Commercial Vehicle Brake Pre-Assembly for Faster Chassis Integration
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Solution Overview
Problem
The manufacturing of commercial vehicles, such as trucks and trailers, is time-consuming and expensive due to the complex wiring and assembly of brake components, which are traditionally installed sequentially on the chassis or floor structure, complicating the process.
Innovation Solution
A pre-assembly unit comprising a modulator unit and wiring harness for brake components is connected as a separate unit to the underside of the floor structure or chassis before the chassis is attached, simplifying the assembly process by allowing simultaneous connection of other components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If brake components and wiring harness are installed sequentially on the chassis or floor structure, then the assembly can be done step by step, but the manufacturing process becomes time-consuming and expensive
Solution Approach 1:
The patent applies preliminary action by pre-assembling the brake components and wiring harness into a integrated pre-assembly unit before attaching it to the chassis. This allows the brake system and electrical connections to be prepared in advance, reducing the time required during final vehicle assembly while maintaining proper installation quality
Solution Approach 2:
The patent merges the brake components and wiring harness into a single integrated pre-assembly unit. By combining these previously separate assembly steps into one unified module, the manufacturing process becomes more efficient, reducing both time and cost while ensuring proper integration of mechanical and electrical systems
2Ease of manufacture
If brake components and wiring harness are installed sequentially, then each component can be installed individually, but the assembly process becomes complex
Solution Approach 1:
The patent applies segmentation by dividing the vehicle assembly into distinct modules: the pre-assembly unit containing brake components and wiring harness, and the main vehicle body. This modular approach simplifies the overall assembly process by allowing the complex brake and electrical systems to be prepared as a self-contained unit, reducing the complexity of on-site assembly operations
3Ease of manufacture
If traditional sequential installation method is used, then components can be installed in order, but manufacturing cost increases
Solution Approach 1:
By performing preliminary assembly of brake components and wiring harness into a pre-assembly unit, the patent reduces manufacturing costs. This approach allows for more efficient use of materials, reduced waste from rework, and lower labor costs during final vehicle assembly, while ensuring proper integration of all components
Data Source
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AI summary
The invention relates to a method for manufacturing a commercial vehicle (1), in particular a truck, trailer, or semi-trailer, comprising a chassis (2) and a superstructure (4) supported by the chassis (2) with a floor structure (10), wherein a pre-assembly (18) is assembled from at least one modulator unit (19) for attaching brake components and a wiring harness (20) for electrically connecting the brake components, wherein the pre-assembly (18) is subsequently connected as a separate unit to the underside of the floor structure (10) or to the chassis (2) via pre-assembly connections, and wherein, after connecting the pre-assembly (18) to the floor structure (10) or the chassis (2), the chassis (2) is connected to the floor structure (10) via chassis connections. In this way, manufacturing can be carried out more simply and cost-effectively.