Foam Underbody Model for Manufacturing Equipment Validation
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Solution Overview
Problem
Conventional methods for validating manufacturing equipment in motor vehicle production are delayed due to the long production times of concept vehicles, with models made from machining board being too heavy and 3D printed models being too flimsy, which hinders the efficient validation of equipment.
Innovation Solution
Creating a foam underbody using data from a three-dimensional model of the vehicle, machined to precise tolerances, to accurately mimic the weight and center of gravity, allowing for early validation of manufacturing equipment before a physical concept vehicle is available.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a concept vehicle is produced by hand to validate manufacturing equipment, then the equipment validation can be performed, but the production time for concept vehicles becomes excessively long
Solution Approach 1:
The patent creates a foam underbody as a simplified copy of the actual vehicle underbody. This foam model replicates the essential geometric features and dimensions needed for equipment validation without requiring a complete hand-built concept vehicle, thereby significantly reducing production time while maintaining validation reliability
Solution Approach 2:
The foam underbody is produced before the concept vehicle is available, allowing manufacturing equipment validation to begin in advance. This preliminary action enables equipment setup and testing to occur months earlier than traditional methods, shortening overall production cycles
2Strength
If a model of the underbody is produced from machining board, then the model is rigid, but it becomes too heavy to accurately reproduce weight and weight distribution
Solution Approach 1:
The patent changes the material parameter from dense machining board to foam material. This parameter change reduces the weight of the model by a significant factor while maintaining sufficient rigidity for equipment validation purposes, and allows for more accurate reproduction of the vehicle's actual weight and center of gravity characteristics
3Loss of time
If a model of the underbody is produced by 3D printing, then production time is reduced, but the model becomes too flimsy to be useful for verifying manufacturing equipment
Solution Approach 1:
The patent changes the material parameter from 3D printed material to machined foam material. This parameter change provides a favorable balance between production time and structural integrity, as foam can be quickly shaped through machining while providing sufficient rigidity and durability for equipment validation
Solution Approach 2:
The patent replaces the 3D printing process with a foam machining process. This substitution eliminates the structural weaknesses associated with 3D printed models while maintaining rapid production capabilities, resulting in a model that is both durable enough for equipment verification and producible in reduced time
Data Source
AI summary
Methods for validating manufacturing equipment for use during the production of a motor vehicle include identifying touchpoints on the underbody of a vehicle, machining a foam underbody, and validating manufacturing equipment using the foam underbody. A three-dimensional model of the underbody of the vehicle may be used to identify the touchpoints and for machining the foam underbody. The foam underbody includes a polyurethane foam. At least the touchpoints of the foam underbody are machined to a tolerance of less than or equal to +/â3 millimeters with reference to the touchpoints on the three-dimensional model.