Modular Bus Door Module with Pre-Tested Drive Assembly

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Solution Overview

Problem

The existing door units for buses are cumbersome to assemble due to their integration with the vehicle chassis, requiring sequential and time-consuming on-site assembly, which limits parallel assembly and increases costs, especially since individual components cannot be pre-tested or replaced easily.

Innovation Solution

A modular door unit design that allows the door and door drive to be assembled and pre-tested outside the bus, with a standardized mounting frame and sub-modules that can be easily connected and replaced, enabling independent assembly and standardized connections for mechanical, electrical, and fluidic interfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the door unit is integrated with the vehicle chassis and assembled on-site, then the structural integrity is ensured, but the assembly time and complexity increase significantly

Engineering Contradiction:

Improvestructural integrityVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The door unit is divided into separate modular components including the door assembly, drive mechanism, and control systems that can be manufactured and tested independently before final installation on the vehicle chassis

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The door unit components are pre-assembled and pre-tested in a controlled environment before being installed on the vehicle, allowing for quality verification and adjustment prior to final installation

Inventive Principle:

Principle #10Preliminary action

2Strength

If the door unit is assembled sequentially on the vehicle, then the structural integrity is maintained, but the productivity decreases due to inability to perform parallel assembly

Engineering Contradiction:

Improvestructural integrityVSAvoidassembly productivity

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The door unit is segmented into independent modules that can be assembled in parallel at different locations and then integrated onto the vehicle chassis simultaneously

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple door unit components are prepared and pre-assembled in advance at different workstations before the final installation phase, enabling parallel processing and significantly reducing overall assembly time

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If the door unit is customized for specific vehicle configurations, then the adaptability to different uses is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvevehicle configuration adaptabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The door unit is designed as a universal module with standardized interfaces and adjustable components that can be configured for different vehicle types, traffic directions, and usage requirements without requiring custom manufacturing for each application

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP1749684B1Door module for a bus

Publication Date: 2009.11.04 MAN TRUCK & BUS SE

Figure 1
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AI summary

Door unit is designed as independently manageable door module (6), which has a mounting frame. The door and the door drive are mounted in the mounting frame outside the omnibus (1). The door module has defined external dimensions and can be inserted over the module opening (5) in the vehicle framework of the mnibus and it can be connected to the vehicle framework.