Roll-Formed Vehicle Frame Assembly for Variable Length Production
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Solution Overview
Problem
Conventional vehicle frame constructions are costly and inefficient for producing vehicles with varying lengths, as they require dedicated frame structures for each model, leading to increased manufacturing expenses and potential performance and safety compromises.
Innovation Solution
A floor and bed frame system with roll-formed longitudinal frame components that can be cut to different lengths, allowing for a single assembly line to produce multiple vehicle types with varying longitudinal lengths, using common and variable parts to reduce costs and enhance flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dedicated frame structures are used for each vehicle model with varying lengths, then each vehicle model can have its own optimized frame design, but manufacturing costs increase and production efficiency decreases
Solution Approach 1:
The patent employs a universal ladder frame structure that can support multiple vehicle types (pickup trucks, sport utility vehicles, minivans, crossovers, sedans, coupes) with varying lengths. The frame is designed with adjustable features including removable sections, extendable components, and standardized mounting points that allow the same basic frame to be configured for different vehicle models, thereby achieving multi-functionality without requiring dedicated frame structures for each model.
Solution Approach 2:
The ladder frame is divided into modular segments including a main ladder frame portion and auxiliary ladder frame sections that can be selectively added or removed. This segmentation allows the frame to be customized for different vehicle lengths by combining different numbers and types of segments, enabling efficient production across multiple vehicle models using a common base structure.
2Adaptability or versatility
If auxiliary ladder frames are added to extend vehicle length, then vehicle length flexibility is improved, but vehicle weight increases
Solution Approach 1:
The auxiliary ladder frame is designed to be selectively removable and installable, transforming the frame from a static permanent structure to a dynamic configurable component. This allows the vehicle weight to be optimized by removing auxiliary sections when not needed, while maintaining the capability to extend vehicle length when required, thus achieving weight flexibility.
Solution Approach 2:
The auxiliary ladder frame sections are designed to match the local structural requirements at specific positions along the main frame. By providing structural support only where needed rather than uniformly throughout the entire frame, the design minimizes unnecessary weight while maintaining adequate strength and rigidity for extended vehicle configurations.
3Adaptability or versatility
If body-on-frame construction is used to allow body assembly modifications, then design flexibility is improved, but vehicle performance and safety are compromised due to weight and structural rigidity
Solution Approach 1:
The ladder frame incorporates composite construction techniques combining high-strength steel components with lighter weight materials where appropriate. This composite approach maintains the structural integrity and safety requirements of a rigid frame construction while reducing overall weight, thereby preserving vehicle performance and safety despite the benefits of design flexibility provided by body-on-frame construction.
Data Source
AI summary
A vehicle frame assembly, system and method includes a vehicle frame assembly having a variable length longitudinal frame component. The longitudinal frame component is formed at a first length when used on a first vehicle type and formed at a second length when used on a second vehicle type.