Sunroof Kinematic System Relocation for Noise and Alignment
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Solution Overview
Problem
Existing sunroof designs face issues with alignment between left and right sliding mechanisms, leading to shaky movement, increased power requirements, and reliability degradation due to misalignment and environmental factors, which constrain the 'hands through' and 'day light' opening characteristics.
Innovation Solution
A system with independent motors and strategically placed hardstops that realign the sunroof during full open and close events, using continuous guide tracks outside the primary sealing system, allowing for larger openings and reduced noise, and simplifying assembly and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the kinematic system is placed at the roof line to control sunroof opening and closing, then the volume of the passenger compartment is reduced, but the interior noise level increases for the operator and passengers
Solution Approach 1:
The kinematic system is extracted from the roof line location and relocated to the lower vehicle structure. This removes the noise source from proximity to the passenger compartment while maintaining the sunroof control function, thus resolving the contradiction between volume reduction and noise reduction.
Solution Approach 2:
A cable or linkage mechanism serves as an intermediary to transmit the driving force from the remotely located motor to the sunroof assembly. This allows the motor to be positioned away from the noise-sensitive passenger area while still effectively controlling the sunroof operation.
2Object-affected harmful factors
If additional soundproofing is used to reduce noise from the kinematic system, then the interior noise level is reduced, but the volume of the passenger compartment is further reduced
Solution Approach 1:
By extracting the kinematic system from the roof line area, the need for extensive soundproofing within the passenger compartment is eliminated. The noise source is removed from the volume-critical area, achieving noise reduction without sacrificing passenger compartment volume.
3Reliability
If the torque capability of the motor is increased to overcome misalignment, then the alignment reliability is improved, but the size of the motor increases
Solution Approach 1:
Hard stops are positioned to pre-align the left and right sliding mechanisms at the beginning of each operation cycle. This preliminary alignment action prevents misalignment from developing during operation, eliminating the need for high-torque motors and reducing motor size while maintaining reliability.
Solution Approach 2:
The hard stops provide automatic self-alignment of the sliding mechanisms through mechanical contact. This self-aligning feature ensures consistent positioning without requiring complex control systems or high-torque motors, thereby reducing motor size while maintaining alignment reliability.
4Ease of operation
If software control is used to stop motors at pre-programmed positions, then the close and open positions are controlled, but reliability and repeatability degrade due to parts becoming looser and foreign matter entering the mechanism
Solution Approach 1:
Software-based position control is replaced with a mechanical hard stop system. The hard stops provide physical, fail-safe positioning that is immune to software errors, sensor drift, or changes in mechanical clearance over time. This mechanical substitution ensures consistent and reliable positioning regardless of foreign matter or wear.
Solution Approach 2:
The hard stops provide automatic mechanical positioning without requiring software intervention. Each operation cycle automatically returns the sunroof to precise positions through physical contact with the hard stops, ensuring reliability and repeatability independent of software state or environmental factors.
5Area of stationary object
If the hands through opening and day light opening are increased to provide more openness, then the feeling of openness is improved, but the constraints of the kinematic system on these characteristics increase
Solution Approach 1:
The kinematic system is extracted from the roof line and relocated to the lower vehicle structure. This removal of constraints from the opening area allows for larger hands through and day light openings without being limited by the physical presence of the kinematic mechanism, thus improving the feeling of openness.
Data Source
AI summary
Continuous cross sectional profile guide tracks in an outer sliding sunroof/moonroof are provided where both the front and rear mechanism or mechanism links travel fore/aft in the same channels as each other and have fore/aft travel that is limited only by vehicle architecture. The guide track channel is partly or entirely outside/outboard of the primary water/wind sealing system of the sunroof.