Vehicle Roof Module With Sensor Cutout for Signal-Permissive Integration
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Solution Overview
Problem
The mounting of separate sensor housings on top of vehicle roofs for autonomous or semi-autonomous driving vehicles negatively affects aerodynamics and vehicle appearance, and existing materials for roof skins are impermeable to electromagnetic signals used by environment sensors.
Innovation Solution
Integrating the environment sensor below the roof skin with cutouts in the panel component and using a cover element that allows electromagnetic signal passage while minimizing exposure to humidity and airflows, and employing temperature sensors to compensate for thermal expansions and maintain signal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate sensor housing is mounted on top of the roof skin, then the environment sensor is protected from harmful environmental conditions, but the aerodynamic properties of the vehicle are negatively affected
Solution Approach 1:
The patent merges the sensor housing function with the roof skin itself by integrating the environment sensor directly into the panel component. The roof skin is designed with a cutout that accommodates the sensor, eliminating the need for a separate sensor housing mounted on top of the roof. This integration maintains sensor protection while preserving aerodynamic properties.
Solution Approach 2:
The roof skin is given multiple functions: it serves as both the protective outer covering and as the housing for the environment sensor. The panel component is designed to simultaneously provide structural integrity, weather protection, and sensor mounting, eliminating the need for additional dedicated sensor housing structures.
2Reliability
If a separate sensor housing is mounted on top of the roof skin, then the environment sensor is protected from harmful environmental conditions, but the vehicle appearance is negatively affected
Solution Approach 1:
The sensor housing function is merged into the roof skin design, creating a seamless integrated appearance. The cutout in the panel component is designed to accommodate the sensor while maintaining the overall aesthetic continuity of the roof surface, avoiding the visual disruption of separate mounted housings.
3Reliability
If the panel component is made of impermeable material such as metal plate or plastic, then the roof skin provides stable protection, but electromagnetic signals of the environment sensor cannot pass through
Solution Approach 1:
The panel component is segmented with a cutout or opening that allows electromagnetic signals to pass through while the surrounding material maintains structural integrity and protective function. The roof skin is divided into protected areas and signal transmission areas, with the cutout strategically positioned to enable sensor operation.
Solution Approach 2:
The panel component has different properties in different locations: the majority of the surface remains impermeable and protective, while the specific region of the cutout is designed to be permeable to electromagnetic signals. This local differentiation allows simultaneous achievement of protection and signal transmission.
4Object-generated harmful factors
If the environment sensor is positioned below the roof skin, then aerodynamic properties are improved, but the sensor may be affected by temperature-related length expansions
Solution Approach 1:
The patent anticipates temperature-related length expansions and provides compensation mechanisms in advance. Expansion joints or adjustable mounting structures are incorporated into the sensor housing design to accommodate thermal expansion of the panel component, preventing distortion of the sensor's beam path and maintaining measurement accuracy.
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
Improves aerodynamics and vehicle design while ensuring uninterrupted electromagnetic signal transmission and maintaining sensor accuracy by addressing thermal expansion issues and positioning the sensor for stable operation.
Implementation Method 1
the cover element being made of a material through which the electromagnetic signals of the environment sensor can pass undisturbed
Implementation Method 2
employing temperature sensors to compensate for thermal expansions and maintain signal integrity
Data Source
AI summary
A roof module for forming a vehicle roof on a motor vehicle has a panel component whose outer surface at least partially forms the roof skin of the vehicle roof, the roof module has at least one environment sensor, and the environment sensor being configured to send and/or receive electromagnetic signals for detecting the vehicle environment, and the panel component being made of a material which is impermeable to the electromagnetic signals of the environment sensor. The panel component has at least one cutout through which the electromagnetic signals of the environment sensor can pass.