Modular Vehicle Frame Rails With T-Slot Power Bus Mounting
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Solution Overview
Problem
Existing vehicle frames and bodies lack efficient and modular systems for mounting vehicle subcomponents and subsystems, requiring invasive modifications like cutting or drilling to accommodate different upfit packages.
Innovation Solution
A vehicle frame with opposing rails featuring T-slots and fastening anchors that allow for secure attachment of interchangeable components without altering the frame, using a variety of mounting brackets and sleeves for electrical connectivity along the rails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional vehicle frames are used for mounting subcomponents, then structural support is provided, but invasive modifications like cutting or drilling are required to accommodate different upfit packages
Solution Approach 1:
The frame is segmented into modular components with standardized T-slots at regular intervals, allowing different upfit packages to be mounted at discrete locations without modifying the frame structure itself. The T-slots provide pre-defined mounting positions that can accommodate various component configurations.
Solution Approach 2:
The T-slot configuration provides universal mounting capability for different types of vehicle subcomponents and upfit packages. The standardized slot geometry and positioning system can accommodate multiple component types and configurations without requiring frame modifications, enabling one frame design to serve multiple functions.
2Adaptability or versatility
If modular components are mounted to the frame, then flexibility in vehicle customization is improved, but the complexity of the mounting system increases
Solution Approach 1:
The T-slot mounting system provides a universal interface that simplifies the overall complexity by using a single standardized mounting mechanism for all modular components. This universal system replaces multiple specialized mounting solutions with one adaptable interface.
Solution Approach 2:
Instead of modifying the frame for each component, the system inverts the approach by providing pre-configured T-slots in the frame that accommodate various components. The complexity is shifted from custom frame modifications to standardized slot configurations that serve multiple purposes.
3Adaptability or versatility
If electrical connectivity is provided for movable components along the rail, then power and data delivery are enabled, but the complexity of the electrical system increases
Solution Approach 1:
The electrical connector is nested within the T-slot mounting structure, with the connector body positioned inside the slot and contacts extending to engage with electrical buses. This nesting integrates the electrical connection system within the existing mechanical mounting framework, reducing overall system complexity.
Solution Approach 2:
The mechanical mounting function and electrical connection function are merged into a single integrated system. The T-slot simultaneously provides mechanical support and houses the electrical connector, while the mounting bracket and electrical connector work together as a unified assembly for both mechanical and electrical connectivity.
Data Source
AI summary
A vehicle electrical system includes a first sleeve, at least one first bus bar, a second sleeve, and at least one second bus bar. The first sleeve defines a first slot extending longitudinally between first and second ends. The first slot is open along a lateral side of the first sleeve. The at least one first bus bar is disposed within the first slot. The second sleeve defines a second slot extending longitudinally between third and fourth ends. The second slot is open along a lateral side of the second sleeve. The at least one second bus bar is disposed within the second slot. The at least one first and second bus bars are configured to collectively engage an electrical connector that is disposed within the first and second slots.