Truck Front End Body Side Modules Assembly
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Solution Overview
Problem
The existing methods for constructing a truck front end with a driver's cab are inefficient and costly due to complex assembly processes and require numerous individual components, leading to high production and assembly outlays.
Innovation Solution
The method involves prefabricating right-hand and left-hand body side modules that extend from the front to the rear of the cab, integrating functional parts, and mounting them to the frame or cab, which eliminates the need for a conventional bumper and allows for simplified assembly by integrating the radiator with underrun protection, using a lattice frame support structure and outer skin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional multi-part structure with numerous individual components is used in the lower body side area, then the structural functionality is comprehensive, but the assembly work and production cost are considerable
Solution Approach 1:
The patent combines multiple individual components (fenders, spray protection devices, headlights, entrances, etc.) into a single pre-assembled body side module. This module includes a support structure with outer skin and integrates various functional parts, eliminating the need for complex line assembly of numerous separate components and reducing both assembly work and production cost.
Solution Approach 2:
The body side module is pre-assembled before final vehicle assembly. Functional parts are installed and integrated into the support structure in advance, allowing the module to be manufactured independently and then easily assembled during line assembly, significantly reducing the assembly cycle time and complexity.
2Object-affected harmful factors
If a conventional bumper is used in the front end construction, then the protective function is provided, but the cost and weight increase
Solution Approach 1:
The radiator structure is designed to serve multiple functions: it provides the traditional radiator function for engine cooling, acts as a protective element in the front end, and integrates with the underrun protection. This multi-functionality eliminates the need for a separate bumper, reducing both weight and cost while maintaining protective capability.
Solution Approach 2:
The patent merges the radiator, radiator grille, and underrun protection into an integrated assembly where the radiator structure itself provides protective functions. This combination eliminates the conventional bumper while maintaining the necessary protection, thereby reducing weight and material cost.
3Productivity
If body side modules are completely pre-assembled with functional parts integrated, then the line assembly cycle time is reduced, but the manufacturing complexity of individual modules increases
Solution Approach 1:
The vehicle body is divided into modular body side modules that can be manufactured independently. Each module is a complete, self-contained unit with integrated functional parts, allowing parallel production and simplifying the final assembly process. The segmentation enables pre-assembly outside the main production line, reducing line assembly cycle time despite the complexity of individual module manufacturing.
Data Source
Figure 1~2
AI summary
The method involves prefabricating right-sided and left-sided body side modules (7) as components of a body (1), where the modules extend in an installed condition of a body front (4) up to a rear edge (5) of a driving cab (2). Headlights are built in the body side modules, and a mudguard and a wheel housing (9) are partially integrated. The pre-mounted body-side modules are fixed to a chassis frame or the driving cab for completion of the body. The headlights and/or mudguards and/or manholes and/or air ducts are installed as functional parts during prefabrication of the modules.