Cold-Joined Structural Modules for Flexible Vehicle Body Assembly
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Solution Overview
Problem
Existing production methods for producing motor vehicles lack flexibility and efficiency in integrating technical changes, and the production process is inefficient, and existing production chains are costly and complex, failing to adapt to market changes and technological advancements.
Innovation Solution
A modular production method for motor vehicles using structural modules that include both structural components and vehicle components, assembled via cold joining techniques, where each structural component is assembled via cold joining methods, and the assembly process is simplified by using a mounting jig.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional production methods are used to produce motor vehicles, then the production process is standardized and reliable, but the flexibility to integrate technical changes is low and the production chain is costly and complex
Solution Approach 1:
The vehicle body is divided into multiple structural modules, each containing structural components and vehicle components. These modules can be independently produced, tested, and modified, enabling flexible integration of technical changes without disrupting the entire production chain. Each module can be developed separately and assembled into the complete vehicle structure.
Solution Approach 2:
Vehicle components are pre-assembled into structural modules before final vehicle assembly. This preliminary integration allows technical changes to be implemented at the module level without affecting the entire vehicle production process, reducing the complexity and cost of implementing changes while maintaining standardized production benefits.
2Productivity
If vehicle components are assembled after body completion in conventional production, then the body structure is complete and stable, but the production efficiency is low and the process is time-consuming
Solution Approach 1:
Vehicle components are pre-assembled into structural modules before final vehicle assembly. This preliminary action allows parallel production of multiple modules simultaneously, significantly reducing total assembly time while maintaining body structural integrity. The pre-assembled modules are then quickly integrated into the complete vehicle.
Solution Approach 2:
The assembly process is segmented into module production and final vehicle assembly. This segmentation enables concurrent production of multiple structural modules with their integrated vehicle components, improving overall productivity by eliminating sequential bottlenecks in the conventional production process.
3Strength
If hot joining techniques are used to assemble structural components, then the joint strength is high and durable, but the process is costly and complex with additional corrosion protection requirements
Solution Approach 1:
Hot joining techniques are replaced with cold joining techniques such as mechanical fastening or adhesive bonding. This substitution eliminates the need for thermal processes, reducing equipment complexity and operational costs while maintaining joint strength. The cold joining process also eliminates the need for additional corrosion protection measures required after hot joining.
Data Source
AI summary
A method for producing a motor vehicle by producing multiple structural modules, wherein each structural module includes at least one structural component of a vehicle body and at least one vehicle component, and assembling the multiple structural modules to form the motor vehicle, whereby the motor vehicle is already provided with a plurality of vehicle components upon completion of the supporting motor vehicle structure, and wherein the structural modules are joined to one another on the structural component side exclusively using cold joining techniques.