Doors Materials/Manufacture/Assembly Concepting
- Adrian Au
- Geoffrey Liu
Ownership
Matl’s/Mfr/Assem DRI | Contributors | Project DRI |
|---|---|---|
@Geoffrey Liu | @kaizen liu , @Name, @Name | @Suhail Jaffer (Deactivated) |
Research
Hinges
Front door and back door space will limit amount of hinges and size as well:
Functional Requirements:
Must be able to support the weight of the door with minimal play
Must allow door to swing open up to 90° from the closed position
Non-Functional Requirements:
Designed for weight optimization
Ease of assembly
Low cost
High strength density (needs to take up less space)
Constraint Requirements:
Safety regulations
Follows rules of comp
Pin install: https://www.youtube.com/watch?v=yqOrkYh_-4c
Hinge install: https://www.youtube.com/watch?v=QFtfyfmmejo
Material Concepting
Hinges
Need strong materials, lightweight preferred
Steel (AISI 4140 or some other carbon steel)
Stainless Steel (304 or something similar)
Aluminum (6000/7000 series)
Manufacturing Concepting
Hinges
Custom made due to volume constraints
Similar design to ones used in real cars
Made using milling or sheet metal bending
Two Designs:
Sheet metal:
Pin: https://www.mcmaster.com/93131A390/
CNC:
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
Need 4 main components
Inner/outer hinge
Pin
Bushings (2 per pin)
Lock ring/retaining clip
Proof-of-Concept Testing
Use FEA to simulate stress to ensure hinges hold up
Loading condition:
Initial FEA:
Sheet metal top:
Sheet metal bottom:
CNC Top:
CNC Bottom: