03-0132 (7161-f1-door e weatherstrip cycle

PININFARINASPERIMENTAZIONE

VEHICLE OFFICE

TEST REPORT n° 03-0132 /9

SPEC. TITLE

Weatherstrip durability Date: 23-01-2004

SPEC. N°9.B.30.11.EN FINAL TEST RESULT

POS [ ]

Ref. Order: 30469Test period from 20-11-03 to 07-01-04

NEG [ ]

Ref. Test Lab 08.HF3.03 TRIAL TEST [ X ]

To:F. GribaudoM. Criveller

c.c: L. Minelli

Vehicle: HF3 Engine type: N/A

Mule [ ] Prototype [ X ] Preproduction [ ] Production [ ] Others [ ] VIN : Body 3.1

Component: Side doors system

Drw. n°:B10021_2B11021_2

Supplier: Pininfarina

CONCLUSION:

During the test has been highlighted the following main issues:

1. Excessive weatherstrip abrasion2. External door skin break at handle fixation points3. Internal door bracket at handle fixation point, break of door structure

Considering point No.3, despite the door design forecasts the internal handle bracket (Picture No.11) made by plastic and welded to the inner door panel, it is strongly suggested an improvement to the door panel. In fact is hardly to expect the same rupture on door body, but on the contrary, it is foreseeable a fatigue rupture on inner panel plastic parts in next phase.An improvement on door body is also suggested on external door skin at external door handle fixation point.Operational effort (door handle) decrease of about 30% from their original value, but anyway, seems to be too high compared to the normal customer expectation value.Gap and flushness value are out from their nominal values, but non significant variation during test have been noticed.

No hot and cold test cycles has been performed in this prototype phase due to material used were at an earlier prototype develop stage.

For more detail on complete endurance test, refer to test description paragraph.

P.E. : M. Sapienza T.M. : F. Quinci

Attachments: Y [ x ] N [ ] Total attached: 2

Remarks:None

Spec. Variation: Y [ ] N [ x ]

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Rapporto di prova n° 03-0132 Pag.3/9

Summary / Test description

Here below the complete test history:

No. ofcycle

Observation Cause Immediate actionPic.No.

Set-up Difficulties in external door handle opening Bad striker set-up Front door striker set-up

1250

1.Start of rear door upper corner weatherstrip abrasion a certain amount of powder is visible on B-pillar2. Minor seal abrasion is visible also on door contour seal on right upper corner

Abrasion due to contact with front door seal

Fatigue abrasion due to door closing operation

None. Worsening monitoring

None. Worsening monitoring

2

3

3000Front and Rear door: Door contour seal installed on door, start of abrasion A certain amount of materials is present on B-pillar

Fatigue abrasion due to door closing operation

None. Worsening monitoring 4

4600 Light increasing of previously detected issues

8120

Front door: Partial break-up of inner door panel. Weatherstrip cut on rear view mirror areaRear door: door contour weatherstrip cut on latch area

Prototype part. Material not representativeFatigue abrasionFatigue abrasion

Eliminated portion of crack inner panelNoneNone

5

67

24120

Front door: inner door panel completely brokenStart of metal part cut on ext door handle frontward fixationRear door: worsening of weatherstip abrasion

Fatigue crack. Prototype part

Fatigue crack due to open/close operation

Broke parts removed

Bolt re-torque 8

28611Break of external door handle rear fixation. Fatigue crack Replaced of failed handle and

repair of door external skin9

36330Rear door: weatherstrip worsening of previously detected abrasion both on door and body weatherstip

Fatigue abrasion due to contact between door and body weatherstrip

None 10

44000 Rear door: break of inner panel Prototype panel, no significant None

45000Front door: torn of door body at internal handle bracket fixing point

Bracket not in design material none 11

End test Status unchanged

Preparation / Test Condition

Test purpose:

The purpose of this cycling test is to verify the endurance requirements on complete sides door, roof rail and related weatherstrip.

