Vehicle End Wall Feedthrough Layout for Modular Cable Assembly
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Solution Overview
Problem
Conventional vehicle manufacturing processes require significant time and effort for manual assembly of cable harnesses and line passages through end walls, leading to high production costs and complexity.
Innovation Solution
An end wall design with a media feedthrough opening that allows for horizontal alignment of connection panels, enabling vertical assembly of modules and components, reducing the need for complex line passages and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manual assembly processes are used for cable harnesses and line passages through end walls, then assembly flexibility is maintained, but production time and costs increase significantly
Solution Approach 1:
The end wall is divided into multiple segments including a first end wall part, a second end wall part, and a connecting part. This segmentation allows each component to be manufactured separately and assembled efficiently, enabling automated assembly processes while reducing overall production time and costs.
Solution Approach 2:
The connecting part protrudes in a direction oblique to the vehicle longitudinal direction, creating a three-dimensional structure that facilitates automated assembly. This dimensional change allows cable harnesses and line passages to be routed more efficiently through the end wall structure, reducing assembly complexity.
2Ease of manufacture
If the connecting part protrudes obliquely to facilitate automated assembly, then assembly efficiency improves, but manufacturing complexity increases
Solution Approach 1:
By segmenting the end wall into distinct parts (first end wall part, second end wall part, connecting part), the complex oblique geometry is broken down into manageable components that can be manufactured using standard processes and assembled efficiently.
3Adaptability or versatility
If multiple separate components are used for the end wall, then manufacturing flexibility increases, but assembly complexity increases
Solution Approach 1:
The first end wall part, second end wall part, and connecting part are designed to be connected together to form an integrated end wall assembly. This merging approach maintains manufacturing flexibility while reducing assembly complexity through the standardized connection interfaces.
Data Source
AI summary
An end wall for a motor vehicle body having a lower end wall part, an upper end wall part, which extends further upward in the vehicle vertical direction than the lower end wall part, and a connecting part, via which the lower end wall part and the upper end wall part are connected to each other. The connecting part protrudes obliquely or perpendicular from the lower end wall part and the upper end wall part and has a media feedthrough opening through which at least one line element can be guided for connecting a first component, which is to be arranged in front of the end wall, and a second component, which is arranged behind the end wall and through which, if required, further line elements can be guided for connecting further components, which are arranged in front of or behind the end wall.