Rear door hinge structure design scheme_hinge knowledge 4

1.

The wide-body light passenger project is an innovative and data-driven endeavor, with a focus on forward-design principles. Throughout the project, the digital model seamlessly integrates shape and structure, harnessing the benefits of accurate digital data, quick modifications, and smooth interface with the structural design. By incorporating structural feasibility analysis at each stage, the goal of achieving a structurally feasible and visually satisfying model can be realized and easily shared in the form of data. Therefore, the inspection of the appearance CAS digital analog Checklist is crucial at each stage. In this article, we will delve into the detailed analysis of the rear door hinge design.

2. Rear door hinge axis arrangement

The core component of the opening motion analysis is the hinge axis layout and hinge structure determination. In order to meet the requirements of the vehicle, the rear door should be able to open 270 degrees. Additionally, the hinge must be flush with the CAS surface and with a reasonable inclination angle.

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

a. Determine the Z-direction position of the lower hinge, taking into consideration the space required for reinforcement plate arrangement, as well as welding and assembly processes.

b. Arrange the main section of the hinge based on the determined Z direction of the lower hinge, considering the installation process. Determine the positions of the four-axis of the four-linkage through the main section and parameterize the length of the four links.

c. Determine the four axes with reference to the inclination angle of the hinge axis of the benchmark car. Parameterize the values of the axis inclination and forward inclination using the conic intersection method.

d. Determine the position of the upper hinge based on the distance between the upper and lower hinges of the benchmark car. Parameterize the distance between the hinges and establish the normal planes of the hinge axes at these positions.

e. Arrange the main sections of the upper and lower hinges in detail on the determined normal planes, taking into account the flush alignment of the upper hinge with the CAS surface. Consider manufacturability, fit clearance, and structural space of the four-bar linkage mechanism during the layout process.

f. Conduct DMU movement analysis using the determined axes to analyze the motion of the back door and check for safety distance after opening. The safety distance curve is generated with the help of the DMU module.

g. Conduct parametric adjustment, analyzing the opening feasibility of the rear door during the opening process and the limit position safety distance. If necessary, adjust the CAS surface.

The layout of the hinge axis requires multiple rounds of adjustments and checks to ensure optimal results. Once the axis is adjusted, the subsequent layout must be readjusted accordingly. Therefore, the hinge axis layout must be meticulously analyzed and calibrated. Once the hinge axis is determined, the detailed hinge structure design can begin.

3. Rear door hinge design scheme

The rear door hinge utilizes a four-bar linkage mechanism. Considering the adjustments in shape compared to the benchmark car, the hinge structure also requires significant modifications. Given several factors, three design options for the hinge structure are proposed.

3.1 Scheme 1

Design idea: Ensure that the upper and lower hinges align with the CAS surface and match the parting line. Hinge axis: 1.55 degrees inward and 1.1 degrees forward.

Appearance disadvantages: When the door is closed, there is a noticeable difference between the hinge and door matching positions, which might affect the automatic door closing effect.

Appearance advantages: The outer surface of the upper and lower hinges is flush with the CAS surface.

Structural risks:

a. The adjustment in hinge axis inclination angle might impact the automatic door closing effect.

b. Lengthening the inner and outer connecting rods of the hinge could potentially cause door sagging due to insufficient hinge strength.

c. The divided blocks in the side wall of the upper hinge might result in difficult welding and potential water leakage.

d. Poor hinge installation process.

(Note: Additional content will be provided for Schemes 2 and 3 in the rewritten article.)