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The analysis presented in this document demonstrates the mathematical model approach for determining the rotation of a door about the hinge axis. Additional results from the model are the torque due to gravity about the axis, opening force, and the door hold open check link force. Vector mechanics, equations of a plane, and parametric equations were utilized to develop this model, which only requires coordinate points as inputs. This model allows for various hinge axis angles and door rotation angles to quickly be analyzed. Vehicle pitch and roll angles may also be input along with door mass to determine the torque about the hinge axis. The vector calculations to determine the moment arm of the door check link and its resulting force are demonstrated for both a standard check link design and an alternate check link design that has the link connected to a slider translated along a shaft.

The origami structures have received increasing attention in recent years due to the high stiffness ratio and lightweight feature. This paper has proposed an origami-based honeycomb structure and investigated the mechanical properties of the structure. The compression response and energy absorption of the structure under quasi-static loading have been investigated experimentally and numerically. The numerical results closely matched the experimental results in terms of the compression force curve and deformation patterns. The effects of different structural parameters on the mechanical response and energy absorption characteristics were analyzed with the validated model. Finally, the comparative results show that the origami-inspired honeycomb structure, which is characterized by rotational folding mode under axial compression, has better performance in terms of mechanical response and energy absorption.

Side doors are pivotal components of any vehicle, not only for their aesthetic and safety aspects but also due to their direct interaction with customers. Therefore, ensuring good structural performance of side doors is crucial, especially under various loading conditions during vehicle use. Among the vital performance criteria for door design, torsional stiffness plays an important role in ensuring an adequate life cycle of door. This paper focuses on investigating the impact of several door structural parameters on the torsional stiffness of side doors. These parameters include the positioning of the latch, the number of door side hinge mounting points on doors (single or double bolt), and the design of door inner panel with or without Tailor Welded Blank (TWB) construction.

The recent surge in platforms like YouTube has facilitated greater access to information for consumers, and vehicles are no exception, so consumers are increasingly demanding of the quality of their vehicles. By the way, the door is composed of glass, moldings, and other parts that consumers can touch directly, and because it is a moving part, many quality issues arise. In particular, the door panel is assembled from all of the above-mentioned parts and thereby necessitates a robust structure. Therefore, this study focuses on the structural stiffness of the door inner panel module mounting area because the door module is closely to the glass raising and lowering, which is intrinsically linked to various quality issues.

The side-door operation of vehicle is vital to the customer, as it reflects the overall build quality of the vehicle. The side door check arm is one of the primary components that determine the operating characteristics of a vehicle door. The profile of the check arm has a significant impact on the closing effort of side doors. In this study, the check arm profiles are analyzed virtually in relation to the side door's closing velocity. A virtual door model was developed in ADAMS to simulate the side door closing and opening. The study involves a check arm that guides the ball spring mechanism housing unit over the guide profile. Typically, a check-arm guide profile has two or three indents at a specific location which serves to maintain the door open in those positions. When a door enters an indent, the user must exert an effort to traverse it. Furthermore, the slope profile of the check arm defines the self-closing assist offered from the initial indent to the latching position.

In automotive market, with competitive car prices, build quality of a car will be a major distinguishing factor. Consumer's need for acoustic comfort has evolved from the removal of annoying noises to perceived sound quality. Operational sounds from electromechanical systems like sunroof system, window regulator, door lock system, HVAC etc. directly interact with users’ senses. The perceived acoustics comfort of these sounds are direct indicators of vehicle character and can influence customer’s buying decision. With the reduction in product development time and stringent cost constraints, a proper structured target setting methodology to benchmark & evaluate these operational sounds is crucial. In this paper, such a target setting methodology is proposed and discussed for operational sound quality evaluation. Electromechanical noises from various vehicles are measured using binaural head measurement system.

The Indian passenger vehicle market has grown by more than 40% by volume in the last decade and has reached a record high in FY23. This has created a more diverse and demanding customer base that values interior design and quality. The modern customer expects a high level of aesthetics and sophistication in their vehicle interiors - including in the luggage area. The Luggage Cover (Parcel Tray) is a component in the luggage area of a passenger vehicle that is used to conceal the luggage & improve its aesthetics. The cover is generally made of thermoplastic material with rotating hinges and is held in its place by the compression from the back door, which is frequently opened and closed. The parts that connect the cover to the door (usually an elastomer interface on the thermoplastic tray) tend to change over a period due to climatic conditions and leads to rattling concerns over a period.

