Modular Vehicle Assembly Tolerance Compensation
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Solution Overview
Problem
Existing methods for manufacturing motor vehicles using modular construction face challenges in achieving high rigidity and strength while maintaining rapid production cycles, as gluing add-on modules to substructures requires lengthy adhesive curing and tight tolerances, slowing down production and complicating the assembly process.
Innovation Solution
The method involves producing substructure and superstructure modules independently, painting their edge regions, and using a tolerance-compensating screw connection to fix their relative positions during adhesive curing, allowing for larger tolerances and preventing crosslinking errors, with the screw connection remaining in the vehicle to enhance strength and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If gluing add-on modules to substructure is performed to achieve high vehicle rigidity and structural strength, then connection strength is improved, but production cycle time increases due to lengthy adhesive curing
Solution Approach 1:
The patent applies preliminary action by pre-assembling modules with temporary fasteners before painting, and pre-positioning components with的定位 features before adhesive application. This ensures proper alignment and positioning is established before the adhesive curing process begins, eliminating the need to wait for curing before proceeding with assembly operations.
Solution Approach 2:
The patent segments the connection process into distinct phases: mechanical pre-assembly with temporary fasteners, painting, and final adhesive bonding. This segmentation allows each phase to be completed independently without blocking others, reducing overall production cycle time while maintaining connection strength.
2Strength
If adhesive bonding is used to achieve high vehicle rigidity, then connection strength is improved, but manufacturing precision requirements increase due to extreme component tolerance demands
Solution Approach 1:
The patent introduces intermediaries in the form of定位 features, guide pins, and temporary mechanical fasteners that mediate between components during assembly. These intermediaries establish and maintain proper positioning and alignment, compensating for tolerance variations and ensuring accurate adhesive application without requiring extreme manufacturing precision.
Solution Approach 2:
The patent applies parameter changes by using adjustable positioning fixtures and tolerance-compensating fasteners that can be adjusted during assembly. This allows the system to adapt to variations in component dimensions and maintain proper alignment, reducing the stringency of tolerance requirements while achieving strong adhesive bonds.
3Shape
If modules are painted before assembly to achieve proper coating coverage, then surface quality is improved, but positioning accuracy decreases due to adhesive application on painted surfaces
Solution Approach 1:
The patent segments the surface preparation and assembly processes by applying adhesive promoters or primers to specific localized areas of the painted surface rather than treating the entire surface. This allows the majority of the surface to maintain its painted quality while the adhesive application areas receive specialized treatment for optimal bonding, preserving both surface quality and positioning accuracy.
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 approach enables the production of motor vehicles with high structural strength and rapid production cycles by maintaining precise positioning and preventing deformation or surface damage, while allowing further processing before adhesive hardening, thus simplifying the manufacturing process and increasing the vehicle's strength and rigidity.
Implementation Method 1
connecting the edge regions of the substructure and superstructure module using adhesive
Implementation Method 2
the substructure and the superstructure module be positioned relative to each other by means of a tolerance-compensating screw connection
Data Source
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AI summary
A method for producing a motor vehicle and a correspondingly produced motor vehicle having a modular construction, in which a substructure and at least one superstructure module are produced independently of one another and are subsequently permanently connected together.