Modular Motor Vehicle Underbody Structure with Common Floor
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Solution Overview
Problem
The production of motor-vehicle structures for different segments with varying transverse dimensions is complex and inefficient, as existing methods require distinct assembly lines and structures, leading to increased costs and logistical challenges.
Innovation Solution
A modular approach that utilizes a common floor structure with adaptable side members of different configurations to produce vehicles of varying transverse dimensions, allowing for the same floor structure and attachments to be used across segments, thereby simplifying the assembly line and production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If distinct assembly lines and structures are used for different motor-vehicle segments, then the specific dimensional requirements for each segment are met, but production complexity and costs increase
Solution Approach 1:
The underbody structure is divided into modular components: a common floor structure and interchangeable side members. The side members are segmented into different configurations (first and second side members) that can be selectively attached to the floor structure, allowing different transverse dimensions to be achieved without requiring distinct assembly lines for each vehicle segment.
Solution Approach 2:
The floor structure is designed as a universal base that can accommodate multiple types of side members. This multi-functional design allows the same floor structure to serve different vehicle segments (e.g., compact and standard segments) by simply changing the side members, thereby reducing production complexity while maintaining the ability to meet specific dimensional requirements.
2Manufacturing precision
If distinct assembly lines are used for different motor-vehicle segments, then specific dimensional requirements are met, but production costs increase
Solution Approach 1:
By segmenting the underbody structure into a common floor structure and separate side members, the patent enables cost-effective production. The floor structure can be manufactured once and used across different segments, while only the side members need to be varied. This reduces tooling costs, assembly line requirements, and overall production expenses compared to manufacturing completely different structures for each segment.
Solution Approach 2:
The universal floor structure design allows a single production line to manufacture vehicles for different segments by simply changing the side members. This eliminates the need for multiple dedicated assembly lines, significantly reducing production costs while still meeting the specific dimensional requirements of different vehicle segments through the interchangeable side member configurations.
3Device complexity
If a common floor structure is used for different segments, then production complexity is reduced, but the ability to meet specific dimensional requirements may be compromised
Solution Approach 1:
The underbody structure is segmented into a standardized floor structure and interchangeable side members. The side members are designed with specific configurations (first side members for one segment, second side members for another segment) that provide the necessary dimensional variations. This segmentation allows the common floor structure to meet production simplicity requirements while the specialized side members ensure specific dimensional requirements are met for each vehicle segment.
Solution Approach 2:
While the floor structure maintains uniform, standardized characteristics across all segments, the side members are designed with local variations specific to each segment's dimensional requirements. This local quality differentiation allows the overall structure to meet both production simplicity and segment-specific dimensional requirements, as each side member type is optimized for its intended application while integrating with the common floor structure.
4Manufacturing precision
If traditional production methods are used for different segments, then specific vehicle dimensions are achieved, but assembly line simplification is prevented
Solution Approach 1:
The underbody structure is divided into modular components that can be assembled in different configurations. The floor structure serves as a common base, and side members of different types can be attached to create different vehicle dimensions. This modular segmentation allows a single assembly line to produce vehicles for different segments by simply changing the side members, thereby simplifying the assembly line while still achieving the required dimensional variations.
Solution Approach 2:
The assembly process is designed to be dynamic and flexible, allowing the same floor structure to be combined with different side members depending on the required vehicle dimension. This dynamic configuration capability enables the assembly line to adapt to different segment requirements without reconfiguration, simplifying the overall assembly line design while maintaining the ability to produce vehicles with specific dimensional characteristics.
Data Source
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AI summary
A method for the production of motor-vehicle structures, wherein an underbody structure (1) is provided including a floor structure (2), and two side members (17) that are welded to two longitudinal lateral edges of the floor structure (2). Each side member comprises an inner element (19, 20) of side member, welded to a respective longitudinal lateral edge of the floor structure, and an outer element (23, 24) of side member, welded to the inner element (19, 20) of side member. The method envisages the use of a common floor structure suitable both for motor-vehicle structures belonging to a first, lower, segment and for motor-vehicle structures belonging to a second, upper, segment. Each lateral edge of the floor structure (2) has for a prevalent portion of its length a flange (L) vertically bent upwardly and welded to an intermediate wall of the respective inner element (19, 20) of side member.