Optimal door fitting with systematic fixture adjustment

A systematic approach is presented to obtain the best door gap quality through optimal door fitting in automobile body manufacturing. First, three indexes of gap quality are defined; they are: (1) door gap width deviation relative to design nominal; (2) door gap parallelism; and (3) car-to-car gap consistency. Then the door-fitting problem is formulated into a general constrained optimization problem. The effects of optimal door fitting on the three quality indexes are evaluated through computer simulation. These results provide a lower bound on the design of nominal door gap by considering process capability. Finally, a computer-aided fixture adjustment scheme is developed to orient a door in a body side opening to achieve the optimal fitting. The amount of adjustment, with the desired orientation obtained from optimization, is calculated based on parametrically modeled local surface features of the fixture and the door. The adequacy of door feature modeling is verified through a door-fitting experiment.