JP6183473B2 - Auto body manufacturing method - Google Patents

Description

In the present invention, a metal tube is bent by three-dimensional bending to produce an upper frame in which an A-pillar upper and a roof side rail are continuously integrated, and the upper end of the A-pillar lower and the middle of the upper frame on the welding jig. It relates to a vehicle body manufacturing how automotive welding the upper end of the upper end and the tail end of the pillar of the pillar.

  Japanese Patent Application Laid-Open No. 2004-228667 discloses a structure of a roof side rail of an automobile without requiring an expensive press die by three-dimensional hot bending a hollow closed cross-section steel pipe into a predetermined shape.

  Further, in order to connect the roof side rail with the hollow closed cross section and the roof arch with the hollow closed cross section, the roof side rail and the roof are combined with the roof side rail previously welded with the lower gusset and the roof arch previously welded with the upper gusset. Patent Document 2 below discloses that an arch is integrally laser-welded via an upper gusset and a lower gusset.

Japanese Unexamined Patent Publication No. 2012-188115 Japanese Unexamined Patent Publication No. 2010-2335014

  By the way, three-dimensional bending without using a bending die has a relatively low processing accuracy, so that the position of the middle part in the front-rear direction of the three-dimensional bent roof side rail can be prevented from shifting in the vehicle width direction or the vertical direction. If the roof side rail, which is misaligned, is welded to the outer edge of the roof arch in the vehicle width direction or the upper end of the B pillar as an intermediate pillar through the gusset, there is a gap in the weld due to the position error of the roof side rail. May occur and the welding strength may decrease.

  The present invention has been made in view of the above circumstances, and an object thereof is to firmly weld the upper end portion of an intermediate pillar without being affected by the dimensional accuracy of a roof side rail.

  In order to achieve the above object, according to the present invention, a first step of manufacturing an upper frame in which an A pillar upper and a roof side rail are integrally formed by bending a metal tube by three-dimensional bending, and welding The upper end of the A pillar lower and the upper end of the last pillar are positioned in the vertical direction and the vehicle width direction with respect to the upper frame on the tool, and the upper end of the B pillar as an intermediate pillar is positioned in the vehicle width direction. And a third step of assembling the vehicle body side frame by welding the upper end of the A pillar lower, the upper end of the B pillar, and the upper end of the rearmost pillar to the upper frame via a gusset. In the third step, the gusset for connecting the upper end of the B pillar to the upper frame is vertically adjusted with respect to the upper end of the B pillar. Body manufacturing method of the motor vehicle to the first, characterized in that a capability is proposed.

  According to the present invention, in addition to the first feature, in the third step, the gusset for connecting the upper end of the B pillar to the upper frame may include a longitudinal direction of the upper frame and a longitudinal direction of the B pillar. A vehicle body manufacturing method for automobiles is proposed, which is characterized by being continuously welded in the direction.

  According to the present invention, in addition to the first or second feature, the gusset includes a first gusset located on one side surface in the vehicle width direction and a second gusset located on the other side surface in the vehicle width direction, In the third step, after the first gusset is welded to one side surface in the vehicle width direction of the vehicle body side frame supported by the first welding jig, the vehicle body side frame is turned upside down so that the first welding treatment is performed. A vehicle body manufacturing method for an automobile is proposed, which is supported on a second welding jig adjacent to a tool and welds the second gusset to the other side surface of the vehicle body side frame in the vehicle width direction. .

  According to the present invention, in addition to the third feature, in the third step, the first gusset and the second gusset may be joined by spot welding, friction stir welding, or self-piercing rivet joining. The automobile body manufacturing method according to the fourth feature is proposed.

  According to the invention, in addition to any one of the first to fourth features, the A pillar lower and the last pillar are made of steel pipes, and the B pillar is made of a three-dimensional bent steel pipe. A lower frame to which a lower end of the A pillar lower, a lower end of the B pillar, and a lower end of the rearmost pillar are connected is a hollow closed cross section in which an inner member and an outer member formed by roll forming are joined by a joining flange A method for manufacturing a vehicle body, which is a fifth feature of being a member, is proposed.

  According to the invention, in addition to any one of the first to fifth features, the fourth step of connecting the upper ends of the B pillars of the pair of vehicle body side frames to both ends of the roof arch in the vehicle width direction. In the fourth step, the gusset that connects the upper end of the B pillar to the upper frame can be adjusted in the vehicle width direction with respect to both ends of the roof arch in the vehicle width direction. A vehicle body manufacturing method is proposed.

  According to the invention, in addition to any one of the first to sixth features, in the second step, the upper end of the D pillar is positioned in the vertical direction and the vehicle width direction, and as an intermediate pillar, The upper end of the C pillar is positioned in the vehicle width direction. In the third step, the upper end of the A pillar lower, the upper end of the B pillar, the upper end of the C pillar, and the upper end of the D pillar are placed on the upper frame. The side frame of the vehicle body is assembled by welding through the gusset, and the gusset that connects the upper end of the C pillar to the upper frame can be vertically adjusted with respect to the upper end of the C pillar. A method for manufacturing a vehicle body having the seventh feature is proposed.

