This project involved the design and development of a van door lock system aimed at preventing "peel type" attacks and securely locking three hardpoints on a van door.

Project Overview: The team designed, 3D modeled, performed Finite Element Analysis (FEA), and planned the manufacturing of the lock using tools like Fusion 360 and workshop CNC machines.

Design and Mechanism: The chosen design utilizes a central spinner with cables to pull the locks, powered by gears attached to a standard euro lock. This design was favored for being small, lightweight, and not requiring long bars. The main casing was designed for CNC machining from steel to ensure strength and ease of manufacturing. Components like internal gears, a tumbler for cable motion, and cylindrical spacers were also designed with specific functionalities and material considerations, primarily steel for robustness. A deadbolt mechanism, including a casing, bolt, lid, and spring, was also developed to provide the physical stopping point for the door.

FEA Analysis: FEA simulations were conducted on key components to test their resistance to various attacks.

• Deadbolt: Tested against a 6000N crowbar force, the design demonstrated good shape retention with no bending or buckling, and a safety factor above 3 for all load-bearing parts.

• Main Casing/Eurolock: Simulated with a 5000N sledgehammer force, the internal locking mechanism remained unaffected, ensuring the lock's functionality even if the external Eurolock was damaged.

• Deadbolt Spring: Tested for its ability to return the deadbolt to the locked position, the spring showed desirable stress distribution and sufficient displacement to mechanically open the lock with a simple turn.

Manufacturing Considerations: The project outlines manufacturing processes such as CNC machining (milling and turning), stamping, and plasma cutting for various components. Some standardized parts like springs, screws, and certain gears were planned to be sourced directly from suppliers for cost-effectiveness. Steel was the primary material choice for its strength and machinability.

Conclusion: This project successfully delivered a functional van door lock design that meets the objective of securing three hardpoints and resisting common theft techniques. The CAD, FEA, and CAM processes were crucial in developing a sturdy and effective solution.