Door hem length measurement tool

A device for measuring a flange in a creased sheet of metal is provided, along with a method of use thereof. The device includes a block including at least two slots and a body extending from the block in a first direction. The device also includes at least two retractable teeth. Each tooth is mounted in a respective one of the at least two slots. Each tooth is biased toward the first direction and retractable in a second direction opposite the first direction. A foot is mounted to an end of the body and includes a groove configured to receive an edge of the sheet of metal. A free edge of the flange is received in the groove and a creased edge is retained by the teeth. The flange may be measured by inserting a depth gauge through the block to a surface of the sheet of metal.

BACKGROUND

A vehicle door typically includes a structural member, a door skin, and a molding. The door skin is a finished sheet of metal that provides the outside surface of the door. Typically, an edge of the door skin is folded back on itself to form a flange. The molding is used to cover the flange and present an ornamental surface (e.g., chrome). Seals and wipers may also be attached to the molding to contact a door window.

During design and manufacture of a vehicle, the dimensions of the flange may need to be adjusted in order to properly contact and mount the molding. For example, the flange may be trimmed to ensure a proper fit of the molding. The inventors of the present application have discovered that a useful measurement of the flange is a dimension between a free edge of the flange and an exterior surface of the door skin. This measurement ensures, among other things, that the exterior surface of the door skin meets manufacturing specifications and proper fit of the molding. This dimension is difficult to measure because the door skin and the flange itself obstruct standard tools (e.g., calipers or micrometers).

In practice, the flange may be measured by using putty to make a mold of the flange. A cross-section of the mold may then be measured to determine the dimension between the free edge of the flange and the exterior surface of the door skin. This process may be time consuming due to the length of time it takes for the putty to harden. A “Go/No-Go” tool may also be used to verify that the dimensions of a flange are acceptable. Such tools, however, must be unique for each flange design and do not provide a measurement that can be used to make corrections because they only provide a correct/incorrect output.

In view of the foregoing, there is a need for a measurement device for measuring a flange formed by a crease in a sheet of metal. Further advantages will become apparent from the disclosure provided below.

SUMMARY

According to one aspect of the present disclosure, an apparatus for measuring a flange in a creased sheet of metal includes a block including at least two slots. A body extends from the block in a first direction. The apparatus includes at least two retractable teeth. Each tooth is mounted in a respective one of the at least two slots. Each tooth is biased toward the first direction and retractable in a second direction opposite the first direction. A foot is mounted to an end of the body and including a groove configured to receive an edge of the sheet of metal.

In another aspect, the disclosure provides a method of measuring a flange in a creased sheet of metal. The method may include inserting a free edge of the flange into a groove in a foot of a measuring device. The method may include retracting teeth of the measuring device into a block. The method may include inserting a creased edge of the flange into a space between the groove and the block. The method may include retaining the creased edge of the flange in the space with the teeth. The method may include measuring the flange with a depth gauge inserted through the block to contact the sheet of metal at a measurement point.

DETAILED DESCRIPTION

The following includes definitions of selected terms employed herein. The definitions include various examples and/or forms of components that fall within the scope of a term and that may be used for implementation. The examples are not intended to be limiting.

A “vehicle,” as used herein, refers to any moving vehicle that may be capable of carrying one or more human occupants and is powered by any form of energy. The term “vehicle” includes, but is not limited to: cars, trucks, vans, minivans, SUVs, motorcycles, scooters, boats, personal watercraft, and aircraft. In some cases, a motor vehicle includes one or more engines.

Generally described, the present disclosure provides a tool for measuring a flange formed on a creased sheet of metal such as a door skin. The flange may, for example, provide for alignment with other parts such as a structural door member or decorative molding. Accurate measurement of the flange ensures that the metal part meets manufacturing specifications and that the metal part integrates with other parts.

