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Automotive door system weather-strip seals play a major role in determining door closing effort, isolating the passenger compartment from water and reducing the wind noise inside the vehicle. They are typically dual extrusion bulbs of sponge and dense rubber. The bulbs can be round, triangular or free form in shape with a height of approximately 15-30 mm. The special properties of dense and sponge rubber material are (1) High extensibility. (2) Low extensional and shear modulus. Dense rubbers are nearly incompressible. Sponge rubbers are, on the other hand, very compressible. (3) Nonlinear force vs. extension behavior. Because of the above-mentioned factors, the deformation of the automotive door weather-strip seal during the compression is very complicated. A testing set has been developed for obtaining compression deformation of the door weather-strip by using stereovision theory. Precision instruments of optical grating and force sensor are also integrated in this set.

In order to analyze positioning errors of assembly fixture of car SANTANA 2000, a 3D CAD model of fixture is built in this paper. Six typical deviation models are defined on the basis of six points positioning principle for fixture. The assembly gap distribution between door and side frame is analyzed and the influence of different deviation patterns on assembly gap is studied, and the effect of assembly gaps on door closing force is evaluated meanwhile. The results show that positioning errors of door assembly fixture is one of the most important factors to affect the door closing force.