Segmented Mockup Engine Block Kit for Lightweight Fitment
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Solution Overview
Problem
Existing foam and plastic replica engine blocks used for engine swaps are heavy and costly, making them difficult to handle and maneuver, and require extensive custom fabrication for fitment, posing risks of damage to the actual engine and increased manufacturing costs.
Innovation Solution
A mockup engine block assembly kit comprising interlocking face plates and extension walls with tabs, which are lightweight and easier to assemble, reducing the need for fasteners and fabrication time, and allowing for secure motor mount integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If foam and plastic replica engine blocks are used, then handling and maneuvering become easier, but weight remains non-trivial (exceeding 20 pounds)
Solution Approach 1:
The mockup engine block is divided into multiple separate components including face plates, cylinder extension walls, motor mount extensions, and a bottom plate. These segments can be individually handled, assembled, and stored, significantly reducing the weight burden during handling while maintaining the overall structural integrity when assembled.
Solution Approach 2:
The modular components of the mockup engine block can be nested or stacked together when not in use, compacting the overall storage volume and making transportation and storage more efficient despite the individual weight of components.
2Manufacturing precision
If traditional hoisted engine swap method is used, then fitment measurements can be obtained, but risk of damaging actual engine increases
Solution Approach 1:
A mockup engine block that replicates the external dimensions, shape, and key features of the actual replacement engine is created using lightweight materials. This copy allows for all necessary fitment measurements and vehicle modifications to be performed without risking damage to the actual engine, while maintaining measurement accuracy.
3Object-affected harmful factors
If foam and plastic replica engine blocks are used, then actual engine can be protected, but manufacturing cost increases
Solution Approach 1:
By segmenting the mockup engine block into separate components, manufacturing can be optimized for each individual part using cost-effective materials and processes. This modular approach reduces material costs and allows for more efficient production compared to manufacturing a single solid replica.
Solution Approach 2:
The material composition and structural parameters of the mockup engine block are optimized to achieve the necessary protective function at lower cost. Using lightweight materials like thin-walled plastics or foams with appropriate reinforcement only where needed reduces material costs while maintaining sufficient durability for measurement purposes.
4Ease of operation
If foam and plastic replica engine blocks are used, then assembly and disassembly become easier, but manufacturing complexity increases
Solution Approach 1:
The mockup engine block is designed as a segmented modular structure with standardized connection interfaces between components. This segmentation enables easy assembly and disassembly through simple connection mechanisms while the modular design actually simplifies manufacturing by allowing each component to be produced independently using standardized processes.
Data Source
AI summary
The present disclosure relates to a mockup engine block and kit for assembling same.