The tool includes a block portion having retractable teeth, a body portion, and a foot portion. The tool clamps onto the flange with a free end of the flange engaged with a groove on the foot portion. The retractable teeth retain the flange against the body portion to prevent the tool from rotating about the flange. The block portion includes a through passage that allows for insertion and alignment of a depth gauge. The foot portion may be pivoted to allow zeroing the depth gauge with respect to the groove. Accordingly, the tool allows for a measurement of a distance from the free end of the flange to an external surface of the door skin. The tool may be used to measure similar flanges in other sheet metal parts such as body panels.

Turning toFIG. 1, a perspective view of a vehicle door100shows a door skin110and a structural member130. The door skin110is a sheet of metal that forms an outer surface of the door. The door skin110may include openings114for a door handle. A window (not shown) may be mounted between the door skin110and the structural member130. The door skin110may be formed, for example, by stamping a metal sheet into a desired shape. A top edge of the door skin110may include a flange120. The flange120may be formed along the edge of the door skin110by bending and creasing an edge portion. A molding134may cover the flange120and include an ornamental surface. The molding134may also include a wiper132that contacts the window and a seal140that contacts an outer surface of the door skin110. The molding134may be mounted to the flange via a molding clip136. In the exemplary embodiment, the molding clip136includes a top portion142and a bottom portion144.

FIG. 2illustrates a cross-sectional view of the door100near the flange120. The flange120may be formed on the door skin110by bending the metal sheet back upon itself and forming a crease. Accordingly, the flange120may include a creased edge122(interchangeably referred to herein as a hemmed edge) where the metal sheet is creased. The creased edge122may attach to the top portion142of the molding clip136. The flange120may also include a free edge124where the metal sheet ends. The free edge124may attach to the bottom portion144of the molding clip136. The bottom portion144of the molding clip136may include a tooth138that retains the free edge124. Additionally, the flange120may be oriented at an angle to an outer surface126of the door skin110. The molding134may include a seal140that contacts the outer surface126.

In order to properly retain the door skin110in relation to the molding clip136, the flange120may have a critical dimension D between the free edge124and the outer surface126. In an aspect, the critical dimension D may be measured at a distance G from the flange120. In an aspect, the distance G may indicate the location of the seal140. The distance G may be specified for a particular vehicle model based on the curvature of the door skin110. If the dimension D is too small, the door skin may be inadvertently pulled over the tooth138. If the dimension D is too large, the molding134may contact the outer surface126and the molding134may not seat properly. Accordingly, it is desirable to ensure that the dimension D is within manufacturing tolerances for a particular vehicle. It may also be possible to design or select a molding clip136based on a measurement of the flange120. Accordingly, it may be desirable to have a precise and accurate measurement of the dimension D. As an example, door skins may have flanges with a flange length of between approximately 10 mm and 20 mm. The dimension D may be approximately 3 mm to 4 mm and may have a tolerance of approximately 0.5 mm. The distance G may be between approximately 2 mm and 10 mm It should be appreciated that door skins may be designed with different sized flanges and tolerances, but it may still be useful to obtain an accurate measurement of the flange120during manufacturing.

The present disclosure provides a tool and method for measuring the dimension D of a sheet of metal having a folded flange. Although the various exemplary embodiments may refer to a door skin, it should be appreciated that other vehicle components as well as other construction and manufacturing applications are conceived. For example, sheet metal with flanges may be used for other vehicle panels, building interior or exterior surfaces, fixtures, or appliances.

FIGS. 3-7illustrate various views of an example of a measuring device300.FIG. 3is a perspective view showing the device300in a calibration position.FIG. 4is a top view of the device300.FIG. 5is a back view of the device300.FIG. 6is a side view of the device300.FIG. 7is an exploded view of the device300. The device300may include a block portion310, retractable teeth320and321, a body portion330, and a foot portion340. The retractable teeth320,321and the body portion330may extend downward from the block portion310toward the foot portion340. The foot portion340may be mounted to the body portion330and extend forward from the body portion330. Generally, the flange120may be inserted into a space between the foot portion340and the block portion310against the body portion330for measuring the dimension D. The retractable teeth320,321may retain the flange120against the body portion330to provide a consistent measurement.