  According to the present invention, in addition to the seventh feature, in the third step, the gusset for connecting the upper end of the C pillar to the upper frame may include a longitudinal direction of the upper frame and a longitudinal direction of the C pillar. An automobile body manufacturing method is proposed, characterized in that it is continuously welded in the direction.

According to the invention, in addition to the seventh or eighth feature, in the third step, the gusset is located on the first gusset on the one side in the vehicle width direction and on the other side in the vehicle width direction. A vehicle body manufacturing method for an automobile is proposed, comprising a second gusset, wherein the first gusset and the second gusset are joined together by spot welding, friction stir welding, or self-piercing rivet joining .

Incidentally, in response to an intermediate pillar B-pillar 19 according to the present invention of the embodiment corresponds to the middle of the pillar or the end of the pillar of the C-pillar 20 according to the present invention of the embodiment, the embodiment D-pillar 20 'Corresponds to the last pillar of the present invention, the lower gusset 42 of the embodiment corresponds to the first gusset of the present invention, the outer gusset 44 of the embodiment corresponds to the second gusset of the present invention, The upper gusset 43 of the embodiment corresponds to the third gusset of the present invention, and the first welding jig 45 and the second welding jig 46 of the embodiment correspond to the welding jig of the present invention . Le-safe side rail abutment surface 42a corresponds to the positioning contact surface of the present invention, a roof arch abutment surface 42b and the B-pillar abutment surface 42c of the embodiment corresponds to the slide contact surface of the present invention, the embodiment The roof arch side flange 42d B-pillar side flange 42e, a roof arch flange 43c and the B-pillar side flange 44c corresponds to the peripheral flange of the present invention, B-pillar side flange 42e of the embodiment corresponds to the flange portion of the present invention.

  According to the first feature of the present invention, the metal tube is three-dimensionally bent in the first step to produce an upper frame in which the A pillar upper and the roof side rail are continuously integrated, and on the welding jig in the second step. In step 3, the upper end of the A pillar lower and the upper end of the rearmost pillar are positioned in the vertical direction and the vehicle width direction, and the upper end of the B pillar as an intermediate pillar is positioned in the vehicle width direction. Then, the vehicle body side frame is assembled by welding the upper end of the A pillar lower, the upper end of the B pillar, and the upper end of the rearmost pillar to the upper frame via a gusset. In the third step, the gusset that connects the upper end of the B pillar as an intermediate pillar to the upper frame can be adjusted in the vertical direction with respect to the upper end of the B pillar. Even if it exists, the B-pillar as the upper frame and the intermediate pillar can be welded through the gusset without any trouble.

  According to the second feature of the present invention, in the third step, the gusset for connecting the upper end of the B pillar to the upper frame is continuously welded in the longitudinal direction of the upper frame and the longitudinal direction of the B pillar. Also, the strength of the vehicle body side frame can be increased by firmly welding the B pillar as an intermediate pillar.

  According to a third aspect of the present invention, the gusset includes a first gusset positioned on one side surface in the vehicle width direction and a second gusset positioned on the other side surface in the vehicle width direction. In the third step, the first welding is performed. After welding the first gusset to one side surface in the vehicle width direction of the vehicle body side frame supported by the jig, the vehicle body side frame is reversed and supported on the second welding jig adjacent to the first welding jig. Since the second gusset is welded to the other side surface of the vehicle body side frame in the vehicle width direction, it is possible to weld the gusset to both side surfaces of the vehicle body side frame in the vehicle width direction using the same welding device. Is reduced.

  According to the fourth aspect of the present invention, in the third step, the first gusset and the second gusset are joined by spot welding, friction stir welding, or self-piercing rivet joining. The strength of the vehicle body side frame can be further increased by integration.

  According to the fifth feature of the present invention, since the A pillar lower and the last pillar are made of steel pipe, the required strength can be ensured even if the cross section is reduced and the weight is reduced, and the manufacture is easy. Inexpensive. Since the B pillar is made of a three-dimensional bent steel pipe, the required strength can be ensured even if the cross section is made smaller and lighter. The lower frame to which the lower end of the A pillar lower, the lower end of the B pillar, and the lower end of the last pillar are connected is a hollow closed cross-section member in which an inner member and an outer member formed by roll foam are joined by a joining flange, and more Since it is easy to mold a high-strength material, it is possible to increase the strength against side collision, and it is easy to manufacture and inexpensive.

  According to a sixth aspect of the present invention, the method includes a fourth step of connecting the upper ends of the B pillars of the pair of vehicle body side frames to both ends in the vehicle width direction of the roof arch. The gusset that connects the upper end of the B-pillar to the upper frame can be adjusted in the vehicle width direction with respect to both ends of the roof arch in the vehicle width direction. The roof arch can be welded through the gusset without any trouble, and the number of parts can be reduced by using a common gusset for welding the B pillar and the roof arch.

  According to a seventh aspect of the present invention, in the second step, the upper end of the D pillar is positioned in the vertical direction and the vehicle width direction, and the upper end of the C pillar as an intermediate pillar is positioned in the vehicle width direction. In the third step, the vehicle body side frame is assembled by welding the upper end of the A pillar lower, the upper end of the B pillar, the upper end of the C pillar, and the upper end of the D pillar to the upper frame via a gusset, The gusset that connects the upper end of the C pillar to the upper frame can be adjusted in the vertical direction with respect to the upper end of the C pillar. Therefore, even if there is a vertical dimensional error in the upper frame, the upper frame and C The pillar can be welded through the gusset without any trouble.

