Adjustable Jig for Motor Vehicle Side Door Strength Testing
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Solution Overview
Problem
The high cost of manufacturing different jigs for various vehicle types and the complexity of demounting processes in side door strength tests due to welding and fixed bolt positions in existing technologies.
Innovation Solution
A jig with a sliding structure using linear motion guides and guide pins that allows for adjustable positioning of support units, enabling the jig to accommodate different vehicle types and simplify the mounting and demounting process by avoiding direct contact with bolt fastening portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different jigs are manufactured for different vehicle types, then the strength test can be performed accurately for each vehicle type, but the manufacturing cost increases
Solution Approach 1:
The jig is designed with a universal structure that can accommodate multiple vehicle types through adjustable support portions. The support portions can be repositioned along the jig frame to match different door frame positions and dimensions, allowing a single jig to perform strength tests for various vehicle models without requiring separate dedicated jigs for each type.
Solution Approach 2:
The jig incorporates movable and adjustable support portions that can be dynamically repositioned to adapt to different vehicle door dimensions and configurations. This dynamic adjustability enables the same jig structure to maintain accurate test conditions across different vehicle types, eliminating the need for multiple fixed jigs.
2Reliability
If welded connections are used to fix the product, then the strength test can be performed with high reliability, but the demounting process becomes complex and time-consuming
Solution Approach 1:
The connection system is segmented into separate functional components: the jig frame with support portions and the product with mounting holes. This segmentation allows the product to be independently mounted and demounted from the jig using removable fasteners rather than permanent welds, simplifying the demounting process while maintaining test reliability during the actual testing phase.
Solution Approach 2:
The jig is pre-configured with multiple support portions and mounting positions before the product is mounted. This preliminary preparation allows for quick alignment and attachment of the product to the jig, reducing the time and complexity of both mounting and demounting operations while ensuring proper positioning for reliable testing.
3Strength
If multiple bolts are fastened to fix the product, then the product can be securely held during testing, but the mounting and demounting time increases
Solution Approach 1:
The jig includes pre-positioned support portions and alignment features that are prepared in advance. When mounting the product, these pre-positioned elements guide the alignment of mounting holes and bolts, enabling rapid attachment with minimal adjustment time while maintaining secure fixation strength during testing.
Data Source
AI summary
A jig for strength test of a side door of a motor vehicle for supporting a side outer component product includes a jig frame, a first roof rail jig unit installed in an upper rear end of the jig frame and configured to support a roof rail of an upper end portion of a center pillar of a product, a second roof rail jig unit installed in an upper central portion of the jig frame and configured to support a roof rail of the center pillar of the product, a cowl crossbar jig unit installed in a front upper end of the jig frame and configured to support a front roof and a hinge portion of the product, and a plurality of side seal jig units installed in a lower end portion of the jig frame and configured to support a lower end portion of the product.