The block portion310may be a rectangular prism, although other shapes are possible. The block portion310may include an passage312extending through the block portion310from a top surface318to a bottom surface319. As best seen inFIG. 4, the passage312may include a shoulder316. That is, the passage312may have a first diameter above the shoulder316and a second diameter below the shoulder316. As described in further detail below, a depth gauge may be inserted through the passage312. The shoulder316may serve as a stop for the depth gauge. The first diameter may be selected to accommodate a body of the depth gauge and align the depth gauge with the passage312. The second diameter may allow a measurement rod of the depth gauge to pass through the passage312. The block portion310may also include slots314. For example, the block portion310may include at least two slots314located at opposite sides of the block portion310. The slots314may house the retractable teeth320and321, which may retract into the respective slot314.

The retractable teeth320,321may retain the flange120against the body portion330. By using at least two retractable teeth320,321that are spaced apart from each other, the measuring device300may be positioned on the flange120without tilting. The retractable teeth320,321may be located in the slots314and may be retained by the fasteners322, which may be, for example, threaded bolts. As best seen inFIG. 7, the retractable teeth320,321may each include a fixed portion326and a movable portion324. The fixed portion326may include an opening for receiving the fastener322to fix the fixed portion326within the slot314. The fixed portion326may also include a projection for attaching a biasing device, for example, a spring350or351. The movable portion324may include a similar projection for attaching the spring350,351. Accordingly, the movable portion324of the retractable teeth320,321may be biased downward (e.g., by a respective spring350,351). In an aspect, the retractable teeth320,321may each include an angled surface328that contacts the creased edge122. The angled surface328may slope downward and away from the block portion310from back to front. Accordingly, the angled surface328may urge the creased edge122back toward the body portion330as the retractable teeth320,321are biased downward.

The body portion330extends downward from the block portion310. In an aspect, the body portion330is a separate component that is mounted to the block portion310via fasteners332, which may be threaded bolts. In an aspect, the body portion330may be movable with respect to the block portion310in order to adjust the distance G where the measurement is made. For example, the fasteners332may be adjusted to move the body portion330with respect to the block portion310in a direction transverse to an axis of the passage312. For example, the body portion330may move perpendicular to the axis of the passage312. In another aspect, a shim may be inserted between the body portion330and the block portion310to obtain the desired distance G for the measurement. In another aspect, the body portion330may be integrally formed with the block portion310and the distance G may be fixed for the device300. Additionally, the body portion330may include a magnet334. The magnet334may help retain the device300on the flange120.

The foot portion340may receive the free edge124of the flange120during a measurement process. The foot portion340may include a groove342extending the length of the foot portion340. During a measurement, the free edge124may be placed in the groove342to align the door skin110with the passage312. The groove342may be aligned with a surface of the body portion330such that the flange120rests flat against the surface of the body portion330. The magnet334may help position the flange120within the groove342in case the groove342is wider than a thickness of the free edge124. The foot portion340may also include a calibration surface344. The calibration surface344may be a recessed area having the same depth as the groove342. Accordingly, although a depth gauge may not fit within the groove342, the calibration surface344may be used to calibrate (e.g., zero) the depth gauge to the bottom of the groove342.

In an aspect, the foot portion340may be pivotably mounted to the body portion330. The foot portion340may include a washer346extending upward from the foot portion340. The body portion330may include an opening336for receiving the washer346and/or a fastener348(e.g., a bolt) for pivotably mounting the foot portion340to the body portion330. The foot portion340may pivot from a measurement position where the groove342is aligned with a surface of the body portion330to a calibration portion where the calibration surface344is aligned with the passage312. The body portion330may also include a stop338extending downward from the body portion330. As best seen inFIG. 9, the stop338may prevent pivoting the foot portion340past the measurement position. For example, the stop338may align the groove342with the surface of the body portion330when the foot portion340contacts the stop338. The stop338may be angled to urge the foot portion340upward when the foot portion340is in the measurement position.