  According to the eighth aspect of the present invention, in the third step, the gusset that connects the upper end of the C pillar to the upper frame is continuously welded in the longitudinal direction of the upper frame and the longitudinal direction of the C pillar. And the C pillar as an intermediate pillar can be firmly welded to increase the strength of the vehicle body side frame.

According to a ninth feature of the present invention, in the third step, the gusset includes a first gusset located on one side surface in the vehicle width direction and a second gusset located on the other side surface in the vehicle width direction. Since the second gussets are joined by spot welding, friction stir welding, or self-piercing rivet joining, the strength of the vehicle body side frame can be increased by integrating the first gusset and the second gusset .

FIG. 1 is a perspective view of a vehicle body side frame of an automobile. (First embodiment) FIG. 2 is a view in the direction of the arrow 2 in FIG. (First embodiment) FIG. 3 is a view in the direction of arrows 3 in FIG. (First embodiment) FIG. 4 is a view in the direction of arrows 4 in FIG. (First embodiment) FIG. 5 is an enlarged sectional view taken along line 5-5 of FIG. (First embodiment) 6 is an enlarged sectional view taken along line 6-6 of FIG. (First embodiment) 7 is an enlarged sectional view taken along line 7-7 of FIG. (First embodiment) FIG. 8 is an explanatory diagram of the first step and the second step. (First embodiment) FIG. 9 is an explanatory diagram of the third step. (First embodiment) FIG. 10 is an explanatory diagram of the third step. (First embodiment) FIG. 11 corresponds to FIG. (Second Embodiment) FIG. 12 corresponds to FIG. (Third embodiment)

11 Car body side frame 12 Roof side rail 14 Upper frame 16 A pillar upper 17 A pillar lower 19 B pillar (middle pillar)
20 C pillar (middle pillar or last pillar)
20 'D pillar (the last pillar)
21 gusset 23 gusset 25 gusset 25i first gusset 25o second gusset 27 gusset 30 lower frame 41 roof arch 41a reinforcing bead 42 lower gusset (first gusset)
42a Roof side rail contact surface (positioning contact surface)
42b Roof arch contact surface (slide contact surface)
42c B pillar contact surface (slide contact surface)
42d Roof arch side flange (peripheral flange)
42e B-pillar side flange (peripheral flange or flange)
42f bulge 43 upper gusset (third gusset)
43c Roof arch side flange (peripheral flange)
44 Outer gusset (second gusset)
44c B-pillar side flange (peripheral flange)
45 First welding jig (welding jig)
46 Second welding jig (welding jig)
47 Inner member 47a Joining flange 48 Outer member 48a Joining flange W1 Welding W2 Welding W3 Welding W4 Welding W7 Welding W8 Welding W9 Welding W11 Welding

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the present specification, the front-rear direction, the left-right direction (vehicle width direction), and the up-down direction are defined with reference to an occupant seated in the driver's seat.

First embodiment

  First, a first embodiment of the present invention will be described with reference to FIGS.

  As shown in FIG. 1, a vehicle body side frame 11 of an automobile includes an upper frame 14 made of a steel tube having a circular cross section, in which a roof side rail 12 and an A pillar upper rear portion 13 are integrated. The upper frame 14 is configured by bending a straight steel pipe into a predetermined shape by three-dimensional bending. Connected to the front end of the A-pillar upper rear portion 13 is an A-pillar upper front portion 15 that is formed by welding a pressed steel plate to form a hollow closed cross section. The A-pillar upper rear portion 13 and the A-pillar upper front portion 15 are connected to A. A pillar upper 16 is configured.

  Below the upper frame 14, a lower frame 30 that is continuous from the side sill 18 to the rear frame 29 having a hollow closed cross section is disposed, and the front portion of the A pillar upper 15 and the front end of the side sill 18 are formed in a Y shape. The front and rear intermediate portions of the roof side rail 12 and the front and rear intermediate portions of the side sill 18 are connected by the B pillar 19 and the front and rear intermediate portion of the roof side rail 12 and the side sill 18 are connected to each other. The rear end (front end of the rear frame 29) is connected in the vertical direction by the C pillar 20, and the rear end of the roof side rail 12 and the rear end of the rear frame 29 are connected in the vertical direction by the D pillar 20 '.

  The side sill 18 constituting the front portion of the lower frame 30 is formed by joining a roll-formed inner member 47 and an outer member 48 at joining flanges 47a and 48a to form a hollow closed section having a large cross-sectional area, and is easy to manufacture. It has high strength against side collision.

