Modular Roof Rack Assembly with Sliding Mounting Bars
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Solution Overview
Problem
The variability in mounting fixtures across different vehicle brands, models, and generations makes it challenging to manufacture a roof rack that can be accommodated on a range of vehicle roofs, requiring a large number of unique parts and complex machining to ensure proper engagement positions.
Innovation Solution
A modular roof rack assembly with sliding mounting bars and adjustable connector assemblies that can be positioned and secured along longitudinally extending channels, allowing for adaptation to various mounting fixture types and arrangements without the need for custom machining or partial disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-determined engagement positions are machined into mounting flanges for different vehicle types, then mounting precision and reliability are improved, but device complexity and manufacturing cost increase due to requiring many unique parts
Solution Approach 1:
The side rail is designed with a universal longitudinally extending channel that can accommodate mounting bars for multiple different vehicle types and mounting fixture configurations. This single channel structure replaces the need for multiple pre-determined engagement positions machined into separate mounting flanges for different vehicles, allowing one roof rack design to serve multiple functions across various vehicle platforms.
Solution Approach 2:
The mounting bar is made adjustable and movable along the channel rather than being fixed at pre-determined positions. This dynamic design allows the mounting bar to be repositioned to match different mounting fixture locations on various vehicles, eliminating the need for multiple static engagement position designs while maintaining reliable mounting for each specific vehicle type.
2Adaptability or versatility
If custom machining is performed for each vehicle type, then adaptability to specific vehicles is improved, but manufacturing time and productivity decrease
Solution Approach 1:
The mounting system is segmented into modular components: the side rail with channel, the adjustable mounting bar, and the connector assembly. This segmentation allows the main roof rack structure to be manufactured once using the universal channel design, while only the mounting bar position needs adjustment for different vehicles, significantly reducing manufacturing time compared to custom-machining entire assemblies for each vehicle type.
Solution Approach 2:
The side rail is pre-manufactured with the universal channel structure that anticipates future mounting needs for different vehicle types. This preliminary action of creating a versatile base structure eliminates the need for time-consuming custom machining later, as the channel already provides the adaptability needed for various mounting fixture configurations.
3Strength
If mounting positions are fixed for specific vehicle models, then structural integrity at load-bearing points is improved, but ease of manufacture decreases due to requiring multiple part variants
Solution Approach 1:
The channel structure serves multiple functions: it provides structural support, defines mounting bar positions, and accommodates different vehicle-specific mounting fixtures. This universal design maintains load-bearing capacity at appropriate positions for each vehicle type while allowing a single manufacturing process for the side rail, eliminating the need to manufacture multiple part variants for different vehicles.
Data Source
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AI summary
An assembly for a load supporting structure for a vehicle which includes, a support frame adapted to be connected to the vehicle, which comprises two longitudinally extending side rails, a front rail and a rear rail, each of the side rails having at least one channel longitudinally extending along at least a portion of the length of the underside surface thereof, and which faces the vehicle. The assembly also includes a plurality of modular longitudinal base elements, one or more mounting bars adapted to mount the load supporting structure to the vehicle wherein at least one of the one or more mounting bars is slidable forward and aft at least partially along the length of the longitudinally extending channels of the side rails and base elements.