Meritor Introduces New Roof Module
26 February 1998
Meritor Introduces New Roof Module
New, One-Piece Roof Module Provides Significant
Cost Reductions and Increased Flexibility
DETROIT, Feb. 26 -- Meritor Automotive, Inc. (NYSA: MRA) has
introduced a new modular roof system that will provide significant savings to
automotive OEMs by reducing assembly time and parts. The new module increases
flexibility and allows OEMs to standardize roof sizes among numerous vehicle
bodies.
Depending on the module design used, OEMs can also reduce from 30 to 50
percent of the weight of a conventional steel roof (headliner included).
A version of the new, one-piece roof module will be displayed by Meritor at
the 1998 SAE International Congress and Exposition (exhibit #2113), and will
make its debut on the Smart City Coupe.
The unique Meritor roof module can be delivered to OEM assembly plants
with integrated components such as sunvisors, grab handles, speakers, air
vents, interior lights, switches, wire harness, headliner, mounting device for
roof rack, roof antenna and third brake light already integrated into the
roof. Different kinds of sunroofs can be integrated into the roof module
providing OEMs with a high variety of options for a single body version
providing end-users with a variety of roof choices.
"The new and innovative roof module moves our business toward reaching our
ultimate goal to provide our customers with complete roof systems," said Ken
Myers, general manager of Meritor Roof Systems - Americas. "We believe this
new development can change car and light truck assembly processes. The roof
module eliminates the tedious tasks traditionally performed by the OEM, such
as screwing in grab handles or securing headliners and allows OEMs to top load
internal components which will save significant assembly time."
According to Myers, the module greatly simplifies electrical hook-ups, by
integrating electric wiring and electronics into the roof. Therefore, such
options as car alarms, microphones for cellular phones or Global Positioning
Satellite (GPS) connections can be easily integrated through one electrical
connection.
Increased Standardization While Reducing Parts
The roof module is consistent with the trend of OEM single-body style
standardization. Our new roof module allows our customers to move toward this
objective.
"Furthermore, modifications to the roof module can be made quickly and
easily without disrupting OEM assembly and production," Myers said.
The new module also allows significant reductions in component parts
including the roof frame lining, roof rails, sunroof frame, water channel, and
roof reinforcements.
In addition, car assembly time is substantially reduced. This new module
is designed to allow robot assembly through the body roof opening for
components such as seats, carpets and wire harnesses through the body roof
opening resulting in added savings for customers.
Meritor estimates that automatic assembly of the roof module takes
approximately one minute to install. The completely pre-assembled roof module
is delivered to the OEM after final inspection assuring stricter quality
control.
Simple Production Process
Meritor manufactures and ships the modules in a specially-designed storage
rack that can be used with standard lift-and-place robotics. As the vehicle
body proceeds down the assembly line, the robot applies an adhesive to the
vehicle's roof opening. After the adhesive is applied, the robot picks up the
module and positions it above the opening.
Before installing the module in place, the robot folds the corners of the
headliner down, while the electrical connector is plugged into the appropriate
electrical outlet on the vehicle.
The module also reduces weight, according to Myers. The module is the
result of various layers of advanced synthetic materials, which include: an
outer skin-injected hardened plastic, a glass fiber mat and fabric for the
interior. Meritor injects a specially designed polyurethane foam into the
middle of the roof to further achieve rigidity.
The roof module stands up to stringent static and dynamic body stiffness
tests and passes all Federal Motor Vehicle Safety Standard regulations.
Meritor Automotive, with 1997 sales of approximately $3.3 billion, is a
world leading supplier of a broad range of components and systems for
commercial, specialty and light vehicles. Meritor consists of two global
businesses: Heavy Vehicle Systems, a leading supplier of drivetrain systems
and components for medium- and heavy-duty trucks, trailers and off-highway
equipment and specialty vehicles including military, bus and coach, and fire
and rescue; and Light Vehicle Systems, a major supplier of roof, door, access
control and seat adjusting systems, electric motors and electronic controls,
suspension systems and wheels for passenger cars, light trucks and sport
utility vehicles.
SOURCE Meritor Automotive, Inc.