Cable Pulley Bracket Structure for Door Panel Stress Relief
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Solution Overview
Problem
The existing cable pulley assemblies in vehicle door systems experience noise and potential damage due to the tension of the cable, which leads to stress concentration on the pulley shaft and door panel, causing vibration and risk of breakage during repeated window operations.
Innovation Solution
A cable pulley assembly design featuring a pulley shaft with a screw portion and a pulley bracket that includes a shaft guide and bracket flange portion, where the pulley bracket is firmly fixed to the panel and the pulley shaft, distributing the tension force to prevent stress concentration and noise, and incorporating a friction-reducing protrusion for smoother rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a cable pulley is installed on the door panel to contact-support the cable, then the cable traveling direction is bent, but a large load is applied to the cable pulley due to cable tension causing stress concentration and potential damage
Solution Approach 1:
The door panel is segmented into a panel body and a separate reinforcement plate that is coupled to the panel body. The reinforcement plate specifically reinforces the region where the pulley shaft is installed, distributing the stress from cable tension across a larger area and preventing stress concentration at critical points.
Solution Approach 2:
A pulley bracket is introduced as an intermediary component between the cable pulley and the door panel. The bracket includes a shaft guide portion that guides the pulley shaft and a bracket flange portion that extends into a groove in the panel body, providing a stable mounting structure that distributes loads effectively.
2Reliability
If the cable pulley is fixed to the door panel, then the cable tension is supported, but noise is generated between the cable pulley and pulley shaft or between the pulley shaft and door panel during repeated operations
Solution Approach 1:
A damping member is installed between the cable pulley and the pulley shaft, and another damping member is placed between the pulley shaft and the door panel. These damping members are positioned in advance to cushion and absorb vibrations and impacts that occur during cable tension changes, preventing noise generation from direct metal-to-metal contact.
3Force
If the pulley shaft is firmly fixed to the panel, then the cable tension is securely supported, but stress concentration occurs at the fixed insertion area leading to potential breakage
Solution Approach 1:
The door panel is divided into a panel body and a separate reinforcement plate. The reinforcement plate is coupled to the panel body and specifically reinforces the region where the pulley shaft is installed, distributing the stress from cable tension across a larger area and preventing stress concentration at the fixed insertion points.
Solution Approach 2:
The door panel assembly combines the panel body with a reinforcement plate made of a material suitable for withstanding cable tension. This composite structure provides both secure fixation for the pulley shaft and adequate stress distribution to prevent breakage.
Data Source
AI summary
A cable pulley assembly is disclosed, and the cable pulley assembly includes a pulley shaft of which a first side is fixedly inserted into a panel and a second side protrudes outward from the panel; a cable pulley configured to support a cable so that a traveling direction of the cable is bent and coupled to the second side of the pulley shaft to be rotatable relative to the pulley shaft about an axis of the pulley shaft; and a pulley bracket fixed to the panel and in contact with the pulley shaft.