Design Analysis of Automotive Component

Question: You are required to design and develop a standard four door saloon front door Central Door Locking (CDL) latch. Here is your opportunity to apply some of the wide ranging knowledge and skills you have acquired during your degree to find and highlight the links between core knowledge like mechanics, tools like FEA, and the overall design development process. Essentially we want you to: Identify the current legislative requirements for a front door CDL latch. Identify the latch sub-system specifications. Perform 3G calculations (manual or otherwise) to determine the operating forces of the claw / pawl spring(s) for a standard CDL front door latch. Design and model the back-plate and the back-plate housing. Develop the design / packaging in more detail to include the pawl, claw, inside handle and outside handle levers. Apply DFM and DFA principles to your design, use appropriate sketches and discuss how you would manufacture the back-plate and housing. Evidence of engineering design with production intent and analysis is required here. Answer: Introduction: For designing the different locking components used in automobiles and their assembly with the vehicle door. For the automobile door we have the following structure. The door of the automobile is hinged very typically with the pockets of the (or the small slots) for the bolting of the door with that and also the techniques of tracking is used for the door assembly. The structure of the entering and the exiting door is somehow same in the structure. As we know that a vehicles is door in any vehicle plays a very specific role in the automobile. As the door is used to give access the driver and it is used to close in order to make it secure. These doors are opened or closed manually or by connecting the assembly with the electronically powered devices which gives command via using sensors to control the movement of the door. Generally these types of doors can be seen in the very high modified types or in the high end cars. A car door latch generally refers to the mechanical device used to align the door of the automobile in a closed position relative to the vehicle frame work. The major role of the latch is used to perform the lock /unlock and the latch and the unlatch function. For describing the components advanced components which are used in the door like Central Door Locking Latch, are assembled with the door of the automobiles. The inner side of the automobile door is known as car door panel. Here we are just dealing with the CDL mechanism and the basic locking system which are the precise components of the internal component of the door. By the help of the different types latches we can secure the entrance of unauthorized person in the automobiles . If we study for the mechanism then we came to know that latches are nothing but the electrically powered sensors. Door Locking Mechanism: As by the invention of such device it provides facility to the handle of the automobiles to give the motion of the handles of the door ,very smooth going. By the help different handle are fitted with such an ease that it will open or close in the single movement of the hand. For making the vehicle automatically prevented from the unauthorized user we use different latch (or the assembly of such latches is CDL latch).For the designing , manufacturing of the Central Door locking latches used in the locking system . It comprises of different types of the strikers and the latch engagement . Requirements of Components used for designing Central Door Locking latches Striker plates Back plates If we starts for the designing of the Central Door Locking Latches we have to start with the design of the striker plates used in the Locking mechanism. For the preparation of the striker assembly used in the latch engagements of the different types of the engagements which are mounted on the mounted plates. As there is the intersection of the engagement of different latches and the striker plates, a black plate is used. The main purpose of the back plates used here is to provide a huge amount of the structural strength to the base of the striker. And also it helps to save the striker from making the latch firm under the bad working condition or in the overload condition. Striker plates: Striker plates is a main component used in the Central Door Locking Latch , as this is the component having the symmetrical sides which are used to grip the door of the saloon used in the automobile. The main spring used in the locking device adjust the proportion of the latching system. By the help of the striker plates the configured assembly is mounted on the latch mechanism. If we see the exact mechanism of the locking device we can see that a parallel alignment breaker is used. For describing the components advanced components which are used in the door like Central Door Locking Latch, are assembled with the door of the automobiles. The inner side of the automobile door is known as car door panel. Here we are just dealing with the CDL mechanism and the basic locking system which are the precise components of the internal component of the door. By the help of the different types latches we can secure the entrance of unauthorized person in the automobiles. If we study for the mech anism then we came to know that latches are nothing but the electrically powered sensors. For manufacturing the striker plates assembly is used by making it with the mounting plates. For the design of the striker plate we have used different cap weld for holding the springs, back plates and the sensor