Aluminum Alloy Vehicle Door Hinge Casting Method
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Solution Overview
Problem
Current vehicle door hinge manufacturing methods fail to achieve weight reduction and improved production efficiency while maintaining the desorption function and high support strength required for modern vehicles.
Innovation Solution
The method involves using aluminum alloy for at least one base member of the door-side or vehicle body-side base members, which are manufactured by casting, with a hinge shaft and bush system allowing for detachable assembly and a conical portion for secure fixation, enabling the door to be easily attached and detached from the vehicle body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel mold cutting is used to manufacture door hinge base members, then high strength and rigid opening/closing feeling are achieved, but production time increases and productivity decreases
Solution Approach 1:
The invention changes the manufacturing method from traditional steel mold cutting to a new process involving semi-finished product formation by casting followed by pressing. This parameter change in the manufacturing process reduces production time while maintaining the required strength through optimized material selection and process parameters
Solution Approach 2:
The invention applies preliminary action by forming semi-finished products through casting before the final pressing operation. This preliminary formation of the base member structure reduces the time required for subsequent processing steps, thereby improving overall productivity while ensuring high strength in the final product
2Ease of manufacture
If traditional manufacturing methods are used, then production process is established, but weight reduction demand cannot be met
Solution Approach 1:
The invention applies composite materials by combining different materials for the door-side base member and vehicle body-side base member. Specifically, it uses materials with different densities and properties to reduce overall weight while maintaining manufacturing feasibility and structural strength requirements
Solution Approach 2:
The invention changes material parameters by selecting lighter materials for the base members compared to traditional steel mold constructions. This parameter change in material selection enables weight reduction while the pressing process ensures the structural integrity and ease of manufacture are maintained
3Productivity
If door hinge structure is simplified, then production efficiency improves, but desorption function is lost
Solution Approach 1:
The invention applies segmentation by dividing the door hinge into separate components: a door-side base member and a vehicle body-side base member that can be detachably connected. This segmentation enables the desorption function (easy detachment) while maintaining production efficiency through simplified manufacturing of individual components that are assembled rather than complex integrated structures
Data Source
AI summary
A vehicle door hinge that has a desorption function while enabling weight reduction and increasing production efficiency. The vehicle door hinge comprises a base member (2U) fixed to the door-side of the vehicle, a base member (3U) fixed to the vehicle body side; a hinge shaft (4U) rotatably connects the base members (2U, 3U) to each other; a screwed body (5U) that is detachably screwed in the axial direction to the hinge shaft (4U) so that the base member (3U) and the hinge shaft (4U) rotate integrally; bushes (6U, 7U) fitted into a shaft holes (22U) of the base member (2U) so that the base member (2U) and the hinge shaft can rotate relative to each other; and a retaining portion (8U) for preventing the hinge shaft (4U) from coming off from the shaft hole (22U) of the base member. The base members (2U, 3U) are cast from aluminum alloy.