Design of backdoor

BACK DOOR DESIGN

OBJECTIVE: The main objective of this project is to design the back door including inner, outer panel and reinforcements required.

INTRODUCTION:

Back doors are one of the types of doors of the vehicle which are located next to the passenger seat which provides access to the luggage compartment. In the most of the cars, these back doors are operated with the help of gas stay which in turn reduces the effort required to lift the door. The back door is an assembly of many parts such as inner panel, outer panel upper, outer panel lower and reinforcement. Inner panel is attached to the outer panel using mastic sealant.

Total number of parts in backdoor are

1. Back door outer panel(upper)
2. Back door outer panel(lower)
3. Back door inner panel
4. Hinge reinforcements
5. Gas stay reinforcements
6. Latch and striker reinforcements
7. Wiper motor reinforcements

INNER PANEL DESIGN:

Inner panel is made of either steel or aluminium. Wiper motor, latch reinforcements , hinge and gas stay reinforcements are mounted on the inner panel . And the embosses are provided on the inner panel helps in stiffening the panel and act as local reinforcements and to distribute impact forces towards hinges.

DESIGN CONSIDERATIONS:

1. Rear visibility.
2. Support structures like hinges and gas stays.
3. Mounts for wiper motor , tail lamps, and other wiring loops.
4. Fit and clearances.
5. Boot space.
6. Rear crash regulations and requirements.
7. Sealing and its functions.
8. Joining techniques like hemming , spot welding etc.

TOOL DIRECTION:

OUTER PANEL DESIGN:

outer panel is styling surface of back door. Glass for rear visibility is mounted on the outer panel upper . rear lights are also mounted on the outer panel upper. Number plate is mounted on the outer panel lower.

HINGE REINFORCEMENT:

Hinges support the weight of the whole back door. Hence the reinforcements are provided. Hinges is connected to the rear roof of the car.

WIPER MOTOR REINFORCEMENT:

Wiper is used to wipeout the rain water falls on the back door window. It is actuated by the motor which is mounted on the inner panel. Due to vibration and heat created by the motor the inner panel where the motor is mounted gets deform and the parts attached to the motor starts to vibrate which leads to poor nvh. So reinforcements are provided where the wiper motor is placed.

LATCH AND STRIKER REINFORCEMENT:

at the bottom of the panel reinforcement and emboss are given to accommodate the latch and striker assembly.

GAS STAY REINFORCEMENT:

Gas stay is used to lift the back door automatically.

MASTIC SEALANTS:

DRAFT ANALYSIS:

HEMMING:

RELIEF:

FINAL ASSEMBLY:

CONCLUSION:

Thus the final assembly of back door including reinforcements was done .