REDESIGN OF WINDOWS AND DOORS OF A CONVERTIBLE CAR Bachelor Degree Project in Product Design Engineering 22,5 ECTS Spring term 2015 López Fernández, Antonio José López López, Aída Supervisor: Dan Högberg Assistant Supervisor: Lennart Ljungberg Company supervisor: Francisco Javier Hurtado Salas Examiner: Erik Brolin Assurance of own work This project report has on August 24th of 2015 been submitted by Antonio José López Fernández and Aída López López to University of Skövde as part in obtaining credits on basic level G2E within Product Design Engineering. We hereby confirm that for all the material included in this report which is not our own, we have reported a source and that we have not – for obtaining credits – included any material that we have earlier obtained credits within our academic studies. Antonio José López Fernández Aída López López II Abstract The objective to this bachelor degree project was to redesign a structure of the doors and add windows of a convertible car. This was carried out in collaboration with the company Hurtan Desarrollos S.L. To establish the requirements for the design, initial studies were performed: a literature review, a benchmark of related products and a study of standard car door designs. After this the final requirements were defined and the concept generation design phase was begun. In this phase a number of design methods were applied. The design concepts were systematically evaluated in respect to if, and to what degree, the concepts met the defined demands and needs of the design. The final concepts were completed with the demands of the company to obtain the results. In order to define, create and communicate ideas and solutions, the design was modelled in Solidworks software and exported to Creo Parametric 2.0 to create the final renders. Once the overall design was defined, materials and accessories were specified. The final result is presented in detail in photorealistic renderings and a physical design made by Hurtan Desarrollos S.L. III Table of Contents 1. INTRODUCTION............................................................................................................. 1 1.1 Organizational environment ................................................................................... 1 1.2. Problem description ............................................................................................... 2 1.3. Current Design ....................................................................................................... 2 1.4. Objectives .............................................................................................................. 5 1.5. Conditions and limitations ..................................................................................... 5 1.6. Design strategy and methodology ......................................................................... 6 1.7. Mission statement ................................................................................................. 7 2. PRE-STUDY .................................................................................................................... 9 2.1. Literature review .................................................................................................... 9 2.1.1. Overview about cars ....................................................................................... 9 2.1.2. Mechanisms for windows and doors in vehicles .......................................... 10 2.1.3. 3D Software .................................................................................................. 11 2.2. Benchmark competitive products........................................................................ 11 2.3. Study of classic car door and window designs .................................................... 11 2.4. Study of standard car door .................................................................................. 12 2.4.1. External cover ............................................................................................... 13 2.4.2. Mechanisms .................................................................................................. 14 2.4.3. Architecture of the door ............................................................................... 17 2.5. Function Analysis ................................................................................................. 22 2.6. Target specification .............................................................................................. 22 3. CONCEPT GENERATION .............................................................................................. 24 3.1. Early ideas ............................................................................................................ 24 3.1.1. Why? Why? Why? ........................................................................................ 24 3.2. Concept Classification Tree, decomposing by user needs ................................... 24 3.2.1. Window ........................................................................................................ 27 3.2.2. Door .............................................................................................................. 31 3.3. External decision .................................................................................................. 35 IV 3.4. Concept Combination Table ................................................................................ 35 3.4.1. Window combinations.................................................................................. 35 3.4.2. Door combinations ....................................................................................... 38 4. CONCEPT SELECTION .................................................................................................. 41 4.1. Positive, Negative and Interesting. Concept comparison.................................... 41 4.2. Evaluation of the most important concepts ........................................................ 43 5. Results ......................................................................................................................... 46 5.1. Final design .......................................................................................................... 46 5.2. Materials and unions ........................................................................................... 53 5.2.1 Hinges, handles, door stay and crank ............................................................ 53 5.2.2. Window lifter ................................................................................................ 55 6. Discussion ................................................................................................................... 57 APPENDIX 1: Visit to the Automobile Museum of Málaga ............................................. 61 V 1. INTRODUCTION The first chapter of the report introduces the reader into the purpose of the project; the problems that were covered with the development of this product and where the project was performed. 1.1 Organizational environment This thesis describes a project performed in Spain for the fulfilment of a Bachelor of Science degree in Product Design Engineering at University of Skövde, Sweden. The project is carried out in collaboration with the company Hurtan Desarrollos S.L. in Granada, Spain, during the spring 2015. The firm Hurtan is an automotive manufacturer. The company’s cars are inspired by the models of the ’40s and ’50s. In 1991, the plans for the first car were designed. In 1996, the company finished the first Hurtan T2, a car with Renault’s motorizations and coachwork manufactured entirely by the Hurtan Company. Juan Hurtado, the company director, obtained the approvals and permits to begin to market the new prototype in 2004. In 2009, Hurtan Grand Albaycín (Figure 1.1) is introduced, the most advanced model (Hurtan, 2014). Figure 1.1: The newest model, Hurtan Grand Albaycín (http://www2.diariomotor.com) 1 Currently, Hurtan is working in new projects to expand the market. The company is developing new improvement systems that allow producing top quality automobiles. Furthermore, an “I+D+i” (investigation, development and innovation) department was recently added, to innovate the design process and the automobile models. 1.2. Problem description The Hurtan cars were initially designed for temperatures and dry climates like in Spain where it usually is not necessary to keep the car closed. Therefore, the current model has a simple design where priority is given to the main aspect of the product, partly renouncing to functionality. As shown in Figures 1.3 and 1.4 in Section 1.3, the Hurtan Grand Albaycín has snap fasteners to attach the plastic windows to the car. Aesthetically the snap fasteners look good for the company style, but to put on the windows is not comfortable for the user. Nowadays, Hurtan S.L. wants to expand its market abroad since new customers are interested in the company vehicles. These customers are from countries such as Russia, Dubai or Saudi Arabia. For this purpose, it is required that the most requested model of their automobiles is redesigned, the Hurtan Grand Albaycín. Hence it is necessary to isolate the car better against rain and similar weather conditions and to enable comfort when temperatures are high or low outside the car, which is typical for markets in cold and warm regions of the world. Accordingly, the company has decided to make a total redesign on the automobile top. It includes the