Vehicle Roof Structural Mount Assembly for Sensor Attachment
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Solution Overview
Problem
The existing methods for mounting sensor structures on vehicle roofs are time-consuming due to the need for drilling holes and extensive modifications, which increases the complexity and duration of the mounting process.
Innovation Solution
A structural mount assembly comprising an exterior bracket secured to the roof panel's exterior surface and interior brackets attached to both the roof panel and the vehicle frame, allowing for secure mounting of sensor structures with reduced modifications and assembly steps, utilizing metal materials and various fastening methods like welding and clinching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drilling holes and extensive modifications are made to the roof for mounting sensor structures, then secure mounting is achieved, but the mounting time and process complexity increase
Solution Approach 1:
The bracket assembly is pre-configured with attachment features that align with pre-existing roof structure elements (roof rails, reinforcement beams), eliminating the need for drilling holes during installation. The bracket is designed to clamp onto these existing structures, allowing for rapid mounting without time-consuming roof modifications.
Solution Approach 2:
The mounting system is divided into separate components: the bracket assembly that attaches to the roof structure, and the sensor structure that mounts to the bracket. This segmentation allows the bracket to be independently designed for optimal attachment without requiring modifications to the roof, while the sensor structure can be easily attached or removed from the bracket.
2Reliability
If drilling holes and extensive modifications are made to the roof for mounting sensor structures, then secure mounting is achieved, but the assembly complexity increases
Solution Approach 1:
The bracket is pre-designed with specific attachment features (clamps, brackets, or adhesive surfaces) that match the vehicle's existing roof structure. This preliminary design ensures that the bracket can be securely mounted using simple fastening operations rather than complex drilling and welding procedures, reducing assembly complexity while maintaining mounting security.
Solution Approach 2:
The bracket assembly is designed to utilize existing roof structure elements (roof rails, reinforcement beams) that are present in most vehicle designs. This universal approach allows the same bracket design to be applied across different vehicle models without requiring custom modifications, thereby reducing assembly complexity while ensuring secure mounting.
3Reliability
If multiple brackets and support members are used to mount sensor structures, then mounting security is improved, but the number of components and assembly steps increase
Solution Approach 1:
Multiple support functions are merged into a single integrated bracket assembly. The bracket combines mounting attachment features, sensor structure support, and positioning alignment into one component that attaches to the roof structure and secures the sensor structure, eliminating the need for multiple separate brackets and support members.
Solution Approach 2:
The bracket assembly is designed as a multi-functional component that performs multiple roles: attaching to the roof structure, supporting the sensor structure, providing positioning alignment, and ensuring secure mounting. This consolidation of functions into a single component reduces the number of parts required while maintaining mounting security.
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 solution reduces the time and effort required for mounting sensor structures by minimizing roof penetrations and assembly steps, while providing robust support for sensors and preventing fluid ingress into the cabin.
Implementation Method 1
the exterior bracket is secured to the exterior surface of the roof panel via welding or clinching
Implementation Method 2
the exterior bracket is secured to the exterior surface of the roof panel via welding or clinching
Implementation Method 3
the interior brackets are secured to the exterior bracket through the roof panel via clinching or welding
Implementation Method 4
the interior brackets are secured to the exterior bracket through the roof panel via clinching or welding
Data Source
AI summary
A structural mount assembly for a roof panel of a vehicle. The structural mount assembly includes an exterior bracket and a plurality of interior brackets. The exterior bracket is secured to an exterior surface of the roof panel. The exterior bracket includes a plurality of stanchions for mounting a sensor structure. The plurality of interior brackets are disposed on an interior surface of the roof panel and being secured to the exterior bracket through the roof panel.