Split Tailgate Carrier Plate for Faster Modular Assembly
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Solution Overview
Problem
Conventional tailgate assembly processes are inefficient, requiring high cycle times for assembly and lacking the ability to test or verify functional components until the installation is complete, and manual operation of deployable components is cumbersome.
Innovation Solution
A tailgate assembly with a carrier plate integrated with functional components and a drive mechanism, featuring a lost-motion mechanism to automate the deployment of components like a tailgate step, and an assembly module that includes a carrier plate, deployable member, linear actuator, and force-transmission member to facilitate automated and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional tailgate assemblies are assembled step-by-step with all components, then complete functionality is achieved, but assembly cycle time increases
Solution Approach 1:
The tailgate assembly is divided into modular sub-assemblies: the minor gate assembly (including carrier plate, hinges, and functional components) can be pre-assembled and tested separately, then integrated with the major gate. This segmentation allows parallel assembly processes and reduces the critical path time for complete assembly.
Solution Approach 2:
The minor gate assembly is pre-assembled with all functional components (latch, step assembly, drive mechanism) attached to the carrier plate before integration with the major gate. This preliminary assembly allows verification of functional component operations and reduces on-site assembly cycle time.
2Adaptability or versatility
If functional components are integrated into the tailgate assembly, then functionality is enhanced, but testing and verification become difficult until complete assembly
Solution Approach 1:
The carrier plate serves as a separate testable module that carries functional components. This module can be detached from the major gate assembly, allowing independent testing and verification of functional components (latch operation, step deployment, drive mechanism) before final integration, thus reducing testing difficulty.
3Reliability
If multiple components are assembled together in conventional tailgates, then complete functionality is achieved, but assembly time increases
Solution Approach 1:
The minor gate assembly with all functional components is pre-assembled and pre-tested before being integrated with the major gate. This preliminary action ensures component reliability is verified early, and the final assembly process is reduced to connecting pre-tested modules, significantly reducing total assembly time.
Solution Approach 2:
Multiple functional components (hinges, latch assembly, step assembly, drive mechanism) are merged onto a single carrier plate structure. This consolidation reduces the number of separate assembly operations needed and simplifies the integration process with the major gate.
Data Source
AI summary
A tailgate assembly including a first gate and a second gate. The first gate configured to rotate with respect to a vehicle body and the second gate configured to rotate with respect to the first gate. The second gate includes an outer panel, an injection molded carrier plate, and a drive mechanism. The injection molded carrier plate is configured to be fixed the outer panel to form a cavity. And the injection molded carrier plate is configured to carry a number of functional components. The drive mechanism is fixed to the carrier plate and operably connected to at least one functional component of the number of functional components. Drive mechanism is configured to actuate and move the at least one functional component with respect to the second gate between the number of positions.