Method for mounting a front-end module and a front headlamp on a body of a passenger car and holding arrangement for holding a front headlamp on a front-end module

Abstract

A method is provided for mounting a front-end module and at least one front headlamp on a body of a passenger car, including the steps of: holding the front headlamp in at least one pre-mounting position on the front-end module via a holding device, by which the front headlamp is held on the front-end module so as to be movable relative to the latter; arranging the front-end module on the body together with the front headlamp held thereon via the holding device so as to be movable relative to the front-end module, wherein the front-end module and therewith also the front headlamp are moved relative to the body; and fixing the front headlamp in a final mounted position.

Claims

1. A method of mounting a front-end module and at least one front headlamp on a vehicle body of a passenger car, the method comprising the steps of: (a) holding the front headlamp in at least one preassembly position at the front-end module by way of a holding device, by which the front headlamp is held at the front-end module while being movable relative to the latter, wherein the holding device has at least one joint by which the front headlamp is swivelable in the preassembly position relative to the front-end module, (b) arranging the front-end module on the vehicle body, together with the front headlamp movably held relative to the front-end module by way of the holding device, the front-end module and, together with the latter, the front headlamp being moved relative to the vehicle body, and (c) fixing the front headlamp in a final assembly position, wherein, in step b), at least a first aligning element provided at the front headlamp is caused to interact with a second aligning element assigned to the body of the passenger car, the front headlamp being moved by way of the interacting aligning elements during the motion of the front headlamp relative to the vehicle body into a position relative to the vehicle body and relative to the front-end module.

2. The method according to claim 1, wherein the position relative to the vehicle body and relative to front-end module is a final assembly position.

3. The method according to claim 2, wherein the holding device holds the front headlamp in the final assembly position.

4. A holding arrangement of a front headlamp on a front-end module of a passenger car, comprising: a holding device configured to hold the front headlamp in a final assembly position at the front-end module, wherein the holding device is configured to hold the front headlamp in at least one preassembly position at the front-end module in a manner movable relative to the front-end module, a first aligning element provided at the front headlamp; a second aligning element assigned to a body of the passenger car, wherein the front headlamp is alignable relative to the front-end module and the body of the passenger car by way of the first aligning element interacting with the second aligning element, and wherein the holding device has at least one joint by which the front headlamp is swivelable in the preassembly position relative to the front-end module.

5. The holding arrangement according to claim 4, wherein the holding device comprises at least one holding element by which the front headlamp is held in the preassembly position at the front-end module while being movable relative to the front-end module.

6. The holding arrangement according to claim 4, wherein the holding device comprises: at least a first position element provided at the front headlamp; at least a second positioning element corresponding with the first positioning element and being provided at the front-end module, wherein motion of the front headlamp in the preassembly position is restricted relative to the front-end module by way of the first and second positioning elements.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic frontal view of a front headlamp for a passenger car according to a first embodiment, which front headlamp is held in a final assembly position on the front-end module by way of a holding device, by which the front headlamp is to be movably held in at least one preassembly position at the front-end module relative to the front-end module;

(2) FIG. 2 is a schematic and perspective rear cut out view of the front headlamp according to a second embodiment, which front headlamp is movably held relative to the front-end module in its preassembly position by way of the holding device on a corresponding holding element of the front-end module; and

(3) FIG. 3 is a schematic and perspective frontal cut out view of a module component including the front-end module and the front headlamp during the mounting of the module component on the body of the passenger car, during which, because of the movability of the headlamp held on the front-end module, an adjusting of the front headlamp can take place, within whose scope the front headlamp is moved relative to the front-end module and/or relative to the vehicle body.

DETAILED DESCRIPTION OF THE DRAWINGS

(4) In the figures identical elements or elements having the same function are provided with the same reference numbers.

(5) FIG. 1 illustrates a front headlamp, marked as a whole by reference number 10, according to a first embodiment for a passenger car. Within the scope of a holding arrangement visible in FIG. 3-FIGS. 2 and 3 showing the front headlamp 10 according to a second embodiment, the front headlamp 10 is held by way of a holding device visible in FIG. 2 and as a whole marked by reference number 13 on a front-end module (FIG. 3) marked by reference number 12. In other words, the front-end module 12 is equipped with the front headlamp 10. For this purpose, a holding element 16 of the front-end module 12 is provided and corresponds with the front headlamp 10. The holding element 16 is visible in FIG. 2 and holds the front headlamp 10. The front headlamp 10 includes a shell 18 and a disk 20 connected with the shell 18, which disk 20 is usually also called a lens. The holding element 16 is a component of the holding device 13. In other words, the holding device 13 includes the holding element 16. In addition, the holding device 13 includes a fixture device 14.

