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Water Avoidance Design Strategy for Capacitive Exterior Handles

Ford Motor Company-Douglas Demori, Júlio Magalhães, Anderson Ferreira, Filipe Camargo, Bruno Freitas
Huf Hülsbeck & Fürst-Pedro Dias, Michel Turbiani
  • Technical Paper
  • 2019-36-0187
Published 2020-01-13 by SAE International in United States
Nowadays, capacitive handles are increasing their use in high-end commercial vehicles. This particular handle applies a technology that permits to unlock and even lock the vehicle without a key. As benefit for current life, the customer has the possibility to access and close the vehicles more efficiently and faster, just possessing the key in the pocket or any close compartment that the user is carrying, for example, bag, purse, backpack. Even though, the design of capacitive exterior handle must follow several design strategies to avoid nonfunctional in rainy climate. Water could work as a blocker for the sensor signal captured, special design strategies that must be taken in order to minimize that the liquid could ingress the handle and even be retained on the region that sensor is located. On this two-piece handle not only the parting line location, drain holes and a favorable drainage for liquids inside the handle must be designed, but also a control on the painting capacitance is hugely important for a successful project. Overall, to validate physically the design, test…
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Ignition Switch Material Definition to Avoid Hard to Start Issue

Ford Motor Company-Júlio Magalhães, Douglas Demori, Rosiane Viegas, Bruno Freitas
Huf Hülsbeck & Fürst-Michel Turbiani
  • Technical Paper
  • 2019-36-0138
Published 2020-01-13 by SAE International in United States
Nowadays, develop and launch a new product in the market is hard to every company. When we talk about a launch new vehicle to the customers, this task could be considered more difficult than other products whether imagine how fast the technology should be integrated to vehicle. There are main pillars to be considered in this scenario: low cost, design, innovation, competitiveness and safety. Whereas Brazilian economic scenario, all OEM has to be aware to opportunity to make the product profitable and keep acceptable quality. This combination between low cost and quality could be broken or not distributed equally between the pillars. Based on that, in some cases could have a quality broken that will affect directly the customer. This paper will focus on project to define of the new ignition switch, when the main challenge to achieve the cost reduction target was defined to change a material to electrical terminals. Beyond the material definition, we will discuss about the validation in component level and VOW, quality indicators (internal and external), prevent reoccurrences actions and…
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Buzz Avoidance on Sunroof Light Sunshades: Design and Validation

Ford Motor Company-Douglas Demori, Marcos Paulo de Oliveira, Rosiane Viegas
MSX International-Douglas França
  • Technical Paper
  • 2019-36-0148
Published 2020-01-13 by SAE International in United States
Sunroof is placed in certain high-end vehicles to give user a better driving experience. All automakers are searching alternatives to reduce weight and cost in the vehicle, in which sunroofs are also impacted. Some alternatives are already applied, as a honeycomb paper used in some sunshades that presents benefits, as less weight and with a good cost reduction. Although, due the reduced weight for this part produced in this material, it shows more susceptibility to reproduce the vibration that vehicle propagates in movement, especially in bad condition roads. The sunroof assembly is dependent of the roof reinforcement and roof skin, but in this special case, the validation could be done in the components itself because the interaction of the sunshades is directly dependent of the other sunroof parts, as rails and front frame. These buzz noise in lights sunshades is perceptible when it is almost or totally close, since lighter material vibrates freely without rail anchorage, then clashing against the front frame surface. Considering the package, the key point is to design the sunshade to…
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Robustness Design to Avoid Noise on Exterior Handle System

Ford Motor Company-Douglas Demori, Júlio Magalhães, Cristiane Carla Gonçalves, Helano Santos, Rosiane Viegas
  • Technical Paper
  • 2019-36-0137
Published 2020-01-13 by SAE International in United States
Squeak and rattle are two undesirable occurrences during component operation and during vehicle driving condition, resulting in one of the top complains from costumers. One common grievance could happen during the user exterior handle operation and during side door closing. The exterior handle system during the operation could generate a squeak between interface parts, if materials and geometric tolerances was not been carefully designed. Also, vibration generated during door closing effort, might generate squeak between parts since the reinforcement for exterior handle touches the outer sheet metal internally. For this reason several guidelines might be included to avoid potential noise condition for this system during vehicle lifetime as correct material reduce friction between parts, taking into consideration the geometric condition between parts. Plus, coupling system on handles two pieces should also be evaluated to avoid squeak during use. Not less important, if required anti-shock material system may be applied to eliminate a clash produced between parts during excessive vibration. It is extremely important to evaluate the environment that the vehicle will be exposed since the…
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Rattle Evaluation: Sunroof Glass Against Roof Flange

Ford Motor Company-Douglas Demori, Fernando Camargo, Karine Chagas, Marcos Paulo de Oliveira, Thais Cardoso
Webasto Roof Systems Brasil Ltda-Oswaldo Tursi Neto
  • Technical Paper
  • 2019-36-0140
Published 2020-01-13 by SAE International in United States
Sunroof is installed in the vehicles to generate a better satisfaction for customer. Normally, the glass is maintained closed or fully opened, when the user would like to exterior air to get in. The glass runs in the sunroof rail that interacts directly with the roof skin and the roof reinforcement, where the whole sunroof structure is fixed. In general, sunroofs are equipped with two stages button, were the final or second stage, more used by users, allows the glass to move until the final position directly, without stops. Even though, the first stage could move the glass according user desire. For validation, the vehicle runs in several roads in order to capture any unusual response given by the sunroof. During specific test validation created, the glass was been positioned in the critical region that by design has the minimum distance against the roof flange. Consequently, to solve the issue found, all the possible interactions were measured as the roof profile, flange height, sunroof dimensions and sunroof installation. Hence, all boundary conditions must be under…
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Design guidelines to avoid hygroscopic effects on outer handles

Ford Motor Company-Douglas Demori, Bruno Freitas, Helano Santos
Huf Hülsbeck & Fürst-Pedro Dias
Published 2018-09-03 by SAE International in United States
Generally, exterior handles are one of the first parts that the user has physical interaction in the vehicle. A robust handle concept gives the user the idea of trust and good quality vehicle as first impression. Exterior handles, in which the concept is a handle body operated by applying a horizontal pull force, always pivoted in the front end and sliding against a reinforcement rail at rear end, are called strap handles. The kinetics seems to be simple, nevertheless special attention must be given regarding the interaction materials used in this system. Various plastic materials used in this system are subjected to water absorption at molecular level, changing their internal structure, resulting in swell and consequently a volume increase. This phenomenon that modifies the dimensions is known as hygroscopic expansion. In one hand, handles must present reduced wobble and free play. Although, it must be remembered that hygroscopic phenomenon may be associated with cases of handle jamming, where the handle presents higher resistance to be operated or simply do not return to home position, configuring…
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