Vehicle Roof Assembly Pivoting Accessory Frame Installation
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Solution Overview
Problem
The installation of large, pre-assembled vehicle components is burdensome for a single worker due to their size and weight, and the cost and impracticality of using additional workers or robotic lift-assist machines make it inefficient and costly.
Innovation Solution
A vehicle roof assembly design featuring a roof structure with mounting slots and flanges that allow an accessory frame to pivot and be secured, enabling a single worker to easily install large accessory frames like shade assemblies by engaging complementary mounting structures, reducing the need for additional labor or expensive machinery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large pre-assembled vehicle components are used, then productivity and efficiency are improved, but the difficulty of installation increases due to weight and size
Solution Approach 1:
The accessory frame is divided into two main ends (first frame end and second frame end) with distinct mounting features. Each end has complementary mounting structures that engage with corresponding roof sections, allowing the frame to be installed in segments rather than as a single heavy unit. This segmentation enables a single worker to install the component by working from one end to the other.
Solution Approach 2:
The mounting flange acts as an intermediary element between the accessory frame and the roof structure. The flange engages with the mounting slot to provide a pivot point and temporary support, mediating the transition from pre-installation to installed position. This intermediary mechanism reduces the direct lifting and positioning burden on the installer.
2Ease of operation
If additional workers or robotic lift-assist machines are used, then the ease of installation is improved, but the cost and device complexity increase
Solution Approach 1:
The accessory frame's mounting structures are designed to be self-aligning and self-supporting during installation. The complementary mounting structures at each end engage with the roof sections in a sequence that allows the frame to support its own weight progressively, eliminating the need for external lifting equipment or multiple workers.
Solution Approach 2:
The installation process utilizes dynamic movement through the pivot mechanism. The accessory frame transitions from a horizontal pre-installation position to a vertical installed position by pivoting on the mounting flange. This dynamic installation method converts a static heavy-lifting problem into a dynamic rotational movement that a single worker can manage.
3Ease of operation
If additional workers are hired, then the ease of operation is improved, but the loss of energy and cost increase
Solution Approach 1:
The accessory frame is pre-assembled with all mounting structures attached before delivery to the installation site. The mounting flanges and complementary mounting structures are pre-positioned and configured, so that during installation, the worker only needs to engage these pre-prepared features with the roof sections. This preliminary preparation eliminates the need for multiple workers during the actual installation process.
Data Source
AI summary
A vehicle roof assembly includes a vehicle roof structure, an accessory frame and a moveable member. The vehicle roof structure includes a first roof section with a mounting slot and a second roof section with a mounting structure. The accessory frame includes a first frame end that includes a mounting flange, and a second frame end that includes a complementary mounting structure. The mounting flange engages the mounting slot to couple the accessory frame to the vehicle roof structure and to enable the accessory frame to pivot relative to the vehicle roof structure between a pre-installation position and an installed position where the complementary mounting structure engages the mounting structure. The movable member is coupled to the accessory frame and moves between a first position proximate to one of the first and second frame ends, and a second position proximate to the other of the first and second frame ends.