Worm Gear Drive Unit Interface for Vehicle Assembly
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Solution Overview
Problem
Conventional vehicle assembly processes require significant infrastructure and are costly, as they necessitate overhead cranes, automated carts, and multiple fasteners that need to be hidden or covered, increasing complexity and expenses.
Innovation Solution
A modular fastening system that allows for the horizontal attachment and detachment of vehicle subassemblies using worm drives and automated torque tools, eliminating the need for overhead cranes and enabling fasteners to be hidden within the assembly, reducing infrastructure requirements and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional overhead crane assembly methods are used, then vehicle subassemblies can be assembled, but infrastructure requirements and costs increase significantly
Solution Approach 1:
The patent inverts the conventional assembly approach by having the driveshaft engage the worm gear from the side rather than requiring overhead cranes to lower components from above. The worm gear is integrated into the vehicle body structure, and the driveshaft with attachment assembly engages it laterally, reversing the traditional vertical assembly sequence and eliminating the need for overhead infrastructure.
Solution Approach 2:
The attachment assembly includes self-aligning features where the driveshaft automatically positions itself relative to the worm gear through guided engagement surfaces. The system performs its own alignment and positioning functions without requiring external overhead equipment, making the assembly process self-sufficient and infrastructure-independent.
2Strength
If multiple fasteners are used to connect assemblies, then connection strength is improved, but the need for additional trim components and sealing operations increases
Solution Approach 1:
The patent merges the fastening function into the worm gear assembly itself. The worm gear structure incorporates integrated fastening features that combine structural support and connection functions into a single integrated component, eliminating the need for separate trim pieces and sealing operations that would be required with conventional multi-fastener approaches.
Solution Approach 2:
The worm gear serves multiple functions simultaneously: it provides mechanical engagement for the driveshaft, structural support for the vehicle body, and integrated fastening capability. This multi-functionality eliminates the need for separate trim components and sealing operations, reducing overall system complexity while maintaining connection strength.
3Manufacturing precision
If overhead cranes and automated carts are used for assembly, then assembly precision can be maintained, but capital investment and infrastructure costs increase
Solution Approach 1:
The attachment assembly includes self-aligning features where the driveshaft automatically positions itself relative to the worm gear through guided engagement surfaces. The system performs its own alignment and positioning functions without requiring external overhead equipment, making the assembly process self-sufficient and infrastructure-independent.
4Productivity
If visible fasteners are used on the complete vehicle, then assembly is simplified, but additional trim and sealing operations are required
Solution Approach 1:
The patent merges the fastening function into the worm gear assembly itself. The worm gear structure incorporates integrated fastening features that combine structural support and connection functions into a single integrated component, eliminating the need for separate trim pieces and sealing operations that would be required with conventional multi-fastener approaches.
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 approach simplifies vehicle assembly by reducing infrastructure needs, enhancing serviceability, and lowering costs by allowing for efficient, single-step fastening and hiding of fasteners, thereby reducing capital investment and improving maintenance efficiency.
Implementation Method 1
a worm drive to change a direction of rotation of the driveshaft from a first direction (e.g., vertical) to a second direction (e.g., horizontal)
Data Source
AI summary
A system for detachably coupling subassemblies to vehicles or other components is discussed herein. The system can include one or more driveshafts and worm drives to drive fasteners to couple the subassembly to the vehicle. The system can enable drive interfaces located in a substantially conventional location (e.g., located vertically on the bottom of the vehicle) to drive fasteners horizontally into the body or other subassembly. In this manner, fasteners can be hidden and to utilize blind holes in the body of the vehicle. The system can be partially disassembled in situ to enable parts replacement and fastener access in the event of a failure. The system can be used in conjunction with a robotic cart to enable subassemblies to be removed from the vehicle for service and repair. A portion of the system can also act as a portion of, or to reinforce, the crash structure of the vehicle.