Systems and methods for assembling a front end module to a vehicle

The present disclosure provides a Front End Module (FEM) assembly and associated assembly method with a rail system to enable efficient assembly, tighter clearances between the front end module assembly and the vehicle, and time and cost savings. The present disclosure provides a FEM assembly including grilles and headlamps and a rail system enabling the FEM to be assembled on a vehicle. Advantageously, the present disclosure allows the FEM to pass between fenders on the vehicle with a very tight clearance condition. The rail system included in the present disclosure allows the FEM to be assembled efficiently while protecting grilles and headlamps from being damaged by fenders and protecting the fenders from damage from the FEM.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to vehicle assembly. More specifically, the present disclosure relates to a front end module assembly and an associated assembly method which includes a rail system to guide the front end module assembly onto a frame of the vehicle enabling efficient assembly, tighter clearances between the front end module assembly and the vehicle, and protection of the front end module assembly and the vehicle front damage during assembly.

BACKGROUND OF THE DISCLOSURE

Vehicles include a front end module (FEM) assembly with a front fascia to provide openings for cooling air. Additionally, the FEM can include a vehicle-specific grille texture, headlamp housing, means to connect to the vehicle frame and bumper, and the like. Advantageously, FEM assemblies benefit vehicle assemblers through a modular assembly approach allowing component integration, time and cost savings, and the like. Despite the advantages of the modular FEM assembly, assembling existing FEM assemblies is time-consuming and complex. Existing FEM assemblies and assembly methods include complicated lift and positioning plant assist devices. Further, plant operators require specific skill and care to assemble such existing FEM assemblies. Finally, existing FEM assemblies are prone to damaging vehicle fenders and FEM grilles costing considerable repair time and cost during assembly followed by increased warranty costs on possible corrosion in the fenders due to damage from assembly. Accordingly, current FEM assemblies do not allow tight gaps to exist between the FEM and fenders with frontal projections without damaging both parts during regular production processes.

BRIEF SUMMARY OF THE DISCLOSURE

In various exemplary embodiments, the present disclosure provides a FEM assembly and associated assembly method with a rail system to guide the front end module assembly onto a frame of the vehicle enabling efficient assembly, tighter clearances between the FEM assembly and the vehicle, and protection of the FEM assembly and the vehicle from damage during assembly. The present disclosure provides a FEM assembly including grilles and headlamps and a rail system enabling the FEM assembly to be assembled on a vehicle. Advantageously, the present disclosure allows the FEM assembly to pass between fenders on the vehicle with a very tight clearance condition. The rail system included in the present disclosure allows the FEM assembly to be assembled efficiently while protecting grilles and headlamps from being damaged by fenders and protecting the fenders from damage from the FEM assembly. The rail system substantially constrains movement of the FEM assembly when being placed onto the vehicle during assembly avoiding contact with any portion of the fenders in a dynamic condition. The rail system includes a guide on the fenders, such as a fender reinforcement bracket tab, and a rail connected to the FEM assembly. Once the FEM is in the final installation position, the rail can be disengaged from the fender, allowing final assembly by rotating the FEM rearward.

In an exemplary embodiment of the present disclosure, a front end module assembly for a vehicle includes a front end module carrier and a rail disposed on the front end module carrier, wherein the rail is configured to engage a tab disposed on a fender of the vehicle, and the rail is configured to substantially constrain movement of the front end module assembly while the front end module assembly is positioned on a frame on the vehicle. The front end module assembly further includes any of a grille, a headlamp housing, a coolant module, and combinations thereof. The fender includes a fender reinforcement bracket, and the tab is disposed on the fender reinforcement bracket. The substantially constrained movement of the front end assembly while the front end module assembly is positioned allows the front end module assembly to pass between fenders on the vehicle with a tight clearance condition. The carrier rail and the tab are configured to guide the front end module assembly onto the vehicle for assembly avoiding front end module assembly contact with any portion of the fender. The substantially constrained movement of the front end assembly while the front end module assembly is positioned protects the grille and headlamp housing from being damaged by the fender, and protects the fender from being damaged by the front end module assembly. The carrier rail is one of integrally formed with the front end module carrier and mountably attached to the front end module carrier.

