Vehicle Structural Assembly with Pre-Attached Anchoring Parts
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Solution Overview
Problem
The existing assembly processes for motor vehicle structural parts are ergonomically poor and time-consuming, particularly when attaching reinforcing elements and safety belt return parts, which restricts efficiency and increases costs due to the need for manual intervention by multiple technicians.
Innovation Solution
A method that involves securing anchoring parts for a rear seat striker and seat belt return to the structural parts before welding the lower and upper structural parts together, allowing for partial automation and improved ergonomics, enabling efficient assembly with reduced manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual screwing is used to attach reinforcement parts and seat belt return parts, then the attachment can be performed with simple tools, but the assembly process becomes time-consuming and ergonomically poor
Solution Approach 1:
The reinforcement part is pre-assembled with the first part (locking striker anchoring) before the main assembly operation. This preliminary action allows the second part (seat belt return anchoring) to be attached more efficiently during the main welding process, improving overall productivity while maintaining ease of manufacture.
Solution Approach 2:
The patent combines the attachment of the reinforcement part with the main structural assembly by integrating it into the welding process. The reinforcement part is positioned and fixed simultaneously with the lower and upper structural parts, merging multiple attachment operations into one efficient process that improves assembly speed without complicating the manufacturing process.
2Ease of operation
If multiple technicians are deployed for manual attachment operations, then the attachment can be performed with flexibility, but the assembly costs increase
Solution Approach 1:
The reinforcement part is divided into two distinct parts: the first part attached to the locking striker anchoring point, and the second part attached to the seat belt return anchoring point. This segmentation allows each part to be optimized for its specific function and attached using appropriate methods, maintaining operational flexibility while simplifying the overall assembly process through modular design.
Solution Approach 2:
The reinforcement part acts as an intermediary element between the structural parts and the anchoring points for the locking striker and seat belt return. This intermediary component standardizes the attachment interface, allowing for consistent welding procedures and reducing the need for multiple technicians, thereby lowering assembly costs while maintaining flexibility.
3Strength
If reinforcement parts are attached after structural assembly, then the structural integrity is maintained, but the assembly process becomes more restrictive and time-consuming
Solution Approach 1:
The reinforcement part is pre-positioned and pre-assembled with the first part before the main structural welding takes place. This preliminary action ensures that the reinforcement is integrated into the structural assembly process itself, not added as a separate post-assembly step. The structural integrity is maintained through proper welding sequencing, while the assembly duration is reduced by eliminating subsequent attachment operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances the structural reinforcement and reduces assembly time and costs by enabling robotic assistance and improved ergonomics, resulting in a more efficient and cost-effective assembly process.
Implementation Method 1
the first parts to the second parts by welding and the first rear side walls to the second rear side walls
Data Source
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AI summary
A method makes it possible to assemble the lower (PSI) and upper (PSS) structural portions of a vehicle comprising two first rear side walls (PL1) which define two wheel arches and to which two side reinforcing elements (ELR) are rigidly connected, and two second rear side walls (PL2). Said method comprises a first step wherein a first part (P1) for anchoring a trigger (GV) for locking a seat back is rigidly connected to the free end (ELE) of each side reinforcing element (ELR), and a second part (P2) for anchoring a return part (PR) of a seatbelt is rigidly connected to each of the second rear side walls (PL2), and a second step wherein the lower (PSI) and upper (PSS) structural portions are assembled by welding the first parts (P1) to the second parts (P2) and the first rear side walls (PL1) to the second rear side walls (PL2).