Vehicle B-Pillar Module Support for Ergonomic Seatbelt Assembly
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Solution Overview
Problem
Conventional vehicle body assembly processes are ergonomically unfavorable and inefficient, leading to increased workload for workers due to the manual assembly of seat belt system components within the vehicle interior.
Innovation Solution
A module carrier is pre-assembled with seat belt system components and pillar trim, which is then attached to the inner sheet metal part using a positioning aid and screw connections, allowing for a more efficient and ergonomic assembly process by separating the pre-assembly from the vehicle body assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components of the seat belt system are assembled manually inside the vehicle body after painting, then the assembly can be performed on the complete structure, but the worker must assume an ergonomically unfavorable position and the process is physically demanding
Solution Approach 1:
The assembly process is divided into two segments: pre-assembly of seat belt components on the module carrier outside the vehicle body, and final assembly by attaching the pre-assembled module carrier to the vehicle body. This segmentation allows workers to perform pre-assembly in an ergonomic position while maintaining efficient final integration.
Solution Approach 2:
The seat belt system components are pre-assembled on the module carrier before being integrated into the vehicle body. This preliminary action is performed outside the vehicle body where workers can access components more easily and assume ergonomic positions, reducing physical strain while maintaining productivity.
2Strength
If conventional welding is used to attach the module carrier to the inner sheet metal part, then a strong connection is achieved, but the paint layer may be damaged
Solution Approach 1:
The welding process is replaced with a mechanical screw connection system. The positioning aid with keyhole-shaped opening and positioning bolt provides precise alignment, while screws create a strong mechanical connection without the heat and spatter that would damage the paint layer, thus eliminating the harmful effects of welding while maintaining connection strength.
3Device complexity
If the module carrier is attached without a positioning aid, then the assembly process is simpler, but correct positioning and alignment are difficult to achieve
Solution Approach 1:
A positioning aid with a keyhole-shaped positioning opening serves as an intermediary element between the module carrier and the inner sheet metal part. This positioning aid provides precise alignment through its geometric shape, guiding the positioning bolt into the correct position, while the overall system remains relatively simple in construction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production time and improves worker ergonomics by allowing for a more organized and efficient assembly process, avoiding damage to the paint layer and enabling a positive screw connection instead of welding.
Implementation Method 1
moved downwards under the influence of gravity until the positioning bolt rests on a bottom edge of the positioning opening
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a body structure for a vehicle, comprising a vehicle pillar (3), in particular a B-pillar, made of a vehicle-interior sheet metal inner part (9) and a vehicle-exterior sheet metal outer part (11) which form a hollow support (12) with a hollow profiled section (13) that runs in the vehicle vertical direction (z) and has a closed cross-section, wherein functional elements (20, 21, 23) of a seatbelt system (19) can be assembled on the hollow support (12) of the body pillar (3). According to the invention, the body pillar (3) has a module support (14) that can be provided as a pre-assembly unit which is separate from the vehicle body (50) and on which the functional elements (20, 21, 23) of the seatbelt system (19) and/or a pillar cover (17) can be pre-assembled. The module support (14) together with the functional elements (20, 21, 23) and/or pillar cover (17) already pre-assembled thereon can be joined to the sheet metal inner part (9) of the hollow support (12) at at least one pillar-side attachment point (S1, S2), in particular an adhesive connection and/or screw-in connection, in an assembly process step (ZSB).