Fiber Composite Roof Frame with Adjustable Installation Domes
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Solution Overview
Problem
Manufacturing tolerances in motor vehicle body shell structures complicate the precise installation of roof frames and structures, leading to potential errors and increased complexity in mounting processes.
Innovation Solution
A roof frame made from fiber composite materials with height-adjustable installation domes and spacer elements, produced from plastic resin and ethylene-propylene-diene rubber, allows for simple compensation of manufacturing tolerances through interchangeable inserts, ensuring a secure and precise fit with the body shell structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fixed-height spacer elements are used for mounting the roof frame, then the installation process becomes complex and error-prone due to manufacturing tolerances of the body shell structure, but using height-adjustable installation domes with interchangeable inserts increases device complexity
Solution Approach 1:
The installation domes are designed with height-adjustable interchangeable inserts that can be selected and installed based on the actual spacing requirements. This dynamic adjustment capability allows the same dome structure to adapt to varying manufacturing tolerances of the body shell structure, resolving the contradiction between maintaining precision and avoiding excessive complexity.
Solution Approach 2:
The invention changes the height parameter of the installation domes by using interchangeable inserts with different thicknesses. This allows precise adjustment of the dome height to compensate for manufacturing tolerances in the body shell structure, achieving accurate positioning without requiring completely different dome designs for each tolerance variation.
2Manufacturing precision
If different spacer elements of varying heights are attached to individual positions to compensate for tolerances, then positioning precision improves, but the susceptibility to installation errors increases
Solution Approach 1:
The invention makes all installation domes universally interchangeable by using the same dome design with different height inserts. This universal design eliminates the risk of installing wrong-height spacers at incorrect positions, as any dome can be fitted to any position. The inserts are designed to be identifiable and interchangeable, maintaining positioning precision while significantly reducing installation errors.
Solution Approach 2:
The invention segments the height adjustment function into separate interchangeable inserts that can be independently selected and installed. This segmentation allows the height adjustment capability to be separated from the dome structure itself, making the system more flexible and less error-prone during installation.
3Weight of moving object
If a fiber composite material roof frame is used to reduce mass, then vehicle weight decreases and fuel efficiency improves, but the structural strength and mechanical stability requirements become more challenging to meet
Solution Approach 1:
The invention uses fiber composite materials for the roof frame to achieve weight reduction while maintaining structural strength. The composite material properties are optimized to provide the necessary mechanical strength and stiffness for the roof structure, resolving the contradiction between reducing vehicle mass and maintaining structural integrity.
Data Source
AI summary
A roof frame (1) for a roof structure (2) of a motor vehicle is closed in the circumferential direction and can be mounted on a body shell structure of the motor vehicle and connected to a roof outer shell (3). The roof frame (1) is produced from a fiber composite material. A side of the roof frame (1) that faces the body shell structure of the motor vehicle has height-adjustable installation domes (5) and spacer elements (6) are attached to each of the installation domes (5). The roof frame (1) and the roof outer shell (3) are connected to each other in an integrally bonded manner.