Fairing Mounting Assembly Using Wedge Locators
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Solution Overview
Problem
The existing methods for mounting roof fairings on semi-trailer trucks are aesthetically unpleasing due to visible fasteners, complicated and labor-intensive, with limited access and accuracy, leading to increased installation time and labor costs.
Innovation Solution
A fairing mounting assembly that includes a fairing locator assembly with wedge-shaped locators on the interior surface of the fairing and corresponding locator brackets on the vehicle roof, allowing for interference fit without visible fasteners, reducing installation complexity and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners are used to secure the forward portion of the fairing to the sleeper compartment roof, then the fairing can be securely mounted, but the aesthetic finish is diminished due to visible fasteners
Solution Approach 1:
The fasteners are extracted from the exterior view by using interior mounting brackets that attach to the sleeper compartment roof from inside the fairing structure. The fastening function is separated from the exterior aesthetic surface, allowing secure mounting without visible fasteners on the fairing exterior.
Solution Approach 2:
The mounting brackets are nested within the fairing structure, with the fastening mechanism contained inside the fairing's interior space. The brackets attach to the roof from the interior side, nesting the fastening function within the fairing's own structure rather than exposing it externally.
2Strength
If fasteners are used to mount the fairing, then secure attachment is achieved, but installation becomes complicated and labor-intensive requiring simultaneous alignment of multiple fastener holes
Solution Approach 1:
The mounting brackets are pre-positioned and secured to the sleeper compartment roof before the fairing is installed. This preliminary action establishes fixed reference points that guide the fairing into proper alignment, eliminating the need for simultaneous alignment of multiple fastener holes during installation.
Solution Approach 2:
The mounting brackets serve as intermediary components between the fairing and the sleeper compartment roof. These brackets provide a simplified interface that translates the complex multi-hole alignment requirement into a single-point or few-point attachment system, reducing installation complexity.
3Ease of manufacture
If fasteners are used with limited access space in the forward portion of the fairing, then mounting is possible, but the operation becomes cumbersome and time-consuming
Solution Approach 1:
Instead of accessing the fastening points from the exterior forward portion of the fairing where space is limited, the mounting system inverts the approach by accessing and securing the fasteners from the interior of the fairing. This provides operators with adequate working space while maintaining mounting feasibility.
Solution Approach 2:
The mounting approach transitions from a two-dimensional exterior surface operation to a three-dimensional interior volume operation. By moving the fastening access into the interior space of the fairing, operators gain additional dimensional freedom for tool manipulation and position adjustment, reducing installation time.
4Strength
If fasteners are used for mounting, then the fairing can be secured to the roof, but the results are inconsistent and lack repeatability
Solution Approach 1:
The manual alignment and fastening process is replaced with a mechanical positioning system using pre-positioned mounting brackets and corresponding receptacles. This mechanical system provides inherent guidance and alignment features that ensure consistent, repeatable mounting accuracy without relying on operator skill or manual alignment.
Data Source
AI summary
A fairing mounting assembly for securing a fairing to a vehicle includes a fairing locator assembly having at least one fairing locator securable to an interior surface of a forward portion of a fairing, wherein the at least one fairing locator has a predetermined size and shape. The fairing mounting assembly further includes a locator attachment assembly securable to a portion of a vehicle that has at least one isolator receptacle that is substantially sized and shaped to correspond to the predetermined size and shape of the at least one fairing locator. The fairing mounting assembly further includes a rear fairing attachment assembly configured to secure an aft portion of the fairing to the vehicle.