Integrated Roof Module Element for Commercial Vehicles
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Solution Overview
Problem
The assembly of roof cove elements in commercial vehicles is costly and time-consuming due to the separate manufacturing and installation of outer and inner components, with limited accessibility for subsequent installation of vehicle components like pneumatic and hydraulic lines, leading to increased manufacturing and assembly costs.
Innovation Solution
An integrated roof module element is designed with pre-fabricated components that include integrated pneumatic and hydraulic lines, pressure accumulators, air ducts, and electrical lines, allowing for complete equipping during manufacturing and easy assembly onto the vehicle body, reducing assembly time and costs through adhesive or screw connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the outer roof cove and inner roof cove are manufactured and mounted separately, then the watertight connection and functional separation are achieved, but the assembly costs and manufacturing complexity increase significantly
Solution Approach 1:
The patent combines the outer roof cove and inner roof cove into a single integrated roof cove element. The outer and inner parts are formed as one piece through extrusion or molding processes, eliminating the need for separate manufacturing and assembly operations. This integration maintains the watertight connection function while significantly reducing assembly complexity and manufacturing costs.
2Strength
If vehicle components are installed after the outer roof cove is installed, then the structural integrity is maintained, but the accessibility for installation and maintenance deteriorates
Solution Approach 1:
The integrated roof cove element incorporates removable or openable sections that allow access to the interior space where vehicle components are installed. These access points can be opened from the exterior, enabling installation and maintenance of pneumatic lines, hydraulic lines, and other components without compromising the overall structural integrity of the roof assembly.
3Adaptability or versatility
If multiple separate components are assembled to form the roof cove, then the functional requirements are met, but the assembly time and production costs increase
Solution Approach 1:
The patent integrates multiple functions into a single roof cove element structure. The extruded or molded profile incorporates both the outer protective shell and inner functional space in one component, allowing all structural and functional requirements to be met simultaneously. This eliminates multiple assembly steps and significantly increases production speed and efficiency.
4Productivity
If the roof module elements are pre-assembled with all components integrated, then the assembly time is reduced, but the manufacturing complexity of the module itself increases
Solution Approach 1:
The patent replaces traditional mechanical assembly processes with modern extrusion or molding technologies. The integrated roof cove element is produced in one piece through continuous extrusion or single-shot molding, which automatically integrates all structural features and functional spaces. This manufacturing approach reduces the complexity of post-assembly operations while maintaining ease of production through standardized industrial processes.
Data Source
Figure 1
Figure 2
AI summary
The unit (10) has multiple additional functional units in an integrated manner, where the unit forms a longitudinal edge area of a vehicle structure. An air duct (24) and /or a pneumatic pipe and/or hydraulic pipe is integrated in the roof module unit. The pneumatic pipe and/or hydraulic pipe forms a structural reinforcing unit of the roof module unit. The pneumatic pipe and/or hydraulic pipe is designed as a closed pressure reservoir.