Modular Load Carrier System with U-Profile Connecting Elements
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Solution Overview
Problem
Existing load carrier systems for the automotive and commercial vehicle industries are complex, expensive, and lack flexibility in adapting to different cargo sizes, weights, and shapes, leading to high maintenance costs and prolonged development times.
Innovation Solution
A modular load carrier system featuring a base part and superstructure connected via U-profile shaped elements, allowing for detachable assembly and reassembly, enabling quick adaptation to various loads and dimensions through standardized, cost-effective components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex corner profiles with hollow structures are used, then structural strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The corner profile is segmented into a U-shaped base element and separate connecting elements that attach to the load carrier structure. This segmentation simplifies the main corner profile while distributing connection functions to separate standardized components, reducing overall device complexity while maintaining structural integrity
Solution Approach 2:
The U-shaped corner elements serve multiple functions: they provide structural support, enable detachable connections, and allow for standardized assembly. This multi-functionality reduces the need for specialized complex components, simplifying the overall system while maintaining strength
2Ease of manufacture
If standardized connecting elements are used, then ease of manufacture and cost-effectiveness are improved, but adaptability to different cargo configurations may be limited
Solution Approach 1:
The system employs detachable and reconfigurable connecting elements that can be dynamically assembled and disassembled to adapt to different cargo configurations. This dynamic reconfigurability maintains versatility while using standardized components for ease of manufacture
Solution Approach 2:
The connecting elements can be positioned at different locations and configured in various arrangements to change the effective parameters of the load carrier system, enabling adaptability to different cargo sizes and shapes while using the same standardized components
3Adaptability or versatility
If modular detachable connections are implemented, then adaptability to different loads is improved, but connection strength and structural reliability may be reduced
Solution Approach 1:
The connecting elements are pre-designed with optimized connection geometries and attachment points that ensure reliable and strong connections when assembled. This preliminary design of connection features maintains structural reliability while enabling detachable modular assembly for adaptability
Data Source
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AI summary
The modular load carrier system (LS) comprises a bottom portion (1) and a main structure in which the floor elements (2) and strut elements (3) are mounted. The main structure includes several U-shaped connecting elements (6) which are connected detachably to assemble the carrier system, such that the outer and/or inner dimensions of the system are made variable. The main structure further comprises a cladding element (4). Two connecting elements each having a floor element, are detachably connected and oriented at right angles to each other.