Modular Vehicle System for Small Series Production
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Solution Overview
Problem
Current modular solutions for motor vehicles are inadequate for transferring concept vehicles with low forecast sales volumes into economical series production, as they do not effectively reduce development and manufacturing costs for small series vehicles.
Innovation Solution
A modular system comprising a basic modular system, a derivative modular system, and a design modular system, where the basic modular system provides a roadworthy basic configuration with a basic body structure, chassis, and drive, the derivative modular system offers structural modules for derivative body designs, and the design modular system includes design modules for brand-specific and vehicle-specific exterior and interior components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional modular solutions are used for motor vehicles, then development and manufacturing costs can be reduced for high sales volumes, but they are insufficient for making small series vehicles economically viable
Solution Approach 1:
The vehicle is divided into three distinct modular systems: basic modular system (BMS) containing structure-supporting and safety-relevant components, derivative modular system (DMS) with body design modules, and design modular system (DiMS) with brand-specific design modules. This segmentation allows each module to be independently developed and manufactured, reducing costs while enabling flexibility for small series production of different vehicle types and designs.
Solution Approach 2:
The basic modular system is designed to be universal and platform-independent, serving as a common foundation for multiple vehicle types. The same BMS can support different DMS body designs and DiMS brand-specific features, allowing a single basic platform to economically produce various vehicle configurations for different manufacturers and market segments.
2Adaptability or versatility
If concept vehicles with low forecast sales volumes are produced, then brand emotional impact is enhanced, but development and manufacturing costs are not sufficiently reduced
Solution Approach 1:
The structure-supporting and safety-relevant components are pre-developed and standardized in the basic modular system before specific vehicle projects are undertaken. This preliminary development of common modules allows concept vehicles to be rapidly realized with minimal additional development costs, enabling manufacturers to bring emotionally impactful vehicles to market even with low forecast sales volumes.
3Reliability
If a basic configuration is created with all essential structure-supporting and safety-relevant elements, then roadworthiness is achieved, but the vehicle lacks derivative body designs and brand-specific features
Solution Approach 1:
The vehicle system is segmented into three independent modular systems: BMS for roadworthiness (structure and safety), DMS for body design variety, and DiMS for brand-specific features. This segmentation allows the basic configuration to achieve roadworthiness through the standardized BMS while enabling unlimited customization through combination with different DMS and DiMS modules.
Solution Approach 2:
The modular systems are structured hierarchically where the basic modular system forms the core foundation, into which derivative modular system modules and design modular system modules can be nested or attached. This nested structure allows the basic roadworthy platform to contain and support multiple layers of customization, from structural body variations to superficial design elements.
Data Source
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AI summary
In order to provide a modular system for motor vehicles, by means of which the development and manufacturing effort can be reduced to such an extent that even for small series vehicles can be produced economically, a modular system (100) for motor vehicles, in particular for battery-electric motor vehicles, is proposed, comprising a basic modular system (10), a derivative modular system (11) and a design modular system (12), wherein the basic modular system (10) comprises modules (15) for constructing at least one basic configuration (16) for a motor vehicle (200) of a predetermined vehicle class, wherein the modules (15) of the basic modular system (10) comprise a basic body structure (18), a chassis structure (17) and a drive system (19), wherein the derivative modular system (11) comprises superstructure modules (20) for developing at least one derivative body shape (21, 21a, 21b, 21c) of the basic configuration (16),and wherein the design toolkit (12) comprises design modules (25) for the expression of at least one vehicle- or brand-specific design of the derivative body body form (21, 21a, 21b, 21c), wherein the design modules (25) comprise components for a vehicle exterior comprising a vehicle outer skin.