used in the locking devices of the automobiles. The main part of the strikers assembly and process used for the manufacturing. For the manufacturing of the striker mechanism we used such assembly and the some components. Fig : different components of the striker plates The components used are: Firstly we have two pieces of the contoured type of steel plates used for metal support and Along with this latch system we have used some steel stamping plates, which are bent along the axis lines of the plates. With the use of different back plates back to back alignment to the intersecting it gives striker assembly. By the help of the different striker plates it used perimeter striker plates. The specification of the latch sub system: Latch sub system:- As by the discovery of the latch system in the automobiles it facilitates the movement of the automobile door in the translator motion of the door. In the saloon front of the compartment the door movement is restricted by the hinges provided on the edges of the compartment. For the assembly of the door in the saloon front quadrilateral type or the hexagonal types of the hinges system is used in the locking devices. By the help of such type of one can move the door in the outwardly and the forwardly direction. Thus the motion of the door is propagating in the compound motion towards the door. For describing the components advanced components which are used in the door like Central Door Locking Latch, are assembled with the door of the automobiles. The inner side of the automobile door is known as car door panel. Here we are just dealing with the CDL mechanism and the basic locking system which are the precise components of the internal component of the door. By the help of the differe nt types latches we can secure the entrance of unauthorized person in the automobiles. For describing the components advanced components which are used in the door like Central Door Locking Latch, are assembled with the door of the automobiles. The inner side of the automobile door is known as car door panel. Here we are just dealing with the CDL mechanism and the basic locking system which are the precise components of the internal component of the door. By the help of the different types latches we can secure the entrance of unauthorized person in the automobiles. If we study for the mechanism then we came to know that latches are nothing but the electrically powered sensors. If we study for the mechanism then we came to know that latches are nothing but the electrically powered sensors. Such motion of the latching system is used in the door in order to provide the motion very freely we use the pillars to support the door system. Now in the modern era, the modern type of latching system is used which gives the latch system automatic system and gives the transmission or the operation of the door movement from the button itself present in the dashboard. Generally the latching system used in the locking devices is totally based on the principle of the kinematic linkages system. The primary movement of the door can be adjusted by the door ditching system and release the movement of the door relative to the primary latching engaging pillar and also a detent based system is used to operate the sub-systems of the latching. For the movement of the door by the help of the secondary method used in the door stabilizing latching means comprising two shaft which are rotary bolts journeyed on opposite jamb facing which is used in the door for the latching engagement which are used on the strikers adjustably mounted on the adjacent pillars of the vehicle body. The different technical components used for making locking device: Actuator: These are the electro-mechanical device used for controlling a component of the latch used in the locking system. Analysis of the locks: For making the simulation of the product and the specified condition using different mathematical models algorithm used in the equation. Back door: A door and the different types of the door system used in the locking system of the automobiles can use for the loading and the unloading of the user. Block out: This is a type of the design parameter which is used to make the input device of the user which can be blocked by the preference of the user. Centre hinge: These are a door which support assembly mounted at the rear of the sliding door are neighbored of the middle door height. In hinge of the door it includes the rollers which can run through the centre and the pivot pin which allow the roller to follow the track at when the track turns the curves rapidly inboard as the door reaches the final closed position. Central door locking mechanism: Different types locking system used in the saloon front of the automobile door. For the purpose of such central locking system, a different rod locking devices is used. These types of the locking devices are used with the help kinematics mechanism. The features used for the designing of the kinematics rod locking devices, these are: These types of the locking devices are used to stop and hold the rod of the cylinder under load in the event of air pressure or power failure. For the movement of the rod it is an elastic mechanical devices acting on the brake pads. These types of the locking device are used pressure for the engagement and the disengagement. We just apply the pressure on the system just by pressing the button of the ram. In this type of the locking device it holds and stops the piston of its stroke . By the help of the rod type of the locking device it will allow the maximum allowable cylinder load without