In another exemplary embodiment of the present invention, a method of assembling a front end module assembly onto a vehicle frame includes providing a front end module assembly, wherein the front end module assembly includes a rail disposed on a front end module carrier; positioning the front end module assembly substantially over a vehicle frame; engaging the rail with a tab disposed on the vehicle frame; and guiding the front end module assembly into a final assembly position on the vehicle frame, wherein the rail and the tab are configured to substantially constrain movement of the front end module assembly during the guiding step. The method of assembling a front end module assembly of further includes disengaging the rail from the tab and attaching the front end module assembly to the vehicle frame. The front end module assembly further includes any of a grille, a headlamp housing, a coolant module, and combinations thereof. The vehicle frame includes a fender, and the fender includes a fender reinforcement bracket, and wherein the tab is disposed on the fender reinforcement bracket. The substantially constrained movement of the front end assembly of the guiding step allows the front end module assembly to pass between fenders on the vehicle with a tight clearance condition. The rail and the tab are configured to guide the front end module assembly onto the vehicle frame avoiding front end module assembly contact with any portion of a fender attached to the vehicle frame. The substantially constrained movement of the front end assembly of the guiding step protects the grille and headlamp housing from being damaged by a fender attached to the vehicle frame and protects the fender from being damaged by the front end module assembly. The rail is integrally formed with the front end module carrier and mountably attached to the front end module carrier.

DETAILED DESCRIPTION OF THE DISCLOSURE

In various exemplary embodiments, the present disclosure provides a FEM assembly and associated assembly method with a rail system to guide the front end module assembly onto a frame of a vehicle enabling efficient assembly, tighter clearances between the FEM assembly and the vehicle, and protection of the FEM assembly and the vehicle from damage during assembly. The present disclosure provides a FEM assembly including grilles and headlamps and a rail system enabling the FEM assembly to be assembled on a vehicle. Advantageously, the present disclosure allows the FEM assembly to pass between fenders on the vehicle with a very tight clearance condition. The rail system including in the present disclosure allows the FEM assembly to be assembled efficiently while protecting grilles and headlamps from being damaged by fenders, and protecting the fenders from damage from the FEM assembly. The rail system substantially constrains movement of the FEM assembly when being placed onto the vehicle during assembly avoiding contact with any portion of the fenders in a dynamic condition. The rail system includes a guide on the fenders, such as a fender reinforcement bracket tab, and a rail connected to the FEM assembly. Once the FEM is in the final installation position, the rail can be disengaged from the fender, allowing final assembly by rotating the FEM rearward.

Referring toFIG. 1, a side perspective view illustrates a FEM assembly10for a vehicle including a headlamp housing12, a grille14, a FEM carrier16, and a FEM upper cross member18according to an exemplary embodiment of the present disclosure. The headlamp housing12contains headlamps for the vehicle. The grille14is an opening located on the front of the FEM assembly10of the vehicle. The grille14allows air to flow over the radiator and cool the engine compartment of the vehicle. Additionally, the grille14provides a distinctive styling element typically used for vehicle brand identification. The headlamp housing12and grille14attach to the FEM carrier16which provides the support for the various components integrated within the FEM assembly10. The FEM upper cross member18attaches to the FEM carrier16. Optionally, a coolant module attaches to the FEM cross member18. Advantageously, the FEM assembly10provides a modular assembly approach allowing component integration, cost savings, and the like. This modular assembly approach streamlines the vehicle assembly process.

In an exemplary embodiment, the FEM carrier16is a frame including attachment means to support the headlamp housing12, the grille14, and the FEM upper cross member18. The FEM carrier16also includes attachment means to connect to a vehicle frame once the FEM assembly10is positioned in an engaged position. The headlamp housing12is attached to the FEM carrier16, and includes electrical connections for a headlamp. The grille14attaches to the FEM carrier16covering the headlamp housing12. The grille14includes an opening for the headlamp and openings to allow air to flow through the FEM assembly10. The FEM upper cross member18is attached to an upper portion of the FEM carrier16, and is a bar extending substantially across the FEM assembly10. Optionally, the FEM upper cross member18can support a coolant module.

The vehicle includes a fender30and a fender reinforcement bracket32. The fender30is the part of the vehicle that frames a wheel well. The fender reinforcement bracket32is attached to the fender30. The FEM assembly10is configured to attach to the vehicle, such as at the fender reinforcement bracket32. In an exemplary embodiment of the present disclosure, the FEM assembly10includes a carrier rail20on the FEM carrier16. The carrier rail20enables the FEM assembly10to be assembled on the vehicle efficiently and farther protects both the FEM assembly10and the fender30on the vehicle from damage during the assembly process.

The carrier rail20slides into the reinforcement bracket32located on the fender30, such as through a tab or groove included on the reinforcement bracket32or the like. Once the carrier rail20is engaged in the reinforcement bracket32, the carrier rail20guides the FEM assembly10into position allowing the FEM assembly10to pass between the fender30on the vehicle with a very tight clearance condition. The carrier rail20guides the FEM assembly10onto the vehicle for assembly avoiding contact with any portion of the fenders30. Effectively, the carrier rail20and the fender reinforcement bracket are configured to substantially constrain the movement of the FEM assembly10along a vertical axis with respect to the vehicle frame. In one embodiment, the carrier rail20is attached to a tab in the fender reinforcement bracket32, and once the FEM assembly10is in the final installation position, the carrier rail20can be disengaged from the tab, allowing final assembly by rotating the FEM assembly10rearward.