Test target:

The test target is to reach 50.000 front/rear door test cycles complying the following requirements:

- The door system must remain functional and no fatigue crack or function deterioration are acceptable

- No abrasive wear through the weatherstrip section are admitted.- Fit & finish test object specification must be fulfilled- Opening & closing efforts must withstand within specific requirement- No squeak & rattle after completion of test requirement

Test object:

The test has been performed on prototype vehicle developing phase 1 VIN number 3.1. This vehicle has been prepared with the following items in order to perform RHS door durability only (front and rear):

- Inner and outer waist seal- Rear view mirror corner seal- Door contour seal- B-pillar seal- Complete door internal trim (panel and window regulator)

Test set-up:

The vehicle has been prepared to carry out the test in automatic way on RHS door only (front and rear doors). Opening step has been achieved by connecting an hydraulic cylinder to the door external handle

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through a proper length dimensioned rope. Opening door has been set-up until 2nd tie rod stop. The pause time has been set-up in order to limited the rebounding at the end of opening cycles.A spring has been connected to the opposite door handle, inside vehicle, in order to obtain the door closing via internal handle (much more closed to customer operation).

Margin and flushness have been set-up in order to fit design objectives (refer to set-up picture for reference).The opening and closing system has been duplicated on rear side door. A PLC system drives two door cylinders.

The following environmental test profile has been adopted:- 45000 cycles at room temperature- 3000 cycles at +70 °C- 2000 cycles at -30 °C

Test results

During the durability test, the following parameters have been monitored:- Fit & finish data- Opening / closing effort and latch load

Gap & Flushness measurement

Refer to picture ‘set-up’ at pag.3 for point reference.

No. ofcycles

1 2 3 4 5 6 7

Gap Flush Gap Flush Gap Flush Gap Flush Gap Flush Gap Flush Gap Flush

Target

4.5 +0.4/-

0.6

4.5 +0.4/-

0.6

4.5 +0.4/-

0.6

4.5 +0.4/-

0.6

4.5 +0.4/-

0.6

4.5 +0.4/-

0.6

4.5 +0.4/-

0.6

0 2.5 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.7 +3.2 6.5 -0.75 5.6 0.952500 2.5 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.955000 2.5 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.957500 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9510000 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9512500 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9515000 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9517500 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9520000 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9522500 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9525000 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9527500 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9530000 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9532500 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9535000 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9537500 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9540000 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9542500 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.9545000 2.6 -0.6 2.8 +0.4 5.2 +0.5 3.4 -0.1 5.8 +3.2 6.5 -0.75 5.6 0.95

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Opening / closing effort and latch load

No,Of

Cycle

External handle

opening effort [N]

Static latch load effort [N]

Front Rear Front RearPF Target <=50 <=50

0 130 130 305 2502500 130 120 310 2305000 130 130 300 2507500 120 130 300 240

10000 120 120 320 26012500 119 100 320 24015000 / 100 310 21017500 120 100 300 21020000 80 85 300 29022500 85 85 290 23025000 85 85 290 23027500 85 85 290 23030000 80 85 280 20032500 90 85 290 23035000 85 85 290 23037500 95 85 290 23040000 85 80 270 23042500 85 85 290 23045000 95 100 290 230

Attachments

Attachment A: Spec variation detailsAttachment B: Test pictures

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Attachment A

Spec variation details

1. The test has been performed on RHS only2. No cycles in climatic chamber have been done. The test comprises 45.000 test cycles only.

Attachment B

Test Pictures

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1

2

3

4

5

6

7

Picture No.1 – Test set-up

Picture No.2 – 1250 cyclesRear door weatherstip abrasion


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Picture No.3 – 1250 cyclesRear door contour seal

Picture No.4 – 3000 cyclesDoor contour weaterstrip abrasion

Picture No.5 – 8120 cyclesFront door inner panel crack


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Picture No.6 – 8120 cyclesFront door weaterstrip abrasion

Picture No.7 – 8120 cyclesRear door weaterstrip abrasion

Picture No.8 – 24120 cyclesFront door external skin damage

Picture No.9 – 28611 cyclesFront door external handle damage


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Picture No.10 – 36330 cyclesRear door weatherstrip abrasion

Picture No.11 – 45000 cyclesFront door int. handle bracket break

03-0132 (7161-f1-door e weatherstrip cycle

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