  The A pillar lower 17 is formed by welding a press-worked steel plate and integrally welding an upper portion 17a having a hollow closed cross section and a lower portion 17b made of a straight steel pipe having a square cross section, and the upper end of the upper portion 17a is an A pillar upper. 16 is welded via a gusset 21, and the lower end of the lower portion 17 b is welded to the side sill 18 via a gusset 22. The B pillar 19 is made of a steel pipe having a quadrangular cross section that is three-dimensionally bent, and has an upper end welded to the roof side rail 12 via a gusset 23 and a lower end welded to the side sill 18 via a gusset 24. The C pillar 20 is made of a steel pipe having a circular cross section that is three-dimensionally bent, and has an upper end welded to the roof side rail 12 via a gusset 25 and a lower end welded to a continuous portion of the side sill 18 and the rear frame 29 via a gusset 26. The The D pillar 20 ′ is made of a three-dimensional bent steel pipe having a circular cross section, and the upper end is welded to the roof side rail 12 via the gusset 27 and the lower end is welded to the rear frame 29 via the gusset 28. These gussets 21 to 28 are divided into two inward and outward in the vehicle width direction. The gussets 21 to 28 are formed on the upper frame 14 and the lower frame 30 with the A pillar lower 17, the B pillar 19, the C pillar 20 and the D pillar 20 'sandwiched from both sides in the vehicle width direction. Connecting.

  Further, since the lower part 17b of the A pillar lower 17, the B pillar 19, the C pillar 20, and the D pillar 20 'are made of steel pipes having a constant cross section, the necessary strength can be ensured even if the cross section is reduced to reduce the weight. .

  The end portion of the roof arch 41 extending in the vehicle width direction is connected by the gusset 23 that connects the B pillar 19 to the roof side rail 12. That is, the three members of the roof side rail 12, the B pillar 19, and the roof arch 41 are integrally connected by the gusset 23.

  Next, based on FIGS. 2-7, the structure of the connection part of the roof side rail 12, the B pillar 19, and the roof arch 41 is explained in full detail.

  The gusset 23 includes a lower gusset 42 connecting the roof side rail 12, the B pillar 19 and the roof arch 41, an upper gusset 43 connecting the roof side rail 12 and the roof arch 41, and the roof side rail 12 and the B pillar 19. The outer gusset 44 is connected.

  The lower gusset 42 is formed in an L shape when viewed in the front-rear direction, from the roof side rail contact surface 42a along the outer peripheral surface of the roof side rail 12 having a circular cross section, and from the upper end of the roof side rail contact surface 42a. A roof arch contact surface 42b extending inward in the vehicle width direction and connected to the lower surface of the roof arch 41, and extending downward from the lower end of the roof side rail contact surface 42a and connected to the inner surface in the vehicle width direction of the B pillar 19 B pillar 19 contact surface 42c, a pair of front and rear roof arch side flanges 42d, 42d provided between the roof side rail contact surface 42a and the roof arch contact surface 42b, and the roof side rail contact surfaces 42a and B A pair of front and rear B-pillar side flanges 42e and 42e provided between the contact surfaces 42c of the pillar 19 and the vehicle width direction from both front and rear sides of the upper end of the B pillar contact surface 42c. Front and rear of the bulging portion 42f bulging inward, and a 42f.

  The upper gusset 43 is connected to the upper surface of the roof arch 41 extending inward in the vehicle width direction from the roof side rail contact surface 43a along the outer peripheral surface of the roof side rail 12 having a circular cross section. A roof arch contact surface 43b and a pair of front and rear roof arch side flanges 43c and 43c provided between the roof side rail contact surface 43a and the roof arch contact surface 43b are provided.

  The outer gusset 44 extends downward from the roof side rail contact surface 42a along the outer peripheral surface of the roof side rail 12 having a circular cross section, and is connected to the vehicle width direction outer surface of the B pillar 19. A B pillar contact surface 44b and a pair of front and rear B pillar side flanges 44c and 44c provided between the roof side rail contact surface 44a and the B pillar contact surface 44b are provided.

  The roof arch 41 is made of a pipe material having a rectangular cross section with a small vertical dimension and a large longitudinal dimension, and groove-shaped reinforcing beads 41a and 41a extending in the vehicle width direction are formed on the upper and lower surfaces. Further, the B pillar 19 is made of a pipe material having a rectangular cross section with a small size in the vehicle width direction and a large size in the front-rear direction, and groove-shaped reinforcing beads 19a extending in the vertical direction are formed on the inner and outer surfaces in the vehicle width direction.

  In the lower gusset 42, the roof side rail contact surface 42a is laser-welded W1 along the longitudinal direction (front-rear direction) of the roof side rail 12, and the roof arch contact surface 42b is formed on the lower surface of the roof arch 41 in the longitudinal direction ( MIG welding W2 is performed along the vehicle width direction) and MIG welding W3 is performed along the direction (front-rear direction) perpendicular to the longitudinal direction (see FIGS. 2, 3 and 5).

  In the upper gusset 43, the roof side rail contact surface 43a is laser-welded W4 along the longitudinal direction (front-rear direction) of the roof side rail 12, and the roof arch contact surface 43b is the longitudinal direction (vehicle width) of the roof arch 41. Laser welding W5 is performed along (direction) and laser welding W6 is performed along a direction (front-rear direction) orthogonal to the longitudinal direction (see FIGS. 2 and 5). Then, the roof arch side flanges 43c, 43c of the upper gusset 43 and the roof arch side flanges 42d, 42d of the lower gusset 42 are overlapped in the vertical direction and spot welding W7 is performed (see FIGS. 2 and 5).

  At this time, as shown in FIG. 6, a gap α is formed between the upper surfaces of the roof arch side flanges 42 d and 42 d of the lower gusset 42 and the lower surfaces of the roof arch side flanges 43 c and 43 c of the upper gusset 43. .

