Cockpit Module Bulkhead Stacking for Faster Vehicle Assembly
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Solution Overview
Problem
The existing method of assembling cockpit modules in motor vehicles, which involves inserting a pre-assembled large assembly through a door opening, results in long assembly times and limited installation space due to the dimensions of the cockpit module, requiring significant upstream and downstream assembly, such as routing wiring harnesses through separate holes in the bulkhead.
Innovation Solution
The method involves stacking the first wall element, which carries the cockpit module, onto the second wall element from above, allowing gravity to assist in the assembly and enabling larger cockpit modules to be installed without being limited by the size of the door opening, and providing through-openings for components to pass through the bulkhead, eliminating the need for separate routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the cockpit module is inserted through a door opening using a manipulator, then the assembly process can be automated, but the assembly time increases and the installation space is limited by the door opening dimensions
Solution Approach 1:
The patent changes the assembly direction from horizontal (through door opening) to vertical (from above). The cockpit module is lowered from above the vehicle body onto the chassis, utilizing the vertical dimension. This dimensionality change allows the manipulator to approach from a different direction, avoiding the space constraints of door openings and enabling faster assembly.
2Extent of automation
If the cockpit module is inserted through a door opening, then automation is possible, but the scope of work is limited due to confined installation space
Solution Approach 1:
By changing the assembly direction to vertical from above, the manipulator gains access to the entire vehicle body without being constrained by door opening dimensions. This allows for larger and more complex cockpit modules to be installed, and enables upstream and downstream assembly operations that were previously impossible in the confined horizontal space.
3Ease of manufacture
If the first wall element is stacked onto the second wall element from above, then gravity can assist assembly and heavy elements can be handled, but the assembly method must be changed from the conventional horizontal insertion
Solution Approach 1:
The patent inverts the conventional assembly approach by stacking wall elements vertically from above instead of inserting them horizontally from the side. This inversion allows gravity to assist the assembly process, making it easier to handle heavy first wall elements that support the cockpit module, and simplifies the overall manufacturing process despite requiring a different assembly methodology.
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 simplifies the assembly process, reduces assembly time, and allows for larger cockpit modules to be installed, while also providing improved accessibility and efficiency in component installation and removal.
Implementation Method 1
stacking from above allows gravity to be used to stack the first wall element
Data Source
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AI summary
A motor vehicle (1) is disclosed, comprising a front wall (3) that defines a passenger compartment (4) at the front, the front wall (3) comprising several wall elements (6a, 6b), wherein a first wall element (6a) supports a cockpit module (7) for the passenger compartment (4) and a second wall element (6b) is connected to the first wall element (6a). The first wall element (6a) is stacked onto the second wall element (6b) of the front wall (3) from a top-down direction, relative to the motor vehicle (1). A method for manufacturing a motor vehicle (1) is further disclosed, comprising the step (S41, S51) of mounting a cockpit module (7) onto a chassis (2) of the motor vehicle (1).The assembly step (S41, S51) comprises the sub-step of stacking (S411, S511) a first wall element (6a) supporting the cockpit module (7) onto a second wall element (6b) provided on the chassis (2) of the motor vehicle (1) from a direction from above, with respect to the motor vehicle (1), to form an end wall (3) in the motor vehicle (1) which limits the passenger compartment (4) of the motor vehicle (1) at the front.