Panoramic Roof Module Structure for Lightweight Passenger Cars
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Solution Overview
Problem
Existing passenger car designs face challenges in incorporating a transparent roof element in a low-weight and cost-effective manner, as they often require complex and weight-intensive structural components.
Innovation Solution
A passenger car with a monocoque vehicle body featuring a roof opening delimited by lateral roof rails and a transverse element, where a separately configured roof module with a translucent roof element is directly attached to the vehicle body, utilizing a transverse frame part that is integrally joined to the vehicle body, thereby reducing weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a transparent roof element is integrated into the vehicle body structure, then interior illumination is enhanced, but vehicle weight increases
Solution Approach 1:
The vehicle body is divided into modular components: the vehicle body proper, the separate roof module containing the transparent roof element, and the connecting structure. This segmentation allows the transparent roof element to be added only where needed for illumination without requiring the entire vehicle structure to be redesigned or strengthened, thereby minimizing weight increase while achieving the illumination benefit.
Solution Approach 2:
A connecting structure acts as an intermediary between the vehicle body and the roof module. This intermediary component provides the necessary structural support and load transfer path without requiring direct integration of the transparent roof element into the main vehicle body structure, thus reducing the overall weight penalty while maintaining structural integrity and illumination functionality.
2Ease of operation
If a separate roof module is used to hold the transparent roof element, then manufacturing cost increases, but assembly simplicity is improved
Solution Approach 1:
The roof system is segmented into a separate roof module that can be pre-assembled and tested independently before installation on the vehicle body. This modular approach simplifies the final assembly process on the production line while allowing for cost-effective manufacturing of the module itself, as it can be produced in batches and potentially reused across different vehicle models.
Solution Approach 2:
The roof module design incorporates universal mounting features and standardized interfaces that can be applied across different vehicle body types. This multi-functionality allows the same roof module design to be used on various vehicle models, reducing overall manufacturing costs through economies of scale while maintaining simple assembly procedures.
3Loss of time
If the roof module is preassembled independently, then assembly time is reduced, but structural rigidity may be compromised
Solution Approach 1:
The roof module is pre-assembled independently with all necessary internal components, fasteners, and alignment features prepared in advance. This preliminary action ensures that when the module is installed on the vehicle body, it can be quickly secured without requiring complex on-site assembly operations, thereby reducing assembly time while maintaining structural rigidity through pre-engineered connection points.
Solution Approach 2:
The connecting structure serves as an intermediary that provides rigid mechanical coupling between the pre-assembled roof module and the vehicle body. This intermediary component is specifically designed to transfer and distribute loads effectively, ensuring that the structural rigidity required for safety and performance is maintained even though the roof module was assembled separately in advance.
Data Source
AI summary
A passenger car has a self-supporting body, which has a roof opening. The roof opening is outwardly delimited in the vehicle transverse direction by lateral roof rails of the body and in the vehicle longitudinal direction by a transverse element of the body connected to the roof rails. A roof apparatus has a frame and at least one roof element that overlaps with at least part of the roof opening. The roof element is retained on the frame directly and on the body by way of the frame. The frame has a transverse frame part, on which the roof element is retained directly, the transverse frame part being connected directly to the transverse element of the body.