Edison2 Door Handle Competition

10 entries

  • 1st

    $2500.00

  • 2nd

    $2000.00

  • 3rd

    $1500.00

Entries
Challenge Brief
Requirements
Discussion

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About the VLC (Very Light Car)

Edison2 won the top prize ($5 million) in the 2010 Progressive Insurance Automotive X PRIZE with the Very Light Car, a vehicle with an unprecedented combination of light weight and low aerodynamic drag. Weighing 830 lbs and with a drag coefficient of 0.160 ? lowest ever recorded at the GM Aero Lab ? the VLC recorded 110 MPGe (combined cycle) and  129 MPGe (highway) at the X Prize, using a 250 cc internal combustion engine.

 

Since winning the X PRIZE, Edison2 has been working in their Lynchburg, Virginia facility on a stunning new version of the Very Light Car (VLC). Although the next generation VLC uses the same architecture and virtues of efficiency that won Edison2 the X Prize, it is a completely new vehicle. It is designed to be capable of meeting regulatory requirements, and will have production-car fit-and-finish, safety, comfort and handling.

About Edison2

Edison2 is a young, energetic company mapping the boundaries of what is possible with high efficiency, low environmental impact vehicles. Early versions of our Very Light CarTM won the Automotive X Prize and have demonstrated world record energy mileage and emissions numbers on the road and in the lab. As we move towards making cars built to our principles available to buy, Edison2 remains true to the absolute virtues of light weight and low drag. We?re hoping like-minded people can use Solid Edge to help us with the myriad details that go into making the VLC truly the car of the future.

The Challenge

Because of its advanced, streamlined shape, the VLC requires an uncommon door design which opens first out, then swings up. The door will be counterbalanced but will not have power assist.
We would like you to design a door handle which allows the driver to easily open and swing up the door prior to ingress and to swing down and close the door after egress. An example of this motion can be seen in the following video:

Thus, the handle must be rigid to pull and lift to open the door, and to lower the door and push it closed. It also wants to do this while being as light and aerodynamic as possible. Lastly, the door handle you design must operate a 2010 Honda Civic door latch.

2010 Honda Civic Door Latch

The 2010 Honda Civic latch in the above photo has 2 cables running forwards. These interface with the interior door handle. One of the cables releases the latch while the second operates the lock.

The shorter cable on the left side of the photo operates the lock from the exterior.

In the case of this Challenge, your Handle design needs to interface with an arm on the back side of this housing that will release the latch. An image of the arm is shown below:

2012 Honda Civic Door Latch - Latch arm on the back of the latch housing

The arm is 35mm in length measured from the pivot axis to the center of the attachment hole. The total angular displacement of the arm is 36 degrees stop to stop. The latch releases after the arm rotates approximately 20 degrees. Photos below show the latch at its resting position and at full travel:

2010 Honda Civic door latch - Latch at resting position
2010 Honda Civic door latch - latch at full travel

The picture on the left shows the arm in its resting position, and the photo on the right shows the arm at its full travel. The door handle must be designed in such a way that the lever arm will function in its intended range of motion, thus releasing the latch. A solid linkage, cable, or other creative solutions can be used to translate the motion from the handle to the latch.

Image of the Edison2

To summarize, your door handle and mechanism should be designed such that:

  • The external part(s) minimally disturb the air
  • The design of the handle fits with the rest of the vehicle?s aesthetics
  • The mechanism is designed to be as light weight as possible
  • The design must be able to functionally release the door latch and interface with an interior door handle

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Requirements

Door handle mechanism must interface properly with door latch1LM1Door handle must be designed for use by human hands1LM1Door handle must be design such that airflow stays attached on the afterbody1LM1The door handle mechanism, excluding the latch, must not weigh over 1 pound

Guidelines

Designs will be evaluated on how well they comply with the following weighted attributes. Consider the level of importance for each category to be on a scale of 1-10, with 10 being the most critical.1LM1 Manufacturability61LM1 Aesthetics5 1LM1 Aerodynamic performance101LM1 Weight81LM1 Functionality/user interface71LM1 Cost41LM1 Simplicity51LM1 Elegance9

Deliverable Views

Additional Deliverables
Must be a Solid Edge Part or Assembly1LM1All generic fasteners should be specified1LM1Any Engineering drawings appropriate
Challenge Terms and Conditions
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