Door closing velocity optimization plays a critical role in enhancing vehicle comfort, perceived quality, and safety compliance. This case study explores how our engineering team leveraged CAE simulation and design optimization to achieve a 22.8% reduction in door closing speed — delivering a smoother, more ergonomic vehicle experience.
The Challenge
The original door panel design exhibited an excessively high door closing velocity, averaging 1.2 m/s. This created a hard-shut feel, reducing user comfort and negatively impacting perceived vehicle quality. High closing velocity also posed challenges in meeting ergonomic and safety standards, making optimization essential for both customer satisfaction and compliance.
Our Objective
The project aimed to optimize the door panel design by reducing the average door closing velocity from 1.2 m/s to the industry benchmark range of 0.79 m/s to 1.03 m/s. Achieving this target would improve the user experience, enhance perceived build quality, and ensure compliance with ergonomic and safety guidelines. Key parameters influencing door closing velocity included door latch performance, friction at the hinge, check arm profile, weather-strip behavior, hinge axis inclination, door weight and center of gravity (CG), and cabin pressure effects.
Our Solution
The optimization process began with a comprehensive analysis of the parameters affecting door closing velocity, using both CAD data and physical test results. Literature on door closing performance was reviewed to establish a knowledge base, followed by the development of precise mathematical models (FEA) for each parameter. These models were validated through CAE simulations to ensure accuracy and predictability.
Simulation results were benchmarked against physical test data, leading to multiple design iterations focused on adjusting hinge axis angles, modifying sealing type, and reducing latching force. Each iteration’s performance was tracked in terms of forward/rearward and inward/outward hinge angles, total door closing energy, secondary seal type, and the resulting average closing velocity. Over four iterations, the design progressed from 1.20 m/s to a final optimized value of 0.926 m/s.
The Outcome
The final design achieved a 22.8% reduction in door closing velocity, with the optimized 0.926 m/s falling well within the benchmark range. This represented a 0.274 m/s improvement over the original configuration. Testing confirmed that hinge axis optimization and seal type modification provided the most significant gains, highlighting their critical role in improving door performance. The result was a door system with smoother closing action, enhanced vehicle comfort, improved build quality perception, and compliance with industry safety and ergonomic standards.
