Vehicle Roof Fairing Hinge Design for Shipping Height
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Solution Overview
Problem
Existing two-piece roof fairing arrangements with hinges are cumbersome and costly to manufacture and install due to their complex shape, weight, and permanent coupling, making them difficult to handle and assemble during factory settings, especially when considering the height constraints during 'piggy back' shipping of truck tractors.
Innovation Solution
A roof fairing design comprising a lower and upper body section that form a hinge when in a shipping configuration, allowing the upper section to pivot and extend above the lower section in an operable configuration, enabling easier handling and installation, with the upper section being positioned partially within the lower section's receiving space and secured via tongues and cutouts, reducing the need for complex molds and multiple workers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a two-piece roof fairing with hinges is used to reduce height during shipping, then the height constraint during piggy back shipping is satisfied, but the manufacturing cost and assembly time increase due to complex molds and permanent coupling
Solution Approach 1:
The roof fairing is divided into two separate body sections (upper and lower) that can be manufactured independently using simple molds, then connected through a receiving space mechanism rather than permanent hinges. This segmentation allows each section to be produced separately with simpler tooling while maintaining the height-reduction capability during shipping.
Solution Approach 2:
The upper fairing body section is designed to nest within the lower fairing body section during shipping configuration. The upper section fits into the receiving space of the lower section, creating a compact stacked arrangement that reduces overall height without requiring complex hinged connections.
2Adaptability or versatility
If piano hinges or living hinges are used to connect fairing sections, then the fairing can be lowered during shipping, but the manufacturing complexity and mold requirements increase
Solution Approach 1:
Instead of using a single complex hinged structure, the fairing is segmented into two separate body sections with a simplified connection interface. The upper section contains a front wall with cutouts that mate with tongues on the lower section, creating a straightforward mechanical connection without requiring complex hinge mechanisms or large common molds.
Solution Approach 2:
The complex hinge mechanism is extracted and replaced with a simpler tongue-and-cutout coupling system. The upper fairing body section is extracted as a separate component that can be independently molded and then connected to the lower section through the receiving space, eliminating the need for integrated complex molding.
3Stability of the object's composition
If the upper and lower fairing sections are permanently coupled via hinges, then the fairing maintains its extended position, but the handling and installation become difficult requiring multiple workers
Solution Approach 1:
The fairing is segmented into two separately handleable sections that can be maneuvered independently during installation. The lower section can be mounted to the cab roof first, then the upper section can be positioned and connected, allowing a single worker to handle each section separately rather than managing a large combined assembly.
Solution Approach 2:
The lower fairing body section is preliminarily installed and secured to the cab roof before the upper section is connected. This preliminary positioning establishes a stable base, allowing the upper section to be subsequently attached in a controlled manner, simplifying the overall installation process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies the manufacturing and installation process by allowing separate handling and installation of the fairing sections, reducing manufacturing costs and time, while maintaining the ability to extend the roof fairing height post-delivery, thus addressing the height constraints during shipping.
Implementation Method 1
the upper roof fairing section and the lower fairing body section mate to form at least one hinge
Data Source
AI summary
The present invention relates to a roof fairing body and a method of installing a roof fairing on a vehicle. The roof fairing includes a lower fairing body section, an upper fairing body section, a shipping configuration, and an operable configuration. The lower fairing body section includes a front wall and side walls extending rearward from opposite ends of the front wall. The front wall and side walls cooperate to define an upper roof fairing section receiving space. The upper fairing body section is configured to mate with the lower fairing body section to form at least one hinge. When in the shipping configuration, the upper roof fairing section is positioned at least partially within the upper roof fairing section receiving space of the lower fairing body section, whereby the roof fairing body is provided with a shipping height and the upper roof fairing section and the lower fairing body section mate to form at least one hinge. When in an operable configuration the upper roof fairing section pivots about the at least one hinge whereby the upper roof fairing section is situated at least partially above the lower fairing body section and the roof fairing body is provided with an operable height that is greater than the shipping height.