The Design And Development Of Rope-wheeled Electric Window Regulator

As an indispensable standard accessory in the car door system, auto window regulator is used to ensure that the glasses smoothly go up and down and can stay in any position. Window regulator can be divided into3types—arm-crossed, flexible and rope-wheeled. The rope-wheeled window regulator is receiving more and more attention of the automobile manufacturers, because it has many advantages, such as simple structure, light weight, economy, low noise, easy installation and so on. In this condition, the problem many domestic auto parts manufacturers are facing is how to design the rope-wheeled window regulator to adapt different automobile types. This paper studies the rope-wheeled window regulator and implements the following research work:The functions, installation positions and mutual cooperation relations of parts of the rope-wheeled window regulator are analyzed. The principles, which are used to determinate the main parameters of guide rail, sliding plate, bracket, base plate, wrapping box and so on, are given to lay the foundation of the design. As for double curvatures glasses, in order to determinate the curvature of guide rail, a ring surface is used to approximate its surface. Both mathematical equation and geometric method based on that are given.According to the determination principles above, the design process and modeling methods of parts of the rope-wheeled window regulator are introduced with UG software, based on the data model of B501auto door provided by one auto parts manufacturer. After modeling, use assembly function of UG to check geometric dimension of parts of the window regulator. The results shows that there is no interference, which verifies the correctness of the design.In addition to checking the interference, the method of checking the motion track is also put forward. The actual motion track determined by guide rail and the theoretical motion track of the glass can be extracted after the design. Use UG to check the maximum deviation of the two tracks, whose result shows that the maximum deviation is in the required range of the glass motion deviation and that the design meets the requirement. The stress of the combination of window regulator pulley, which includes wire rope, pulley and pin, is analyzed in the condition of motor stall with ANSYS software according to the performance report of the motor provided by the manufacturer. The analysis result shows that the maximum stress of wire rope is in the force-slanting end, and that the maximum stress of pulley is in the groove, which is contacted with the force-vertical end of wire rope, and that the stress of pin is very small. All of these contribute to the optimization of the regulator for future.The potential failure mode of the regulator is analyzed. Combined with the information provided by the manufacturer, many preventing and solving measures are put forward. At last the DFMEA of the rope-wheeled window regulator is summarized.