Design of backdoor
Aim :
To develop the car Backdoor(Tail gate) with the reference of given skin data as per engineering standared
Functions of the Backdoor:
- It protects the occupants and luggage from getting damaged.
- It houses assembly of tail lamps, wiper motor and other components.
- It houses windshield glass which helps in rear visibility.
- Parking sensors, rear view camera are mounted on it.
Types based on Working Mechanism:
1.Gas Stays type.
2.Powered Lift system.
1.Gas Stay type:
Gas Stay type backdoor is an ideal and most commonly used tailgate mechanism from lower segment car to luxury car segment. The ideal components of tailgate consist of a hinge, door, gas stay and some rubber beadings for sealing of door.
2.Powered Lift System:
Power trunk lift system is another sophisticated way of trunk or liftgate opening mechanism which is to automatically open and close of the trunk and release of the latch by the touch of a bottom. Powered trunk Lift system consists of a power latch, anti pinch switch, PTG assly, PTG main switch. When the switch is pressed in the compartment or outside the power latch releases the latch and the entire backdoor is opened. The anti pinch switch is located in order to avoid accidental hand insertion during the operation of the door.
Components of Back Door :
The Components of Back Door as follows,
- Inner Panel
- Upper Panel
- Lower panel
- Hing Reinforcement
- Latch and Stricker Reinforcement
- Gas stay Reinforcement
- Wiper motor Reinforcement
Inner Panel
The inner panel is a component which is used for strengthen the door assembly and it is one of the most important components on which all accessories are mounted like hinges, glass guide channel, molded trim, latch etc. the possible method is the integration method. In the integration method, the part is stamped out of a single blank. This reduces the number of tools needed, the assembly cost and eliminates any fit ability problem.
Upper Panel
Lower pane
Hinge reinforcements
Hinge is a pivot mechanism which supports the total weight of the backdoor. So reinforcements are added for strength and rigidity.
Gas stay reinforcements
Gas stay is used to lift the backdoor automatically and is used to support the backdoor in its open position. It can be of Two types Semi-automated and fully automated.
Wiper Motor reinforcement
Wiper is used to wipeout the dust particles/water on the windshield glass which affects the rear visibility. It is actuated by the motor which is mounted on the inner panel. Due to vibration and heat of the motor, inner panel gets deformed which results in loss of strength & rigidity of the panel thus leading to poor NVH. So reinforcement is provided to avoid these conditions.
Latch and Striker reinforcement
In the bottom part of the panel emboss is created for placemnet of latch and striker assembly. There is over slamming and abusing while opening and closing of the door, thus arising the need for reinforcement to be placed.
HEMMING
Hemming is a sheet metal forming process in which sheets are joined by bending it to 180°. Automotive body panels and automotive parts such as deck-lids, trunk-lids, doors, hoods and tailgates are formed by hemming process. In this process, usually a sheet is bent with the help of inner sheet in three different stages
Draft analysis
Every part which is manufactured from press tool or other forming tools require some positive draft on the faces which are parallel to the tooling direction. If we don’t give draft (Zero Draft) or give negative drafts on these faces it will stick to the mould surface and when the mould is in motion it will destroy surface thus reducing its surface finish. Thus Draft Analysis command enables us to detect if the part we have drafted can be easily ejected or not. It also give insights about the critical zones, so that appropriate changes in the design can be made if needed.
CONCLUSION:--
Thus the Back Door of a car is designed with following the engineering standards and also the deep drawing requirements were satisfied.