Composite Lower Body Structure for Modular Vehicle Assembly

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Solution Overview

Problem

Current car manufacturing methods are inefficient due to the reuse of only a small portion of the self-supporting structure for different vehicles within the same segment, leading to high engineering and assembly costs, and requiring workers and robots to access the vehicle interior from the side for assembly, which is inconvenient.

Innovation Solution

A manufacturing method that uses a lower self-supporting structural element as a base onto which interchangeable bodywork, mechanical, and interior elements are assembled in any sequence, with the structural element pre-equipped with interior components and made of composite materials to reduce costs and simplify assembly, allowing for the production of vehicles across different segments from a single platform.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a traditional manufacturing method is used where only a small portion of the self-supporting structure is reused for different vehicles within the same segment, then the manufacturing process maintains flexibility for segment-specific designs, but the engineering and assembly costs increase significantly

Engineering Contradiction:

Improvedesign flexibility for different segmentsVSAvoidengineering and assembly costs

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent applies universality by designing a lower self-supporting structural element that serves as a common platform for multiple vehicle segments (city cars, off-road vehicles, flagship vehicles). This single structural element replaces the traditional approach of creating separate structures for each segment, thereby reducing engineering costs while maintaining the ability to produce diverse vehicle types through interchangeable bodywork and mechanical elements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent applies segmentation by dividing the vehicle into distinct modular components: a common lower self-supporting structural element, interchangeable bodywork elements, interchangeable mechanical elements, and interchangeable interior elements. This segmentation allows each component to be independently designed and manufactured, enabling cost-effective production across segments while preserving design flexibility.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If the assembly of car interiors is performed by having workers and robotized arms enter inside the structure from side access, then the assembly process can be completed, but the assembly cost and complexity increase due to inconvenient access

Engineering Contradiction:

Improveaccess convenience for assemblyVSAvoidassembly cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent applies inversion by reversing the traditional assembly sequence. Instead of assembling interiors from the inside out through side access, the lower self-supporting structural element is first provided with interior components pre-integrated or pre-assembled. This allows workers and robots to access components from the outside, significantly improving access convenience and reducing assembly costs.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent applies preliminary action by pre-equipping the lower self-supporting structural element with interior components before final assembly. This preliminary integration of interior elements allows for more efficient assembly operations and reduces the complexity of accessing and installing interior components during final vehicle assembly.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If a lower self-supporting structural element is used as a common base for vehicles across different segments, then engineering and assembly costs are reduced, but the structural element must be designed to accommodate diverse mechanical and bodywork requirements

Engineering Contradiction:

Improveengineering and assembly costsVSAvoiddesign complexity of universal structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent applies local quality by designing the lower self-supporting structural element with specific localized features that accommodate different vehicle segments. Rather than requiring the entire structure to be overly complex, only specific local areas are designed with adaptability features, allowing the rest of the structure to remain simple and cost-effective.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9108692B2Manufacturing method of a motor vehicle and motor vehicle thereby obtained

Publication Date: 2015.08.18 GANDINI MARCELLO

AI summary

There is described a manufacturing method of motor vehicles which achieves the object of reducing the costs deriving from the manufacturing of vehicles belonging to different segments and the costs deriving from the traditional assembly of vehicles which starts from the external shell onto which the elements forming the interiors and the mechanical members are assembled, by suggesting the arrangement of a single self-supporting structural element formed by composite material, already provided with many interior elements, to which a new other interior elements, bodywork elements and mechanical elements can be connected in any assembly order.