Development and Research of Tailgate Hinge Positioning Tooling for a certain Model_Hinge Knowledge

The door hinge plays a crucial role in connecting the body and the door. Its primary function is to ensure that the door and body are properly aligned, meeting the company's standards for gaps and step differences after installation. Therefore, the accuracy of hinge positioning is of utmost importance. The design of the hinge positioning fixture must meet the requirements for positioning and installation of the hinge parts on the door. It should effectively position the welding parts of the car body and ensure high-quality welds. Additionally, the fixture design should also consider the installation requirements, such as providing ample space and ergonomic positioning for the air gun used to install the hinge.

In this study, we deeply analyze the key elements of the tailgate hinge assembly process, including positioning and ergonomics. By optimizing the design of the tailgate hinge positioning tooling for a specific car model, we meet the assembly production requirements of the production line.

1. Hinge Mechanism Analysis:

1.1 Analysis of Hinge Positioning Points:

The hinge is connected to the door side using two M8 screws and to the body side using an M8 screw. The hinge can rotate around the middle axis. Our project involves first installing the hinges on the door using an air gun and then attaching the door to the body. By analyzing the processing technology of the hinges and the size control, we determine the positioning strategy shown in Figure 2.

1.2 Determining the Initial Design of the Hinge:

In the fixture design, we align the adjustment direction of the fixture with the relative coordinate system established during measurement. This makes it easier to make adjustments on-site by directly removing the appropriate gasket. The initial posture of the hinge is determined by ensuring that the positioning surface on the side of the hinge body is parallel to the bottom plate surface, aligning the adjustment direction with the three-coordinate measurement coordinate system.

2. Digital-Analog Design of Hinge Positioning Fixture:

To avoid interference between the door and the hinge positioning fixture when lifting and removing the door, a telescopic mechanism is designed. This mechanism allows the hinge positioning fixture to be retracted after hinge installation. Additionally, a flip clamping mechanism is included to compress the hinge during the positioning process.

2.1 Design of Telescopic Positioning Fixture:

The telescopic mechanism integrates the hinge support, hinge side limit, and body side hinge limit. By incorporating these functional parts, we ensure stable placement and accurate positioning of the hinge.

2.2 Design of Overturning and Pressing Fixture:

The overturning and pressing fixture includes a cylinder and hinge pressing blocks. Careful attention is given to the selection of the rotation point of the fixture cylinder to avoid interference between the hinge block and the hinge during the rotation and opening process. The minimum distance from the door after the clamp is opened is also considered to maintain a safe distance of 15mm.

3. On-Site Measurement and Adjustment of Fixtures:

Measurement of the fixture is done using three-coordinate measurement to establish the measurement coordinate system. Data collected by the three-coordinate measuring instrument is compared with the digital-analog design value to determine the adjustment amount. The fixture adjustment focuses on controlling dimensional tolerances, such as clearance and step difference.

4.

The optimized design of the tailgate hinge positioning fixture has been successfully implemented, offering a simple structure, high positioning accuracy, easy adjustment, and good ergonomics. The fixture fulfills the positioning requirements of the hinge, ensuring high-quality installations. AOSITE Hardware's Metal Drawer System offers stylish and well-crafted options, meeting the diverse needs of consumers.