Modular Vehicle Floor Layout for Wheelbase and Battery Pack Variants
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Solution Overview
Problem
The development cycle of vehicle floors is prolonged due to the need for extensive redesign and retooling of die-casting molds to accommodate changes in wheel base and battery pack size, which cannot keep pace with the rapid updates in vehicle software.
Innovation Solution
A vehicle floor design featuring a front floor and rear floor with a connecting assembly, where the rear floor has a fixed and variable area, allowing the mold for the variable area to be easily adjusted according to the battery pack and wheel base size, enabling unified molds for the front and rear floors, thus reducing manufacturing time and matching software update speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the die-casting mold is extensively redesigned and retooled to accommodate changes in wheel base and battery pack size, then the vehicle floor can adapt to different vehicle configurations, but the development cycle of the vehicle floor is prolonged
Solution Approach 1:
The vehicle floor is divided into a front floor and a rear floor, with the rear floor further segmented into a first area (obtained through a fixed mold) and a second area (obtained through a variable mold). This segmentation allows the first area to remain consistent across different vehicle configurations while the second area adapts to different wheel bases and battery pack sizes, significantly reducing the development cycle
Solution Approach 2:
The fixed mold used for the first area of the rear floor is designed to be universal and can be applied across different vehicle models. This universal mold handles the common structural elements that do not change with vehicle configuration, while only the variable mold for the second area needs to be changed, reducing overall development time
2Productivity
If a unified mold is used for the front floor and rear floor first area, then manufacturing time is reduced, but the ability to accommodate different battery pack positions is limited
Solution Approach 1:
The rear floor is segmented into a first area produced by a unified fixed mold and a second area produced by a variable mold. This segmentation enables the first area to be manufactured efficiently with a unified mold while the second area is specifically adapted to accommodate different battery pack positions and wheel bases
Solution Approach 2:
Different regions of the rear floor are assigned different manufacturing approaches: the first area uses a fixed mold for efficiency and consistency, while the second area uses a variable mold for adaptability. This local differentiation optimizes both manufacturing time and adaptability to different vehicle configurations
Data Source
AI summary
Disclosed are a vehicle floor, a body-in-white and a vehicle. The vehicle floor includes: a front floor and a rear floor provided in sequence from a vehicle head to a vehicle tail of a vehicle body, and a connecting assembly. The rear floor includes a first area obtained through a fixed mold and a second area obtained through a variable mold, and the second area of the rear floor is connected to the front floor. The connecting assembly is provided on the second area of the rear floor and is configured to connect to a battery pack of a vehicle, and a position of the connecting assembly on the second area is determined by a size of the battery pack and a wheel base of the vehicle body.