  In the lower gusset 42, the B pillar contact surface 42c is further laser welded W8 along the longitudinal direction (vertical direction) of the B pillar 19 (see FIGS. 2 and 3). In the outer gusset 44, the roof side rail contact surface 44a is laser-welded W9 along the longitudinal direction (front-rear direction) of the roof side rail 12, and the B pillar contact surface 44b is the longitudinal length of the outer surface in the vehicle width direction of the B pillar 19. Laser welding W10 is performed along the direction (vertical direction), and the B pillar side flanges 44c, 44c of the outer gusset 44 and the B pillar side flanges 42e, 42e of the lower gusset 42 are overlapped in the vehicle width direction to perform spot welding W11. (See FIGS. 3 and 4).

  At this time, the lower gusset 42, the upper gusset 43, and the outer gusset 44 are positioned with respect to the roof side rail 12 in the front-rear direction, the vertical direction, and the vehicle width direction. That is, the positions of the lower gusset 42, the upper gusset 43, and the outer gusset 44 with respect to the roof side rail 12 are uniquely determined. However, the relative position of the roof arch 41 with respect to the roof arch contact surface 42b of the lower gusset 42 and the roof arch contact surface 43b of the upper gusset 43 is adjustable in the vehicle width direction. That is, the roof arch 41 sandwiched in the vertical direction by the roof arch contact surfaces 42b and 43b is in the vehicle width direction with respect to the roof arch contact surfaces 42b and 43b as shown by arrows AA in FIGS. Relative movement is possible.

  As shown in FIG. 7, as in the case of the roof arch 41 described above, the B pillar 19 as an intermediate pillar with respect to the B pillar abutting surface 42c of the lower gusset 42 and the B pillar abutting surface 44b of the outer gusset 44 is provided. The relative position can be adjusted in the vertical direction. That is, the B pillar 19 sandwiched in the vehicle width direction by the B pillar abutting surfaces 42c and 44b is vertically moved with respect to the B pillar abutting surfaces 42c and 44b as shown by arrows BB in FIGS. Relative movement is possible.

  Further, a clearance α is formed between the outer surface in the vehicle width direction of the B pillar side flanges 42e and 42e of the lower gusset 42 and the inner surface in the vehicle width direction of the B pillar side flanges 44c and 44c of the outer gusset 44.

  Next, the operation of the embodiment of the present invention having the above configuration will be described.

  The upper frame 14 obtained by integrally three-dimensionally bending the roof side rail 12 and the A pillar upper rear portion 13 inevitably causes a slight dimensional error. Therefore, the connection portion with the front A pillar lower 17 and the rear end D are inevitable. When the connecting portion with the pillar 20 ′ is positioned, the front-rear direction intermediate portion to which the roof arch 41 and the B pillar 19 are connected is displaced in the vehicle width direction or the vertical direction. And the connection with the upper end of the B pillar 19 as an intermediate pillar may be hindered.

  However, according to the present embodiment, the lower gusset 42 and the upper gusset 43 that connect the roof arch 41 to the roof side rail 12 are in contact with the roof side rail 12 and positioned in the vertical direction and the vehicle width direction. Rail contact surfaces 42a and 43a, and roof arch contact surfaces 42b and 43b that contact the roof arch 41 to position in the vertical direction and allow movement in the vehicle width direction. 43a is continuously welded W1 and W4 along the longitudinal direction of the roof side rail 12, and the roof arch contact surfaces 42b and 43b are continuously welded W2 and W5 along the longitudinal direction of the roof arch 41. Even if the position is displaced in the vehicle width direction due to a dimensional error, the lower gusset 42 and the upper gusset 43 Then, the roof arch 41 is relatively moved in the vehicle width direction (see arrows AA in FIGS. 3 and 5), so that the roof arch 41 is aligned with the lower gusset 42 and the upper gusset 43 without any trouble, They can be welded firmly.

  Further, the lower gusset 42 and the upper gusset 43 and the roof arch 41 are not only continuously welded W2 and W5 along the vehicle width direction, but also continuously welded W3 and W6 in the front-rear direction perpendicular thereto. The welding strength against both the load in the direction and the load in the vehicle width direction can be further increased. Moreover, the roof arch 41 has a rectangular cross section that is long in the front-rear direction and short in the up-down direction, and is provided with reinforcing beads 41a, 41a along the longitudinal direction on the upper surface and the lower surface, so that the height in the vertical direction is ensured while ensuring the strength of the roof arch 41. The ceiling height of the passenger compartment can be secured by reducing the size of the vehicle.

  Further, a gap α is formed between the upper surfaces of the roof arch side flanges 42d and 42d of the lower gusset 42 and the lower surfaces of the roof arch side flanges 43c and 43c of the upper gusset 43. When positioning and joining, there is no interference with the lower gusset 42 due to dimensional variations, and the joint surface between the upper gusset 43 and the roof side rail 12 and the joint surface between the upper gusset 43 and the roof arch 41 are in close contact with each other. By becoming easy to do, the quality of laser welding W4, W5, W6 improves. Further, even if the gap α exists, the roof arch side flanges 42d, 42d, 43c, 43c can be reliably joined by spot welding W7 with spot welding guns and sandwiched, so that the lower gusset 42 and the upper gusset 42 The joint strength between the roof side rail 12 and the roof arch 41 via 43 can be increased.

