f_FinalA3-VPD1
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This document reflects on the author's VPD1 co-op experience at Toyota Technical Center summarizing the projects and skills gained. The author supported the VPD1 team through vehicle development stages, applied classroom knowledge, and strengthened their desire to work in automotive design. Projects included evaluating countermeasures for a tailgate issue, measuring static closing forces of hoods and back doors, and benchmarking competitors. The co-op allowed the author to gain engineering evaluation experience, implement Toyota Way principles, and deepen their understanding of the vehicle development process.
f_FinalA3-VPD1
- 1. VI. CONCLUSION & REFLECTIONS Spring '07 Sum '07 Fall '07 Spring '08 Sum '08 Fall '08 Spring '09 Sum '09 ED2 VPD1 Undergrad TTC Study Abroad Undergrad Graduation Semester! Full Time Fall 2004 - Fall 2006 Undergrad I. PURPOSE Reflect on VPD1 13G Co-op experience & summarize projects and skills gained II. STUDENT BACKGROUND INFORMATION College: University of Michigan Major/Minor: Mechanical Engineering / German Graduation Date: May, 2009 Co-op Term: VPD1 May 21st August 17th, 2007 Project: Support VPD1 team through 470L CV stage preparation and 579L AS evaluations III. OBJECTIVES Bring a high-energy positive attitude Apply classroom knowledge to projects Understand departmental responsiblilities and procedures Strengthen my desire to have a career in automotive design Deepen knowledge of vehicle development process Implement the Toyota Way in daily activities Gain engineering evaluation experience Support VPD1 Kino/Wiper team Daniel Sheline - TTC VPD1 Kino/Wiper Group IV. PROJECTS (Continued) Project Skills Attained 3. 4. Objective Method - Support VPD1- 3G engineers to reduce their workload -Made copies, illustrations drawings, sections, and benchmarked vehicles -Performed other miscellaneous tasks - Learned how to communicate with suppliers - Improved my knowledge of the functionality of the 180L tailgate. - Gained experience with vehicle hoist, air tools, wheel changing, scale measurements, force gage, and claymeasurements. Tundra Tailgate Hinge Counter- measure Description -Gained knowledge of ED1 parts General Document Management Experienced company administrative programs Cracked plastic Objective - Find and confirm counter measure for 180L tailgate issue. Evaluate counter measure ideas and determine an appropriate solution. Current 180L tailgate hinge resin ijiwaru over open condition at around 5 cycles. Counter measure ideas include shimming the hinge, putting a dimple on the edge, reversing the hinge part, baking the hinges to relieve stress, and all combinations of ideas listed. Plan - Cycle counter measure ideas until hinge cracks. Check the hinges every 25 cycles for cracks and deformation. Record the data from the hinge styles to determine which solution is best. Conclusion - Counter measure hasn't yet ben decided; however, the reverse made hinge with a dimple provides significant cycle increases with a minimal cost. 180L Hinge 180L Damper V. CONCLUSION & REFLECTIONS Ù Ù Ù Ù Ù Û Û Ù Deepen knowledge of VPD Gain engineering evaluation experience Bring a high-energy positive attitude Implemented the Toyota Way in daily activities Support VPD1 Kino/Wiper team Understand departmental responsiblilities and procedures Apply classroom knowledge to projects Strengthened my desire to have a career in automotive industry IV. PROJECTS Project Skills Atained 1 2 Description -Gained engineering evlauation experience Static Hood Closing Force -Improved data recording skills. -Learned the TS requirments of static hood closing force. -Learned the TS requirments of static back door closing force. -Increased knowledge of competitor cars -Improved Excel graph and chart skills. Static Back Door Closing Force WO LH, UP STPR RH, UP STPR LH, LWR STPR RH, LWR STPR Static Closing Force vs. Stopper Gap 0 100 200 300 400 500 600 -1.5 -1 -0.5 0 0.5 1 1.5 2 2.5 3 Gap (mm) ClosingForce(N) UPR Stopper LWR Stopper UPR+LWR Stopper Static hood Closing Force 142 182 216 230 390 445 483 524 547 556 610 642 662 667 701 722 390 483 0 100 200 300 400 500 600 700 800 Tribeca Highlander CX-7 CX-9 FX35 Avalon Matrix IS350 RDX RX350 GS450h MDX Escape Versa RAV4 Ridgeline Camry Edge StaticHood ClosingForce(N) Objective - Benchmark RX back door static closing force for 470L worst case tolerance conditions in a pre-CV evaluation. TS for static back door closing is 390N. Plan - Measure initial back door stopper closing gap and static closing force. Proceed to decrease stopper gap by placing 1.5mm thick washers over the stoppers and repeat static closing force measurements for stopper gap distances ranging from 3mm to -1.5mm. RX 400h Objective - Benchmark a varity of vehicles with emphasis on crossovers for use with the 470L project, as well as for general use with both TTC and TMC to determine the market trend for static hood closing forces. TS for static hood closing is 400N and a drop height of 200mm. Force AppliedPlan - Measure hood static closing force, closing drop height, hood latch height, number of rubber stoppers, and record whether the hood uses dampers or a prop rod to Conclusion - Most competitor cars and even some Toyota & Lexus cars have static hood closing forces above the TS. Cosumers in North America tend to dynamically close their hoods; therefore, the TS might be out of date with current consumer desires. > > > Nom Conclusion - 470L will require further study. The LWR stoppers have more contribution to static closing force than the upper stoppers. Ideally both stoppers would contribute the same amout. This problem could potentially be resolved by changing the rigidity of the upper stoppers to twice as much as the lower stoppers. Approved Approved Checked Prepared Date 8/17/2007 shelined@umich.edu