drifting in the cylinder. Generally in this type of the locking system it generally stops when in the absence of the air. These type of the locking are used in the bidirectional action. Generally these types of the pads are used in the cast iron types and are made on the concentric rod. Generally these are very simple types of the locking devices , and mounting position and also in the reduced motion. The forces involved in the operating of the locking device In general terms , a quality control of the locking devices is primarily based on the evaluation of the product that specification and the condition imposed at the start of the development phase. The manual construction of the locking device is based on the back plate. The required operation pressure involved in the locking devices Operating pressure: 9 bar max. Disengage pressure: 4 bar (min) , 9 bar (max) Ambient temperature : -5 degree centigrade Claw forces used : 123 N used while in the operation. Holding forces(static) : 40 mm : 1000N / 60 mm : 63 mm : 2300N / 80mm Locking capacity : in such types of the claw type of the disengagement used in the maximum load is Propogates in the bilateral direction. Max allowable Speed : : 553 mm/s The labelling diagram used for the manufacturing and the dimensioning of the locking device. The procedure and the mechanism used in the locking device are given below: The horizontal mounting of the locking device : Generally in the mechanism of the locking devices we used different types of the valves are used . the valves which are used in the 5/3 valve are made up of the with the centre to be open to the centre port . in general type of assembly used in the pressure is maintained on both sides of the cylinder piston and the forces acted on the cylinder are balanced in the piston. The piton used in the cylinder used to disengage the motion of the piston at the time of the accidental movement. For the motion of the locking device the primarily used sensors used in the system is 3/2 NC solenoid valve . The diameter used in the locking devices is primarily based on the study of the material used. Here in the locking device for the fast breaking of the device we generally used in the absence of the air for fast breaking. In the above circuit diagram we have a diagram to use control valves using the 5/3 control valve. By the help of the following control valve we can transmit command from the saloon front just by having a command from the button by the user. In the following type of the circuit diagram we usually perform the valve operation in order to maintain the motion of the locking device. 3D Calculation Used For The Calculation Of The Forces Of The Flaws : The latching system used here needs the calculation of hinge reaction The estimation of the reaction for the hinges can be used by the use of simple physics. For this purpose if we apply force in the same direction for the partially open door of the automobile, then we have to adjust over hand in the non right angle to the door and the torque so produced is very much dependent on the angle between the hand and the door. For calculating the door we have to use the 3D analysis of the door and the length of the lever used for the purpose of torque estimation . For calculating the forces on the flaws of the hinges ,we have the reaction balance analysis. The distance of the hinge from the point of force application is L= r sinà °Ã‚ Ã¢â‚¬ ºÃ‚ ³ =f. r sin (torque applied on the hinges of the door) When à °Ã‚ Ã¢â‚¬ ºÃ‚ ³ goes out to zero then he torque so applied is also zero. By this reason in order to produce the maximum torque the à °Ã‚ Ã¢â‚¬ ºÃ‚ ³= 45 degree Dfmea (Design Failur Mode And Effect Analysis) For the product to be in the DFMEA , we have to check every product on the guidelines of the basic structures of the DFMEA . Under these guidelines we have to check each component in the following steps Study of the defect concentrated area Study of the different defect involved in that area. Study to overcome that defect. Implementation of the new study. Final analysis to check the efficient running of the system Potential Failure Mode : This is the section of the DFMEA under which we start with different points in the designing and in the manufacturing of any product for which the possibility of the failure is very .after the complete analysis of the failure , then there is a brain storming of the team under which the whole process is going to held. This mode is used just to check for the deficiencies in the system. The procedure used for the potential failure mode are as follows: Checking for the product and the system where the failure had happened. Now comparison of the efficiency from the failure data to the bench marked data found from the organization. Application of different technical methods on the defected component. After the calculation of the values of the error ,step taken to remove that defect from the system. After performing this analysis we starts for the failure effect analysis. Failure Effect(FE) Analysis: These is the heading under which we will discuss on the outcomes and the effect produced due to failure in the system or in the component , by the pre found errors with the team members and make a suitable solution for that . And the elimination method which we going to used for eliminating the failures in the products . The steps taken under this are as follows: Firstly to check the point where the occurrence of the failure is very high. To review the each and every corresponding effect of the design. To mark the priorities to handle the deficiencies and the flaws