Segmented Guide Rail for Compact Load Carrier
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Solution Overview
Problem
Existing load carriers for vehicles face challenges in achieving a balance between being lightweight, compact, and resilient, while also supporting high loads and requiring minimal installation space, which is not adequately addressed by current rail profiles.
Innovation Solution
The design incorporates short reinforcement legs for guide rails, allowing for a compact and lightweight structure with a clamping device that securely fastens runner rails to guide rails using a tie rod, and includes reinforcing ribs and spacers for additional support and guidance, optimizing space usage and load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rail profiles with multiple leg sections are used to withstand high loads, then the load-bearing capacity is improved, but the installation space requirement increases and the weight increases
Solution Approach 1:
The guide rail is segmented into functional sections: a support leg for mounting, a bearing leg for guiding the runner rail, and a reinforcement leg for strengthening. This segmentation allows each part to be optimized independently, achieving high load-bearing capacity with compact dimensions.
Solution Approach 2:
The reinforcement leg extends in the longitudinal direction rather than increasing transverse dimensions. This dimensional change allows strengthening without increasing the installation space footprint, as the reinforcement is distributed along the length of the guide rail.
2Strength
If traditional rail profiles with multiple leg sections are used to withstand high loads, then the load-bearing capacity is improved, but the weight increases
Solution Approach 1:
The guide rail is divided into distinct functional legs (support, bearing, reinforcement) that can be optimized for minimal weight while maintaining strength. Each leg performs a specific function, eliminating unnecessary material.
Solution Approach 2:
Reinforcement is applied locally through the reinforcement leg only where needed to withstand loads, rather than uniformly strengthening the entire rail profile. This localized approach minimizes weight while maintaining load-bearing capacity.
3Area of stationary object
If the guide rail is made compact to save installation space, then the installation space requirement is reduced, but the load-bearing capacity may be compromised
Solution Approach 1:
The compact guide rail maintains load-bearing capacity through segmentation into specialized legs. The reinforcement leg specifically addresses strength requirements while the overall compact design saves installation space.
Solution Approach 2:
Strength is achieved by extending the reinforcement leg in the longitudinal dimension rather than increasing transverse dimensions. This allows the guide rail to be compact in footprint while maintaining load-bearing capacity through longitudinal reinforcement.
4Strength
If the reinforcement leg is made long to increase strength, then the load-bearing capacity is improved, but the available free space below it is reduced
Solution Approach 1:
The reinforcement leg provides localized strengthening exactly where loads are transmitted from the runner rail to the support leg. This targeted reinforcement achieves maximum strength efficiency without requiring excessive length that would consume valuable free space.
Solution Approach 2:
Instead of increasing the height (vertical dimension) of the reinforcement leg, the reinforcement is achieved through longitudinal extension and cross-sectional optimization. This dimensional strategy maintains free space below the leg while providing sufficient strength.
Data Source
Figure 1~2
Figure 3~4
Figure 5a~6
AI summary
The load carrier has a reinforcement shank (63) arranged at longitudinal side of a support shank (62) running toward a longitudinal axis opposite to a protective shank (61). The reinforcement shank is transverse to the longitudinal axis more briefly than the protective shank, so that a free space (65) is present underneath to the reinforcement shank beside that protective shank.