Case Study

Commercial Truck
Sleeper Bunk

Commercial Vehicle bunk systems

Overview:

Commercial Trucking operators are required to take a rest period of 15 minutes for every 3 hours of driving. On long-haul team sleeper cabin configurations, there can be the option to have a two bunk system, lower and upper.

 

The upper bunk is not a popular item. In many cases it simply become a storage shelf or even removed because of its unnecessary added weigh to the vehicle.  accessory. When it is a desired item whether it's included with the original purchase of the vehicle or bought as an accessory, the overall cost and weight are the determining factors. 

Problem:

As standard equipment or an accessory, the cost of upper bunk turned off customers.

 

Goal: My focus is on the customer point of view coupled with market research, employing new manufacturing techniques and evaluating material choices.

Results:

After several unique design iterations, I focused on re-purposing existing components used elsewhere on the vehicle in order to reduce extra tooling and additional expense, the door frame was the perfect component for this application.

 

  • Minimal tooling costs

  • Manufacturing simplified

  • Weight reduction of 5 pounds

  • Cost reduction of 50%

Bunk system concept 

Finite Element Analysis (FEA) evaluation of bunk concepts

Common Parts: Door frame used for bunk frame

3D Cad evaluation

Digital mock up

Full scale functional prototype 

© 2020 by Robert van Weezendonk

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