IP Library › Granted Patent US 12679487
Granted Patent B2
US 12679487 · App. 18/495,075 · Granted Jul 14, 2026

Method of assembling a vehicle

Inventors: Jamil M. Alwan (Ann Arbor, MI); Petros Frantzeskakis (Canton, MI); Michael Jon Gutowski (Saline, MI); Erik Billimoria (Canton, MI); Shawn Michael Morgans (Chelsea, MI); Henry W. Hausler (New Hudson, MI); Christopher Bondanza (Grosse Pointe Shores, MI); Kirk E. Sanborn (Rochester, MI); Meghan Hall (Madison Heights, MI)
Assignee: Ford Global Technologies, LLC
B62D65/022B60K1/04B62D25/04B62D65/06B62D65/10B62D65/12B62D65/14B60K2001/0438
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Quick Facts
Patent No.
US 12679487
App. No.
18/495,075
Granted
Jul 14, 2026
Kind
B2
Abstract

A method of assembling a vehicle that includes performing a first operation on a front vehicle structure, securing a plurality of first vehicle components to the front vehicle structure while performing the first operation on the front vehicle structure, performing a second operation on a rear vehicle structure, securing a plurality of second vehicle components to the rear vehicle structure while performing the second operation on the rear vehicle structure, and coupling the front vehicle structure and the rear vehicle structure to each other to form an intermediate vehicle structure after the first vehicle components have been secured to the front vehicle structure and the second vehicle components have been secured to the rear vehicle structure. The first operation includes continuously or intermittently rotating the front vehicle structure. The second operation includes continuously or intermittently rotating the rear vehicle structure.

Claims (45)

1 . A method of assembling a vehicle, the method comprising:

performing a first operation on a front vehicle structure, the first operation including continuously or intermittently rotating the front vehicle structure, the front vehicle structure includes a left hinge pillar and a right hinge pillar;

securing a plurality of first vehicle components to the front vehicle structure while performing the first operation on the front vehicle structure;

performing a second operation on a rear vehicle structure, the second operation including continuously or intermittently rotating the rear vehicle structure, the rear vehicle structure defining a left door opening and a right door opening and including a left hinge pillar that partially defines the left door opening and a right hinge pillar that partially defines the right door opening;

securing a plurality of second vehicle components to the rear vehicle structure while performing the second operation on the rear vehicle structure;

coupling the front vehicle structure and the rear vehicle structure to each other to form an intermediate vehicle structure after the first vehicle components have been secured to the front vehicle structure and the second vehicle components have been secured to the rear vehicle structure; and

coupling a floor and battery assembly to the front vehicle structure and the rear vehicle structure after the front vehicle structure and the rear vehicle structure are coupled to each other,

wherein coupling the front vehicle structure and the rear vehicle structure includes coupling an interface block on an outermost lateral side of the left hinge pillar of the front vehicle structure to a corresponding channel in the left hinge pillar of the rear vehicle structure and coupling an interface block on an outermost lateral side of the right hinge pillar of the front vehicle structure to a corresponding channel in the right hinge pillar of the rear vehicle structure.

2 . The method of claim 1 , wherein the plurality of second vehicle components include a rear motor and a rear subframe.

3 . The method of claim 1 , further comprising:

painting the front vehicle structure before the first vehicle components are secured thereto; and

painting the rear vehicle structure before the second vehicle components are secured thereto.

4 . The method of claim 1 , wherein the front vehicle structure is rotated using a first robot platform and the rear vehicle structure is rotated using a second robot platform.

5 . The method of claim 1 , wherein rotating the front vehicle structure includes rotating the front vehicle structure up to 360 degrees and rotating the rear vehicle structure includes rotating the rear vehicle structure up to 360 degrees.

6 . The method of claim 1 , further comprising coupling a plurality of doors to the intermediate vehicle structure after the floor and battery assembly is coupled to the front vehicle structure and the rear vehicle structure.

7 . The method of claim 1 , wherein securing the first vehicle components to the front vehicle structure and securing the second vehicle components to the rear vehicle structure include simultaneously securing the first vehicle components to the front vehicle structure and securing the second vehicle components to the rear vehicle structure.

8 . The method of claim 1 , wherein the rear vehicle structure further includes a right front pillar, a left front pillar, a right rocker and a left rocker, and wherein the left hinge pillar of the rear vehicle structure connects the left front pillar and the left rocker and the right hinge pillar of the rear vehicle structure connects the right front pillar and the right rocker.

