Design of backdoor

BACKDOOR DESIGN

The backdoor plays an important role in an automobile including protecting the occupant in case of a rear collision, it also secures the rear end compartment of the vehicle.

There are several other components that make up the backdoor such as:

• inner panel
• outer panel (upper and lower panel)
• hinge reinforcements
• wiper reinforcements
• latch reinforcement

INNER PANEL

In the design of the inner panel which acts as the reinforcement for the outer surface, a class A surface was given. Several tools such as offset surface, trim sheet, and law extension were used. Some part of the surface was trimmed and some embosses were created on the surface to divert the collision energy and also give strength to the surface.

REINFORCEMENT

The part where the gas stay and the wiper will be mounted might become weak due to load concentration. In other to avoid this from happening, some reinforcements were created.

GAS STAY REINFORCEMENT

CLEARANCE

For manufacturability and assembly, certain clearance is needed between the surfaces of the parts. In this challenge, a thickness of 0.75mm was given to both the inner and outer panels of the backdoor. A clearance of 0.2mm was also allowed between the surfaces of the parts.

DRAFT ANALYSIS

After the design of the inner panel of the backdoor, a draft analysis was performed. This is to ensure the part has a proper draw angle and that it can be manufactured. The green color on the surface indicates manufacturability while the yellow color represents a slightly acceptable value.

OUTER PANEL UPPER

The outer panel is divided into two sections, the upper and the lower panel. Both panels are designed with the intention to have proper contact with the rubber sealing with prevents water from entering the rear compartment of the vehicle. The upper outer panel holds the rear glass. With the class-A surface given, a mirrored geometry of the part was designed.

LOWER OUTER PANEL

The given class A surface was used in producing a mirrored geometry of this part.

ASSEMBLY (half)

After all the parts are created, an assembly of the parts is created.

CONCLUSION

After several challenges and redesign, a backdoor was designed with continuous improvements. Performing the draft analysis ensures the designed part can be manufactured.