Modular Work Vehicle Function Modules for Weld-Free Assembly
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Solution Overview
Problem
Existing work vehicles face inefficiencies in arranging and assembling various mounted structures, leading to increased assembly time, potential errors, and reduced operational safety due to the need for welding and complex mechanical assembly processes.
Innovation Solution
The implementation of self-supporting function modules with predefined interfaces and a diagnostic device for pre-assembly checks, allowing for efficient interconnection and minimizing errors, along with a modular design that eliminates welding during final assembly and enables easy maintenance and expansion of operational functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mechanical assembly and welding processes are used to assemble mounted structures on the vehicle, then structural strength and reliability are improved, but assembly time increases and operational safety decreases due to potential errors
Solution Approach 1:
The mounted structures are pre-assembled as complete functional modules with all connections (mechanical, electrical, hydraulic, pneumatic) established before installation on the vehicle. This preliminary assembly allows thorough checking and testing to be performed in advance, eliminating errors before final installation and significantly reducing on-site assembly time.
Solution Approach 2:
The vehicle is divided into modular functional units (mounted structures) that can be independently assembled, tested, and installed. Each module is a self-contained unit with predefined interfaces, allowing parallel assembly of multiple modules and reducing overall assembly time while maintaining structural integrity through standardized connection points.
2Adaptability or versatility
If mounted structures are divided into multiple sections with complex arrangements, then operational versatility is improved, but assembly complexity and error potential increase
Solution Approach 1:
The vehicle platform is designed with universal predefined interfaces that can accommodate different types of mounted structures. The standardized mechanical, electrical, hydraulic, and pneumatic interfaces allow the same base vehicle to support multiple operational configurations by simply changing the mounted structure modules, reducing assembly complexity while maintaining versatility.
Solution Approach 2:
Each mounted structure is pre-configured as a complete functional module with all internal connections established before installation. This preliminary configuration simplifies the final assembly process to a matter of connecting pre-assembled units, reducing complexity despite the variety of operational functions available.
3Strength
If welding processes are used to assemble mounted structures, then structural strength is improved, but manufacturing lead time increases and error costs increase
Solution Approach 1:
All structural connections are established during the pre-assembly phase in controlled manufacturing environments where welding can be performed optimally. Once welded joints are created and verified during module assembly, the modules are transported to the vehicle for installation using non-welding connection methods (mechanical fastening at predefined interfaces), thereby separating the welding process from the final vehicle assembly and reducing manufacturing lead time.
4Reliability
If comprehensive module checks and system verification are performed, then operational safety is improved, but time required for vehicle commissioning increases
Solution Approach 1:
Comprehensive checks including geometric verification, functional testing, and system validation are performed on each mounted structure during the pre-assembly phase before installation on the vehicle. This shifts the commissioning time to the manufacturing phase, allowing thorough verification without extending the actual vehicle deployment timeline.
Solution Approach 2:
The verification process is divided into modular checks that can be performed independently on each mounted structure. This segmentation allows parallel testing of multiple modules and simplifies the commissioning process to connecting pre-verified units, reducing overall commissioning time while maintaining comprehensive safety checks.
Data Source
AI summary
The invention relates to a work vehicle for carrying out work operations on a track, comprising a vehicle frame which can be moved on the track supported on rail running gears, a drive cab which is connected to the vehicle frame, and various mounted structures with assigned functions for a work operation. The mounted structures are designed as self-supporting function modules with predefined interfaces and connected to the vehicle frame and/or each other by means of threaded connections. The predefined interfaces enable the interconnection of different function modules without further adaptations. All modules are continuously checked with regard to their geometry and their functions to enable joinability in the final assembly without welding and adjustment processes.