Modular Vehicle Assembly Pallet for Fast Model Changeovers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional vehicle assembly pallets are inflexible and require significant changes when switching between different vehicle models, leading to inefficiencies in production and the need for substantial storage space.
Innovation Solution
A modular reconfigurable vehicle assembly pallet system that uses interchangeable modular plates with precision-positioned risers and locating pins, allowing for quick reconfiguration to accommodate different vehicle models without altering the underlying pallet structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional rigid pallet systems are used with fixed support beams and risers, then structural stability is maintained, but adaptability to different vehicle models deteriorates
Solution Approach 1:
The pallet system is divided into modular components: fixed support beams provide structural stability, while interchangeable riser assemblies (comprising risers, locating pins, and locking mechanisms) can be swapped to accommodate different vehicle models. This segmentation allows the stable base structure to remain while adapting the configurable components.
Solution Approach 2:
The system transitions from a completely fixed rigid structure to a dynamic reconfigurable system where riser assemblies can be locked in fixed positions for stability during assembly, then unlocked and repositioned for different vehicle models. The locking mechanism enables the structure to be rigid when needed and reconfigurable when model changes occur.
2Adaptability or versatility
If the entire pallet system is reconfigured for each vehicle model change, then adaptability is improved, but loss of time and productivity deteriorates
Solution Approach 1:
By dividing the pallet into fixed support beams and interchangeable riser assemblies, only the necessary components (risers and locating pins) need to be changed for each vehicle model, rather than reconfiguring the entire pallet system. This reduces reconfiguration time while maintaining adaptability.
Solution Approach 2:
Riser assemblies are pre-configured with specific locating pin positions and dimensions suitable for different vehicle models before being brought to the assembly line. This preliminary preparation allows for rapid exchange without on-site customization, reducing model changeover time.
3Adaptability or versatility
If multiple complete pallet systems are stored for different vehicle models, then adaptability is improved, but storage space requirements deteriorate
Solution Approach 1:
Instead of storing complete pallet systems for each vehicle model, only the interchangeable riser assemblies and locating pins are stored in modular racks. The fixed support beams remain on the assembly line, dramatically reducing the volume of equipment that needs storage space.
Solution Approach 2:
A single set of support beams serves multiple vehicle models by accepting different riser assemblies. This universal base structure eliminates the need to store multiple complete pallet systems, as one pallet framework can be configured for different models through component exchange.
4Manufacturing precision
If precision locating pins are rigidly fixed to support beams, then manufacturing precision is maintained, but ease of reconfiguration deteriorates
Solution Approach 1:
Locating pins are segmented from the support beams and integrated into interchangeable riser assemblies. Each riser assembly is precision-manufactured with accurately positioned locating pins, maintaining manufacturing precision. The segmented design allows these precision components to be easily exchanged without affecting the fixed support beam structure.
Solution Approach 2:
The riser assemblies with locating pins function as temporary, replaceable components rather than permanent fixtures. They can be worn, damaged, or become misaligned and are simply replaced with new or repositioned assemblies, maintaining precision without the complexity of adjusting permanently fixed pins.
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
The present disclosure relates to a modular reconfigurable vehicle assembly pallet system (90) and a method for reconfiguring an assembly pallet (90) for use in the assembly of vehicle bodies. In one example, a plurality of modular assembly plates (94) are assembled having vehicle locators positioned specifically for a particular model vehicle. The assembled vehicle-specific plates are easily installed on the universal pallet (90) positioned along an assembly line in an assembly sequence. The vehicle-specific modular plates (94) can be quickly interchanged on the assembly pallet (90) to thereby reconfigure the assembly pallet (90) to coordinate with changing vehicle build assembly sequences.