Modular Off-Road Vehicle Assembly for Variable Seat Rows

Solution Overview

Problem

The existing methods for manufacturing off-road vehicles are inefficient, leading to high production costs due to the complexity and variability in producing vehicles with different numbers of seat rows.

Innovation Solution

The method involves preparing a ladder frame with a length corresponding to the number of seat rows, and attaching modularized parts such as the vehicle front and rear parts, and seat row modules to the frame. The seat row modules are common across different vehicle configurations, reducing the variety of parts needed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional manufacturing methods are used to produce vehicles with different numbers of seat rows, then vehicle configuration versatility is improved, but production efficiency deteriorates and production costs increase

Engineering Contradiction:

Improvevehicle configuration versatilityVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The vehicle body is divided into modular components: a common chassis, a cab assembly, and multiple interchangeable seat row modules. Each seat row module is designed as an independent unit that can be separately manufactured and then assembled onto the common chassis, enabling flexible configuration changes without retooling the entire production line.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A universal common chassis and cab assembly are designed to accommodate multiple types of seat row modules. The standardized mounting interfaces and common structural components allow the same base platform to support vehicles with 6, 8, 10, or 12 seats by simply changing the number and arrangement of seat row modules.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If traditional manufacturing methods are used to produce vehicles with different numbers of seat rows, then vehicle configuration versatility is improved, but production costs worsen

Engineering Contradiction:

Improvevehicle configuration versatilityVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The vehicle body is divided into modular components: a common chassis, a cab assembly, and multiple interchangeable seat row modules. Each seat row module is designed as an independent unit that can be separately manufactured and then assembled onto the common chassis, enabling flexible configuration changes without retooling the entire production line.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple seat rows are combined into standardized module assemblies that share common mounting interfaces and structural characteristics. This merging of design standards across different seat configurations allows for economies of scale in manufacturing common components while maintaining the ability to create varied vehicle configurations.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If modularized parts are used to improve production efficiency, then production efficiency is improved, but device complexity may worsen

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmanufacturing system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The vehicle body is divided into modular components: a common chassis, a cab assembly, and multiple interchangeable seat row modules. Each seat row module is designed as an independent unit that can be separately manufactured and then assembled onto the common chassis, enabling flexible configuration changes without retooling the entire production line.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A universal common chassis and cab assembly are designed to accommodate multiple types of seat row modules. The standardized mounting interfaces and common structural components allow the same base platform to support vehicles with 6, 8, 10, or 12 seats by simply changing the number and arrangement of seat row modules.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250162667A1Method of manufacturing off-road vehicle and off-road vehicle

Publication Date: 2025.05.22 KAWASAKI MOTORS LTD

AI summary

A method of manufacturing a utility vehicle 100 includes: preparing a ladder frame 3; attaching a vehicle front part 4 that includes a front panel 12 defining a front end of a compartment and is mounted on top of the ladder frame 3 to the ladder frame 3; attaching a vehicle rear part 5 that includes a rear panel 13 defining a rear end of the compartment and is mounted on top of the ladder frame 3 to the ladder frame 3; and attaching one or a plurality of seat row modules 6, each of which includes a seat frame 62 supporting a seat row 61 having seats 63 arranged side by side in a lateral direction of the vehicle and is mounted on top of the ladder frame 3 to the ladder frame 3 between the vehicle front part 4 and the vehicle rear part 5. The number of the one or plurality of seat row modules 6 corresponds to the number of the seat rows 61 included in a vehicle body 1.