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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
Engineering 470 Project
  • Redesign proposal for the 1999 Mercury Cougar (SW-164) exterior mirrors

By John Uken

“Introvert”

the 99 cougar ext mirror
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
Current Problems
  • Vertical force
    • Breakaway
    • Failure
  • Car wash test
    • Failure at Ford’s Belgium car wash
  • Assembly
    • 11 Screws
    • 5 Re-orientations
proposed redesign
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
Design Photographs

Electrical Components

design photographs6
Design Photographs

Current Housing Subassembly

design photographs7
Design Photographs

Current Base with Hinge, Hinge Plate and Screws

design photographs8
Design Photographs

Redesign Brackets with Current Actuator

design for assembly
Design for Assembly
  • Design for assembly (DFA) analysis
    • Current design
    • Redesign
conclusion
Conclusion
  • Design feasibility
    • Cost
    • Quality
  • Final decision based on:
    • Cost
    • Quality
    • Reputation
my personal conclusion
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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