PMCS: Panoramic Sunroof

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smurfslayer

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there always needs to be a weak link, and it’s better for it to be a linkage than a large piece of glass.

I was thinking about this earlier and wondering what if the the plastic bits were metal / stronger and I can bet that the failure profile would be different. No doubt metal would potentially over come at least some of the sticking, however, what if the truck was in the worst possible climate, and the moon roof wasn’t opened for months on end ... Now the brackets bend and cause an alignment issue. I think @KAH24 has illuminated at least one possible outcome and certainly is one we would not appreciate. So while many of us - me included- whine about the ‘fragile’ mechanism, it maybe a better alternative in the long run.

He's providing the raw data, no filter. If you disagree, that's fine, but it doesn't change anything.

The best posts on FRF actually make you think; data gone over in this discussion, agree or disagree has to at least make you consider the possibility that someone at Ford decided on this design and use case. Sure, there’s been some failures, and we’ve learned how to avoid them. The recent discussion on the TSB for the cam phaser reprogramming also illustrated there is a lot more to the upgrade aspect than just “changing a couple lines of code”. You change something upstream, it affects many things down stream.

I do think that Ford should document some maintenance / care procedures for the moon roof and wonder why they haven’t, but sometimes it’s not as simple as we users think. Me included.
 
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KAH 24

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Weak motors result in slow operation and eventually motor failure.

I believe that KAH24 has more experience than I do in the intricacies of OEM engineering/design and failure analysis. He's providing the raw data, no filter. If you disagree, that's fine, but it doesn't change anything. The key point is to understand that the information provided is the industry standard, not something that a customer rep or owners manual is going to tell you.

@melvimbe,

As @FordTechOne mentioned, there would indeed be slower operation and early sunroof motor failure if one used a lower torque motor (which of course would create “slow motor” complaints and likely a more expensive repair when the motor fails prematurely—leaving the sunroof partially/fully open). The seals and gaskets need lubrication to keep them from sticking and creating resistance.

From an OEM engineering/design standpoint, I’ve no issues with the panoramic sunroof (as a matter of fact I like my composite oil pan as well).

Food for thought from an OEM statistics standpoint:

1. Believe me, panoramic roofs/sunroofs, sliding rear windows, motorized convertible tops, power window regulators (heck anything mechanical and man made)—periodically fails. Believe me, we see more mechanism failures in the winter (especially in the snow belt)—when for some reason folks get motivated on a 20 degree day to drive with the top down (or roof open)—and do not understand the elementary school physics of frozen water/ice causing binding. Even more sad are the warranty claims for “my windshield wipers broke when they were frozen to the windshield.” Sorry, I digress.

2. The experts on my team have worked for the gamut of OEMs (domestic/foreign) and I trust they can tell a good design vs. a flawed one.

3. Based on cold hard data, I believe my OEM has a world class reputation for reliable design, and yet we have failure rates within an expected range—as we aren’t perfect. Ultimately we change the design or modify recommended procedures at a certain proprietary threshold (which every OEM has). When my guys say that my panoramic roof is well designed, I listen.

4. When a customer (any OEM) experiences panoramic roof failure—to them the failure rate is 100% because it happened to that person—and they blame a flawed design. Statistically, one has to look at the total volume of panoramic roofs installed that year in that specific OEM application (lets use MY 2019 as an example, and lets just say that 200000 F Series pickups/SUVs have that sliding roof—it might be more given the volume of F150s and Expeditions sold worldwide). If 1000 panoramic sunroofs fail that is a whopping 0.005 failure rate (half of 1%).

5. The problem is, we would hear nearly all 1000 of those complaints on forum boards (which is why I’ve never paid any attention to the grousing). I enjoy learning, but don’t rely one iota on forums to figure out what statistically is going to break on any of my vehicles. Forum boards statistically over-represent complaints, as no one posts “wow, jeepers, my panoramic sunroof is simply amazing!”

