Modular Motor Vehicle Chassis with Bolted Subassemblies

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Solution Overview

Problem

Current vehicle construction methods, such as rail chassis and monocoque designs, face limitations in providing structural rigidity while increasing complexity and requiring specialized handling and manufacture, with rail chassis isolating body elements from the chassis and monocoque designs increasing complexity and weight.

Innovation Solution

A semi-monocoque construction approach that incorporates wheeled axles and power train elements into a base chassis, with a vehicle body attached directly to the chassis using mechanical fasteners, forming a unitized frame for structural rigidity, and a removable power train module that can be assembled and installed independently, using bolted interconnects and non-permanent joints to facilitate modular assembly and easier manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a monocoque structure is used to provide structural rigidity, then structural strength is improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvestructural rigidityVSAvoidconstruction complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The vehicle body is divided into modular subassemblies (front subassembly, rear subassembly, middle subassembly) that can be manufactured separately and joined together. This segmentation allows for simplified manufacturing of individual modules while achieving the overall structural rigidity of a monocoque design through their integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines the advantages of both rail chassis and monocoque designs by integrating the body structure with the chassis to form a unitized frame. This merging creates a structurally rigid assembly that provides the benefits of monocoque construction while maintaining the modularity and ease of manufacture of segmented components.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If a monocoque structure is used to provide structural rigidity, then structural strength is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improvestructural rigidityVSAvoidmanufacturing ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular subassemblies are prepared in advance with mounting interfaces and fastening mechanisms pre-installed or pre-configured. This preliminary preparation of components facilitates easier assembly of the complete vehicle body structure, reducing manufacturing complexity while maintaining structural integrity.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If a rail chassis design is used to simplify construction, then ease of manufacture is improved, but structural rigidity deteriorates

Engineering Contradiction:

Improveconstruction simplicityVSAvoidstructural rigidity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The vehicle body structure is designed with adjustable and removable components that allow for dynamic reconfiguration. The mounting interfaces and fastening mechanisms enable the structure to adapt between different assembly states, providing structural rigidity when needed while maintaining ease of assembly and disassembly.

Inventive Principle:

Principle #15Dynamics

4Strength

If welded assembly is used to create a monocoque structure, then structural rigidity is improved, but ease of repair and component substitution deteriorates

Engineering Contradiction:

Improvestructural rigidityVSAvoidcomponent replaceability

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The vehicle body is divided into modular subassemblies (front subassembly, rear subassembly, middle subassembly) connected by mechanically fastened interfaces rather than permanent welds. This segmentation enables individual modules to be removed, replaced, or repaired independently while maintaining the overall structural integrity of the vehicle body.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11161560B2Motor vehicle modular construction

Publication Date: 2021.11.02 ARBOC SPECIALTY VEHICLES LLC

AI summary

A motor vehicle and construction method for a motor vehicle, such as a bus, wherein fabricated subassemblies or modules are joined using mechanical fasteners to form an integrated, load carrying structure. The fabricated subassemblies are configured to allow substitution of subassemblies with alternative configurations in order to produce a number of unique vehicle configurations each sharing a common architecture. Modular construction techniques allow for simplification of construction processes, reduction of welding processes, and the application of physically smaller subassemblies. Interchange and substitution of subassemblies with shared attributes may also facilitate production of vehicles having different characteristics.