Vehicle Floor Module Pre-Assembly for Drive Variant Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity and costliness of the main assembly line in manufacturing motor vehicles are exacerbated by the need to produce numerous variants based on different drive concepts, leading to inefficient and cumbersome assembly processes.
Innovation Solution
A self-supporting floor module design that allows for pre-assembly of variant-specific structural units, such as heat shields, hydraulic lines, and energy storage, independent of the vehicle shell, which can be easily integrated into the vehicle during the marriage process, simplifying the assembly line by relocating variant creation to pre-assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the entire body shell is equipped with interior installation in the main assembly line, then the vehicle can be produced with all variants, but the main assembly line becomes extremely complex and costly
Solution Approach 1:
The vehicle assembly is segmented into two distinct parts: a standardized body shell and a variant-specific floor module. The floor module contains all drive-concept-specific components (batteries for electric vehicles, fuel tanks for combustion engines, hybrid components), allowing variants to be configured in separate pre-assembly facilities without complicating the main assembly line.
Solution Approach 2:
Variant-specific floor modules are pre-assembled with all necessary components (drive units, energy storage, hydraulic lines, heat shields) before being transported to the main assembly line. This preliminary configuration eliminates the need to handle multiple variants during final assembly, simplifying the main production line while maintaining adaptability.
2Adaptability or versatility
If variant-specific components are assembled in the main assembly line, then all vehicle variants can be produced, but production time increases and productivity decreases
Solution Approach 1:
Floor modules are pre-assembled with all variant-specific components in dedicated pre-assembly facilities where specialized equipment and expertise can be concentrated. This parallel pre-assembly process occurs simultaneously with body shell production, and completed modules are then quickly integrated in the main assembly line, maintaining constant production time regardless of variant type.
3Strength
If the body shell is produced without a floor module, then the body shell can be self-supporting and meet safety requirements, but the floor module must be easily integrable during marriage
Solution Approach 1:
The vehicle structure is divided into a permanent, self-supporting body shell and a removable floor module. The body shell maintains all critical structural functions and safety characteristics independently, while the floor module serves as a functional add-on that can be easily attached and detached during assembly and disassembly processes.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a floor module (28) for a motor vehicle, in particular a passenger vehicle, with a floor bodyshell (30) which is fastenable to a bodyshell (42) of the motor vehicle, wherein a system (31) having a plurality of alternative-specific constructional units (32) is arranged on the floor bodyshell (30). Furthermore, the invention relates to a method for assembling a floor module (28) of this type, which comprises a floor bodyshell (30), for a motor vehicle, in particular a passenger vehicle, and to a method for assembling motor vehicles, in which a respective bodyshell (42) of the motor vehicle is provided with a floor module (28) of this type together with an associated chassis (16) and drive train (14).