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Custom made due to volume constraints
Similar design to ones used in real cars
Made using milling or sheet metal bending
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Two Designs:
Sheet metal:
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Pin: https://www.mcmaster.com/93131A390/
CNC:
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Pin: https://www.mcmaster.com/98306A220/
Sheet metal better for mass manufacturing (need 8 of each hinge), but CNC has more strength
Hinge point far away due to mounting location
Due to door geometry, door must swing OUTSIDE side panel instead of INSIDE (conventional)
Results in hinge point needing to be outside of door panel instead of inside
Base mounts on chassis beams, arm mounts to interior panel
Assembly Concepting
Hinges
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Inner/outer hinge
Pin
Bushings (2 per pin)
Lock ring/retaining clip
Proof-of-Concept Testing
What sort of testing should we be doing to ensure our chosen materials/manufacturing processes/assembly methods will work on the end-product?
Could include ordering samples, testing fastening/joining methods, testing assembly procedures.Use FEA to simulate stress to ensure hinges hold up
Loading condition:
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Initial FEA:
Sheet metal top:
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Sheet metal bottom:
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CNC Top:
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CNC Bottom:
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