METHOD OF MANUFACTURING VEHICLES

Abstract: Independent front suspension (IFS) and front beam axle vehicle derivatives are built using shared facilities. Assembly of the beam axle derivative includes bolting leaf spring front bushes (18, 20) of a beam axle suspension to for­ ward location points (14, 16) on a body structure; and assem­ bly of the IFS derivative includes bolting a subframe (62) hav­ ing mounting points (76) for longitudinal and transverse front wheel locating means (74) of a Macpherson strut type front suspension to common forward location points (14, 16) on a similar body structure to the beam axle body structure.

Description: METhOD OF MANUFACTURING VESICLES The present invention relates to a method of manufacturing two vehicle derivatives with different front suspension using shared manufacturing facilities. Because of the high level of investment required to establish the tooling and other facilities needed to manufacture a vehicle, it is highly desirable to be able to utilize the same facilities for the manufacture of as wide a range of different vehicle derivatives as possible. A light van of about one tonne load carrying capacity ideally requires an independent front suspension for carlike ride and handling whereas a heavier van requires a heavy duty beam axle front suspension. These conflicting requirements have hitherto inhibited the use of a common body structure assembled on common facilities for heavy and light duty van derivatives. According to the present invention, there is provided a method of manufacturing independent front suspension (IFS) and front beam axle vehicle derivatives using shared facilities, characterised in that: a) assembly of the beam axle derivative includes connecting leaf spring front bushes of a beam axle suspension to forward location points on a body structure; and b) assembly of the IFS derivative includes connecting a subframe having mounting points for front wheel locating means of a Macpherson strut type front suspension to common forward location points on a similar body structure to the beam axle derivative body structure. The Macpherson strut type suspension may be a conventional Macpherson strut, with the shock absorber and the spring concentric, but it is preferred to use a hybrid Macpherson strut where the spring is mounted in board of the shock absorber and supported by the track control arm. The invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a perspective cutaway drawing of the forward structure of an IFS vehicle made by the method of the invention; Figure 2 is similar cutaway perspective view of the forward structure of a beam axle front suspension derivative of the vehicle shown in Figure 1; Figure 3 is a side view of the front suspension of the IFS vehicle shown in Figure 1. Figure 4 is a side view of the front suspension of the beam axle vehicle shown in figure 2; and Figure 5 is a composite front view showing, to the left of the centre line, a section of the beam axle suspension along the line Vb-Vb of Figure 4, and to the right of the centre line, a section of the IFS derivative along the line Va-Va of Figure 3. The method of manufacturing a vehicle in accordance with the invention involves the assembly of different derivatives of the same basic vehicle using a substantial number of common parts and common dimensions to enable use of common manufacturing facilities. Figures 2, 4 and the left hand side of Figure 5 show the front body structure, front suspension and steering of a two tonne payload van. The body structure includes parallel longitudinal frame members 10 and 12, of channel section Each frame member 10 has downwardly extending plates 13 welded to either side of its forward end to form mounting points 14 and 16. The downwardly extending plates 13 are reinforced by flanges 15. Transversely extending bolts 26 connect forward mounting bushes 18, 20 of front leaf springs 22, 24 to the forward mounting points 14, 16. The ends of the leaf springs 22, 24 are connected by shackles 28, 30 to mounting points 32, 34 on frame members 10 and 12. A beam axle 36 is mounted on the leaf springs 22, 24. Hubs 38 carrying road wheels 40 are pivotally connected to either end of the beam axle. A steering wheel 42 is mounted on an upper steering shaft 44 supported on the vehicle body structure by a bracket 46. A universal joint 48 and lower steering shaft 50 connect the upper steering shaft to a recirculating ball steering gear 52. The left hand hub 38 is connected to the steering gear 52 by a steering rod 54 and to the other hub by a track rod 56. Shock absorbers 58 have their lower ends mounted on the beam axle 36 and connect the axle to the vehicle body structure through upper shock absorber mounting points 60. Figures 1, 3 and the right hand side of Figure 5 shown the front structure, front suspension and steering of a one tonne payload van having a number of parts and hardpoints in common with the two tonne derivative shown in the other figures. The common parts and hardpoints are given the same reference numerals. The body structure includes parallel longitudinally extending frame members 10 and 12 which are substantially the same as those used for the beam axle derivative. A subframe 62 has forward extending arms 64 of inverted channel section received within the frame members 10, 12 and connected to the forward mounting points 14, 16 by transversely extending bolts 26. The rear part of the subframe 62 is formed with upper spring seat portions 66 connected by reinforcing brackets 68 to frame members 10 and 12. The one tonne payload derivative is fitted with a hybrid Macpherson strut independent front suspension comprising shock absorber struts 70 each having a hub 72 fixed to its lower end, and having its upper end connected to the same shock absorber mounting point 60 as is used for the beam axle derivative. Each front road wheel 40 is located laterally by a track control arm 74 connected to the subframe 62 by two pivot bushes 76 and to the corresponding hub 72 by a ball joint 75. One of the pivot bushes is connected substantially in line with the road wheel and one at the front end of the subframe forward arm. A torsion bar 78 (not shown in Figure 1) extends through bushes 80 fixed to the forward arms 64 of the subframe 62 and#has rearwardly extending end portions 82 connected to the track control arm 74 by vertical links 89. Suspension springs 86 each act between a lower spring seat 88 on the track control arm 74 and an upper spring seat portion 66 of the subframe 62, so that the spring loads are transmitted to the subframe and through the subframe mounting points to the frame members 10 and 12. The steering system of the one tonne payload derivative includes a rack and pinion steering gear 90 mounted on the subframe 62 and connected by steering rods 92 to steering arms 94 of the hubs 72. A lower steering shaft 96 connects the steering gear 90 to a universal joint 48 and above this point the same parts are used as in the two tonne payload derivative. The common points used in both derivatives are a) the front locating points defined byt the axis of the bolts 26 b) the shock absorber mounting points 60, and c) the steering column universal joint 48.

