion of the first element (34), corresponding to the hollow of the U-shape of this first element (34), the second and third elements (35,36 ) being attached at their respective ends to the longitudinal members of the ladder frame (22).

7 - light motor vehicle (1) according to any one of the preceding claims, characterized in that a powertrain (4) is disposed at the rear of the vehicle (1), resting on the rear cradle (25) by the intermediate of damping devices (38), type "silent block", fixed on support plates (39) integral with each of the second and third elements (35,36) of said rear cradle (25). 8 - light motor vehicle (1) according to any one of claims 3 to 7, characterized in that horizontal portions (40) arranged projecting at each end of the branches of the first elements (28,34) U-shaped cradle front (24) and the rear cradle (25) are likely to constitute attachment points for a damping device (41), helical spring type or air spring.

9 - Light motor vehicle (1) according to one any of the preceding claims, characterized in that it has a payload ratio on empty weight greater than or equal to 1.