  The lower gusset 42 and the outer gusset 44 that connect the B pillar 19 as an intermediate pillar to the roof side rail 12 are in contact with the roof side rail 12 and positioned in the vertical direction and the vehicle width direction. 42a and 44a, and B pillar contact surfaces 42c and 44b that contact the B pillar 19 to be positioned in the vehicle width direction and allow vertical movement, and the roof side rail contact surfaces 42a and 44a are arranged on the roof side. Since continuous welding W1 and W9 are performed along the longitudinal direction of the rail 12 and the B pillar contact surfaces 42c and 44b are continuously welded W8 and W10 along the longitudinal direction of the B pillar 19, the roof side rail 12 is moved up and down due to dimensional errors. Even if the position is displaced in the direction, the B pillar 19 is moved vertically with respect to the lower gusset 42 and the outer gusset 44 ( By 3 and be relatively moved in the arrow referenced B-B) of FIG. 5, can be a B-pillar 19 without trouble aligned to the lower gusset 42 and the outer gusset 44 is welded them firmly.

  Moreover, since the B pillar contact surface 42c of the lower gusset 42 is provided with the bulging portions 42f and 42f and the B pillar side flanges 42e and 42e between the roof side rail contact surface 42a, the lower gusset 42 is lowered by the bulging portions 42f and 42f. The rigidity of the side gusset 42 can be increased to increase the bonding strength with the B pillar 19, and the B pillar side flanges 42e and 42e can be used as the mounting flanges of the door trim.

  Further, when the outer gusset 44 is continuously welded W10 along the longitudinal direction of the B pillar 19, the outer surfaces of the B pillar side flanges 42e and 42e of the lower gusset 42 and the inner surfaces of the B pillar side flanges 44c and 44c of the outer gusset 44. A gap α is formed between the outer gusset 44 and the roof side rail so that when the outer gusset 44 is positioned and joined, it does not interfere with the lower gusset 42 due to dimensional variations. 12 and the joint surface between the outer gusset 44 and the B pillar 19 are easily brought into close contact with each other, thereby improving the quality of the laser welding W10. Even if the clearance α exists, the B-pillar side flanges 42e, 42e, 44c, and 44c can be reliably joined by spot welding W11 with a spot welding gun and clamped and joined, so the lower gusset 42 and the outer gusset 42 The joint strength between the roof side rail 12 and the B pillar 19 via 44 can be increased, and the support rigidity of the door trim is also improved.

  Furthermore, the number of parts can be reduced by sharing the lower gusset 42 for welding the B pillar 19 and the roof arch 49 to the roof side rail 12.

  In the present embodiment, the gusset 25 that connects the upper end of the C pillar 20 as an intermediate pillar to the roof side rail 12 can also be adjusted in the vertical direction with respect to the upper end of the C pillar 20. 25, the C pillar 20 can be aligned in the vertical direction, and they can be firmly welded.

  Next, the manufacturing process of the vehicle body side frame 11 will be described with reference to FIGS.

  First, in the first step, as shown in FIG. 8A, a steel pipe is bent and formed by three-dimensional bending to produce an upper frame 14 in which the A pillar upper rear portion 13 and the roof side rail 12 are continuously integrated. A member in which the roof side rail 12 and the A pillar upper 16 are integrated is manufactured by connecting the A pillar upper front portion 15 to the upper frame 14. In the first step, the lower frame 30, the A pillar lower 17, the B pillar 19, the C pillar 20, and the D pillar 20 'are manufactured.

  In the subsequent second step, as shown in FIG. 8B, the roof side rail 12 and the A pillar upper 16, the A pillar lower 17 and the B pillar which are integrated at predetermined positions on the first welding jig 45 are provided. 19, C pillar 20, D pillar 20 'and lower frame 30 are placed and positioned.

  The gussets 21 to 28 for connecting these members include a first gusset located on the inner side in the vehicle width direction and a second gusset located on the outer side in the vehicle width direction. Connect by welding. In the present embodiment, the first gusset of the gusset 23 that connects the roof side rail 12 and the B pillar 19 is the lower gusset 42 described above, and the second gusset is the outer gusset 44 described above.

  In the subsequent third step, as shown in FIG. 9C, the integrated roof side rail 12 and A pillar upper 16 positioned on the first welding jig 45, the A pillar lower 17, and the B pillar 19, The first gussets 21i, 22i, 23i (lower gussets 42), 24i, 25i, 26i, 27i, 28i on the inner side in the vehicle width direction on the intersections of the C pillar 20, the D pillar 20 'and the lower frame 30 Is placed. At this time, in the first welding jig 45, the roof side rail 12 is positioned vertically with respect to the upper end of the A pillar lower 17 and the upper end of the D pillar 20 ′, but the upper end of the B pillar 19 and the C pillar 20. It is possible to move in the vertical direction with respect to the upper end.

  Subsequently, as shown in FIG. 9D, the eight first gussets 21i, 22i, 23i (lower gusset 42), 24i, 25i, 26i, 27i, 28i are integrated by a welding robot (not shown). The roof side rail 12 and the A pillar upper 16, the A pillar lower 17, the B pillar 19, the C pillar 20, the D pillar 20 ′, and the lower frame 30 are welded to each other.

