Modular Vehicle Assembly Pallets for Rapid Model Changeover
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Solution Overview
Problem
Conventional vehicle assembly pallets are inflexible and require significant changes when switching between different vehicle models, leading to inefficient use of resources and increased storage needs due to their fixed geometry, which limits their ability to accommodate various vehicle body styles and sizes with the required precision and accuracy.
Innovation Solution
A modular reconfigurable pallet system that uses interchangeable modular plates with adjustable risers and locating pins, allowing for precise positioning of vehicle bodies in three-dimensional coordinates, enabling easy adaptation to different vehicle models by reconfiguring the pallet with specific plates and riser configurations, facilitated by industrial robots for efficient installation and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional fixed-geometry pallets are used, then structural stability is maintained, but adaptability to different vehicle models deteriorates
Solution Approach 1:
The pallet is divided into modular components including interchangeable plates with different geometries, adjustable risers, and removable locating pins. This segmentation allows individual components to be swapped based on vehicle model requirements without redesigning the entire pallet structure.
Solution Approach 2:
The pallet transitions from a static fixed-geometry structure to a dynamic reconfigurable system. Adjustable risers can be repositioned along the plates, and locating pins can be moved to different positions, enabling the pallet to adapt its configuration dynamically to match different vehicle body styles and sizes.
2Adaptability or versatility
If multiple dedicated pallets are maintained for different vehicle models, then adaptability is improved, but storage needs and resource utilization worsen
Solution Approach 1:
A single universal pallet platform can accommodate multiple vehicle models through interchangeable plates and adjustable components. The same base pallet structure serves multiple functions by accepting different plate configurations, reducing the total number of pallets needed from many dedicated pallets to a smaller set of universal pallets with varied attachments.
3Manufacturing precision
If precision locating pins are rigidly fixed, then positioning accuracy is maintained, but reconfigurability for different vehicles deteriorates
Solution Approach 1:
Locating pins are pre-positioned on interchangeable plates with high precision during manufacturing. When a plate is installed on the pallet, the pre-positioned pins automatically achieve the required positioning accuracy for that specific vehicle model without requiring complex adjustment procedures during reconfiguration.
Data Source
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AI summary
A modular reconfigurable vehicle assembly pallet system (90) and a corresponding method are disclosed. In one example, a plurality of modular assembly plates (94) are assembled having vehicle locators (54) positioned specifically for a particular model vehicle. The assembled vehicle-specific plates (94) are easily installed on a universal pallet (12) positioned along an assembly line (22) in an assembly sequence. The vehicle-specific modular plates (94) can be quickly interchanged on the assembly pallet (12) to thereby reconfigure the assembly pallet (94) to coordinate with changing vehicle build assembly sequences.