Planar Bus Door Frame Assembly and Sealing

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Solution Overview

Problem

Current bus door systems face complexities in assembly and adjustment due to curved side members and weld structures, leading to potential faults in door movement and sealing issues, as well as wind noise and locking problems, especially when the fold of the door and outer skin are not identical.

Innovation Solution

A door system featuring a planar door frame with parallel side supports and a cross member, along with a planar portal frame, allows for simpler assembly, adjustment, and sealing, using uniform profiles and interfaces, and includes a drive system and modular design with preassembled components for efficient installation and operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If curved side members and complex weld structures are used in traditional bus door systems, then the door can accommodate complex vehicle body designs, but assembly and adjustment become complicated, leading to potential faults in door movement and sealing issues

Engineering Contradiction:

Improveassembly and adjustment simplicityVSAvoidcurved side members and weld structures

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The door system is divided into modular components: a planar door frame assembly (including door leaf and frame), a planar portal frame assembly (including threshold and side beams), and a drive system. These modular assemblies can be manufactured separately and then assembled together, significantly simplifying the manufacturing process and reducing assembly complexity while maintaining structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using traditional curved side members that require complex welding and adjustment, the patent inverts the approach by using planar side members with standardized interfaces. The planar configuration allows for simpler manufacturing and assembly, while the modular design provides the necessary adaptability for different vehicle body designs

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If traditional door frames with curved side members are used, then the door can fit complex vehicle body designs, but sealing performance deteriorates due to tolerance accumulation and angle errors

Engineering Contradiction:

Improvesealing performanceVSAvoiddoor movement accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The door system is divided into modular components: a planar door frame assembly (including door leaf and frame), a planar portal frame assembly (including threshold and side beams), and a drive system. These modular assemblies can be manufactured separately with controlled tolerances and then assembled together, significantly simplifying the manufacturing process and reducing assembly complexity while maintaining structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the geometric parameters of the door frame from curved to planar configurations. This parameter change simplifies manufacturing while the modular design with standardized interfaces maintains adaptability. The planar structure reduces tolerance accumulation and improves sealing performance by eliminating complex angle relationships

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If three-dimensionally curved side supports are manufactured, then the door can accommodate complex vehicle designs, but manufacturing complexity increases and economies of scale are reduced

Engineering Contradiction:

Improvedoor frame design flexibilityVSAvoidmanufacturing simplicity and scale

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The planar door frame and portal frame assemblies are designed as universal modules that can be used across different bus models and vehicle designs. The standardized interfaces and planar configuration allow these components to be manufactured in large quantities for multiple vehicle series, achieving economies of scale while maintaining design flexibility through modular combinations

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP2540542B1Door system for a motor vehicle

Publication Date: 2017.04.19 MAN TRUCK & BUS SE

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AI summary

The system (1) has a planar door frame (10) functioning as a support structure of a door of a vehicle for opening and closing an aperture of the vehicle. The door frame comprises side supports (11) and a cross beam (12) that connects the side supports. The door frame is displaced or pivoted relative to a planar portal frame (20) by a driving system (30) when the portal frame is mounted at the vehicle. The driving system comprises a mounting structure (31). Two separate sealing elements are secured at the portal frame and the door frame, respectively and extend parallel to each other. An independent claim is also included for a motor vehicle.