Systems and methods for assembling a front end module to a vehicle
View Patent ↗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.
1. A method of assembling a front end module assembly onto a vehicle frame, comprising:
(a) providing a front end module assembly, wherein the front end module assembly comprises a rail disposed on a front end module carrier;
(b) positioning the front end module assembly substantially over a vehicle frame;
(c) engaging the rail with a tab disposed on the vehicle frame;
(d) 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;
(e) disengaging the rail from the tab upon guiding the front end module assembly into the final assembly position in step (d); and thereafter
(f) attaching the front end module assembly to the vehicle frame.
2. The method of assembling a front end module assembly of claim 1 , wherein the front end module assembly further comprises any of a grille, a headlamp housing, a coolant module, and combinations thereof.
3. The method of assembling a front end module assembly of claim 1 , wherein the vehicle frame comprises a fender.
4. The method of assembling a front end module assembly of claim 1 , wherein the substantially constrained movement of the front end assembly of the guiding step (d) is in a vertical direction allowing the front end module assembly to pass between fenders on the vehicle with a tight clearance condition.
5. The method of assembling a front end module assembly of claim 1 , wherein the rail and the tab are configured to slidably guide the front end module assembly onto the vehicle frame during step (d) avoiding front end module assembly contact with any portion of a fender attached to the vehicle frame.
6. The method of assembling a front end module assembly of claim 2 , wherein 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.
7. The method of assembling a front end module assembly of claim 3 , wherein the fender comprises a fender reinforcement bracket, and wherein the tab is integrally formed and extends outwardly therefrom.
8. A method of assembling a front end module assembly onto a vehicle frame, comprising:
(a) providing a front end module assembly, wherein the front end module assembly comprises a pair of spaced apart elongate rails;
(b) positioning the front end module assembly adjacent a vehicle frame;
(c) engaging each one of the elongate rails with a corresponding portion of the vehicle frame; and
(d) guiding the front end module assembly toward an assembly position by engagement between each portion of the vehicle frame and corresponding elongate rail with relative movement therebetween occurring along corresponding elongate rail substantially constraining movement of the front end module assembly in a manner that prevents contact anywhere else between the front end module assembly and the vehicle frame; and
wherein each elongate rail disengages from the corresponding portion of the vehicle frame when the front end module assembly reaches the assembly position.
9. The method of assembling a front end module assembly of claim 8 , wherein relative movement during the guiding step (d) is generally along a lengthwise direction of each elongate rail.
10. The method of assembling a front end module assembly of claim 8 , wherein each portion of the frame comprises a tab.
11. The method of assembling a front end module assembly of claim 9 , wherein during the guiding step (d) engagement between each elongate rail and corresponding portion of the vehicle frame is slidable engagement.