Vehicle Sensor Mount Casting for Extended Reach and Load Capacity
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Solution Overview
Problem
Vehicle sensor support systems face a compromise between weight capacity, distance from the vehicle, and size, requiring a solution that enhances strength and rigidity while minimizing bulk.
Innovation Solution
A modular support system for vehicle sensors, comprising a casting extending outward through exterior paneling, with an electronic device supported on the exterior portion and a cover shielding it from the environment, integrated with the vehicle's frame to maintain stability and collect external data effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the sensor support system extends sensors farther outward from the vehicle, then the distance capability is improved, but the structural size and complexity increase
Solution Approach 1:
The support system is divided into multiple segments: an interior portion mounted on the frame within the vehicle interior, and an exterior portion extending outward to support the sensor. This segmentation allows the system to achieve extended reach without requiring a single large, bulky structure, thus resolving the contradiction between distance capability and system size.
2Weight of moving object
If the sensor support system supports more weight at extended distances, then the weight capacity is improved, but the strength and structural complexity requirements increase
Solution Approach 1:
The interior portion and exterior portion are merged into a single integrated casting structure with continuous material flow. This merging provides optimal structural strength to support heavy sensors at extended distances while avoiding the need for overly complex multi-component assemblies, thus resolving the contradiction between weight capacity and structural strength requirements.
3Volume of stationary object
If the sensor support system is made more compact to reduce size, then the volume is reduced, but the distance capability and weight capacity are compromised
Solution Approach 1:
The support system utilizes three-dimensional space efficiently by extending the exterior portion outward from the vehicle body in a direction that maximizes sensor distance while minimizing interference with vehicle interior space. This dimensional optimization allows compact overall volume while achieving extended reach capability.
Data Source
AI summary
A module support system for a vehicle including exterior paneling defining an interior and exterior of the vehicle, and a frame disposed in the interior of the vehicle, the module support system including a first casting mounted on the frame, where the first casting extends outward from the frame, through the exterior paneling, to the exterior of the vehicle such that the first casting includes an interior portion disposed within the interior of the vehicle and mounted on the frame, and an exterior portion extending outward from the exterior of the vehicle. The module support system includes a first electronic device supported on the exterior portion of the first casting, and a cover fixed with the exterior portion of the first casting such that the cover is disposed over the first electronic device and the exterior portion of the first casting with respect to an external environment.