Modular vehicle construction and assembly method

Abstract

A vehicle construction comprises a series of modules which can be individually fabricated and assembled to include vehicle operating components before the modules are combined in the final assembly of the vehicle. An underbody module, including a passenger platform is preferably integrally constructed with a chassis frame comprising a pair of longitudinal rails sandwiched between upper and lower flooring panels and extending longitudinally beyond the flooring panels, is a support structure for the remaining modules. A second module comprising a cowl having a windshield frame integrally constructed with a dash panel frame provides structural support for vehicle controls and adjacent modules or body panels. Preferably, the underbody and cowl modules are joined by additional structural supports to form a cage enclosing passenger area of the vehicle. A third module encloses the vehicle area in front of the passenger compartment and a fourth module encloses the area behind the passenger compartment. The modular construction permits assembly by means of a plurality of subassembly lines, each of which pertains to the construction of a single module. In one form, the assembly method involves subassembly lines that intersect a single final assembly line. Alternatively, one or more of the subassembly lines may be remotely located with respect to the final assembly line, and the number of subassembly lines used to construct each individual module can be multiplied as necessary for efficient production.