Modular Vehicle Body Assembly with Slide Coupling
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Solution Overview
Problem
Existing vehicle body pillar structures are inflexible and costly due to the need for multiple molds for various designs and models, making them impractical for small-batch production and smart factory applications, while lacking extendibility for connections with other components.
Innovation Solution
A modular vehicle body assembly structure that separates into an upper and lower part, connected via a slide coupling structure, allowing for easy adaptation to different vehicle types and models, enhancing assemblability and rigidity through a combination of slide coupling and space frame structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a monocoque structure with DRAW mold is used for the entire front pillar, then rigidity is improved, but adaptability to different vehicle designs and models deteriorates
Solution Approach 1:
The front pillar is divided into multiple separate members (inner member, outer member, reinforcement member) that can be independently designed and assembled. This segmentation allows each component to be optimized for rigidity while the modular assembly enables adaptability to different vehicle designs without requiring complete redesign of the entire pillar structure.
Solution Approach 2:
The patent creates a universal front pillar structure where the same basic components (inner member, outer member, reinforcement member) can be configured in different ways to serve multiple vehicle models and designs. The reinforcement member with its coupling portions provides multi-functional connectivity that adapts to various mounting requirements across different vehicle types.
2Adaptability or versatility
If separate molds are developed for each vehicle model, then adaptability to different models is improved, but manufacturing complexity and cost deteriorate
Solution Approach 1:
The front pillar structure uses universal components (inner member, outer member, reinforcement member) that can be assembled in different configurations to accommodate multiple vehicle models. This universal design reduces the need for separate molds for each model, as the same basic components serve multiple purposes across different vehicle types.
Solution Approach 2:
The structure allows for dynamic configuration through the reinforcement member that can be positioned and coupled at different locations. This dynamic adaptability enables the same mold-produced components to be assembled in various arrangements to suit different vehicle models, reducing the need for model-specific molds.
3Adaptability or versatility
If the front pillar structure is designed for small quantity batch production, then flexibility in design changes is improved, but production cost deteriorates
Solution Approach 1:
By segmenting the front pillar into separate members that can be independently manufactured and assembled, the structure enables flexible design changes for small batch production. Each segment can be produced using standard molds and then assembled in different configurations, avoiding the need for expensive custom molds while maintaining design flexibility.
Solution Approach 2:
The patent applies partial customization through the reinforcement member and coupling portions, where only specific elements are adapted for different designs rather than the entire structure. This partial action approach allows design flexibility for small batches without the excessive cost of complete customization, as the majority of the structure uses standardized components.
4Device complexity
If the pillar structure lacks connection extendibility, then structural simplicity is improved, but connectivity with other components deteriorates
Solution Approach 1:
The reinforcement member is designed with multiple coupling portions that provide universal connectivity to different components (dash panel, cowl, A pillar, B pillar, etc.). This universal coupling capability extends connectivity without significantly complicating the basic structural form, as the same coupling mechanism serves multiple connection functions.
Solution Approach 2:
The coupling portions act as intermediaries between the front pillar structure and various other vehicle components. These intermediary elements enable easy connection and disconnection with different components while maintaining the simplicity of the core pillar structure, as the coupling portions handle the complexity of connections rather than the main structural members.
Data Source
AI summary
A vehicle body assembly structure includes a floor assembly including a floor, a front coupling portion provided at a front of the floor, and a rear coupling portion provided at a rear of the floor, and an upper assembly including a roof frame, a front mounting portion matched to the front coupling portion at a front of the roof frame, and a rear mounting portion matched to the rear coupling portion at a rear of the roof frame, wherein each of the front coupling portion and the front mounting portion and the rear coupling portion and the rear mounting portion are connected in a slide coupling structure.