Modular Roof Rail Assembly Module for Load Bearing

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Solution Overview

Problem

Existing load bearing elements for vehicles are limited in volume and load capacity, and face challenges in aesthetics, cost reduction, and efficient assembly.

Innovation Solution

A set of load bearing elements comprising first and second roof bars and a roll bar formed of structural elements, with an assembly module that includes coupling elements and a fixing support, allowing for robust mechanical connections and easy assembly, optimized for improved stress resistance and reduced costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional roof bars with fixed architecture are used, then assembly is simple, but load capacity and volume are limited

Engineering Contradiction:

Improveload capacityVSAvoidarchitecture complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The load bearing system is divided into modular components: roof bars, cross bars, and assembly modules that can be independently manufactured and then combined. Each module contains coupling elements that enable flexible configuration while maintaining structural integrity, thus increasing load capacity without requiring complex monolithic architecture.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The assembly modules are designed with universal coupling elements that can connect different types of structural elements (roof bars, cross bars, support elements) in multiple configurations. This multi-functionality allows the same basic module to serve various load-bearing purposes, increasing overall system capacity while using standardized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Volume of stationary object

If more structural elements are added to increase volume, then load capacity improves, but assembly time and cost increase

Engineering Contradiction:

Improveload volumeVSAvoidassembly efficiency

Core Design Contradiction:

Volume of stationary objectVSProductivity

Solution Approach 1:

Coupling elements are pre-integrated into the assembly modules during manufacturing, so that during final assembly, workers or robots only need to connect pre-prepared modules rather than assembling individual components. This preliminary preparation of coupling mechanisms significantly reduces assembly time while enabling complex multi-element configurations.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If complex coupling mechanisms are used to improve connection strength, then stress resistance improves, but manufacturing cost increases

Engineering Contradiction:

Improvestress resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Multiple functions are merged into single components: the coupling elements serve both as mechanical connectors and as stress-distribution features. The assembly module body integrates multiple coupling elements and mounting features into one molded or fabricated piece, reducing the total number of parts while maintaining high stress resistance through optimized geometry and material selection.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3154824B1Elements assembly for supporting load

Publication Date: 2019.08.28 RENAULT SA

Figure 1
Figure 2A~2B
Figure 3~4

AI summary

The invention relates to a module for assembling a roof rail (2a, 2b) with a roll bar and a set of load-bearing elements, the roll bar being made up of structural elements (3a, 3b, 3c), the assembly module (1a, 1b) being provided with a body (8) capable of mechanically connecting said roof rail (2a, 2b) to the first, second and third structural elements (3a, 3b, 3c).