Claims: CLAIMS 1. A- method of manufacturing independent front suspension (IFS) and front beam axle vehicle derivatives using shared facilities, characterised in that: a) assembly of the beam axle derivative includes connecting leaf spring front bushes (18, 20) of a beam axle suspension to forward location points (14, 16) on a body structures; and b) assembly of the IFS derivative includes connecting a subframe (62) having mounting points (76) for front wheel locating means (74) of a Macpherson strut type front suspension to common forward location points (14, 16) on a similar body structure to the beam axle derivative body structure. 2. A vehicle manufacturing method as claimed in Claim 1, where a hybrid Macpherson strut front suspension is used for the IFS derivative, with the spring (86) being arranged between the front wheel locating means (74) and the subframe (62) and the upper end of the shock absorber strut (70) being attached directly to the body structure. 3. A vehicle manufacturing method as claimed in Claim 1 or Claim 2, characterised in that shock absorbers (53) for the beam axle derivative are connected to upper mounting points (60) on the body structure of the beam axle derivative at the same relative positions as the shock absorbers (70) of the IFS derivative. 4. A vehicle manufacturing method as claimed in any preceding claim, characterised in that a common steering column (44) is fitted to both IFS and beam axle derivatives. 5. A method of manufacturing IFS and front beam axle vehicle derivatives using shared facilities substantially as hereinbefore described with reference to and as shown in the accompanying drawings. 6. An IFS vehicle made by the method of any one of the preceding claims. 7. A front beam axle vehicle made by the method of any one of the claims 1 to 5.

Inventors: SELMAN, ALAN
Applicants: FORD FRANCE SOCIETE ANONYME, FORD MOTOR COMPANY LIMITED, FORD-WERKE AKTIENGESELLSCHAFT
Application year: 1986
Main classification: B62D65
IPC codes: B60G15, B62D65