Chassis Adapter for Side-Mounted Component Assembly
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Solution Overview
Problem
The top-down assembly approach for mounting components onto a vehicle chassis is limited by the size and geometry of the components, which can collide with chassis beams, making it difficult to integrate and assemble large or complex components like electrical drivelines and fuel cell devices.
Innovation Solution
A chassis adapter system with a first arm to support the component and a second arm with a contact face, secured by a fixation means, allows for self-alignment and secure mounting of components onto the chassis using a form-locking mechanism, enabling optimal positioning and distribution of load across the chassis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the top-down assembly approach is used to mount components onto the chassis, then the assembly process is simple and heavy components can be securely mounted, but the available space for mounting is limited and large or complex components cannot be integrated due to collision with chassis beams
Solution Approach 1:
The mounting system is divided into separate functional elements: a chassis adapter mounted on the chassis, and a component mounting bracket attached to the adapter. This segmentation allows the component to be mounted from below the chassis rather than from above, avoiding collision with chassis beams while maintaining assembly simplicity through modular installation.
Solution Approach 2:
The mounting approach transitions from a vertical top-down direction to a horizontal side-approach dimension. The chassis adapter is mounted on the chassis side, and the component bracket extends perpendicular to the chassis plane, enabling component installation from a different spatial dimension that avoids obstruction by chassis beams.
2Adaptability or versatility
If components are mounted from beneath the chassis, then larger components can be accommodated without colliding with chassis beams, but the assembly process becomes cumbersome and accessibility for assembly mechanics is reduced
Solution Approach 1:
The chassis adapter serves as an intermediary element between the chassis and the component mounting bracket. It provides a convenient mounting location on the chassis side that allows the component bracket to be attached without requiring mechanics to work underneath the vehicle, thus maintaining accessibility while enabling larger component installation.
Solution Approach 2:
The chassis adapter is pre-mounted on the chassis before the component bracket is attached. This preliminary action establishes a convenient, accessible mounting position that simplifies the subsequent component installation process and eliminates the need for mechanics to access difficult-to-reach areas underneath the vehicle.
3Strength
If the distance between chassis beams is limited, then the structural integrity of the chassis is maintained, but the available packaging space for mounting additional components is reduced
Solution Approach 1:
The mounting system segments the available space by mounting the chassis adapter on the side of the chassis rather than requiring internal space between beams. This allows the component bracket to extend outward from the adapter, utilizing external space that does not compromise the structural integrity or internal packaging volume defined by the chassis beams.
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3C
AI summary
A chassis (10) of a vehicle provided with at least one chassis adapter (20) for mounting (200) a component (30) onto the chassis (10), wherein the chassis adapter (20) comprises a first arm for at least partially supporting the component (30), and a second arm comprising a contact face; wherein the second arm comprises a first profile; wherein the chassis (10) comprises a second profile; wherein the chassis adapter (20) is configured to mount (200) the component (30) onto the chassis (10) by positioning the first arm at least partially under the component (30), and hooking the first profile of the second arm into the second profile of the chassis (10), thereby engaging the contact face of the second arm to the chassis (10) and attaching the component (30) to the first arm.