Integrated Rear Bodywork Casting for Mass Reduction
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Solution Overview
Problem
The assembly of numerous parts in the rear bodywork of a motor vehicle leads to increased mass, production costs, and pollutant emissions due to the need for multiple joining processes and docking surfaces, resulting in lower vehicle performance and higher fuel consumption.
Innovation Solution
A single casting bodywork element with a molten material supply zone and ribs for structural reinforcement, produced by vacuum casting, which eliminates the need for assembly and sealing steps, reducing the number of production steps and mass while maintaining mechanical strength in critical areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple parts are assembled together to form the rear bodywork structure, then the structural functionality and mounting capabilities are improved, but the total mass of the structure increases by up to 30% due to additional mounting surfaces and joining elements
Solution Approach 1:
The patent merges multiple separate bodywork parts (rear wheel arch, quarter panel, longitudinal member, seat mounting structures) into a single integrated casting. This consolidation eliminates the need for separate mounting surfaces and joining elements, thereby reducing the overall structure mass by up to 30% while maintaining all necessary structural functionalities and mounting capabilities.
2Adaptability or versatility
If multiple parts are assembled together with numerous joining processes, then the structural complexity and mounting capabilities are improved, but the production cost and number of production steps increase significantly
Solution Approach 1:
The invention integrates multiple bodywork components into a single cast piece, eliminating the need for separate joining processes, sealing operations, and assembly steps. This consolidation dramatically simplifies the manufacturing process, reducing the number of production steps from multiple assembly operations to a single casting operation, thereby lowering production costs while preserving all mounting capabilities.
3Strength
If multiple joining surfaces and weld points are created to assemble parts, then the structural integrity and mounting functionality are improved, but the surface area dedicated to mounting surfaces increases by a significant percentage, adding unnecessary mass
Solution Approach 1:
By consolidating multiple parts into a single integrated casting, the invention eliminates the need for separate joining surfaces and weld points that would otherwise be required to assemble discrete components. The mounting surfaces are integrated directly into the monolithic structure, reducing the total surface area dedicated to mounting functions while maintaining structural integrity through the inherent strength of the unified casting.
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
This approach reduces the vehicle's mass and production costs, improves performance by minimizing unnecessary weight and assembly processes, and decreases pollutant emissions through lighter, more efficient bodywork design.
Implementation Method 1
produced by vacuum casting
Implementation Method 2
a single cast piece including a molten material feeding zone
Data Source
Figure 1~2
Figure 3
AI summary
A motor vehicle body element (11), comprising a first face (12) and a second face (13) opposite the first face, the element (11) comprising a rear wheel arch plate portion (20), an attachment area (14) for a rear axle bearing of the vehicle, an attachment area for a vehicle shock absorber (16), a rear side rail portion (26), and a lower front portion of a cast quarter panel (22), attachments (33) and hinges (35) for the seat part and back rest of a rear bench seat. The element comprises a single casting comprising a molten material feeding zone (37).