NOTE1: I will concede that perhaps an OEM service manager (some of the sharp ones in the industry already do) could recommend OEM maintenance is done for convertible tops (especially the retractable hardtops), panoramic roofs. Conversely, a consumer can ask to have services performed. To me PMCS is common sense—but perhaps to others who wait until things break, a bit more direction could be of benefit.

NOTE2: As mentioned earlier, one can purchase detailed instructions on how to maintain things—and purchase Krytox(tm), or an equivalent OEM spec, plastic/rubber polymer safe grease. To me that is part of the pride in ownership. Again, I state—that may be just me.

NOTE3: For any OEM panoramic/sun/moon roof design— I’d recommend using the panoramic sunroof regularly (which would allow cleaning to take place). Also, pay attention to creaks/rattles—as that is a sign of need for lubrication.

I genuinely hope this is beneficial as my biases lead me to only look at the black/white data of things.
 

melvimbe

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@melvimbe,

As @FordTechOne mentioned, there would indeed be slower operation and early sunroof motor failure if one used a lower torque motor (which of course would create “slow motor” complaints and likely a more expensive repair when the motor fails prematurely—leaving the sunroof partially/fully open). The seals and gaskets need lubrication to keep them from sticking and creating resistance.

I didn't really state my question clearly. I wasn't thinking about the strengh of the motor per se, but more about the amount of resistance it faces before stopping motion. As an example, the automated trunk lids (or whatever you call them) will stop when they encounter résistance. Obviously that's for safety so that a child's arm doesn't get caught or something. Wondering if the same sort of principle could be used on the panoroof, so that it would not apply enough force to break plastic.

But...I do recognize that the amount of force needed to open/close the roof could fairly greatly depending on different factors. At the same time, weather, wear, and other factors can effect the amount of force needed to break the plastic pieces. Seems likely that there would be significant overlap between force need to do the task and not enough force to break the plastic.
 

Jakenbake

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I didn't really state my question clearly. I wasn't thinking about the strengh of the motor per se, but more about the amount of resistance it faces before stopping motion. As an example, the automated trunk lids (or whatever you call them) will stop when they encounter résistance. Obviously that's for safety so that a child's arm doesn't get caught or something. Wondering if the same sort of principle could be used on the panoroof, so that it would not apply enough force to break plastic.

But...I do recognize that the amount of force needed to open/close the roof could fairly greatly depending on different factors. At the same time, weather, wear, and other factors can effect the amount of force needed to break the plastic pieces. Seems likely that there would be significant overlap between force need to do the task and not enough force to break the plastic.
Might be interesting to see if they could do a variable motor/actuator. One that has a maximum output over the first part of the roof’s travel just overcome an estimated static friction but not too much to break the rails. And provide a warning if roof is “stuck/jammed”

Then it can ramp up for the majority of the roof’s travel until nearing the end where it would slow back down.
 
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KAH 24

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@melvimbe and @Jakenbake

Respectfully, with an unlimited engineering and manufacturing budget anything is possible. Operationally finding the right balance between all departments within an OEM is the topic that drives all companies who want to stay in business (in an intensely competitive industry)—while also managing an ever complex set of federal standards.

One of my mentors and former bosses often said something resonates with me—which I apply in my decision making rubric (paraphrased): “Give me the budget to over-engineer every component in our SUVs and we add $30k and 300 lbs.” I think we all realize that consumers already gripe about price increases.

There is an engineered margin of error for entire systems. That said—let’s add more sensors, more complex motors/actuators, carbon fiber rails vs. composite thermoplastic, a more expensive set of gaskets/seals with greater resistance to UV/dirt/lack of maintenance, add more technology to an already complex ecosystem., etc.

We’d get higher cost, more weight, and yes—other systems that can fail due to more complexity.

Good ideas all. No harm in disagreeing as this is what makes OEM work both fulfilling and challenging.
 
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Jakenbake

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@melvimbe and @Jakenbake

Respectfully, with an unlimited engineering and manufacturing budget anything is possible. Operationally finding the right balance between all departments within an OEM is the topic that drives all companies who want to stay in business (in an intensely competitive industry)—while also managing an ever complex set of federal standards.

