Rear door hinge structure design scheme_hinge knowledge 1

1.

The development of a wide-body light passenger project is a data-driven and forward-designed endeavor. Throughout the project, the digital model seamlessly integrates the shape and structure, taking advantage of the benefits of accurate digital data, fast modifications, and seamless interface with structural design. It incorporates structural feasibility analysis at each stage, ensuring a structurally feasible and satisfactory model. This article focuses on the importance of inspecting the appearance CAS digital analog CheckList at each stage and provides an in-depth look at the backdoor hinge opening check process.

2. Rear door hinge axis arrangement:

The core element of the opening motion analysis is the layout of the hinge axis and the determination of the hinge structure. The rear door of the vehicle needs to open 270 degrees while maintaining flush alignment with the CAS surface and ensuring a suitable hinge axis inclination angle.

The analysis steps for the hinge axis layout are as follows:

a. Determine the Z-direction position of the lower hinge, considering both the space required for reinforcement plate arrangement and welding and assembly process sizes.

b. Arrange the main section of the hinge based on the Z-direction position of the lower hinge, considering the installation process and determining the four-axis positions of the four-linkage with parameterization.

c. Determine the inclination angles of the four axes based on the benchmark car's hinge axis inclination angle, using conic intersection method for parameterization.

d. Determine the position of the upper hinge by referencing the distance between the upper and lower hinges of the benchmark car, with parameterization of the distance between the hinges and creation of normal planes at those positions.

e. Detailed arrangement of the main sections of the upper and lower hinges on the determined normal planes, considering installation, manufacturability, fit clearance, and structural space.

f. Perform DMU movement analysis using the four determined axes to analyze the motion of the rear door and check the safety distance during the opening process.

g. Parametrically adjust the three sets of hinge axis parameters to analyze the feasibility of the rear door opening. If necessary, adjust the CAS surface.

The hinge axis layout requires multiple rounds of adjustments and checks to ensure it fully meets the requirements. Any adjustment will necessitate subsequent layout readjustments, highlighting the criticality of thorough analysis and calibration.

3. Rear door hinge design scheme:

The rear door hinge adopts a four-bar linkage mechanism, and three design options are proposed. Each option has its advantages and disadvantages.

3.1 Scheme 1:

This scheme focuses on matching the upper and lower hinges with the CAS surface and achieving consistency with the parting line. However, it has some appearance disadvantages, such as a larger difference between the hinge matching position and the door when closed.

3.2 Scheme 2:

In this scheme, both the upper and lower hinges protrude outwards to ensure no fit gap between the hinges and the rear door in the X direction. This option offers structural advantages, such as cost savings due to common hinges and good assembly process.

3.3 Scheme 3:

The outer surface of the upper and lower hinges matches well with the CAS surface in this scheme. However, there is a large gap between the hinged door link and the outer link, and installation may be challenging.

After careful analysis and discussion, the "third solution" is confirmed as the optimal solution due to its minimum change to the outer surface, maintaining consistency in modeling.