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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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Striker with bumper implementation to improve chucking noise issues

Ford Motor Company-Rosiane Viegas, Julio Magalhães
Published 2018-09-03 by SAE International in United States
Investing in quality as added value to products becomes a means of guaranteeing satisfaction as well as customer loyalty, making it competitive in its respective segment. In the automotive business, this has not been different, It can observed a progress in the perception and customers demand in quality in the last few years. At the same time, that the industries need to guarantee the cost and time of response to the dissatisfaction of the customers. In this project, was possible to implement a locking door concept, with an effective solution to the door vibration problem in a B platform, vehicle model in South America.
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