Referring toFIG. 2, a top perspective view illustrates the FEM assembly10for the vehicle in an engaged position according to an exemplary embodiment of the present disclosure. The FEM assembly10includes the carrier rail20on both sides of the FEM carrier16. Additionally, the vehicle includes the fender30on both sides with the fender reinforcement bracket32. The fender reinforcement bracket32includes a tab34configured to receive the carrier rail20. The tab34is sized according to the carrier rail20and is operable to constrain the movement of the FEM assembly10when it is placed onto the vehicle. In an exemplary embodiment, the tab34includes a groove adapted to receive the carrier rail20, and to allow the carrier rail20to slide vertically. As described herein, the carrier rail20disengages from the tab34on the fender reinforcement bracket32, and the FEM assembly10is placed into the final, assembly position. The carrier rail20remains attached to the FEM assembly10, but is not engaged with the tab34or the fender reinforcement bracket32once in the final assembly position. Additionally, the FEM upper cross member18can attach to a frame on the vehicle.

Referring toFIG. 3, a side perspective view illustrates an exemplary embodiment of the FEM assembly10. As described herein, the FEM assembly10includes the headlamp housing12which includes a headlamp50. A coolant module40can be attached to the FEM carrier18. The coolant module40can be a cooling system for the engine, transmission, power steering, and the like. In this exemplary embodiment, the FEM assembly10includes the grille14of a Jeep® (available from Daimler Chrysler of Auburn Hills, Mich.). As described herein, the exemplary embodiment of the FEM assembly10inFIG. 3includes the carrier rail20on both sides of the FEM assembly10. Also, the carrier rail20is attached to the FEM carrier16. The present disclosure allows vehicle assemblers to streamline assembly through module integration. For example, a FEM carrier16with the carrier rail20can be utilized in multiple different vehicles. Advantageously, the FEM assembly10allows a single FEM to be used across different vehicles. For example, the grille14can be changed for each different vehicle; different coolants40can be added depending on the vehicle, different headlamp housings12can be utilized, and the like.

Referring toFIGS. 4 and 5, front and rear perspective views illustrate an exemplary embodiment of the FEM assembly10.FIG. 4illustrates a front view of the FEM assembly10showing the headlamp housing12with the headlamp50and the grille14.FIG. 5illustrates a rear view of the FEM assembly10showing the rear housing of the headlamp housing12. BothFIGS. 4 and 5illustrate the carrier rail20located on the side of the FEM assembly10. Additionally, the vehicle includes the fender reinforcement bracket32with the tab34on both sides to engage the FEM assembly10with the carrier rail20on both sides.

Referring toFIGS. 6 and 7, side and top perspective views illustrate an exemplary embodiment of the FEM assembly10.FIG. 6illustrates a side view of the FEM assembly10showing the carrier rail20attached to the FEM carrier16, the headlamp housing12with the headlamp50attached to the FEM carrier16, and the grille14over the headlamp housing12attached to the FEM earner16.FIG. 7illustrates a top view of the FEM assembly10showing the headlamp housing12attached to the FEM carrier16, the FEM upper cross member18attached to the FEM carrier16, and the headlamp50in the headlamp housing12. BothFIGS. 6 and 7illustrate the carrier rail20located on the side of the FEM assembly10.

Referring toFIG. 8, a side perspective view illustrates an exemplary embodiment of the FEM assembly10. As described herein, the headlamp housing12includes the headlamp50. The headlamp housing12is mountably attached to the FEM carrier16. Advantageously, this allows different headlamp housings12to be utilized on the same FEM carrier16for different vehicle types. The FEM carrier16includes the carrier rail20on the side and the FEM upper cross member18on the top. The carrier rail20can be integrally formed, within the FEM carrier16, such as during a casting process. Additionally, the carrier rail20can be mountably attached to the FEM carrier16. The FEM upper cross member18is attached to the FEM carrier16.

Referring toFIGS. 9 and 10, side perspective views illustrate an exemplary embodiment of the FEM assembly10in an installed position and in process of sliding into the installed position.FIG. 9illustrates the FEM assembly10with the headlamp housing12and the FEM upper cross member18attached to the FEM carrier16in the final installed position. Here, the carrier rail20attached to the FEM carrier16is disengaged from the tab34in the fender reinforcement bracket32on the fender30.FIG. 10illustrates the FEM assembly10with the carrier rail20sliding into the tab34located on the fender reinforcement bracket32. As described herein, the carrier rail20guides the FEM assembly onto the vehicle for assembly through the tab34avoiding contact with any portion of the fenders in a dynamic condition.

