Modular Vehicle Truss Member Assembly for Flexible Chassis Manufacturing
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Solution Overview
Problem
Conventional chassis structures require large investments in facilities and have low design flexibility, leading to increased production costs due to the need for multiple molds and complex manufacturing processes, which are not suitable for rapid design changes or eco-friendly smart factory environments, especially with the emergence of autonomous driving technologies.
Innovation Solution
A vehicle truss member structure composed of modularized pipe components that can be easily coupled through bolting or riveting, eliminating the need for press processing, welding, and painting, with end patches welded inside the pipes to maintain distance and avoid welding beads, allowing for simplified manufacturing and assembly in a smart factory setting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional chassis structures are produced by press processing with molds, then structural strength and integrity are improved, but manufacturing complexity and investment in large-scale facilities increase
Solution Approach 1:
The chassis is divided into multiple modular truss members that can be independently manufactured and then assembled together. Each truss member is a separate component with standardized connection interfaces, allowing the complex chassis structure to be broken down into manageable segments that can be produced using simpler processes and then joined through mechanical coupling.
2Adaptability or versatility
If multiple molds are used for producing different chassis types, then design variety is improved, but production cost increases exponentially
Solution Approach 1:
The truss members are designed with universal connection interfaces and standardized geometries that can be used across multiple chassis configurations. By varying the arrangement and combination of standardized truss members rather than creating entirely new molds for each design, the system achieves design flexibility while maintaining manufacturing efficiency and controlling costs.
3Ease of operation
If chassis components are mechanically assembled through bolting or riveting, then assembly simplicity and eco-friendly manufacturing are improved, but coupling strength may be reduced
Solution Approach 1:
End patches are pre-welded to the truss members during manufacturing, creating strong permanent joints at critical locations. This preliminary welding action ensures that the mechanical assembly process using bolts or rivets connects already-strengthened components, maintaining overall coupling strength while preserving the simplicity and eco-friendly nature of the final assembly process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces manufacturing costs and complexity, enabling rapid production of various vehicle models while ensuring strong coupling and improved assembly characteristics, facilitating the creation of autonomous vehicles without the need for extensive facilities and processes.
Implementation Method 1
The end patch may be welded to the member body to be spaced inward from the end thereof
Data Source
AI summary
An embodiment vehicle truss member includes a member body having a pipe shape having an open end and an end patch coupled to the open end of the member body to close the open end of the member body, the end patch including a coupling part configured to be selectively coupled to an external element.