Vehicle Step Device Metal Rail Resin Body
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Solution Overview
Problem
The existing step devices for vehicles are susceptible to high temperature heat during the coating process, requiring specialized parts that increase operation time and man-hours due to the need for fine adjustments after replacing these parts with the step device, which affects the accuracy and efficiency of slide door assembly.
Innovation Solution
A step device comprising a metal-made rail portion fixed to the vehicle body and a resin-made step main body with a rail fitting portion that forms a guide rail, allowing the slide door to move over its entire range of opening and closing, eliminating the need for part replacement and maintaining assembly precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a resin-made step member is used to reduce weight and part number, then weight and complexity are reduced, but the member becomes susceptible to high temperature heat during the coating process
Solution Approach 1:
The step member is divided into two distinct parts: a resin-made step main body (weight reduction) and a separate metal-made rail portion (heat resistance). This segmentation allows each component to be optimized for its specific function while working together as an integrated assembly.
Solution Approach 2:
The step device uses a composite construction combining resin material for the step main body and metal material for the rail portion. This composite approach leverages the advantages of both materials: resin provides weight reduction while metal provides heat resistance during the coating process.
2Manufacturing precision
If a specialized part is mounted during the coating process to ensure assembly accuracy, then manufacturing precision is improved, but operation time and man-hours increase due to subsequent part replacement
Solution Approach 1:
The metal-made rail portion is pre-installed on the vehicle body during the coating process to ensure accurate positioning and assembly of the slide door. This preliminary action establishes the precise assembly geometry before the coating process completes, eliminating the need for subsequent replacement operations.
Solution Approach 2:
The metal-made rail portion serves dual functions: it acts as a temporary specialized part during the coating process to ensure assembly accuracy, and simultaneously serves as the permanent guide rail structure for the slide door operation. This multi-functionality eliminates the need for part replacement.
3Device complexity
If the step member is made integrally from resin to reduce part number, then device complexity is reduced, but the member cannot withstand high temperature heat in the drying furnace
Solution Approach 1:
The step device is segmented into a resin-made step main body and a separate metal-made rail portion. This segmentation allows the resin component to maintain its weight and manufacturing advantages while the metal component provides the necessary heat resistance for the drying furnace and coating process.
Solution Approach 2:
The step device employs composite construction combining resin and metal materials. The resin step main body provides weight reduction and simplified manufacturing, while the attached metal rail portion provides thermal stability and heat resistance during high-temperature processing.
Data Source
AI summary
A step device for a vehicle includes a step member, a drive member provided at the step member and configured to drive a slide door to open and close, the step member including a metal-made rail portion configured to be fixed to a vehicle body and configured to guide the slide door to move at an opening and closing operation of the slide door, and a resin-made step main body integrally including a step panel, a rail fitting portion protruding from the step panel to be fitted onto an outer surface of the rail portion, and a drive member setting portion to which the drive member is set. The resin-made step main body and the metal-made rail portion form a guide rail. The guide rail is configured to guide the slide door to move over an entire range of the opening and closing operation of the slide door.