Interlocking Cast Vehicle Body Components Assembly
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Solution Overview
Problem
Current vehicle manufacturing methods require extensive welding of steel components, which is labor-intensive and costly, and do not allow for easy reconfiguration of vehicle body styles.
Innovation Solution
A method of manufacturing vehicles using interlocking cast vehicle body structure components with integral mating features, allowing assembly without welding and enabling multiple vehicle body styles to be constructed on a common assembly line, with the potential for reconfiguration by replacing select components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to assemble vehicle body components, then structural strength is improved, but labor intensity and manufacturing cost increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical interlocking system using cast components featuring integral mating features. The cast body structure components include built-in mating features that mechanically interlock to replace weld joints, eliminating the need for welding operations while maintaining structural integrity through precision-cast geometric features.
Solution Approach 2:
The patent changes the manufacturing parameter of body structure components from stamped steel requiring welding to cast components with integral mating features. This parameter change in the manufacturing process (from stamping to casting) and in the component design (adding integral mating features) enables mechanical interlocking that eliminates welding while preserving structural strength.
2Strength
If welding is used to assemble vehicle body components, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical interlocking system using cast components featuring integral mating features. The cast body structure components include built-in mating features that mechanically interlock to replace weld joints, eliminating the need for welding operations while maintaining structural integrity through precision-cast geometric features.
Solution Approach 2:
The patent changes the manufacturing parameter of body structure components from stamped steel requiring welding to cast components with integral mating features. This parameter change in the manufacturing process (from stamping to casting) and in the component design (adding integral mating features) enables mechanical interlocking that eliminates welding while preserving structural strength.
3Reliability
If traditional vehicle body assembly methods are used, then structural integrity is maintained, but adaptability for different body styles is reduced
Solution Approach 1:
The patent divides the vehicle body structure into multiple separate cast components (inner fender structures, closure frame structures, floor structures, etc.), each with integral mating features. This segmentation allows individual components to be selectively replaced or reconfigured to create different body styles while maintaining overall structural integrity through the interlocking mating features between components.
Solution Approach 2:
The patent designs cast body structure components with universal integral mating features that can accommodate different body style configurations. The same set of cast components with standardized mating features can be used across multiple vehicle body styles, allowing a common platform to support various configurations (sedan, SUV, truck, etc.) by simply changing or repositioning specific components.
Data Source
AI summary
A method of manufacturing a vehicle. A set of vehicle body structure components is assembled with interlocking mating features.