FIG. 8illustrates an example of an assembled retractable tooth320removed from the device300. The retractable tooth321may be assembled in a similar manner as the retractable tooth320. As discussed above, the retractable tooth320may include a movable portion324, a fixed portion326, and a spring350. The fixed portion326may be fixed within the slots314by the fastener322, which may be retained by the nut352. The fixed portion326may have dimensions slightly smaller than the slot314to prevent movement within the slot314. The spring350may be a coil spring, pneumatic cylinder, or other compressible resilient member. In an aspect, the spring350may couple the movable portion324to the fixed portion326. The movable portion324may include a tooth portion354that extends from the slot314when the spring350is not compressed and an alignment portion356that generally remains within the slot314. The alignment portion356may have dimensions slightly smaller than the slot314to allow sliding within the slot314, but prevent rotation. Accordingly, the movable portion324may be retractably retained within the slot314.

FIG. 9is a cross-sectional view showing the device300in engagement with the flange120. As illustrated, the foot portion340is in the measurement position. The flange120may rest flush against the body portion330. The free edge124is positioned within the groove342. The tooth321may urge the creased edge122against the body portion330, and the tooth321may urge the creased edge122against the body portion330on an opposite side of the device300. An axis of the passage312may be aligned with the outer surface126. In an aspect, the passage312may be aligned with the outer surface126at the distance G from the flange120. A depth gauge may be inserted through the passage312until the body of the depth gauge contacts the shoulder316. Accordingly, the depth gauge may be used to measure the dimension D between the outer surface126and the free edge124.

FIGS. 10-13illustrate various views of another example of a measuring device400.FIG. 10is a perspective view showing the device400.FIG. 11is a top view of the device400.FIG. 12is a back view of the device400.FIG. 13is a side view of the device400. The device400may include the same general components as the device300. For example, the device400include a block portion410, retractable teeth420and421, a body portion430, and a foot portion440that are similar to the corresponding components of the measuring device300. In an aspect, the block portion410, body portion430, and foot portion440of the device400may be integrally formed (e.g., via additive manufacturing or molding). The retractable teeth420,421may be constructed and operated in the same manner as retractable teeth320,321.

The device400may include a first passage460and a second passage462through the block portion410. Each passage460,462may include a corresponding shoulder461,463located at the same depth for contacting a depth gauge. The first passage460may also extend through the body portion430to a calibration surface444. The calibration surface444may be at the same depth as the groove442. The calibration surface444may be viewed through a window466in the body portion430. The first passage460may be used to calibrate a depth gauge by zeroing the depth gauge to the depth of the groove442. The depth gauge may be viewed through the window466to ensure contact with the calibration surface444. The second passage462may aligned with the outer surface126of the door skin110at the distance G from the flange120. A depth gauge may be inserted through the second passage462until the body of the depth gauge contacts the shoulder463and the tip of the depth gauge contacts the outer surface126. Accordingly, the depth gauge may be used with device400to measure the dimension D between the outer surface126and the free edge124. In an aspect, the measurement device400may include markings468indicating a correct measurement and tolerance for the dimension D.

FIG. 14illustrates a flowchart showing an example of a method500for measuring a flange in a sheet of creased metal according to an aspect of the disclosure. The method500may be performed using the measuring device300or the measuring device400. For example, the method500may be used to measure the flange120of the door skin110using the measuring device300or the measuring device400. Optional blocks are shown with dashed lines.

In block510, the method500may optionally include adjusting a distance from the flange of a measurement point. In an aspect, for example, the user may adjust the distance G from the flange120to the measurement point on the outer surface126. For example, the distance G may be based on a designed or specified distance for a part. The measurement point may be adjusted on the measuring device300by adjusting (e.g., loosening or tightening the fasteners332. A shim may also be inserted between the block portion310and the body portion330to adjust the distance G.

