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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

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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


Current problems l.jpg

Current Problems

  • Vertical force

    • Breakaway

    • Failure

  • Car wash test

    • Failure at Ford’s Belgium car wash

  • Assembly

    • 11 Screws

    • 5 Re-orientations


Proposed redesign l.jpg

Proposed Redesign

  • 1994 Ford Mondeo Mirror (European)

    • Robust dual pivot breakaway design

    • Diecast brackets

  • Redesign

    • Incorporate Mondeo- like brackets into current housing and base


Design photographs l.jpg

Design Photographs

Electrical Components


Design photographs6 l.jpg

Design Photographs

Current Housing Subassembly


Design photographs7 l.jpg

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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