Modular Vehicle Frame Assembly Cells for Faster Robotic Production
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Solution Overview
Problem
Current manufacturing methods for vehicles, such as body-on-frame and unibody constructions, face challenges in flexibility, weight savings, and cost efficiency, particularly in the transition to new designs and assembly processes, with conventional space frame chassis being labor-intensive and time-consuming.
Innovation Solution
A manufacturing cell system comprising a positioner, robot carrier, and robot, with a vertical lift and controller, that supports and assembles vehicle frames using modular components and joint members, enabling flexible and automated production with high robot utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional space frame chassis manufacturing is used, then torsional rigidity and customization are improved, but manufacturing time and labor intensity increase significantly
Solution Approach 1:
The space frame chassis is divided into modular components (frame rails, cross members, joints) that can be manufactured separately and assembled automatically. This segmentation enables parallel manufacturing of multiple components while maintaining the structural integrity and torsional rigidity of the complete chassis assembly.
Solution Approach 2:
Manual welding and assembly operations are replaced with automated robotic systems. The patent employs automated welding cells and robotic arms to perform joining operations, substituting labor-intensive mechanical processes with automated systems that maintain quality while dramatically reducing manufacturing time.
2Weight of moving object
If unibody construction is used, then weight and fuel economy are improved, but design flexibility and repair cost increase
Solution Approach 1:
The unibody structure is segmented into modular panels and frame sections that can be independently manufactured, assembled, and replaced. This modularity maintains the weight advantages of unibody construction while enabling flexible design changes and reducing repair costs through component-level replacement rather than entire body replacement.
Solution Approach 2:
The manufacturing system is designed with universal fixtures and positioning devices that can accommodate multiple body styles and configurations. The same automated assembly line can produce different vehicle models by reconfiguring tooling and programming robots, providing design flexibility without requiring dedicated assembly lines for each model.
3Strength
If body-on-frame construction is used, then structural strength and ride comfort are improved, but vehicle weight increases
Solution Approach 1:
The patent employs composite materials and optimized alloy structures in the frame components to achieve high strength-to-weight ratios. By using advanced materials with improved specific strength, the frame maintains structural integrity and ride comfort characteristics while reducing overall vehicle weight compared to conventional body-on-frame constructions.
4Productivity
If automated manufacturing cells are implemented, then productivity and consistency are improved, but initial investment and system complexity increase
Solution Approach 1:
The automated manufacturing system is divided into discrete, modular work cells (positioning cell, welding cell, inspection cell) that can be independently operated and maintained. This modular architecture reduces system complexity by allowing each cell to be optimized and controlled separately while maintaining high overall productivity through coordinated operation of multiple cells.
Data Source
AI summary
Manufacturing cell based vehicle manufacturing systems and methods for a wide variety of vehicles are disclosed. In one aspect, a manufacturing cell configured for assembling a frame of a vehicle is disclosed. The manufacturing cell includes a positioner, a robot carrier and a robot. The positioner is configured to receive a fixture table configured to hold the frame. The robot carrier includes a vertical lift. The robot is configured to assemble the frame. The positioner is configured to support the frame in a vertical position during an assembling process. In another aspect of the disclosure, a system for manufacturing a vehicle based on a manufacturing cell is disclosed. In another aspect of the disclosure, a method for manufacturing a vehicle based on a manufacturing cell is disclosed.