1. Hydraulic Pump Design for Coupe Door System Michigan State University Group Member Faculty Advisor Chris Lowe Dr. Farhang Pourboghrat Jeff Mann Fai Leung Doo-hwan Kim Sponsor (GM) Sponsor (GM) James Karlavage James Karlavage Problem Statement To develop a working concept for a side closures system hold open device, capable of infinite adjustment.To develop a working concept for a side closures system hold open device, capable of infinite adjustment. In essence, the objective is to create a universal door opener that will allow a car door to stay in whatever position the customer opens it to and then release when pushed/pulled closedIn essence, the objective is to create a universal door opener that will allow a car door to stay in whatever position the customer opens it to and then release when pushed/pulled closed The housing must not exceed 80mm X 40mmThe housing must not exceed 80mm X 40mm The mechanism should be capable of applying approximately 40Nm of “hold open” torque to hold the door openThe mechanism should be capable of applying approximately 40Nm of “hold open” torque to hold the door open Hydraulic Pump Concept Hydraulic Pump Concept Simple Hydraulic Pump System with a stationary piston and moving cylinder linked to two fluid passage pipes (one for the opening of the door and the other for closing) and two one-way valves.Simple Hydraulic Pump System with a stationary piston and moving cylinder linked to two fluid passage pipes (one for the opening of the door and the other for closing) and two one-way valves. Piston Stem is fixed to vehicle and the cylinder is attached to the inner door.Piston Stem is fixed to vehicle and the cylinder is attached to the inner door. Cylinder and passage pipes are completely filled with hydraulic fluid.Cylinder and passage pipes are completely filled with hydraulic fluid. As door opens, cylinder moves away from the vehicle allowing the piston head to push fluid backward through the opening passage pipe and vise-versa for door closing.As door opens, cylinder moves away from the vehicle allowing the piston head to push fluid backward through the opening passage pipe and vise-versa for door closing. Design is functional and satisfactory based on the constraints and objective of the projectDesign is functional and satisfactory based on the constraints and objective of the project Modeling of the “Hydraulic Pump Concept”  PISTON ● Piston heads Travels 132.7mm from fully open to fully closed from fully open to fully closed ● Piston Stem is fixed to vehicle interior ● Provides the Driving Force of the Fluid Flow due to an Applied Input Force Flow due to an Applied Input Force ● Ball bearings permit relatively smooth travel of the piston within the cylinder travel of the piston within the cylinder The relative movement of the piston head resembles the direction of door motion. Compressive Motion corresponds to a door closing direction and Tensional Motion corresponds to a door opening direction. ● The relative movement of the piston head resembles the direction of door motion. Compressive Motion corresponds to a door closing direction and Tensional Motion corresponds to a door opening direction.  CYLINDER ● Length is 150mm, Diameter is 40mm ● Grounded to inner portion of the door ● Piston Head is positioned and is translated axially within cylinder. ● Regulates the distance of Piston travel  HYDRAULIC FLUID ● Dot 3 Breaking Fluid ▪ Relatively high boiling point ▪ Relatively low freezing point ▪ Fluid is very Incompressible  OPENING/CLOSING PASSAGE ● Closing Passage will have twice the cross sectional-area of the Opening ● Radius of closing passage will be 1.414 times (square root of 2) larger than the Opening  PRESSURE VALVES ● Each Passage will have 1 one-way pressure valve attached to entering end ● The closing passage will have a pressure reducing one-way valve Assembled Hydraulic Pump design Alternative Hydraulic Pump design Conclusion Conclusion It would be the best idea to implement the alternative hydraulic pump design because it is just as efficient as the original pump design and it better fits within the special constraints of the current GM vehicle models. Although the price of implementing the alternative design seems steep (at $10M the first year and $5M for the years after), these types of prices are minuscule to a prosperous company like GM. Implementing such a concept that allows infinite door positions while applying insignificant force increases customer satisfaction and decreases door opening related accidents. Thus, overall, this will attract more customers to purchase GM vehicles: and in the end, we believe that GM will make a huge profit off sales in comparison to what they would pay to manufacture the pump units. Schematic of Current Door System (Top view) Results Fluid Leakage Problems are Plausible Most likely would occur at the mating and bonding sections Issue: Decreases the efficiency and proficiency Solution: Add O-ring seals and silicone sealants to affected areas Infinite Stop Positions Between Fully Open and Fully Close Equivalent Fluid Pressure on both sides of the Piston Head when applied force is ceased. More Force needed to Open than to Close Using a one-way pressure reducing valve for the closing compressive direction with a greater diameter than the one-way valve for the opening tensional direction should resolve this issue due to the Theory of Least Resistance.