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Engineering 470 Project

Engineering 470 Project. Redesign proposal for the 1999 Mercury Cougar (SW-164) exterior mirrors. By John Uken. “Introvert”. The ‘99 Cougar Ext. Mirror. North American and European designs RHD and LHD Convex glass Heated mirror glass Breakaway design Dual pivot Spring-loaded.

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Engineering 470 Project

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  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 Ford’s 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

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