Modular Roll Cage Joining via Intermediate Member
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Solution Overview
Problem
Existing approaches for assembling and shipping roll cages for vehicles are inefficient, as they often require large volumes and lack a modular, removable design that simplifies assembly and disassembly.
Innovation Solution
A modular roll cage system utilizing an intermediate member with offset shoulder portions and central apertures, along with threaded inserts, allows for secure joining of frame members using bolts and welding, enabling efficient assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the roll cage is shipped detached and modular, then shipping volume is reduced, but assembly complexity increases
Solution Approach 1:
The roll cage is divided into multiple modular frame members that can be shipped separately, reducing shipping volume. Each frame member can be independently packaged and transported, then assembled at the destination to form the complete roll cage structure.
Solution Approach 2:
An intermediate member with offset shoulder portions serves as a connector between frame members. This intermediary component facilitates the joining of modular sections through its central aperture and shoulder geometry, simplifying the assembly process despite the modular configuration.
2Ease of operation
If the roll cage is made removable and modular, then ease of assembly and disassembly is improved, but structural integrity may be compromised
Solution Approach 1:
The roll cage is segmented into removable modular components that can be easily assembled and disassembled. The segmentation allows for simple installation and removal while maintaining structural integrity through proper joining mechanisms.
Solution Approach 2:
The intermediate member features nested shoulder portions that fit within frame members, creating a secure nested connection. The first and second shoulder portions are positioned to nest within respective frame members, providing robust mechanical interlocking that maintains structural strength during use.
3Ease of manufacture
If shoulder portions are offset along an axis, then modular assembly is facilitated, but manufacturing precision requirements increase
Solution Approach 1:
The intermediate member employs asymmetric offset shoulder portions along its axis, where the first and second shoulder portions are positioned at different locations. This asymmetric design facilitates modular assembly by providing distinct engagement points while maintaining manufacturability through standard machining processes.
Solution Approach 2:
The intermediate member acts as a precision intermediary component that bridges frame members. Its offset shoulder portions are manufactured with controlled tolerances to ensure proper positioning and alignment during assembly, balancing manufacturing precision requirements with ease of assembly.
Data Source
AI summary
A roll cage is formed by joining tubes using an intermediate member with shoulder portions that insert within the tubes. Two inserts secure within the tubes, at least one being threaded. A threaded bolt is inserted through a first insert, through the intermediate member, and threaded into the second insert. Other tubes secure to the intermediate member such that the tubes together form a roll cage that may be secured to the chassis of a vehicle. For multi-row vehicles, a third insert secures in the second tube and has a threaded shaft protruding from it. The threaded shaft is passed through a second intermediate member and threaded into a threaded insert in a third tube and the second tube is rotated.