Integrated Vehicle End Structure with Adjustable Brackets
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Solution Overview
Problem
Vehicle assembly in manufacturing plants faces challenges in precisely and accurately integrating thousands of components, particularly in ensuring the correct alignment and positioning of exterior components like headlights and taillights, while also providing structural integrity and load-carrying capabilities.
Innovation Solution
An integrated end structure for vehicles comprising a storage compartment module and a vehicle end module with adjustable brackets, allowing for precise positioning and load-sharing between components, including the use of composite materials and modular assembly techniques to facilitate flexible adjustment and improved craftsmanship.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional vehicle assembly methods are used, then structural integrity can be maintained, but manufacturing precision and alignment of exterior components deteriorates
Solution Approach 1:
The vehicle end structure is divided into modular components: a vehicle end module containing mounting brackets for exterior components, and a separate storage compartment module. This segmentation allows independent positioning and adjustment of each module to achieve precise alignment while maintaining overall structural integrity through designed connection interfaces.
Solution Approach 2:
Mounting brackets serve as intermediary elements between the vehicle end module and exterior components (headlights, taillights). These brackets provide adjustable positioning mechanisms that enable precise alignment of exterior components without requiring direct integration into the main vehicle structure, thus preserving structural integrity while achieving manufacturing precision.
2Adaptability or versatility
If multiple separate components are used for vehicle end structure, then adaptability and adjustability improve, but device complexity increases
Solution Approach 1:
The vehicle end module is designed to serve multiple functions: it provides structural support, contains mounting brackets for various exterior components, and interfaces with the storage compartment module. This multi-functionality reduces the need for separate dedicated components, thereby maintaining adaptability while reducing overall device complexity.
Solution Approach 2:
The storage compartment module is designed to be mounted onto the vehicle end module, creating a nested configuration where one module integrates with another. This nesting approach allows the system to maintain modularity and adjustability while presenting a unified, simplified external structure that reduces perceived complexity.
3Weight of moving object
If traditional materials are used, then structural integrity is maintained, but vehicle mass increases
Solution Approach 1:
The vehicle end module and storage compartment module are constructed using composite materials that combine high strength-to-weight ratio properties. These composites maintain the necessary structural integrity for supporting exterior components and withstanding vehicle operational loads while significantly reducing the mass compared to traditional metal constructions.
Data Source
AI summary
A method for constructing an integrated end structure for a vehicle includes placing a center module for an integrated end structure for a vehicle in a fixture separate from the vehicle, attaching a side bracket to the center module in the fixture to form an assembly, the side bracket configured for holding a light unit of the vehicle, mounting the assembly onto at least a bracket in the vehicle that provides adjustability of the assembly in at least a z-direction, and, after mounting the assembly, mounting a storage compartment module onto the center module and the side bracket.