Cable Guide Assembly for Window Regulator
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Solution Overview
Problem
Current cable guide assemblies for window regulators in automotive applications require complex assembly processes, are heavy, costly, and have high warranty claims due to the use of multiple fastening elements and complex configurations.
Innovation Solution
A cable guide assembly with a fixed mounting to a guide rail, featuring a cable guide with a groove and circular cavity, including tabs and recesses for secure engagement and rotation between temporary and final positions, reducing the need for additional fastening elements and simplifying assembly, while maintaining high tension and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fastening elements such as stepped pins and washers are used for supporting forces on the cable pulley, then the cable pulley assembly can support the required forces, but the manufacturing steps and assembly complexity increase
Solution Approach 1:
The cable guide is merged with the guide rail into a single integrated component. The cable guide is formed as an integral part of the guide rail, eliminating the need for separate fastening elements like stepped pins and washers. This integration maintains the structural strength required for force support while significantly simplifying the assembly process and reducing the number of manufacturing steps.
Solution Approach 2:
The guide rail is designed to serve multiple functions: it provides structural support, guides the cable, and integrates the cable guide function directly into its structure. This multi-functionality eliminates the need for separate dedicated fastening elements, reducing assembly complexity while maintaining the required force support capability.
2Strength
If multiple fastening elements are used in the cable pulley assembly, then the assembly can support required forces, but the weight and cost of the component increase
Solution Approach 1:
The cable guide is merged with the guide rail into a single integrated component. This integration eliminates the weight of separate fastening elements like stepped pins and washers while maintaining the structural strength required for force support. The unified structure uses material more efficiently, reducing overall component weight.
3Strength
If multiple fastening elements are used in the cable pulley assembly, then the assembly can support required forces, but the manufacturing cost increases
Solution Approach 1:
The cable guide is merged with the guide rail into a single integrated component that can be manufactured as one piece. This integration eliminates the need to purchase, inventory, and assemble multiple separate fastening elements, significantly reducing manufacturing costs while maintaining the required force support capability.
Solution Approach 2:
The guide rail is designed to serve multiple functions including structural support, cable guidance, and force transmission. This multi-functionality reduces the total number of components required, lowering material costs, manufacturing complexity, and assembly costs while maintaining the required strength.
4Strength
If a complex configuration of cable guide and fastening elements is used, then the assembly can support required forces, but the warranty claims increase due to potential assembly issues
Solution Approach 1:
The cable guide is merged with the guide rail into a single integrated component with no moving parts or separate fastening elements. This eliminates potential assembly issues such as loose fasteners, misalignment, or fastening element failure, significantly reducing warranty claims while maintaining the required force support capability.
Data Source
AI summary
A cable guide assembly adapted for use with a guide rail for a motor vehicle, for redirecting a cable of a window regulator, includes a cable guide formed with an outer perimeter and a cable guide receiving site formed in the guide rail adapted to receive and mount the cable guide. The cable guide includes a cable guide groove to guide the cable wrapping around the cable guide and a generally circular interior cavity to mount to the guide rail. In the cable guide assembly, the cable guide is securely engaged with a center support in the cable guide receiving site and rotatable between two rotatable positions, a temporary holding position and a final position. In the temporary holding position, the cable is at a first tension and the cable is at a second tension higher than the first tension in the final position.