  Subsequently, as shown in FIG. 10 (E), the unfinished vehicle body side frame 11 on the first welding jig 45 is reversed and transferred onto the second welding jig 46 for positioning. Eight first gussets 21i, 22i, 23i (lower gusset 42), 24i, 25i, 26i, 27i, 28i and eight second gussets 21o, 22o, 23o (outer gusset 44), 24o, 25o, 26o, 27o and 28o are superimposed.

  Subsequently, as shown in FIG. 10 (F), eight second gussets 21o, 22o, 23o (outer gussets 44), 24o, 25o, 26o, 27o, 28o are used by a welding robot (not shown). Between the first gusset 21i, 22i, 23i (lower gusset 42), 24i, 25i, 26i, 27i, 28i, the roof side rail 12 and the A pillar upper 16 integrated with each other, and the A pillar lower 17; The B pillar 19, the C pillar 20, the D pillar 20 ′, and the lower frame 30 are welded so as to be sandwiched therebetween. At this time, the first welding jig 45 and the second welding jig 46 are arranged adjacent to each other, and the welding robot performs the welding operation on the first welding jig 45 and the welding on the second welding jig 46. Shared for work.

  In the fourth step, the upper ends of the B pillars 19, 19 of the pair of left and right vehicle body side frames 11, 11 are welded to both ends of the roof arch 41 in the vehicle width direction via the pair of upper gussets 43, 43.

  As described above, in the third step, the gussets 23 and 25 that connect the upper end of the B pillar 19 as the intermediate pillar and the upper end of the C pillar 20 as the intermediate pillar to the roof side rail 12 are Since the position can be adjusted in the vertical direction with respect to the upper end and the upper end of the C pillar 20, the B side pillar 19 and the C pillar 20 may interfere with the roof side rail 12 even if there is a vertical dimension error in the roof side rail 12. It can be welded without.

  In the third step, the first gussets 21i to 28i are welded to the inner surface in the vehicle width direction of the vehicle body side frame 11 supported by the first welding jig 45, and then the vehicle body side frame 11 is turned upside down to perform the first welding. Since it supports on the 2nd welding jig 46 adjacent to the jig | tool 45 and welds the 2nd gussets 21o-28o to the vehicle width direction outer surface of the vehicle body side part frame 11, it uses the same welding robot and uses the same welding robot. Thus, it is possible to weld both side surfaces in the vehicle width direction of 11 and the equipment cost is reduced.

  In the third step, since the first gussets 21i to 28i and the second gussets 21o to 28o are spot-welded, the strength of the vehicle body side frame 11 is integrated by integrating the first gussets 21i to 28i and the second gussets 21o to 28o. Can be increased.

  Further, the gusset 25 that connects the upper end of the C pillar 20 to the roof side rail 12 is continuously welded in the longitudinal direction of the roof side rail 12 and the longitudinal direction of the C pillar 20, so that the roof side rail 12 and the C pillar 20 are strengthened. The strength of the vehicle body side frame 11 can be further increased by welding.

Second embodiment

  Next, a second embodiment of the present invention will be described with reference to FIG.

  The vehicle body side frame 11 of the first embodiment includes the D pillar 20 'as the last pillar, but the vehicle body side frame 11 of the second embodiment does not include the D pillar 20'. , C pillar 20 is the last pillar. Therefore, the C pillar 20 is not adjusted in the vertical direction with respect to the roof side rail 12, and the B pillar 19 is the only intermediate pillar that is adjusted in the vertical direction with respect to the roof side rail 12.

Third embodiment

  Next, a third embodiment of the present invention will be described with reference to FIG.

  The roof arch 41 of the first embodiment is made of a pipe material having a rectangular closed cross section, whereas the roof arch 41 of the third embodiment is made of a plate material having an open cross section. The roof arch 41 is reinforced by two groove-shaped reinforcing beads 41b and 41b that extend in the vehicle width direction and open upward. At the outer end of the roof arch 41 in the vehicle width direction, Strength is ensured by forming a closed cross-section by cooperating with two groove-shaped reinforcing beads 43d and 43d that extend in the vehicle width direction and open downward.

  Moreover, since the roof arch 41 is made of a plate material having an open cross section, the height of the roof arch 41 can be lowered to ensure the ceiling height of the passenger compartment, and the design flexibility of the shape of the roof arch 41 can be increased.

  The embodiments of the present invention have been described above, but various design changes can be made without departing from the scope of the present invention.

  For example, in the embodiment, the upper frame 14 is bent by three-dimensional bending, but it may be bent by three-dimensional hot bending or hydroforming.

  The steel pipe of the embodiment can be replaced with a metal pipe such as an aluminum pipe.

  The cross-sectional shape of the frame such as the B pillar 19 may be any cross-sectional shape such as a circular cross-section, a rectangular cross-section, or a polygonal cross-section.

  Further, even if friction stir welding (FSW) or self-piercing rivet coupling (SPR) is used instead of spot welding in the embodiment, the overlapping joining flanges can be joined without gaps.

  Further, the roof side rail 12 does not necessarily have a circular cross section, and may be a rectangular cross section or other irregular cross section.