Referring toFIG. 11, a side perspective view illustrates an exemplary embodiment of the FEM assembly10in a final assembly position with the fender30. Advantageously, the FEM assembly10is configured to pass between fenders30on the vehicle with a very tight clearance condition. The carrier rail20allows the FEM assembly10to be assembled efficiently while protecting grilles14and headlamps50from being damaged by fenders30and protecting the fenders30from damage from the FEM assembly10. InFIG. 11, the FEM assembly10includes the FEM carrier16with the headlamp housing12with the headlamp50, the grille14, and the FEM upper cross member18each attached to the FEM carrier16. In this embodiment, the FEM upper cross member18attaches to the fender reinforcement bracket32, such as with a bolt or the like. The carrier rail20is mountably attached or integrally formed in the FEM carrier16.FIG. 9illustrates the final assembly position with the carrier rail20disengaged from the fender reinforcement bracket32.

Referring toFIGS. 12,13, and14, perspective views illustrate an exemplary embodiment of the FEM assembly10sliding into the lab34in the fender reinforcement bracket32.FIG. 12illustrates the FEM assembly10with the carrier rail20on the FEM carrier16sliding onto the tab34located on the fender reinforcement bracket32on the fender30.FIG. 13illustrates a top view of the FEM assembly10sliding in position.FIG. 14illustrates a side view of the FEM assembly10with the carrier rail20engaged with the fender30while sliding in position. As shown inFIGS. 13 and 14, neither the fender30nor the grille14on the FEM assembly10touch during assembly. This allows the FEM assembly10to be assembled on a vehicle without complicated lift and positioning equipment which is used to carefully guide the FEM assembly10to avoid contact. The FEM assembly10provides reduced cost through preventing damage to tenders30, grilles14, and the like by reducing repair time due to assembly accidents and future warranty costs on possible corrosion in the fenders due to damage from assembly.

Referring toFIGS. 15 through 18, the FEM assembly10is illustrated during various stages of assembly onto a vehicle frame60according to an exemplary embodiment of the present disclosure.FIG. 15illustrates the FEM assembly10with the carrier rail20in a first position during the assembly process. The vehicle frame60includes the fender reinforcement bracket32with a tab configured to engage the carrier rail20. In this first position, the FEM assembly10is positioned upright and moved towards the vehicle frame60.

FIG. 16illustrates the FEM assembly10with the carrier rail20in a second position during the assembly process. The FEM assembly10is positioned adjacent to the vehicle frame60with the carrier rail20positioned substantially vertical to the tab in the fender reinforcement bracket32.FIG. 17illustrates the FEM assembly10with the earner rail20in a third position during the assembly process. Here, the FEM assembly is positioned similarly as inFIG. 16, i.e., with the carrier rail20positioned substantially vertical to the tab34in the fender reinforcement bracket32, and the carrier rail20is engaged with the tab located in on the fender reinforcement bracket32. The tab34is configured to engage the carrier rail20so that the FEM assembly10can be lowered onto the vehicle frame60. For example, the tab34and carrier rail20are configured to substantially constrain movement of the FEM assembly10, such as along a vertical axis with respect to the vehicle frame60. This allows the FEM assembly10to be placed onto the frame60with a tight clearance condition between components on the FEM assembly10and the fender30, i.e., the tab34and carrier rail20prevent contact between the FEM assembly10and the fender30.

FIG. 18illustrates the FEM assembly10with the carrier rail20in a fourth position during the assembly process. Here, the carrier rail20is engaged to the tab on the fender reinforcement bracket32, and the FEM assembly10is sliding into position on the vehicle frame60. Once the FEM assembly10is lowered to an installation level along the vertical axis, the carrier rail20is disengaged from the tab34on the fender reinforcement bracket32. For example, the FEM assembly10can be rotated rearward once lowered to the installation level with the rotation disengaging the carrier rail20from the tab34on the fender reinforcement bracket32. Once in this final assembly position, the FEM assembly10is attached to the vehicle frame60, such as through bolts or the like.

As described herein, the present disclosure provides a FEM assembly and associated assembly method with a rail system to enable efficient assembly, tighter clearances between the front end module assembly and the vehicle, and time and cost savings. The FEM assembly includes grilles, headlamps, a coolant module, and the like along with a rail system to enable the FEM assembly to be assembled on a vehicle. Advantageously, the FEM assembly can pass between fenders on the vehicle with a very tight clearance condition. The rail system allows the FEM to be assembled efficiently while protecting grilles and headlamps from being damaged by fenders and protecting the fenders from damage from the FEM. The rail system guides the FEM onto the vehicle for assembly avoiding contact with any portion of the fenders in a dynamic condition. The rail system is attached to a fender reinforcement bracket tab, and once the FEM is in the final installation position, the rail can be disengaged from the fender tab, allowing final assembly by rotating the FEM rearward.