Modular Vehicle Structure With Interchangeable Cabin and Battery Modules
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Solution Overview
Problem
Existing vehicle manufacturing processes require time-consuming assembly of different vehicle components due to fixed support structures, which do not easily accommodate varying consumer demands for vehicle body types, shapes, and battery capacities, especially in the electric vehicle segment.
Innovation Solution
A modular vehicle assembly system comprising a cabin module, front end module, and rear end module, each with specific attachment interfaces, allowing for secure mating and easy customization of vehicle components such as batteries, wheels, and support structures, enabling various body styles and battery sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed support structure is used in traditional vehicle manufacturing, then structural stability is ensured, but assembly time increases and adaptability to varying consumer demands decreases
Solution Approach 1:
The vehicle support structure is divided into multiple detachable modules including a subframe assembly, a body assembly, and a battery assembly. Each module can be independently manufactured and then quickly assembled together using standardized attachment interfaces, significantly reducing assembly time while maintaining structural integrity
Solution Approach 2:
The standardized attachment interfaces and modular design allow the same support structure components to be used across different vehicle configurations and body styles. This universal interface system enables rapid reconfiguration to meet varying consumer demands without requiring entirely new platform designs
2Adaptability or versatility
If a modular skateboard design with fixed battery tray is used, then ease of assembly is improved, but the ability to modify battery size and capacity decreases
Solution Approach 1:
The battery system is segmented into a standardized battery assembly module that includes the battery tray and battery components as an integrated unit. This module can be independently attached to or removed from the subframe assembly, allowing easy modification of battery size and capacity without affecting other vehicle systems
Solution Approach 2:
The standardized attachment interfaces on the subframe assembly are designed to accommodate different sized battery assemblies. The same interface system can support various battery capacities and configurations, providing adaptability without requiring different mounting structures for each battery type
3Ease of manufacture
If different underlying support structures are designed for different vehicle types, then vehicle performance is optimized, but manufacturing complexity and cost increase
Solution Approach 1:
The subframe assembly incorporates standardized attachment interfaces that can accommodate multiple body styles and vehicle configurations. The same basic subframe module can serve as the underlying support structure for sedans, SUVs, delivery vehicles, and other body types by simply changing the upper body panels and modules attached to it
Solution Approach 2:
The vehicle structure is segmented into a common subframe assembly and various detachable body assemblies. This segmentation allows manufacturers to produce a standardized subframe in high volume for efficiency, then quickly assemble different body types using the same base platform, reducing manufacturing complexity while maintaining vehicle type variety
Data Source
AI summary
A modular vehicle system includes a cabin module, front end module, and rear end module. The cabin module includes a floor structure of the vehicle and has a front end and a rear end, and a plurality of panels extending upwardly from the floor structure. The front end module is configured to include the front wheels of the vehicle. The rear end module is configured to include rear wheels of the vehicle. The front end module is configured to securely attach to the front end of the cabin module, and the rear end module is configured to securely attach to the rear end of the cabin module. Various types of modules can be constructed and assembled to define various types of vehicles. The floor structure of the cabin module may include an electric vehicle battery, and different cabin modules may have different battery types enabling different vehicle ranges.