in the design. To make each and every method by brain storming to eliminate the occurred error in the system. After proposing any method to remove error in the system, implementation of the method on the planned system. Synthetic cost analysis for the CDL Latch device used in the front of the saloon door. Under this head we have the basic evaluation of the different cost evolved in the process. These are: Firstly creating the block diagram showing the whole system analysis. Identify the different component and the cost evolved in the process. No of member and the strength of equipment used in the process. Boundary analysis of the cost by evaluating the total cost involved. At last profit incurred in the whole process. Design and modelling of the back plate and the back plate device. The back plate are the component used in the locking devices used to support the movement of the door and the step controllers used in the locking device. The locking device which are primarily used in the front door opening . in the front door opening of the saloon of the compartment used to deprive the motion of the door . in such type of the opening system the back plates are used which are having the same the clearance in the motion . the primarily door of the saloon supports inner hinges 24 and also the 3G cooperate with the intermediate outwards mounted control hinges . The quadrilateral swinging bar linkages are used in the back plate system. The back plate system which supports the motion in the linkage of the locking device. The main purpose of using the back plates system is that is gives the perfect base to the locking device in the back plates system. Design and packaging of the locking device : The main component of the devices used in the Central Door Locking. Base plate vs. catch /pawl rivet Catch Rivet Vs Catch Pawl Vs Pawl Rivet Top plate Vs Catch /Pawl Rivet The solid work analysis of the locking device shows different components of the CDL locking device , the main parts used in the locking used are the metal crossed plates and the high tension spring and the valve system used in the locking system. The lever used for the locking system is used for propagating the high mechanical advantage . The manual construction of tolerance check list only deals with worst case of the analysis . In the locking device used the motion is generally used to the length and diameter dimension. Side door latch protects the vehicles occupants from being ejected from the door which have the designation to motion while in the accidents . the main task of the pawls and the claws used to the locking system . The riveting which is done on the back plate of the latch system is much more strength with the weld used in the device . The intent of this work was to redesign the front saloon of the automobile. Apply DFM and DFA principles to your to design The application of the DFM (design for manufacturability) are the design analysis which are used in the designing of the components . Under this head the tolerance is stack up and the reading used by the manufacturer in order to manufacture the components is full of the tolerance and the allowances . The design analysis used to make the components . The assembly variation for inside release of the outside release the latch with the tolerances 1.5 mm compared to that of the outside release of the latch which was determined with the 1mm . The main analysis of the DFM on the Central Door Locking comprises the following terms: In the analysis of the components by the help of DFM , the main analysis and the study of the components is used to check for the clearance and the tolerances. DFA (design for the Analysis) : The design for analysis is used in the analysis is used generally done in the analysis of the design . In the design analysis , the tolerance is used for the analysis of component which is done upto the extent of the design . in the designing analysis of the component the maintaining government standards is used to maintain the original equipment manufacturer . The design for analysis amd the assembly guidelines were directly and the indirectly applied to redesign of the component . The following objectives were establishment for the redesign of the component. Fastening process were eliminated. Stopper feature on the top plate was eliminated. Double sign riveting process was designed . Functional improvement was improved by the analysis of the component The manufacturing procedure of the back plate and the back plate housing are Back plate: while manufacturing of the back plates used in the locking devices has a wide variety manufacturing system. Back plates are generally have a contour on the edges so for the manufacturing of the plate firstly we used the have a sniping process then after this the metal is cut with the prescribed limits then with the help of the bending mold it is bend to prescribed limits. And in the back plates in order to reduce the stress concentration factor of the sharp edges we reduce it to by greater extent back with the grinder plates. Then process here is done to make the plate free from the sharp edges. While the manufacturing of the these type of the plates, the clearance used by the manufacturer is prescribed by the manufacturer . Under this head we gone through the overall production of the component from the base scrape to the finished good. Conclusion: In the study in the analysis of the CDL latch (Central Door Locking) by this it gives equivalent alteration of the motion of the doors and the smooth motion of the door . 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