Engineering 470 Project

1
Engineering 470 Project

• Redesign proposal for the 1999 Mercury Cougar
  (SW-164) exterior mirrors

By John Uken
Introvert
2
The 99 Cougar Ext. Mirror

• North American and European designs
• RHD and LHD
• Convex glass
• Heated mirror glass
• Breakaway design
• Dual pivot
• Spring-loaded

3
Current Problems

• Vertical force
• Breakaway
• Failure

• Car wash test
• Failure at Fords Belgium car wash
• Assembly
• 11 Screws
• 5 Re-orientations

4
Proposed Redesign

• 1994 Ford Mondeo Mirror (European)
• Robust dual pivot breakaway design
• Diecast brackets

• Redesign
• Incorporate Mondeo- like brackets into current
  housing and base

5
Design Photographs
Electrical Components
6
Design Photographs

• Current Housing Subassembly

7
Design Photographs

• Current Base with Hinge, Hinge Plate and Screws

8
Design Photographs

• Redesign Brackets with Current Actuator

9
Design for Assembly

• Design for assembly (DFA) analysis
• Current design
• Redesign

10
Conclusion

• Design feasibility
• Cost
• Quality
• Final decision based on
• Cost
• Quality
• Reputation

11
My Personal Conclusion

• Proceed with redesign
• Save reputation with Ford
• Encourage further business
• Improve current relationship
• Produce only quality parts
• Reduce warranty costs
• A product you can be proud of