Vehicle Door Hinge Alignment Under Cantilever Sag

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Solution Overview

Problem

Existing door attachment methods for vehicles face challenges in achieving high accuracy due to variations in component accuracy and assembly errors between the door panel, hinges, and vehicle body, leading to inconsistencies in the inclination of the door panel caused by its own weight.

Innovation Solution

A door attachment method that involves primary fastening of hinges to the vehicle body, measuring the door panel position in a cantilevered state, correcting the door position based on the measurement, and secondary fastening, all while maintaining the grip mechanism's hold on the hinges to ensure accurate alignment and reproducibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the door panel is attached to the hinge arm in a temporary door joining step with anticipated inclination adjustment, then the door can be assembled to the vehicle body, but the actual inclination after completion differs from the anticipated inclination due to variations in component accuracy and assembly error

Engineering Contradiction:

Improvedoor attachment accuracyVSAvoidattachment process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The hinge positioning keeping means is attached to the vehicle body in advance to hold the hinge arm at a predetermined position. This preliminary positioning allows for accurate alignment before the actual door panel attachment, ensuring that the hinge arm is correctly positioned relative to the vehicle body opening even before the door weight causes inclination.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces manual adjustment and estimation of door inclination with an automated fastening mechanism that applies specified torque values. The fastening mechanism automatically controls the tightening force of fastening members, eliminating the need for manual inclination adjustment and ensuring consistent, accurate door attachment across different vehicles despite component variations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If the position of the hinge positioning keeping means is adjusted in anticipation of inclination, then assembly can proceed, but the actual inclination differs from anticipated inclination due to component variations

Engineering Contradiction:

Improveassembly easeVSAvoiddoor inclination accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The hinge positioning keeping means automatically maintains the hinge arm at the correct position without requiring manual adjustment. The positioning mechanism itself provides the necessary alignment function, eliminating the need for operators to manually adjust positions in anticipation of inclination issues.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention controls the attachment process by specifying torque parameters for the fastening members. By controlling the tightening force parameter, the system ensures accurate door inclination and positioning without requiring manual position adjustments, transforming the control approach from positional adjustment to force parameter control.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If manual adjustment of hinge positioning is performed, then assembly flexibility is maintained, but assembly error varies from one vehicle to another

Engineering Contradiction:

Improveassembly flexibilityVSAvoiddoor attachment consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The automated fastening mechanism replaces manual positioning and tightening operations. The mechanism automatically applies the correct torque to fastening members, ensuring consistent door attachment accuracy across all vehicles while maintaining the flexibility to accommodate different door and vehicle body configurations through programmable control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The hinge positioning keeping means and fastening mechanism are designed to be universally applicable to different vehicle models and door types. The system maintains assembly flexibility through its ability to adapt to various configurations while ensuring consistent precision through automated torque control, eliminating vehicle-to-vehicle variation in assembly accuracy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11685454B2Door attachment method, and door moving device and sagging measurement device used therefor

Publication Date: 2023.06.27 MAZDA MOTOR CORP

AI summary

A door attachment method assembles a door with a high degree of accuracy. Embodiments include a primary fastening step of bolting hinges to attachment surfaces of a vehicle body; a door panel position measurement step of measuring a relative position of a door panel in an opening when a door is brought into a cantilevered state and the hinges are fastened; a loosening step of loosening the fastening; a door position correction step of moving the door within the attachment surfaces based on a measurement result in the door panel position measurement step; and a secondary fastening step of re-fastening the hinges to the attachment surfaces. Throughout the primary fastening step, the door panel position measurement step, the loosening step, the door position correction step, and the secondary fastening step, a state where clamps respectively grip the hinges to cause the hinges to abut the attachment surfaces is maintained.