  Further, in the embodiment, the indoor gusset 42 is L-shaped, but it may be divided into two gussets on the roof arch 41 side and gussets on the B pillar 19 side.

  Further, the upper outdoor gusset 43 and the side outdoor gusset 44 are not limited to two-dimensional positioning in the vertical direction and the vehicle width direction, and may be one-dimensional positioning. For example, the upper outdoor side gusset 43 may be positioned at least in the vertical direction with respect to the roof side rail 12, and positioning in the vehicle width direction is performed by the indoor side gusset 42, so there is no problem. Similarly, the side outdoor side gusset 44 may be positioned at least in the vehicle width direction with respect to the roof side rail 12, and the vertical positioning is performed by the indoor side gusset 42, so there is no problem.

In the embodiment, the B-pillar contact surface 42c of the indoor gusset 42 is welded W8 only in the longitudinal direction of the B-pillar 19, but it is further welded in a direction orthogonal to the longitudinal direction of the B-pillar 19. Is desirable.

Claims (9)

A first step of bending the metal tube by three-dimensional bending to produce an upper frame (14) in which the A-pillar upper (16) and the roof side rail (12) are integrally continuous;
On the welding jig (45, 46), the upper end of the A pillar lower (17) and the upper end of the rearmost pillar (20, 20 ') are positioned in the vertical direction and the vehicle width direction with respect to the upper frame (14). And a second step of positioning the upper end of the B pillar (19) as an intermediate pillar in the vehicle width direction;
The upper end of the A pillar lower (17), the upper end of the B pillar (19), and the upper end of the rearmost pillar (20, 20 ') are connected to the upper frame (14) with gussets (21, 23, 25, 27) and assembling the vehicle body side frame (11) by welding via
In the third step, the gusset (23) for connecting the upper end of the B pillar (19) to the upper frame (14) can be vertically adjusted with respect to the upper end of the B pillar (19). An automobile body manufacturing method characterized by the above.   In the third step, the gusset (23) for connecting the upper end of the B pillar (19) to the upper frame (14) includes the longitudinal direction of the upper frame (14) and the longitudinal direction of the B pillar (19). The method for manufacturing an automobile body according to claim 1, wherein the vehicle body is continuously welded.   The gusset (23) includes a first gusset (42) located on one side in the vehicle width direction and a second gusset (44) located on the other side in the vehicle width direction. In the third step, the first welding treatment is performed. After welding the first gusset (42) to one side surface in the vehicle width direction of the vehicle body side frame (11) supported by the tool (45), the vehicle body side frame (11) is turned upside down and the first gusset (42) is turned over. It is supported on a second welding jig (46) adjacent to the welding jig (45), and the second gusset (44) is welded to the other side surface in the vehicle width direction of the vehicle body side frame (11). An automobile body manufacturing method according to claim 1 or 2.   The automobile according to claim 3, wherein, in the third step, the first gusset (42) and the second gusset (44) are joined together by spot welding, friction stir welding, or self-piercing rivet joining. Car body manufacturing method.   The A pillar lower (17) and the rearmost pillar (20, 20 ') are made of metal, and the B pillar (19) is made of three-dimensionally bent metal, and the lower end of the A pillar lower (17) The lower frame (30) to which the lower end of the B pillar (19) and the lower end of the rearmost pillar (20, 20 ') are connected includes an inner member (47) and an outer member (48) formed by roll foam. The vehicle body manufacturing method for an automobile according to any one of claims 1 to 4, wherein the member is a hollow closed section member joined by joining flanges (47a, 48a).   Including a fourth step of connecting the upper ends of the B pillars (19) of the pair of vehicle body side frames (11) to both ends of the roof arch (41) in the vehicle width direction. In the fourth step, the B pillars (19 The gusset (23) connecting the upper end of the upper arch (14) to the upper frame (14) can be adjusted in the vehicle width direction with respect to both ends of the roof arch (41) in the vehicle width direction. The automobile body manufacturing method according to any one of claims 1 to 5. In the second step, the upper end of the D pillar (20 ') is positioned in the vertical direction and the vehicle width direction, and the upper end of the C pillar (20) as an intermediate pillar is positioned in the vehicle width direction,
In the third step, the upper end of the A pillar lower (17), the upper end of the B pillar (19), the upper end of the C pillar (20), and the upper end of the D pillar (20 ') are connected to the upper frame. The vehicle body side frame (11) is assembled by welding to (14) via the gussets (21, 23, 25, 27), and the upper end of the C pillar (20) is connected to the upper frame (14). The vehicle gusset (25) according to claim 1, wherein the gusset (25) is vertically adjustable with respect to an upper end of the C pillar (20). Body manufacturing method.   In the third step, the gusset (25) for connecting the upper end of the C pillar (20) to the upper frame (14) includes a longitudinal direction of the upper frame (14) and a longitudinal direction of the C pillar (20). The automobile body manufacturing method according to claim 7, wherein the vehicle body is continuously welded.   In the third step, the gusset (23) includes a first gusset (25i) positioned on one side surface in the vehicle width direction and a second gusset (25o) positioned on the other side surface in the vehicle width direction. The method of manufacturing a vehicle body for an automobile according to claim 7 or 8, wherein the two gussets (25i) and the second gusset (25o) are joined by spot welding, friction stir welding, or self-piercing rivet joining.

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