Vehicle Body-Chassis Assembly with Pivoting Alignment Supports
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Solution Overview
Problem
Current vehicle assembly methods face challenges in efficiently interconnecting vehicle chassis and bodies, particularly in aligning and supporting them during the assembly process, which can lead to inefficiencies and potential misalignment.
Innovation Solution
The method involves using a first carrier to support the chassis and a second carrier to support the body, with pivotable supports that pivot out of the chassis's path to allow for efficient alignment and interconnection, utilizing a four-post lift system for precise positioning and adjustment along orthogonal axes, and spring-loaded stops to facilitate the return of supports to their initial position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the chassis and body are supported on separate carriers and translated toward each other for interconnection, then alignment precision is improved, but the complexity of the assembly station increases
Solution Approach 1:
The assembly station is divided into two separate carriers: a first carrier for supporting the chassis and a second carrier for supporting the body. This segmentation allows independent positioning and alignment of each component, improving alignment precision while distributing the system complexity across modular units.
Solution Approach 2:
Multiple pivotable supports are introduced as intermediary elements between the carriers and the chassis/body. These supports facilitate controlled movement and positioning, enabling precise alignment during the translation process while managing the overall system complexity through standardized mechanical components.
2Ease of operation
If multiple pivotable supports are used to facilitate chassis movement and alignment, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The supports are designed to be pivotable rather than fixed, allowing them to dynamically adjust their position and orientation. This enables the supports to automatically adapt to the movement of the chassis and body during assembly, improving ease of operation while using relatively simple mechanical pivot mechanisms.
Solution Approach 2:
The pivotable supports are positioned to automatically facilitate chassis movement and alignment as the carriers translate toward each other. The supports self-adjust through pivoting motion to maintain proper positioning without requiring additional active control mechanisms, improving operational ease while limiting complexity growth.
3Productivity
If the first carrier is translated in the positive z-direction toward the second carrier during interconnection, then assembly time is reduced, but the risk of misalignment increases
Solution Approach 1:
The supports are pre-positioned in a retracted configuration before the translation begins. This preliminary positioning allows the carriers to translate toward each other without obstruction, reducing assembly time. The supports are then pivoted into their engagement positions to ensure proper alignment during the connection process, thereby maintaining precision despite the rapid translation.
Solution Approach 2:
The pivotable supports enable dynamic adjustment during the translation process. As the first carrier moves in the positive z-direction toward the second carrier, the supports can pivot to maintain optimal alignment, allowing fast translation without sacrificing alignment precision.
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 enables efficient and precise interconnection of vehicle chassis and bodies, improving assembly efficiency by allowing for concurrent translation and alignment, reducing the risk of misalignment, and enabling smooth transfer to subsequent assembly stations.
Implementation Method 1
engaging a surface of the at least a portion of each support of the plurality of supports with a respective spring-loaded stop. The spring-loaded stop is adapted to apply a biasing force to pivot the at least a portion about the pivot axis to return the plurality of supports to the first position.
Data Source
AI summary
An assembly station for interconnecting a chassis and a body of a vehicle comprises a first carrier to support the chassis. A second carrier is suspended in a positive z-direction with respect to the first carrier and includes a plurality of spaced apart rests adapted to support the body prior to interconnecting the chassis and the body. A plurality of supports are coupled to the second carrier and spaced apart from the body when the body is supported on the rests. A portion of each of the supports is pivotable from a first position in a path of travel of the chassis to a second position outside of the path of travel of the chassis. The first carrier is moveable relative to the second carrier. The supports are adapted to engage the chassis and simultaneously support both the chassis and the body when the supports are in the first position.