Interchangeable Drive Modules for Fast Vehicle Service and Assembly
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Solution Overview
Problem
Traditional vehicle manufacturing and assembly processes result in complex, large, and expensive operations due to the assembly of numerous disparate parts, making vehicle servicing difficult and time-consuming, requiring specialized skills and extensive inventories.
Innovation Solution
The implementation of a modular vehicle architecture comprising a body module and drive modules, where the drive modules include major vehicle systems, allowing for simplified assembly, enhanced reliability through redundancy, and efficient serviceability by enabling quick replacement of faulty modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional vehicle assembly processes are used to assemble numerous disparate parts and assemblies, then complete vehicles can be manufactured, but the assembly plants become large, complex, and expensive operations
Solution Approach 1:
The patent applies segmentation by dividing the vehicle into modular assemblies (powertrain assembly, chassis assembly, body assembly) that can be manufactured separately and then integrated. This modular approach simplifies the overall assembly process and reduces plant complexity while maintaining manufacturing capability.
2Ease of manufacture
If traditional vehicle assembly processes are used to assemble numerous disparate parts and assemblies, then complete vehicles can be manufactured, but the assembly plants become large and expensive operations
Solution Approach 1:
By segmenting the vehicle into standardized modular assemblies, the patent reduces the total number of unique parts that need to be inventoried. Each module can be designed to fit multiple vehicle configurations, thereby reducing inventory requirements and associated costs.
Solution Approach 2:
The patent implements universality through modular assemblies that can serve multiple functions and be used across different vehicle models. This multi-functionality allows a single assembly plant to produce various vehicle configurations using the same core modules, reducing inventory needs.
3Ease of repair
If a component of a vehicle fails or the vehicle needs service, then the vehicle can be repaired, but the process is complex and time-consuming requiring specialized skill and training
Solution Approach 1:
The patent applies segmentation to vehicle serviceability by designing modular assemblies that can be easily detached and replaced. When a component fails, the entire module can be quickly swapped out without requiring complex disassembly procedures, thereby reducing service time and the need for specialized training.
4Ease of repair
If a component of a vehicle fails or the vehicle needs service, then the vehicle can be repaired, but the process requires specialized skill or training
Solution Approach 1:
By segmenting the vehicle into standardized modular assemblies with clear interfaces, the patent simplifies the service process. Technicians can easily identify and replace faulty modules without needing to understand complex internal configurations, reducing both the complexity of the service process and the level of specialized training required.
Data Source
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AI summary
Vehicles may be composed of a relatively few number of "modules" that are assembled together during a final assembly process. An example vehicle may include a body module, a first drive module coupled to a first end of the body module, and a second drive module coupled to a second end of the body module. One or both of the drive modules may include a pair of wheels, a battery, an electric drive motor, and/or a heating ventilation and air conditioning (HVAC) system. One or both of the drive modules may also include a crash structure to absorb impacts. If a component of a drive module fails or is damaged, the drive module can be quickly and easily replaced with a new drive module, minimizing vehicle down time.