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Next Generation Automotive Sun Visor

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Next Generation Automotive Sun Visor Next Generation Automotive Sun Visor Product Development Nästa Generations Solskydd i Personbil Produktutveckling Erik Torehov Ronnevik Faculty of Health, Science and Technology Degree project for master of science in mechanical engineering 30 hp Supervisor: Mikael Grehk Examiner: Jens Bergström 2019-06-17 Abstract The main purpose of the sun visor is to prevent the driver and passengers to get blinded by the sunlight. It is essential that the sun visor is not blocking the view and that the driver has a clear line of sight so that collisions can be prevented. However, the solution of today is limited as it only covers superior parts of the light and its functionality depends on the head position of the driver and passengers. Therefore, ÅF has initiated this thesis project to develop and improve the product with the goal to further prevent the driver and passengers from being blinded by the sunlight. The scope of the project is to generate new concepts for the sun visor using product development methods. The product development process involves various phases. Collecting and identifying customer needs and wishes resulted in a detailed requirement specification. Competitor analysis, or benchmarking, was conducted to create awareness of what already exists on the market. New concepts were created by two separate brainstorming sessions. These new concepts were evaluated by concept screening and concept scoring matrices and a final concept was chosen for further development. The final concept was modeled and developed with all necessary components in CAD with help of the software Catia V5. A material selection was performed on the new components with help of CES Edupack and a final material suggestion for each component was presented. The new sun visor consists of a sun curtain that is connected to profiles in the WEM cover and the a-pillar. An electric motor in combination with a spring regulates the upward and downward motion of the sun visor to a precise position. The driver or passenger can regulate the height of the sun curtain by pushing a button. An advantage with the new design is that it eliminates the leakage between the sun visor and the WEM cover and to the a-pillar. The designed sun visor does not fit in the current interior of the driver compartment but has been created as close as possible to fit the current space with only small adjustments to the interior. In addition, the components of the new sun visor needs to be redesigned, mainly the WEM cover, to allow the new sun visor to reach down to the lowest allowed point. The new concept has the potential to increase the visibility more efficient than the standard sun visor. Sammanfattning Solskyddets huvuduppgift är att förhindra att föraren och passagerarna blir bländade av solljus. Det är viktigt att solskyddet inte blockerar sikten samt att föraren har fri sikt så att kollisioner kan förebyggas. Dock är dagens lösning begränsad eftersom den endast täcker en viss del av det inkommande ljuset och dess funktion är beroende av huvudets position. Därför vill ÅF utveckla och förbättra dagens produkt till ett nytt koncept med hjälp av produktutvecklingsmetoder som förhindrar att föraren och passagerarna blir bländade. Produktutvecklingsprocessen omfattar olika faser. Genom att samla och identifiera kundernas behov och önskemål kunde en detaljerad kravspecifikation erhållas. Konkurrensanalys genomfördes för att skapa medvetenhet om vad som redan finns på marknaden idag. Nya koncept skapades genom brainstormning. Dessa nya koncept utvärderades genom konceptscreening och konceptscoring och ett slutgiltigt koncept valdes för vidareutveckling. Det slutgiltiga konceptet designades och utvecklades med alla ingående komponenter i CAD med hjälp av programvaran Catia V5. Ett materialval utfördes på de nya komponenterna med hjälp av CES Edupack och ett slutgiltigt materialvalsförslag för varje komponent presenterades. Det nya solskyddet består av en gardin som är kopplad till profiler i WEM covern och a-stolpen. En elektrisk motor i kombination med en fjäder kontrollerar solskyddets uppåtgående och nedåtgående rörelse till en exakt position. Föraren eller passageraren kan reglera höjden på solskyddet genom att trycka på en knapp. En fördel med det nya solskyddet är att läckage har eliminerats mellan solskyddet och WEM cover samt a-stolpen. Det nya solskyddet får dock inte plats i den nuvarande interiören men har designats så nära som möjligt för att passa i det aktuella utrymmet med endast små ändringar av interiören. Dessutom måste vissa komponenter designas om, huvudsakligen WEM covern, på grund av att gardinen inte går hela vägen ner till den lägsta tillåtna punkten. Det nya konceptet har dock potential att blockera det inkommande ljuset effektivare än det nuvarande solskyddet. Table of contents 1 Introduction 1 1.1 Sun visor . .1 1.2 ÅF Industry AB . .2 1.3 Objective and purpose . .2 1.4 Delimitations . .2 1.5 Product Development . .3 2 Analysis of current design 4 2.1 Functional content . .4 2.2 Components . .5 2.2.1 Body . .7 2.2.2 Fixing points . .7 2.2.3 Hinge . .7 2.2.4 Frame . .7 2.2.5 Sub frame . .7 2.2.6 Vanity pack . .7 2.3 Problem identification . .7 3 Method 9 3.1 Identification of customer needs . .9 3.2 Requirement specification . .9 3.2.1 QFD . 10 3.3 Competitor analysis . 11 3.4 Concept generation . 12 3.4.1 Formulation of the problem . 12 3.4.2 Functional analysis . 12 3.4.3 Creative methods . 12 3.5 Concept selection . 13 3.5.1 Concept screening . 14 3.5.2 Concept scoring . 15 3.6 Product design . 16 3.7 Material selection . 17 3.7.1 Translate design requirements . 17 3.7.2 Screen using constraints . 18 3.7.3 Rank using objective . 18 3.7.4 Seek documentation . 18 3.8 Future trends of sun visors . 18 4 Results 19 4.1 Identification of customer needs . 19 4.2 Requirement specification . 19 4.2.1 QFD . 20 4.3 Competitor analysis . 20 4.3.1 Volvo V60 . 20 4.3.2 Tesla Model X . 22 4.3.3 Kia Ceed . 24 4.3.4 SAAB 9-5 . 25 4.4 Concept generation . 27 4.5 Concept selection . 31 4.5.1 Concept screening . 31 4.5.2 Concept scoring . 34 4.6 Product design . 37 4.6.1 Shaft . 40 4.6.2 Housing . 41 4.6.3 Curtain . 42 4.6.4 A-pillar . 42 4.6.5 WEM . 43 4.6.6 Roof . 44 4.6.7 Snap hook . 45 4.6.8 Wheel shaft . 45 4.7 Material selection . 46 4.7.1 Shaft . 46 4.7.2 Housing . 50 4.7.3 Curtain . 51 4.7.4 A-pillar . 51 4.7.5 WEM . 52 4.7.6 Roof . 52 4.7.7 Snap hook . 52 4.7.8 Wheel shaft . 52 4.8 Future trends of sun visors . 52 5 Discussion 54 5.1 Product development . 54 5.2 Product design . 55 5.3 Material selection . 55 5.4 Future trends of sun visors . 55 6 Conclusion 56 6.1 Future work . 56 7 Acknowledgments 57 References 58 Appendices 60 1 Introduction Vehicle functionality is one of the leading segments in innovation and component development. Despite this fact there is a component in the cockpit environment that has kept just about the same function design for various years - the sun visor. The main purpose of the sun visor is to increase visibility on the road by blocking the sunlight. However, the solution of.
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