Variable Length Vehicle Frame Joints for Modular Production
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Solution Overview
Problem
Conventional vehicle frame constructions are costly and inefficient for manufacturing vehicles with varying lengths, as they require dedicated frame structures for each model, leading to increased production expenses and compromised performance due to weight and handling issues.
Innovation Solution
A floor frame system with roll-formed longitudinal frame components that can be cut to different lengths for various vehicle types, allowing for a single assembly line to produce vehicles with multiple length configurations, 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 type can have optimized frame design, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The patent applies universality by designing a single ladder frame structure that can serve multiple vehicle types with different lengths. The frame is configured to accommodate various body assemblies (cabs and beds) through standardized mounting locations, allowing one frame design to fulfill multiple functions across different vehicle models without requiring dedicated frame structures for each model.
Solution Approach 2:
The patent applies segmentation by dividing the vehicle into separate functional modules: a standardized ladder frame and interchangeable body assemblies (cabs and beds). This segmentation allows the frame to remain constant while body assemblies are modified or substituted, enabling efficient production where completed body assemblies can be mounted to the ladder frame without substantial redesigning.
2Adaptability or versatility
If body-on-frame construction is used to provide flexibility in varying vehicle designs, then vehicle configurations can be easily modified, but vehicle weight increases leading to lower performance and higher fuel consumption
Solution Approach 1:
The patent applies universality by creating a standardized ladder frame that can support multiple body configurations without requiring separate frame structures. This allows the same frame to serve multiple vehicle types, reducing the need for additional frame components and thereby reducing overall vehicle weight while maintaining design flexibility.
3Adaptability or versatility
If body-on-frame construction is used to support different body assemblies, then design modifications are simplified, but handling performance deteriorates due to lack of torsion flexing
Solution Approach 1:
The patent applies local quality by providing torsion flexing capability at specific locations in the ladder frame where needed, while maintaining rigidity in other critical areas. This localized flexibility allows the frame to absorb torsional stresses and improve handling performance without compromising the overall structural integrity or the ability to support different body assemblies.
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.