One of my mentors and former bosses often said something resonates with me—which I apply in my decision making rubric (paraphrased): “Give me the budget to over-engineer every component in our SUVs and we add $30k and 300 lbs.” I think we all realize that consumers already gripe about price increases.

There is an engineered margin of error for entire systems. That said—let’s add more sensors, more complex motors/actuators, carbon fiber rails vs. composite thermoplastic, a more expensive set of gaskets/seals with greater resistance to UV/dirt/lack of maintenance, add more technology to an already complex ecosystem., etc.

We’d get higher cost, more weight, and yes—other systems that can fail due to more complexity.

Good ideas all. No harm in disagreeing as this is what makes OEM work both fulfilling and challenging. I don’t drink, but if I did—a good bottle of scotch might come in handy some days, lol.
I agree completely, they are complicated enough and people would just complain about cost. I would guess @melvimbe would agree as well. I like “solving” hypothetical problems, figuring out why that solution doesn’t work, and coming up with a new one, as it keeps you sharp/efficient for when a real problem is presented.

I do believe if this particular component does require a periodic maintenance, then it should be communicated to the customer better though. Even though changing oil is “common sense” the owners manual does communicate that to them.
 

melvimbe

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I agree completely, they are complicated enough and people would just complain about cost. I would guess @melvimbe would agree as well. I like “solving” hypothetical problems, figuring out why that solution doesn’t work, and coming up with a new one, as it keeps you sharp/efficient for when a real problem is presented.

Agreed. I'm not so naïve to think that an engineer who's tasked with making the panoroof work hasn't consider any solution I could think of, but I often prefer to work things out myself rather than just assume.

I do believe if this particular component does require a periodic maintenance, then it should be communicated to the customer better though. Even though changing oil is “common sense” the owners manual does communicate that to them.

Yes, I agree, and it feels we've beaten that topic to death. It does make me wonder what other maintenance is 'common knowledge' that I don't know about. I don't know what I don't know.

I guess there is mandatory maintenance (oil change), recommended maintenance(lube the panoroof), conditionally recommended maintenance (spray the under carriage to protect from rust), overkill maintenance, and nonsense (change your blinker fluid).
 

FL4x4

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4. When a customer (any OEM) experiences panoramic roof failure—to them the failure rate is 100% because it happened to that person—and they blame a flawed design. Statistically, one has to look at the total volume of panoramic roofs installed that year in that specific OEM application (lets use MY 2019 as an example, and lets just say that 200000 F Series pickups/SUVs have that sliding roof—it might be more given the volume of F150s and Expeditions sold worldwide). If 1000 panoramic sunroofs fail that is a whopping 0.005 failure rate (half of 1%).

Since you're not quoting actual statistical data we also know that if 200000 F Series pickups/SUVs have that sliding roof and 200000 fail that that is a whopping 100% fail rate.

That's statistics 101.

Quote actual statistics. Telling us how statistics work is meaningless. I know 1000 out of 200000 is 0.005.

People don't know what they don't know.
 

JAndreF321

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Resurrecting this thread instead of starting a new one…I took my truck in Today due to leaky sunroof. I checked the hoses in front and everything was clear but couldn’t seem to figure out how to check the rear. The hoses are all definitely connected. I scheduled an appointment a week out and went in. Dealer told me that I had to pay $360 if they find debris in the hoses despite being under warranty because the manual clearly explains that the owner must clean the hoses and details how to do it. I refused to sign and grabbed my manual. It doesn’t say anywhere in there how to clean the hoses or that I have to clean the hoses. The service advisor looked through his computer version and my version and couldn’t find it. He then said he would email me later today with the page in the manual that gives directions on how to clean the hoses. I don’t mind doing this myself because I hate going to the dealer, but now I’m just angry they wasted my time, lied about the manual, and tried to suggest my warranty was expired. The guy didn’t believe I bought the truck new myself
 
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