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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 l.jpg
Engineering 470 Project

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

By John Uken

“Introvert”


The 99 cougar ext mirror l.jpg
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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Current Problems

  • Vertical force

    • Breakaway

    • Failure

  • Car wash test

    • Failure at Ford’s Belgium car wash

  • Assembly

    • 11 Screws

    • 5 Re-orientations


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Proposed Redesign

  • 1994 Ford Mondeo Mirror (European)

    • Robust dual pivot breakaway design

    • Diecast brackets

  • Redesign

    • Incorporate Mondeo- like brackets into current housing and base


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Design Photographs

Electrical Components


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Design Photographs

Current Housing Subassembly


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Design Photographs

Current Base with Hinge, Hinge Plate and Screws


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Design Photographs

Redesign Brackets with Current Actuator


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Design for Assembly

  • Design for assembly (DFA) analysis

    • Current design

    • Redesign


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Conclusion

  • Design feasibility

    • Cost

    • Quality

  • Final decision based on:

    • Cost

    • Quality

    • Reputation


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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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