Vehicle Interior Module Assembly Using a Separate Body Top-Hat
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Solution Overview
Problem
The traditional vehicle assembly process limits the size and shape of interior components due to constraints imposed by door and roof openings, leading to reduced modularity and increased complexity and cost.
Innovation Solution
A method involving assembling a chassis platform, mounting a floor pan to the platform, and then attaching a modular interior, followed by assembling and mounting a body top-hat separately, allowing for greater flexibility in interior component design and installation, including electric storage devices and motors, and using a corrosion-resistant coating for the floor pan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If interior components are inserted through door and roof openings in traditional assembly process, then assembly process is simplified, but the size and shape of interior components are limited
Solution Approach 1:
The vehicle body is segmented into separate components (floor pan, body top-hat, interior components) that can be assembled independently and then joined together. This allows interior components to be manufactured separately with greater design freedom, then integrated into the final vehicle assembly without being constrained by door opening dimensions.
Solution Approach 2:
The assembly approach transitions from inserting components through lateral door openings to assembling components in a different dimensional sequence - first assembling the floor pan and interior components on the ground plane, then raising the complete assembly and attaching the body top-hat from above. This dimensional reorganization eliminates the constraint of door opening size.
2Device complexity
If interior components are assembled through narrow door openings, then assembly tools must be small and simple, but modularity of interior components is reduced and complexity increases
Solution Approach 1:
Interior components are pre-assembled onto the floor pan in a preliminary assembly stage before the body top-hat is attached. This preliminary action allows the use of larger, more capable assembly tools and fixtures during the initial component attachment, without being constrained by the need to insert components through narrow door openings later. The sequence is: attach floor pan to platform, then attach interior components to floor pan, then attach body top-hat.
Solution Approach 2:
The assembly process utilizes vertical dimension by raising the floor pan assembly and attaching the body top-hat from above, rather than attempting to insert components laterally through door openings. This dimensional change enables the use of larger assembly equipment and fixtures during component attachment.
3Device complexity
If traditional assembly process is used with door opening constraints, then vehicle structure is simplified, but cost and complexity of assembly process increase
Solution Approach 1:
The vehicle body is divided into separable modules (floor pan assembly with interior components, body top-hat) that can be manufactured and prepared independently. This segmentation enables parallel production processes, reduces assembly complexity, and allows for more efficient resource utilization, ultimately reducing manufacturing costs despite the additional structural elements required.
Solution Approach 2:
Interior components are pre-assembled onto the floor pan before final vehicle assembly. This preliminary action allows for more efficient use of assembly resources, enables better quality control during component attachment, and reduces the overall complexity of the final assembly process, leading to cost reductions that offset the additional structural elements required.
Data Source
AI summary
A vehicle assembly method includes assembling a chassis platform, mounting a floor pan to the platform, mounting a modular interior to the floor pan, assembling a body top-hat separate from the platform and the floor pan, and mounting the body top-hat to the platform and the floor pan after mounting the modular interior to the floor pan.