Vehicle Tailgate Motor Mounting Gusset System
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Solution Overview
Problem
Conventional methods for reinforcing the power tailgate motor mounting location in vehicles can result in deflection of the outer roof panel due to severe directional loading, especially in vehicle configurations with increased distance between the load point and the body structure, requiring a more rigid mount.
Innovation Solution
A power tailgate mounting system utilizing a first and second gusset member secured to the roof rail, with overlapping gusset tailgate motor mounting portions to provide a rigid and stable mounting configuration, complemented by an outward and upper reinforcement member for enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single drawn sheet metal stamping reinforcement is used at the power tailgate motor mounting location, then the manufacturing process is simple and cost-effective, but the mounting rigidity is insufficient under severe directional loading conditions
Solution Approach 1:
The reinforcement structure is divided into multiple discrete gusset members (first gusset member, second gusset member, third gusset member) that are separately formed and then assembled together. Each gusset member can be manufactured independently using simple stamping processes, yet when combined they create a complex three-dimensional reinforcement structure that provides the necessary mounting rigidity for the power tailgate motor.
Solution Approach 2:
The reinforcement structure combines multiple sheet metal components (different gusset members) into a composite assembly that provides enhanced structural properties. The overlapping arrangement of gusset members creates a composite reinforcement structure that achieves the required strength and rigidity while maintaining manufacturing simplicity through the use of individual stamped parts.
2Adaptability or versatility
If the distance between the load point for the power tailgate motor and the body structure is increased, then the vehicle package design is improved, but the mounting rigidity decreases under forced closed loading conditions
Solution Approach 1:
The gusset members extend in multiple spatial dimensions from the roof rail, creating a three-dimensional reinforcement structure. The first gusset member extends in one direction while the second and third gusset members extend in different directions, forming a multi-dimensional load path that maintains mounting rigidity even when the motor is positioned at an increased distance from the body structure.
Solution Approach 2:
The gusset members are formed with curved and angled geometries that optimize the load path from the motor mounting location to the roof rail attachment points. The curved profiles of the gusset members provide structural efficiency in resisting the severe directional loading forces while accommodating the increased distance between the motor and body structure.
3Strength
If a rigid mount is used for the power tailgate motor to withstand severe directional loading, then the mounting strength is improved, but the outer roof panel may deflect
Solution Approach 1:
The reinforcement structure is applied locally at specific critical locations where loads are transmitted to the roof rail, rather than reinforcing the entire roof panel. The gusset members are strategically positioned and dimensioned to provide localized reinforcement that handles the severe directional loading forces without causing global roof panel deflection.
Solution Approach 2:
The load path is segmented through multiple gusset members that distribute the mounting forces across different attachment points on the roof rail. This segmentation of the reinforcement structure allows the mounting system to achieve the necessary strength while distributing stresses in a way that prevents roof panel deflection.
Data Source
AI summary
A power tailgate mounting system for a vehicle includes a first gusset member and a second gusset member. The first gusset member is secured to an inward side of a roof rail of the vehicle at a rear end portion of the roof rail. The first gusset member has a first gusset tailgate motor mounting portion extending laterally inwardly from the roof rail for mounting an associated tailgate motor. The second gusset member is secured to the inward side of the roof rail at the rear end portion of the roof rail. The second gusset member has a second gusset tailgate mounting portion extending laterally inwardly from the roof rail for mounting the associated tailgate motor. The second gusset tailgate mounting portion overlaps the first gusset tailgate mounting portion.