Modular Commercial Vehicle Assembly With Standardized Interfaces
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Solution Overview
Problem
Existing modular vehicle assembly processes face challenges in parallelizing assembly across multiple locations with varying production quantities, leading to non-uniform automation levels and increased documentation efforts, particularly in CKD manufacturing.
Innovation Solution
A modular commercial vehicle design comprising a frame module, front axle module, cab module, rear axle drive module, and energy supply module, each with standardized interfaces, allowing for independent functional testing and assembly, reducing part variety and inventory, and enabling centralized module manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional commercial vehicles are built with separately developed components (chassis, powertrain, body), then each component can be optimized independently, but the final assembly process becomes complex and time-consuming
Solution Approach 1:
The vehicle is divided into standardized modules including cab module, front axle module, rear axle drive module, and frame module. Each module can be manufactured and optimized independently through specialized production lines, then assembled quickly using standardized interfaces and common fasteners, resolving the contradiction between independent optimization and assembly efficiency
Solution Approach 2:
The patent implements universal standardized interfaces and common fasteners that can be used across all module types. This allows the same assembly tools, fastener inventory, and interface specifications to serve multiple different module combinations, enabling both specialized component optimization and rapid standardized assembly
2Reliability
If a commercial vehicle is designed as a complete integrated system, then system integration is optimized, but design flexibility and customization capability are reduced
Solution Approach 1:
The vehicle system is segmented into independent standardized modules (cab, front axle, rear axle drive, frame) that maintain reliable system integration through defined interfaces while allowing flexible recombination. Different module configurations can be assembled to create customized vehicles for different applications, maintaining both integration reliability and design flexibility
Solution Approach 2:
The modular architecture enables dynamic reconfiguration of vehicle systems. Modules can be selectively assembled or disassembled based on specific application requirements, allowing the same set of standardized modules to be dynamically reconfigured for different cargo types, payload requirements, or operational conditions
3Reliability
If traditional vehicle assembly uses many different fasteners and joining methods, then specific joining requirements can be met, but inventory complexity and assembly time increase
Solution Approach 1:
The patent specifies common fasteners and standardized joining methods that can satisfy multiple different joining requirements across various module types. This universal fastening system reduces inventory complexity and allows assembly workers to use the same fasteners and procedures for different joining applications, reducing assembly time while maintaining joining reliability
4Adaptability or versatility
If commercial vehicles are manufactured with high customization capability, then customer-specific requirements can be met, but production efficiency and cost-effectiveness decrease
Solution Approach 1:
The vehicle is segmented into standardized modules that can be manufactured through efficient specialized production lines, then quickly assembled in configurable combinations. This allows high-volume production of standardized modules (maintaining productivity) while enabling flexible customization through different module selections and arrangements (maintaining adaptability)
Solution Approach 2:
The modular system enables customization through parameter changes in module selection and configuration rather than custom manufacturing. Different cab types, axle configurations, and body styles can be selected from standardized options, allowing customer-specific requirements to be met through configuration selection rather than custom production, maintaining both customization and production efficiency
Data Source
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AI summary
The invention relates to a commercial vehicle (10), preferably a truck, comprising a frame module (16) which includes a vehicle frame (68). The commercial vehicle (10) includes a front axle module (14), a cab module (12), a rear axle drive module (20), and an energy supply module (18). The modules (12, 14, 18, 20) can be mounted to the vehicle frame (68). The invention provides an overall concept for a modular commercial vehicle (10). This overall concept simplifies the assembly system during final vehicle assembly. Final assembly is achieved by assembling a small number of functional main modules via standardized interfaces. Each main module integrates several related functions of the commercial vehicle (10).