Vehicle Front Body Module Stay and Self-Aligning Connector
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Solution Overview
Problem
The existing assembly procedures for vehicle front body modules in heavy-duty vehicles, such as trucks, face challenges with vibration issues due to the lateral extension of the front module beyond the connection point with the chassis, leading to durability and quality concerns, and require flexibility to accommodate manufacturing tolerances.
Innovation Solution
A support arrangement featuring a longitudinally extending connecting member and a stay with a self-aligning pin and aperture, optionally incorporating a vibration isolator like an inflatable member or flexible section, allows for efficient attachment and reduced vibration by aligning the front body module with the chassis in a simple linear motion, accommodating tolerances and providing vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the front body module is attached to the chassis by a single connection location, then the assembly procedure is simple and efficient, but the lateral portions of the front module experience vibration and durability issues
Solution Approach 1:
The support arrangement is divided into multiple independent components: a connecting member attached to the front body module, a stay attached to the chassis, and a connector joining them. This segmentation allows each component to be optimized independently while collectively solving both assembly efficiency and vibration resistance requirements
Solution Approach 2:
The connector features a nested structure with a receptacle receiving a protrusion, allowing the connecting member and stay to be joined in a compact, self-aligning manner. The nested design enables simple linear motion for assembly while providing rigid connection to minimize vibration
2Ease of operation
If the outermost side portions of the front module extend beyond the connection location, then the lateral access is improved, but the level arm effect causes increased vibration
Solution Approach 1:
The stay acts as an intermediary structural element between the chassis connection location and the lateral portions of the front module. It provides intermediate support at the outermost side portions, reducing the effective level arm length and thereby minimizing vibration while preserving lateral access
3Reliability
If rigid connection is used between the stay and front module, then vibration is reduced, but manufacturing tolerances cannot be accommodated
Solution Approach 1:
The connector parameters (receptacle and protrusion geometry) are designed to provide both rigidity for vibration resistance and compliance for tolerance accommodation. The specific dimensional parameters allow the connection to be rigid in service while accommodating manufacturing variations during assembly
4Reliability
If complex support arrangement is used to reduce vibration, then durability is improved, but assembly complexity increases
Solution Approach 1:
The connector is designed to be self-aligning and self-assembling through simple linear longitudinal motion. The receptacle and protrusion geometry automatically guides the assembly process, eliminating the need for complex alignment procedures or additional fastening steps while providing durable vibration-resistant connection
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables efficient, durable, and high-quality assembly of the front body module by minimizing vibrations and accommodating manufacturing tolerances, enhancing the perceived quality and durability of the vehicle while maintaining assembly efficiency and operator ergonomics.
Implementation Method 1
a vibration isolator, such as an elastomeric vibration isolator 55, is provided between the stay 40 and the front body module 10
Implementation Method 2
In a further embodiment the vibration isolator may comprise an inflatable member
Data Source
AI summary
The invention relates to a subassembly for a vehicle, the subassembly comprising a chassis (50) assembly and a front body module (10). The front body module (10) is attachable to a forward portion of the chassis (50) assembly. The front body module includes a side portion (20) which extends outwardly beyond the chassis in a transverse direction. A stay (40) is provided which extends transversely outwardly from the chassis assembly (50) to support the side portion. One of the front body module (10) or the stay (40) is provided with a connecting member (30) which extends in a substantially longitudinal direction. The other of the stay (40) or front body module is provided with a corresponding longitudinally aligned aperture (42) for receiving the connecting member in use to support the side portion (20) of the front body module (10). A method of assembly is also disclosed.