Fused Vehicle Roof Sensor Bracket for Precise Sealed Mounting
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Solution Overview
Problem
Existing vehicle sensor assemblies face challenges in achieving repeatable and accurate assembly within location tolerances while providing structural reinforcement and effective sealing against environmental elements.
Innovation Solution
A mounting bracket is fused to the vehicle body, specifically the vehicle roof, using welded joints to structurally reinforce the roof and ensure precise sensor assembly placement, while seals are used to prevent water and wind ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a mounting bracket is fused to the vehicle body using welded joints, then structural integrity and manufacturing precision are improved, but device complexity increases
Solution Approach 1:
The mounting bracket is fused to the vehicle body through welded joints, merging two separate components into a unified structural assembly. This combining approach enhances structural integrity by creating a permanent, rigid connection that distributes loads effectively across the vehicle roof while maintaining precise sensor assembly placement.
2Manufacturing precision
If multiple welded joints are used to fuse the mounting bracket, then manufacturing precision and reliability are improved, but ease of manufacture deteriorates
Solution Approach 1:
The mounting bracket is designed with pre-determined welded joint locations that are established during the manufacturing process. By pre-planning the exact positions and configurations of multiple welded joints, the system achieves high assembly location precision for sensors while managing manufacturing complexity through standardized joint patterns and procedures.
3Reliability
If seals are added to prevent water and wind ingress, then reliability is improved, but device complexity increases
Solution Approach 1:
Seals are introduced as intermediary components between the mounting bracket and the vehicle body, or between sensor housing and mounting bracket. These seal elements act as mediators that prevent water and wind ingress into the sensor assembly, enhancing reliability by creating protective barriers without requiring fundamental changes to the core mounting structure.
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
The solution enables repeatable and accurate sensor assembly with enhanced structural integrity and effective sealing, ensuring reliable operation of object-detection sensors in various environmental conditions.
Implementation Method 1
The mounting bracket may be fused to the exterior surface at a welded joint
Data Source
AI summary
A vehicle includes a vehicle body having an exterior surface. A sensor assembly has a mounting bracket and a sensor housing. The mounting bracket is on the exterior surface of the vehicle body and is fused to the exterior surface of the vehicle body. The sensor housing is releasably connected to the mounting bracket.