The car door handle is an essential component of any vehicle, as it plays a crucial role in providing access to the cabin and ensuring safety of the passenger. The primary function of the car door handle is to allow entry and exit from the vehicle while preventing unauthorized access. In addition to this, car door handles also play a critical role in ensuring passenger safety by keeping the door closed during accidents or when there is a significant amount of G-force acting on the vehicle. A typical car door handle comprises several components including the structure, cover, bowden lever, bracket, pins and other child parts. The structure provides the ergonomics and rigidity for grabbing the handle, while the cover gives the handle an aesthetic appearance. The Bowden lever facilitates the unlatching of the door and the intermediate parts ensure that the handle operates smoothly.

Low-dimensional materials are essential in optoelectronic, electrical, and contemporary photonics areas because of their specific properties with decreased dimensions. Low-dimensional materials are those with dimensions in the nanoscale range that are between 1 and 100 nm. Halide perovskites of low dimension can be produced inexpensively using solution-processable procedures, unlike usual semiconductor nanomaterials. Since halide perovskite in thin layers may be produced utilizing a variety of solution-based techniques like simple spin coating. It is possible to produce it with a variety of compositions using low-cost, simple, and large-scale procedures. Quantum dots, perovskite nanoplatelets, nanosheets, perovskite nanorods or nanowires, and other low-dimensional perovskites are all examples of such small-dimensional devices that have been created in a range of morphologies (two-dimensional).

Thin plates buckle after applying load and return to normal position after the load is released, this process is called oil canning. Waviness in thin panels can be seen on various plates of metals. Oil canning is a major issue if panels are too thin and these panels create vibration and noise in the vehicle body panel. If the panels are wider, then there are more chances of oil canning issues. Different digital simulations and physical techniques are currently available to check the canning performance, but they required geometrical data and physical setup. In this paper machine learning (ML) approach to predict the oil canning performance is presented. This approach adds a new process to the existing process of vehicle door design, but it helps avoid the number of simulations and unwanted structural modifications at the early design stage, making it a handy and powerful tool for the designer.

In an automotive vehicle, the Window Regulator is an electro-mechanical assembly that is mounted inside the door. The basic function of the Window Regulator is to raise or lower the glass when required and hold the glass in closed position or in any desired position. During Water servicing or rains, Water will typically enter inside the door through the seals and on to the Window Regulator mechanism. Hence these conditions must be physically tested in the laboratory to assess the Window Regulator’s functionality which could get affected by Water intrusion. The Water spray test conditions are based on mutual agreement between Inteva Products and the OEMs. Water spray test involves moving the electric Window Regulator to upper stall position (Window closed) at a defined voltage and line resistance. The glass must be dwelled followed by spraying defined amount of Water which simulates the rain. The agreed number of test cycles would be around 4500 which lasts about 7 weeks.

An automotive door latch that functions manually or electronically is a vital component of a door closure system. It primarily aims to provide security of the occupants by securing the door system by ensuring timely locking and unlocking of the doors. A wide range of factors like safety, ergonomics, and security influence the development of these latches to eliminate safety. With the growing trend and advancements, automotive electronics is becoming more complex and prevalent. Hence, any exposure of electrical/electronic components to water make them susceptible to short circuits, corrosion etc., thereby may make it the functionality of systems and increasing the chances of failure in these devices. Intrusion of water possible into the latch system can be disastrous depending on the climatic conditions. Stringent safety criteria have given rise to unconventional test methods that are time-consuming and hence necessitate virtual validation techniques.

The present work focusses on development of AlSi10Mg alloy component from the pre-alloyed powder by laser powder bed fusion (LPBF), one of the popular additive manufacturing technologies. The effect of heat treatment on microstructure and mechanical properties has also been studied. In accordance with T6 heat treatment process, the LPBF specimens were solution treated at 535°C for 2 h, then water quenched and subsequently, artificially aged at 160°C for 10 h. The role of printing direction on microstructure and mechanical properties has also been investigated. The printing parameters such as laser power, scan speed and hatch space were optimized for defect free automotive component. The as-printed and heat treated components were subsequently evaluated to assess their performance.