9 . The method of claim 1 , wherein the plurality of first vehicle components include a front suspension assembly, an instrument panel structure, a front motor and a front subframe.

10 . The method of claim 9 , wherein the plurality of second vehicle components include a rear motor and a rear subframe.

11 . A method of assembling a vehicle, the method

comprising:

performing a first operation on a front vehicle structure, the first operation including continuously rotating the front vehicle structure, the front vehicle structure permitted to rotate up to 360 degrees, the front vehicle structure includes a left hinge pillar and a right hinge pillar;

securing a plurality of first vehicle components to the front vehicle structure while performing the first operation on the front vehicle structure;

performing a second operation on a rear vehicle structure, the second operation including continuously rotating the rear vehicle structure, the rear vehicle structure permitted to rotate up to 360 degrees, the rear vehicle structure defining a left door opening and a right door opening and including a left hinge pillar that partially defines the left door opening and a right hinge pillar that partially defines the right door opening;

securing a plurality of second vehicle components to the rear vehicle structure while performing the second operation on the rear vehicle structure;

coupling the front vehicle structure and the rear vehicle structure to each other to form an intermediate vehicle structure after the first vehicle components have been secured to the front vehicle structure and the second vehicle components have been secured to the rear vehicle structure; and

coupling a floor and battery assembly to the front vehicle structure and the rear vehicle structure after the front vehicle structure and the rear vehicle structure are coupled to each other,

wherein coupling the front vehicle structure and the rear vehicle structure includes coupling an interface block on an outermost lateral side of the left hinge pillar of the front vehicle structure to a corresponding channel in the left hinge pillar of the rear vehicle structure and coupling an interface block on an outermost lateral side of the right hinge pillar of the front vehicle structure to a corresponding channel in the right hinge pillar of the rear vehicle structure.

12 . The method of claim 11 , wherein the plurality of second vehicle components include a rear motor and a rear subframe.

13 . The method of claim 11 , further comprising:

painting the front vehicle structure before the first vehicle components are secured thereto; and

painting the rear vehicle structure before the second vehicle components are secured thereto.

14 . The method of claim 11 , wherein coupling the front vehicle structure and the rear vehicle structure includes extending a plurality of first fasteners through the left hinge pillar of the front vehicle structure and the left hinge pillar of the rear vehicle structure and extending a plurality of second fasteners through the right hinge pillar of the front vehicle structure and the right hinge pillar of the rear vehicle structure.

15 . The method of claim 11 , wherein the front vehicle structure is rotated using a first robot platform and the rear vehicle structure is rotated using a second robot platform.

16 . The method of claim 11 , further comprising coupling a plurality of doors to the intermediate vehicle structure after the floor and battery assembly is coupled to the front vehicle structure and the rear vehicle structure.

17 . The method of claim 11 , wherein the plurality of first vehicle components include a front suspension assembly, an instrument panel structure, a front motor and a front subframe.

18 . The method of claim 17 , wherein the plurality of second vehicle components include a rear motor and a rear subframe.

19 . A method of assembling an electric vehicle, the method comprising:

performing a first operation on a front vehicle structure, the first operation including continuously or intermittently rotating the front vehicle structure, the front vehicle structure includes a left hinge pillar and a right hinge pillar;

securing a plurality of first vehicle components to the front vehicle structure while performing the first operation on the front vehicle structure;

performing a second operation on a rear vehicle structure, the second operation including continuously or intermittently rotating the rear vehicle structure, the rear vehicle structure defining a left door opening and a right door opening and including a left hinge pillar that partially defines the left door opening and a right hinge pillar that partially defines the right door opening;

securing a plurality of second vehicle components to the rear vehicle structure while performing the second operation on the rear vehicle structure;

coupling the front vehicle structure and the rear vehicle structure to each other to form an intermediate vehicle structure after the first vehicle components have been secured to the front vehicle structure and the second vehicle components have been secured to the rear vehicle structure, coupling the front vehicle structure and the rear vehicle structure includes coupling an interface block on an outermost lateral side of the left hinge pillar of the front vehicle structure to a corresponding channel in the left hinge pillar of the rear vehicle structure and coupling an interface block on an outermost lateral side of the right hinge pillar of the front vehicle structure to a corresponding channel in the right hinge pillar of the rear vehicle structure;

coupling a floor and battery assembly to the front vehicle structure and the rear vehicle structure after the front vehicle structure and the rear vehicle structure are coupled to each other; and

coupling a plurality of doors to the intermediate vehicle structure after the floor and battery assembly is coupled to the front vehicle structure and the rear vehicle structure.