Sliding Car Door

SLIDING CAR DOOR A Baccalaureate thesis submitted to the School of Dynamic Systems College of Engineering and Applied Science University of Cincinnati in partial fulfillment of the requirements for the degree of Bachelor of Science in Mechanical Engineering Technology by Brian Neumann April 2014 Thesis Advisor: Professor Ahmed Elgafy Ph.D. ACKNOWLEDGEMENTS TABLE OF CONTENTS ACKNOWLEDGEMENTS ...................................................................................................... II TABLE OF CONTENTS .......................................................................................................... II LIST OF FIGURES ................................................................................................................ III LIST OF TABLES .................................................................................................................. IV ABSTRACT ............................................................................................................................. V INTRODUCTION .................................................................................................................... 1 PROBLEM STATEMENT ................................................................................................................................ 1 INTERVIEWS ........................................................................................................................................................ 2 MINI VAN SLIDING DOOR ............................................................................................................................ 3 BMW Z1 DOOR ................................................................................................................................................ 4 1954 KAISER DARRIN ROADSTER DOOR ................................................................................................. 5 CUSTOMER FEEDBACK, FEATURES AND OBJECTIVES .............................................. 6 SURVEY ANALYSIS .............................................................................................................................................. 6 PRODUCT FEATURES AND OBJECTIVES ................................................................................................................ 7 ENGINEERING CHARACTERISTICS ........................................................................................................................ 9 CONCEPT GENERATION AND SELECTION ................................................................... 10 TWO BRACKET HINGE DESIGN ........................................................................................................................... 10 TWO BRACKET SLIDE DESIGN ........................................................................................................................... 11 TWO BRACKET TRACK DESIGN ......................................................................................................................... 12 SELECTION ....................................................................................................................................................... 12 DESIGN CALCULATIONS .................................................................................................. 13 SUM OF THE MOMENTS WITH 100 LB FORCE ...................................................................................................... 13 BENDING STRESS ............................................................................................................................................... 14 TWISTING .......................................................................................................................................................... 15 SHEAR STRESS ON BOLT .................................................................................................................................... 18 BEARING LOAD RATING ..................................................................................................................................... 18 SPRING CALCULATIONS ..................................................................................................................................... 20 FABRICATION AND ASSEMBLY ...................................................................................... 22 BRACKET FABRICATION .................................................................................................................................... 22 VEHICLE MODIFICATION ................................................................................................................................... 23 ASSEMBLY OF TRACK ONTO VEHICLE ................................................................................................................ 25 ASSEMBLY OF DOOR ONTO BRACKET SYSTEM ................................................................................................... 26 TESTING ................................................................................................................................ 28 TESTING METHODS ........................................................................................................................................... 28 TESTING RESULTS ............................................................................................................................................. 28 ii SCHEDULE AND BUDGET ................................................................................................. 31 SCHEDULE .................................................................................................................................................... 31 BUDGET ......................................................................................................................................................... 31 CONCLUSION ....................................................................................................................... 32 WORKS CITED ................................................................................................................................................... 33 APPENDIX A - RESEARCH ................................................................................................. AI APPENDIX B – SURVEY ..................................................................................................... BI APPENDIX C – QUALITY FUNCTION DEPLOYMENT .................................................. CI APPENDIX D – PRODUCT ODBJECTIVES ....................................................................... DI APPENDIX E – SCHEDULE ................................................................................................. EI APPENDIX F – BUDGET ...................................................................................................... FI APPENDIX G - EQUATIONS ............................................................................................... GI APPENDIX H - DRAWINGS ................................................................................................ HI APPENDIX J - B.O.M. AND HARDWARE .......................................................................... JI LIST OF FIGURES Figure 1 – Wing Doors ............................................................................................................. 1 Figure 2 – Suicide Doors .......................................................................................................... 1 Figure 3 - Toyota Sienna (Door Closed) ................................................................................... 3 Figure 4 - Toyota Sienna (Door Open) ..................................................................................... 3 Figure 5 - BMW Z1 (Closed Door) .......................................................................................... 4 Figure 6 - BMW Z1 (Open Door) ............................................................................................. 4 Figure 7 - 1954 Kaiser Darrin Roadster .................................................................................... 5 Figure 8 - Hinge Bracket Concept .......................................................................................... 10 Figure 9 - Slide Bracket Concept ............................................................................................ 11 Figure 10 - Middle Bracket Sketch ......................................................................................... 12 Figure 11 - Free Body Diagram of Door ................................................................................ 13 Figure 12 - Middle Bracket Sub-Assembly ............................................................................ 14 Figure 13 - Bottom Bracket Sub-Assembly ............................................................................ 14 Figure 14 - Bending Stress on Middle Bracket Sub-Assembly .............................................. 15 Figure 15 - Bending Stress on Bottom Bracket Sub-Assembly .............................................. 15 Figure 16 - Twisting on Middle Bracket Sub-Assembly ........................................................ 16 Figure 17 - Angular Displacement Equation .......................................................................... 16 Figure 18 - Strain Equation ..................................................................................................... 17 Figure 19 - Max Shear Equation ............................................................................................. 17 Figure

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