Trunk and Roof Prop and Tilting Project Overview

Functional Requirements

The assembly of components that make up the trunk prop and tilting system must:

• Support the trunk when it is fully opened

  • Trunk weight plus force of wind on the trunk panel

• Allow for the trunk panel to be closed by a user

  • Without requiring levels of force that would be harmful to the user or the panel itself

• Support the ability for the trunk panel to be detachable

• Tilt the trunk sideways when it has been detached

• Be compatible with the trunk hinge and latches

Overview

Research

• Trunk Prop Rods

• Determining trunk prop mounting locations

  • i.e. How to mount the trunk prop such that it will obtain the desired range of motion for the trunk while being able to support its weight

• Trunk Prop Mounting Methods / Styles

• Design for Adhesives for Mounting Brackets

• Trunk Tilting Structure

  • Methods to do it

  • Placing it inside vs outside the car

Concepting and Initial Design

• Mounting Bracket - to Chassis

• Mounting Bracket - to Trunk Panel

• Additional Tilting Structure

• Trunk Prop

Testing and Validation

• Hand calculations

  • Determine if trunk prop can actually support trunk panel

• FEA

  • Ensure mounting brackets will be properly attached to chassis / trunk panel

    • More of a concern with adhesive based mounting methods

  • Ensure mounting brackets are designed so that they won’t yield / deform

  • Ensure chassis tube we mount to will not yield / deform

  • Ensure accessory tilting structure can securely hold in place the trunk panel

• Motion Study

  • Ensure trunk props can account for motion of the trunk panel

    • Ensure the motion is continuous

Detailed Design

• Mounting locations and methods for brackets finalized

• Additional tilting mechanism placement (inside vs outside the car) finalized

• Proper trunk prop has been specified

  • Both length and rated force

• DFM and DFA verification

  • If needed to be made outside, connecting with SI to see if there are available suppliers

• Manufacturing Drawings

Manufacturing

• Mounting Brackets

• Additional Tilting Mechanism (may be a sub-assembly - TBD)

Integration

• Mounting brackets to: chassis, trunk panel

• Fastening trunk prop to mounting brackets

• Additional tilting mechanism either: mounted to or stored within the car

Functional Requirements

The assembly of components that make up the roof prop and tilting system must:

• Support the roof when it is fully opened

  • Roof weight plus force of wind on the roof panel

• Tilt the roof to the side

  • In such a way it does not: collide with other panels, or put undue levels of stress on the roof panel

• Be compatible with roof panel fastening methods

Overview

Research

• Roof Prop Rods

• General Roof Tilting Methods

  • Hinge and hinge-less designs

• Roof Hinge Designs and Feasibility

  • Roof Hinge Mounting Locations

• Roof Hinge Mounting

• Design for Adhesives for Mounting Brackets

Concepting and Initial Design

• Mounting Bracket - to Chassis

• Mounting Bracket - to Roof Panel

• Hinge Mounting

• Roof Prop

• Roof Hinge

Testing and Validation

• Hand Calculations

  • For geometry of roof hinge and mounting brackets

  • For roof hinge mounting method

    • Ensuring roof hinge will be securely mounted and stationary as it is expected to be

  • For attachment method for mounting brackets

  • For roof prop to ensure it can withstand bending and compression loads

• FEA

  • Same scenarios as above

    • May give more accurate results, potentially with attachment method for mounting brackets (fasteners, adhesives)

• Motion Study

  • Ensure roof hinge will articulate roof panel in the desired motion

    • No collision with other panels

    • Able to tilt to desired angle

• Scaled Down Prototype

  • Can create a scaled down prototype using scrap materials / 3D Printed parts

    • Go through motion in real life to ensure Motion Study captured all variables

Manufacturing

• Mounting Brackets

• Roof Hinge

  • Likely a sub-assembly of parts

• Roof Hinge Mounting

  • Likely be a panel plus other mounting hardware

• Roof Prop

  • Likely to be largely purchased

Integration

• Mounting brackets to: chassis, trunk panel

• Attaching hinge to hinge mount

• Securing hinge mount to chassis

• Ensuring roof prop can secure to the mounting brackets