(6) The front-end module 12 includes, for example, at least one support not visible in FIG. 3, to which the holding element 16 is fastened. A bumper covering 21 which is visible in FIG. 3 is also fastened to the support and/or to a different support of the front-end module, by which bumper covering 21, a bending cross-member of a bumper of the passenger car is covered. The cross-member extends at least essentially in the transverse direction of the vehicle. The bumper including the bending cross-member and the bumper covering 21 is a part of a module component which, as a whole, has the reference number 22. The module component 22 therefore comprises the bumper with the bumper covering 21, the front headlamp 10 as well as the front-end module 12 and additional attachment parts. The module component 22 may, for example, be preassembled simultaneously with the manufacturing of the passenger car and, in particular, simultaneously with the manufacturing of the body of the passenger car and can subsequently be joined with the vehicle body as a preassembled module component.

(7) A joining direction into which the module component 22 and therefore the front-end module 12 are moved relative to the vehicle body, in order to join the module component 22 with the vehicle body, is indicated in FIG. 3 by direction arrows 24. This joining direction coincides with the longitudinal direction (x-direction) of the vehicle and, in the present case, extends from the front to the rear. The joining direction can also coincide with the transverse direction (y-direction) of the vehicle or extend in different directions.

(8) A side wall in the form of a front fender 26 is also fixed to the vehicle body. The fender 26 is a covering element for covering the vehicle body shell. As illustrated in FIG. 3, a receiving area 28 is bounded by the fender 26, into which receiving area 28 the front headlamp 10 is moved, at least in sections, when the front-end module 12, together with the front headlamp 10 held on it, is moved in the joining direction relative to the vehicle body. As an alternative, the receiving area 28 could be bounded by an attachment part held on the fender 26, in which case, after the mounting of the front headlamp 10, the attachment part could, for example, be removed again from the fender 26.

(9) A first fixing element 30 visible in FIG. 1 is provided for fixing the front headlamp 10 on the front-end module 12. The fixing element 30 is, for example, a lug having a passage opening 32, whereby a screwing point is provided. By way of the fixing element 30, the front headlamp 10 can be screwed to the front-end module 12 in the x-direction. In the case of front headlamps of large dimensions and/or a heavy weight, several fixing elements may be provided. This takes place, for example, after the mounting of the front-end module 12 on the vehicle body. The fixing element 30 may have a tolerance compensation element, in order to, for example, be able to compensate production-caused tolerances and offsets.

(10) FIG. 1 also illustrates in a particularly schematic manner fixing elements which also have the purpose of fixing the front headlamp 10 at the front-end module 12, preferably when the passenger car is already standing on its own wheels. The fixing elements 34, 36 each have a screw opening 38. As a result, a respective screwing point is provided by the fixing elements 34, 36, so that the front headlamp 10 can be screwed to the front-end module 12. The fixing element 34 permits, for example, the screwed connection in the vertical direction (z-direction) of the vehicle, in which case the fixing element 34 may or may not have a tolerance compensation element. In contrast, the fixing element 36 provides the screwed connection of the front-end module 12 with the vehicle body in the vertical direction (z-direction) of the vehicle, in which case the fixing element may or may not have a tolerance compensation element.

(11) The fixture device 14 includes holding elements 40, 42, which are provided at the front headlamp 10 and by which the front headlamp 10 is to be held on the holding element 16 and, by way of latter, at the front-end module 12. The fixture device 14 includes, for example, also holding elements for the holding of the front headlamp 10 at the front-end module 12, which correspond with the holding elements 40, 42 and are provided at the front-end module 12, particularly at the holding element 16.

(12) In this case, the front headlamp 10 is held in a final assembly position of the front headlamp 10 at the front-end module 12 by way of the holding device (fixture device 14 and holding element 16). In other words, the holding device 13 permits the holding of the front headlamp 10 at the front-end module 12 in a final assembly position of the front headlamp 10. By means of the holding device 13, the front headlamp 10 is to be movably held relative to the front-end module 12 also in at least one preassembly position at the front-end module 12. This preassembly position is illustrated in FIGS. 2 and 3. In other words, the front headlamp 10 is held in its preassembly position at the front-end module by way of the holding device 13, in which case the front headlamp 10 can be moved relative to the front-end module 12 in this condition held at the front-end module 12. This means that the holding device 13 permits a motion of the front headlamp 10 relative to the front-end module 12 and therefore relative to the vehicle body, although the front headlamp 10 is already held at the front-end module and is therefore preassembled on it.

(13) As a result of this mobility of the front headlamp 10 in its condition held at the front-end module 12, tolerances and offsets of the front headlamp 10 relative to the vehicle body and particularly to the fender 26 held at the vehicle body can be compensated. The holding element 40 permits, for example, an alignment of the front headlamp 10, i.e. a motion of the latter relative to the front-end module 12 and relative to the vehicle body or to the fender 26 in the longitudinal direction of the vehicle and in the vertical direction of the vehicle. The holding element 42 permits an alignment of the front headlamp 10 in the longitudinal direction of the vehicle. This means that the front headlamp 10 can be moved in its preassembly position relative to the front-end module 12 in the transverse direction of the vehicle and in the vertical direction of the vehicle, which is illustrated in FIG. 2 by direction arrows 44, 46.

(14) Furthermore, the fixture device 14 has swivel joints 48, which permit a swiveling of the front headlamp 10 relative to the front-end module 12 about a swiveling axis 50 in the preassembly position of the front headlamp 10. This means that the front headlamp 10 can be moved not only relative to the front-end module and relative to the fender 26 but can also be swiveled.

(15) The fixture device 14 further has a first positioning element 52 provided at the front headlamp 10 as well as at least a second positioning element 54 corresponding therewith and provided at the front-end module 12. The second positioning device 54 has a receiving fixture 56 for the first positioning element 52. The receiving fixture 56 is bounded by mutually diagonally extending surfaces of the second positioning element 54. The mutually diagonally extending surfaces of the second positioning element 54 are able to interact with mutually diagonally extending surfaces of the first positioning element 52. The respective mutually diagonally extending surfaces act as insertion chamfers, so that the front headlamp 10 is positioned in the longitudinal direction of the vehicle, the transverse direction of the vehicle and the vertical direction of the vehicle when the first positioning element 52 is moved into the receiving fixture 56. By means of this prepositioning, the front headlamp 10 in its prepositioned state at the front-end module 12 can be securely moved together with the front-end module 12 and can thereby be transported.

(16) During the joining of the front-end module 12 with the vehicle body, the positioning elements 52, 54 preferably permit a motion of the front headlamp 10 relative to the front-end module 12 and relative to the fender 26 within predefinable limits. When the front-end module 12 and, together with the latter, the front headlamp 10 are moved into the joining direction in order to join the front-end module 12 with the vehicle body, the front headlamp 10 is at least partially moved into the receiving fixture 28. In this case, the swivel joints and the holding elements 40, 42 permit a motion, i.e. a swiveling as well as a moving of the front headlamp 10 when the front headlamp 10, for example, slightly contacts the fender 26 bounding the receiving area 28. As a result, a force- and/or form-locking alignment of the front headlamp 10 relative to the vehicle body can be implemented, which is accompanied by the motion of the front-end module 12 and the front headlamp 10 relative to the vehicle body.

(17) As an alternative or in addition, at least one aligning element 58 (FIG. 1) is provided at the front headlamp 10, which aligning element 58, when the front-end module 12 is arranged on the vehicle body, is caused to interact with a second aligning element provided at the vehicle body or held on the vehicle body. By means of these aligning elements, the front headlamp 10, during its motion, is aligned relative to the vehicle body and particularly is positioned relative to the fender 26. This positioning or aligning takes place, for example, in a force- and/or form-locking manner by way of the interacting aligning elements. A pin or a bolt, a ball or another aligning element may be used as such an aligning element.

(18) By the interaction of the aligning elements and/or the interaction of the front headlamp 10 with the fender 26, a clearance of a joint is set, for example, between the front headlamp 10 and the fender 26 without the requirement of time-consuming and costly refinishing. As an alternative or in addition, a clearance of a joint between the front headlamp 10 and the bumper covering 21 and/or a clearance of a joint between the front headlamp 10 and a front-opening hood in the form of an engine hood, which is not shown in the figures, can thereby be adjusted in its closed position.

(19) By means of the alignment, the front headlamp 10 is moved into its final assembly position, in which it is finally fixed at the front-end module 11 and/or at the vehicle body. This fixing can, for example, take place by screwed connections. In this case, the fixing of the front headlamp 10 in its final assembly position can take place independently of a process structure. As a result, the entering of tensions into the front headlamp 10 can be minimized. Furthermore, a particularly advantageous joint image with a uniform clearance can thereby be implemented.

(20) The mounting of the front headlamp 10, for example, takes place such that, by way of the fixture device 14, particularly the holding elements 40, 42, the front headlamp 10 is first hung in at the front-end module 12. The holding element 40 and/or 42 is, for example, fitted into an oblong hole, which extends in the transverse direction (y-direction) of the vehicle. In this state, the front headlamp 10 is held accurately to size in the vertical direction (z-direction) of the vehicle and in the longitudinal direction (x-direction) of the vehicle at the front-end module but can still be moved. In this case, the front headlamp 10 can still be moved in the y-direction, tilted about the x-direction and swiveled about the z-direction. Furthermore, the front headlamp 10 could be lifted off the front-end module 12 upward in the z-direction. First, only three of six degrees of freedom are therefore restricted. For restricting a fourth degree of freedom, the front headlamp 10 is fixed, for example, by means of a holder, in such a manner that it is fixed in the z-direction so it can also no longer be lifted off in the upward direction. Finally, a further fixing takes place in the x-direction, so that the front headlamp 10 can no longer be swiveled about the z-direction. In this state, the front headlamp 10 could still only be moved in the y-direction. In order to fix the front headlamp in its mounted position, the sixth and last degree of freedom will also be restricted, so that the front headlamp 10 can also no longer be moved in the y-direction. As a result, a simple alignment of the front headlamp 10 relative to the front-end module 12 and to the vehicle body can take place first, whereupon the front headlamp 10 is securely fixed.

(21) The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.