Modular Vehicle Body Joint Structure with Connection Pipe
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Solution Overview
Problem
Conventional vehicle body joint structures, particularly monocoque designs, face challenges in expandability and cost-effectiveness during small batch production and design changes, as they require numerous molds and are inflexible for various vehicle designs.
Innovation Solution
A modular vehicle body joint structure featuring a lower panel, upper panel, and connection pipe that can be easily adapted and extended to connect with other parts, allowing for secure rigidity and flexibility, with components such as a wheel mounting part and support structures to enhance assembly and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional monocoque structure with multiple mold parts is used, then rigidity is improved, but expandability and design flexibility deteriorate
Solution Approach 1:
The vehicle body is divided into modular segments including a first vehicle body part, a second vehicle body part, and a third vehicle body part. The connection pipe serves as a standardized interface that can connect different segments together, allowing the vehicle body to be assembled from separate modules rather than requiring a complete monocoque structure to be formed in one piece.
Solution Approach 2:
The connection pipe is designed with a universal interface that can connect to both the first vehicle body part and the second vehicle body part, serving multiple connection functions. This standardized connection mechanism can be used across different vehicle configurations and designs, providing adaptability without requiring design-specific custom connections for each vehicle type.
2Adaptability or versatility
If design changes are made for small quantity batch production, then various vehicle designs are achieved, but production cost increases due to significant increase in number of molds
Solution Approach 1:
By segmenting the vehicle body into separate parts that connect through standardized pipes, each segment can be manufactured independently using the same molds. This allows different vehicle designs to be created by assembling different combinations of standardized segments rather than creating entirely new molds for each design variant.
Solution Approach 2:
The connection pipe serves as a universal interface that can accommodate different vehicle body configurations. The same connection pipe design can be used across multiple vehicle types and designs, eliminating the need to develop new molds for each design variation and reducing production costs for small batch manufacturing.
3Ease of manufacture
If an entirety of the front pillar is designed with one inner member and draw mold, then manufacturing is simplified, but expandability to connect with other parts deteriorates
Solution Approach 1:
The vehicle body structure is segmented into separate parts (first vehicle body part, second vehicle body part, third vehicle body part) that are connected through standardized connection pipes. This segmentation allows each part to be manufactured independently using simple processes while maintaining the ability to connect with other parts through the standardized interface.
Solution Approach 2:
The connection pipe acts as an intermediary element between different vehicle body parts. Rather than requiring direct integration of all parts into a single monocoque structure, the connection pipe mediates the connection, enabling expandability and adaptability while keeping the manufacturing of individual parts simple and independent.
Data Source
AI summary
A vehicle body joint structure includes a lower panel disposed on a side surface of a floor assembly, an upper panel extending upward from the lower panel and connected to a roof assembly for a roof of a vehicle body, and a connection pipe extending vertically to connect the floor assembly to the roof assembly, disposed to face the upper panel, and coupled to the upper panel.