In block520, the method500may optionally include pivoting a foot of a measuring device to align a recessed area with a depth gauge. In an aspect, for example, a user may pivot the foot portion340of the device300to align the calibration surface344with a depth gauge. For example, the depth gauge may be inserted into the passage312and aligned with the axis of the passage312. The foot portion340may be pivoted to the calibration position. The foot portion340may be pivoted approximately90degrees such that the foot portion340extends transverse to the body portion330and the calibration surface344is aligned with the axis of the passage312.

In block530, the method500may optionally include zeroing the depth gauge with the depth gauge contacting the recessed area. In an aspect, for example, the user may zero the depth gauge while the depth gauge contacts the calibration surface344or the calibration surface444. Using the measuring device300, the user may insert the depth gauge though the passage312while the foot portion340is pivoted to the calibration position. Using the measuring device300, the user may insert the depth gauge through the first passage360to the calibration surface344. The user may zero the depth gauge, for example, on a digital depth gauge, by pressing a button. For an analog depth gauge, the user may take a reading. The calibration surface344,444may have the same depth as the groove342,442. Accordingly, zeroing the depth gauge based on the calibration surface344,444may set the depth to the depth of the groove342.

In block540, the method500may optionally include pivoting the foot to align a groove in the foot with a body of the measuring device. In an aspect, for example, the user may pivot the foot portion340to align the groove342with the body portion330of the measuring device300. The groove342may be aligned when parallel to a surface of the body portion330. The foot portion340may be pivoted to the measurement position.

In block550, the method500may include inserting a free edge of the flange into a groove in the foot of the measuring device. In an aspect, for example, the user may insert the free edge124into the groove342,442in the foot portion340,440of the measuring device300,400. In an aspect, the groove342,443may be sized to receive the free edge124. In another aspect, the groove342may be wider than the thickness of the free edge124. The magnet334may pull the flange120against the body such that the free edge124contacts an edge of the groove342adjacent the body portion330.

In block560, the method500may include retracting teeth of the measuring device into a block. In an aspect, for example, the user may retract the teeth320,321of the measuring device300into the block portion310. For example, the teeth320,321may be retracted into the slots314of the block portion310. The teeth320,321may be retracted by pressing the flange120against the teeth320,321. The teeth420,421may be retracted in a similar manner.

In block570, the method500may include inserting a creased edge of the flange into a space between the slot and the block. In an aspect, for example, the user may insert the creased edge122of the flange120into the space between the groove342,442and the block portion310,410.

In block580, the method500may include retaining the creased edge of the flange in the space with the teeth. In an aspect, for example. The user may retain the creased edge122of the flange120in the space with the teeth320,321. For example, the teeth320,321may be biased downward toward the flange120. As the user pushes the creased edge122past the teeth320,321, the teeth320,321may move downward to contact the creased edge122. The angled surfaces328may contact the creased edge122and urge the flange120toward the body portion330. The teeth420,421may retain the creased edge of the flange120in a similar manner.

In block590, the method500may include measuring the flange with a depth gauge inserted through the block to contact the sheet of metal. In an aspect, for example, the user may measure the flange120with a depth gauge inserted through the passage312in the block portion310to contact the door skin110. When using the measuring device400, the user may measure the flange12with a depth gauge inserted through the second passage362in the block portion410to contact the door skin110. In an aspect, the measurement of the flange120may be the dimension D from the free edge124of the flange120to the outer surface126. Since the depth gauge is zeroed in block530to the bottom to the bottom of the groove342,442, which contacts the free edge124, the measurement of a zeroed digital depth gauge when the depth gauge contacts the door skin110will be the dimension D inFIG. 2between the free edge124and the outer surface126of the door skin110. In the case of a mechanical depth gauge the dimension D may be found by subtracting the reading when the depth gauge is in contact with the door skin from the reading when the depth gauge is in contact with the calibration surface344,444.