Modular Vehicle Structural Component with Interchangeable Inserts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Vehicle structural components are often designed to meet maximum requirements, leading to unnecessary weight and manufacturing costs, as they are not optimized for varying vehicle models, resulting in resource inefficiency and increased vehicle weight for models with lower requirements.
Innovation Solution
A modular system comprising a basic body with receptacles and interchangeable inserts, where additional inserts can be added to enhance stiffness, allowing for flexible design to meet specific vehicle model requirements, using plastics components with continuous fibers for increased strength and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If vehicle structural components are designed to meet maximum requirements, then the stiffness and strength are sufficient for all vehicle variants, but the weight and manufacturing costs increase unnecessarily for variants with lower requirements
Solution Approach 1:
The vehicle structural component is divided into a basic body and multiple interchangeable inserts. The basic body provides the fundamental structure, while separate inserts (first insert, second insert, etc.) provide additional stiffening. This segmentation allows the component to be configured with different numbers and types of inserts based on specific vehicle variant requirements, rather than always including maximum stiffening. For example, a basic body with only a first insert can be used for variants with lower stiffness requirements, reducing weight, while the same basic body can accommodate additional inserts for variants requiring higher stiffness.
Solution Approach 2:
The design enables dynamic configuration of the structural component by allowing selective assembly of different insert combinations into the basic body. The receptacle structure allows for flexible arrangement of one or more inserts depending on the specific application requirements. This dynamic adaptability permits the component to optimize its weight-stiffness ratio for each vehicle variant rather than being fixed at maximum specifications.
2Adaptability or versatility
If vehicle structural components are designed to meet maximum requirements, then all vehicle variants are covered, but the manufacturing complexity increases due to the need to control multiple variants
Solution Approach 1:
The basic body is designed as a universal component that can accommodate different combinations of inserts through a standardized receptacle structure. The receptacle is configured to receive one or more inserts of different types, allowing a single basic body design to serve multiple vehicle variants. This universality simplifies manufacturing by reducing the number of different component designs that need to be produced and controlled, while still maintaining adaptability to various stiffness requirements through insert selection.
3Strength
If additional inserts are added to the receptacle, then the stiffness of the vehicle structural component increases, but the manufacturing costs increase
Solution Approach 1:
The stiffening function is segmented into separate insert components rather than being integrated into the basic body. This allows the stiffening elements to be manufactured independently, potentially using more efficient production methods, and only assembled when required. The modular nature enables cost-effective manufacturing by producing inserts in bulk and storing them for later assembly, rather than manufacturing complete assembled components for each variant, reducing overall manufacturing complexity and cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular system enables vehicle structural components to be optimized for varying requirements, reducing weight and manufacturing costs by allowing additional inserts to be added as needed, enhancing stiffness and adaptability while maintaining a compact design.
Implementation Method 1
The continuous fibers preferably extend unidirectionally in the inserts, with the result that they display an anisotropic material behavior. Consequently, the vehicle structural component has a high degree of stiffness especially in the longitudinal direction.
Implementation Method 2
The at least one first insert and/or the at least one further insert can consist of a fiber-reinforced plastic. The use of a continuous fiber material is suitable for the inserts.
Data Source
AI summary
A vehicle structural component includes a main body having a receptacle and a first insert for reinforcing the vehicle structural component. The insert is accommodated in the receptacle and only partially fills the latter. At least one further insert fits in the receptacle. A modular system for producing vehicle structural components and a method for producing vehicle structural components are provided.