Roller Gate Upper Holder Mounting for Simpler Vehicle Body Assembly
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Solution Overview
Problem
Existing commercial vehicle bodies with roller shutters are complex and costly to manufacture, primarily due to the intricate design and multiple components required for the upper roller holders.
Innovation Solution
The commercial vehicle body design incorporates upper roller holders that are mounted in T-slots of the top panel using separate mounting means, allowing for adjustable alignment and simplified assembly, reducing the number of components and material consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional upper roller holder design with multiple components is used, then reliable alignment and support of the roller shutter is achieved, but manufacturing complexity and production costs increase
Solution Approach 1:
The patent combines multiple separate components (mounting plate, roller holder, and alignment mechanisms) into a single integrated upper roller holder component. This merging reduces the number of parts, simplifies assembly, and lowers manufacturing complexity while maintaining the functional requirements for reliable alignment and support of the roller shutter.
Solution Approach 2:
The integrated upper roller holder performs multiple functions simultaneously: it provides structural support for the roller, enables precise alignment with the rail system, and facilitates easy installation. By combining these functions into a single component, the design achieves multi-functionality that reduces overall device complexity while maintaining reliability.
2Reliability
If traditional upper roller holder design with multiple components is used, then adequate support and alignment is achieved, but production costs and material consumption increase
Solution Approach 1:
By merging multiple components into a single integrated upper roller holder, the total material consumption is reduced. The design eliminates redundant materials from separate mounting plates, fasteners, and alignment components, while still providing adequate support and alignment functionality through the optimized single-component structure.
3Manufacturing precision
If complex traditional assembly process is used, then precise alignment of upper roller holders is achieved, but assembly time and production complexity increase
Solution Approach 1:
The integrated upper roller holder is pre-designed and pre-assembled as a complete unit with built-in alignment features. This preliminary action eliminates the need for complex on-site alignment procedures, allowing workers to simply install the pre-aligned component, thereby reducing assembly time while maintaining manufacturing precision.
Solution Approach 2:
The design incorporates self-aligning features that automatically ensure precise alignment during installation without requiring complex external alignment tools or procedures. The component serves itself by incorporating alignment mechanisms that work automatically, reducing both assembly time and production complexity while maintaining alignment precision.
Data Source
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AI summary
A commercial vehicle body (2) for a commercial vehicle with a roller door (8), comprising a wall element (9) which can be adjusted from a closed position to an open position and back again, and a rail system (10) for guiding the wall element (9), wherein the wall element (9) has a series of panels (18, 19), wherein the panels (18, 19) are positively connected to one another at adjacent edges via connecting profiles (31, 31), wherein at least one upper roller holder (16) is provided on the uppermost panel (18) of the wall element (9), and wherein the at least one roller holder (16) holds at least one roller (15) guided on the rail system (10).It is provided that the at least one upper roller holder (16) is held in a T-slot (25) of the uppermost panel (18) via at least one separate mounting means (21) and that the at least one mounting means (21) extends in sections through at least one elongated hole (24) extending transversely to the T-slot (25) in the at least one upper roller holder (16).