Foaming materials such as 2C-PUR or expandable baffles are increasingly used in the car body acoustic package of modern passenger vehicles. Over the last several decades the primary function of foaming materials was the moisture sealing and airborne noise absorption / insulation in various areas of the car body such as pillars, door sills or other cavities. Recent developments also show an increasing application of expandable foams, functioning as structural dampers and reducing structure-borne noise transmission through frames and pillars. This paper summarizes the results of various studies that deal with the impact of expandable baffle materials on structure-borne noise in car bodies with special focus on mid and high frequencies which become more relevant in the acoustic optimization efforts of EV’s. Structural vibrations are evaluated experimentally on foamed generic frames and double sheet metal systems under free-free boundary conditions.

Optimization design of hard point parameters for hinge mechanism has been paid more attention in recent years, attributable to their significant improvement in dynamic performance. In this paper, the experimental analysis and dynamic optimization design of hinge mechanism is performed. The acceleration measurement experiments are carried out at different arrangement points and under different working conditions. Furthermore, the accuracy of established multi-body dynamics model is verified by three-axis accelerometer measurement experiment. In addition, sensitivity analysis for electric strut and gas strut coordinates is performed and shows that the Y coordinate of the lower end point of the electric strut is the design variable that has the greatest impact on the responses.

The passenger car segment has been extremely competitive and automotive OEMs are thriving to provide superior customer experience. Door closing is an event that requires slamming of the door with a certain velocity to get the door latched. A good latching provides that thud sound and assurance of the door getting closed for an SUV. While the door is closed, it pushes the volume of air inside the cabin. As the amount of air moved in is proportionate to the size of the door it becomes more critical for the SUV segment of vehicles to ensure the air extraction path is efficient. Else, steep pressure rise inside the cabin causes severe discomfort to the passengers sitting inside the vehicle. Current work focused on the process of simulation of cabin pressure while door closing, implementing changes based on results and validating with test results. Test results are in close correlation with simulation predictions.

Side Door closing velocity is one of the key customer touch points which depicts the build quality of the vehicle. Side door closing velocity results from the interaction of different parts like door and body seals, door check arm, door hinge, latch, and alignment of door hinge axis. In this paper, a high door closing velocity issue in a sports utility vehicle is discussed. Physical studies are carried out to understand each parameter in door closing velocity and its contribution is defined in terms of velocity. Many physical trials are conducted to conclude the contribution of each parameter. Studies revealed that the body and door seal are contributing around 70% of door closing velocity. Check arm and hinge axis deviation are contributing around 10% of the door closing velocity. Physical trials are conducted by reducing the compression distance of the body seal.

The side door closing effort is one of the main evaluating parameters which demonstrates the build quality of the vehicle. The side door hinge axis inclination is one of the key attributes that affect the side door closing effort. Commonly, the hinge axis is inclined in two directions of a vehicle to have necessary door rise during the door opening event. Due to the process and assembly variations in the door assembly, the upper and lower hinge axis of the side door deviates from the design axis. In this paper, the deviations in the side door hinge axis and its effects on the side door closing velocity is discussed. The deviations of the side door hinge axis are studied with a coordinate measuring machine. The side door closing velocity of the vehicle is measured with the velocity meter. The study revealed that side door closing velocity is increasing with an increase in the deviation of the top and bottom door hinge axis from the design hinge axis.

Premium instrument panels (IPs) contain passenger airbag (PAB) systems that are typically comprised of a stiff plastic substrate and a soft ‘skin’ material which are adhesively bonded. During airbag deployment, the skin tears along the scored edges of the door holding the PAB system, the door opens, and the airbag inflates to protect the occupant. To accurately simulate the PAB deployment dynamics during a crash event all components of the instrument panel and the PAB system, including the skin, must be included in the model. It has been recognized that the material characterization and modeling of the skin tearing behavior are critical for predicting the timing and inflation kinematics of the airbag. Even so, limited data exists in the literature for skin material properties at hot and cold temperatures and at the strain rates created during the airbag deployment.

Making manned and remotely-controlled wheeled and tracked vehicles easier to drive, especially off-road, is of great interest to the U.S. Army. If vehicles are easier to drive (especially closed hatch) or if they are driven autonomously, then drivers could perform additional tasks (e.g., operating weapons or communication systems), leading to reduced crew sizes. Further, poorly driven vehicles are more likely to get stuck, roll over, or encounter mines or improvised explosive devices, whereby the vehicle can no longer perform its mission and crew member safety is jeopardized. HMI technology and systems to support human drivers (e.g., autonomous driving systems, in-vehicle monitors or head-mounted displays, various control devices (including game controllers), navigation and route-planning systems) need to be evaluated, which traditionally occurs in mission-specific (and incomparable) evaluations.