Commercial Vehicle Cab Center Roof Module Design
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Solution Overview
Problem
Existing commercial vehicle cab designs require complex assembly processes and additional stiffening elements to manage transverse forces, limiting flexibility and increasing design effort, while also not efficiently integrating various vehicle components into the roof structure.
Innovation Solution
A modular cab design featuring a center roof module that connects to the side and rear roof parts, absorbing transverse forces without additional stiffening elements, and can be pre-grouped with various components such as electronics and storage spaces, allowing for a single module to cover the entire roof area from the rear wall to above the windshield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional roof structure with additional stiffening elements (roof struts) is used to absorb transverse forces, then the structural integrity is improved, but the device complexity and design effort increase
Solution Approach 1:
The patent combines the roof skin component with integrated stiffening elements into a single monolithic component. The roof skin component (10.1) incorporates stiffening ribs (10.3) that extend in the longitudinal direction, merging the load-bearing skin function with the stiffening function that would traditionally require separate roof struts. This integration absorbs transverse forces directly within the roof skin structure itself, eliminating the need for additional separate stiffening elements.
2Adaptability or versatility
If a large-area outer roof skin component is used to accommodate various vehicle components, then the adaptability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent segments the roof structure into a modular roof skin component (10.1) that can be manufactured as a standardized unit with integrated stiffening elements. This segmentation allows the large-area component to be produced with controlled precision in a manufacturing setting, then installed as a complete module. The standardized design of the roof skin component with pre-integrated stiffening ribs enables versatile accommodation of different vehicle components (antennas, lights, ventilation) while maintaining manageable manufacturing precision requirements through modular production.
3Productivity
If a modular center roof module is used to pre-group functional components, then the productivity is improved, but the assembly precision requirements increase
Solution Approach 1:
The patent implements preliminary action by pre-assembling the roof skin component (10.1) with integrated stiffening elements and accommodating various vehicle components before final installation. The roof skin component is manufactured and prepared in advance with all necessary functional elements (antennas, lights, ventilation openings) already in place. This preliminary preparation enables faster final assembly by simply installing the complete pre-configured module, thereby improving productivity while managing assembly precision through standardized interface design.
Data Source
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AI summary
The cab (1) has a roof structure (10) partially and upwardly locking a carcass module, and including a roof frame with two side roof parts (3) that are section-wise upwardly limit side walls (7). The frame has rear roof parts (4) upwardly limiting a rear wall (6) and connecting the side roof parts. A central roof module (2) is insertable into the frame in such a manner that the module is attached to the rear roof parts in an installation position and to the side roof parts. The module extends from the rear roof parts into a region above a front screen (18) of a commercial motor vehicle.