Vehicle Side Door Motor Mounting Assembly Radial Alignment
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Solution Overview
Problem
Conventional manufacturing processes for vehicles with motor-driven doors face complications due to the need for precise alignment of motor mechanisms, which cannot be exposed to processes like corrosion protection and painting, leading to increased labor and costs, especially with inter-vehicle dimensional variations.
Innovation Solution
A side door motor mounting assembly with a radial adjustment feature allows for alignment of the motor with the door hinge axis, enabling proper installation and alignment after these processes, using a modified vehicle body-mounted upper hinge and a motor mounting bracket with L-shaped configuration and support brackets for adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the motor is installed on the hinge before corrosion protection and painting processes, then the alignment can be performed earlier in the manufacturing process, but the motor mechanism is exposed to harmful processes that can damage it
Solution Approach 1:
The motor mounting system is divided into separate components: a motor mounting bracket that attaches to the door, a check bracket that provides positioning, and a hinge assembly. This segmentation allows the motor to be installed on the door separately from the hinge, enabling the door to be removed before harmful processes while maintaining alignment capabilities during final assembly.
Solution Approach 2:
The motor mounting bracket and check bracket are pre-configured with alignment features that establish the motor's position relative to the hinge axis before final assembly. The check bracket provides preliminary positioning that ensures proper alignment is maintained when the door is reinstalled after corrosion protection and painting processes.
2Object-affected harmful factors
If the motor is installed after corrosion protection and painting processes, then the motor is protected from damage, but the alignment process becomes more complicated and requires additional labor
Solution Approach 1:
The check bracket serves as an intermediary component between the motor mounting bracket and the hinge assembly. It provides a reference surface and positioning features that simplify the alignment process during final assembly, eliminating the need for complex alignment procedures while ensuring precise motor-to-hinge-axis alignment.
Solution Approach 2:
The motor mounting bracket incorporates self-aligning features including radial adjustment capability and positioning elements that work with the check bracket to automatically establish correct alignment. This self-service alignment mechanism reduces the skill level and time required for the alignment process during final assembly.
3Object-affected harmful factors
If the motor is installed after corrosion protection and painting processes, then the motor is protected from damage, but labor and assembly costs increase
Solution Approach 1:
By segmenting the motor mounting system into a door-mounted bracket assembly and a hinge assembly that connect through standardized interfaces, the motor can be installed on the door as a pre-assembled unit. This segmentation enables efficient final assembly where the entire motor assembly is mounted in one operation rather than requiring multiple separate operations, thereby maintaining productivity.
Solution Approach 2:
The motor mounting bracket and check bracket are designed as universal components that can accommodate different motor types and hinge configurations. This multi-functionality allows the same mounting system to be used across various vehicle models and door designs, reducing the need for custom alignment procedures and specialized labor, thereby maintaining assembly efficiency.
Data Source
AI summary
A mounting assembly for a vehicle side door motor includes an upper hinge element configured for receiving a side door motor drive shaft and a motor mounting bracket configured to receive the side door motor drive shaft and to allow a radial adjustment of the drive shaft for alignment of an axis of the motor with a side door hinge axis. The upper hinge element may define a clevis including a lower clevis portion having a motor drive shaft mounting aperture dimensioned to allow the radial adjustment feature. The motor mounting bracket includes one or more mounting apertures dimensioned to allow a vehicle fore/aft adjustment and in/out adjustment of the side door motor element. The motor mounting assembly is further configured to allow a vehicle up/down adjustment of the side door motor.