Door Cable Pulley System for Space-Efficient Power Assistance
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Solution Overview
Problem
Modern vehicle design faces challenges in providing power-assisted closure systems that are cost-effective and space-efficient, especially with increasing features and varying usage demands, requiring a solution that balances mechanical support and economic viability.
Innovation Solution
A door cable pulley system with a motor-driven cable drum, tension pulleys, and adjustable clutch, which uses a pair of drive cables to move a closure between open and closed positions, minimizing space and eliminating the need for idler pulleys, allowing for both automatic and manual operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a traditional power-assisted closure system is used, then sufficient power assistance is provided, but the system occupies excessive space and increases device complexity
Solution Approach 1:
The patent reconfigures the cable routing from a traditional planar arrangement to a three-dimensional spatial arrangement using tension pulleys positioned at different heights and locations within the door assembly. This dimensional change allows the cables to achieve the necessary mechanical advantage and power transmission while occupying significantly less overall space, as the cables can route through the depth of the door rather than requiring lateral clearance.
Solution Approach 2:
The patent integrates the tension pulleys and cable routing system within the existing door structure, nesting the power-assisted closure components within the door's internal volume rather than requiring external space. The tension pulleys are positioned within the door assembly, and the cables are routed through channels and openings in the door structure, effectively hiding the mechanical components within the door's own volume.
2Adaptability or versatility
If more features are added to the closure system, then functionality is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The tension pulley assembly serves multiple functions simultaneously: it provides mechanical advantage for power assistance, guides the cables along their routing paths, maintains cable tension through its positioning, and structures the overall closure mechanism. This multi-functionality eliminates the need for separate components for each function, reducing the total number of parts and simplifying the system while maintaining enhanced functionality.
Solution Approach 2:
The patent combines the tensioning function, cable guidance function, and structural support function into a single integrated pulley assembly rather than using separate components for each function. The pulleys are mounted on a common structure that provides both the mechanical advantage needed for power assistance and the geometric routing needed for cable guidance, merging multiple functions into one compact unit.
3Device complexity
If cable routing is simplified, then device complexity is reduced, but tension control and reliable operation deteriorate
Solution Approach 1:
The tension pulleys are pre-positioned at specific locations and angles within the door assembly during manufacturing, establishing the correct cable routing geometry before the system is assembled. This preliminary positioning ensures that the cables are properly aligned and tensioned when installed, maintaining reliable tension control while keeping the actual cable routing simple and straightforward during assembly.
Solution Approach 2:
The tension pulleys act as intermediary elements that mediate between the cable drum and the closure mechanism, translating the rotational motion of the drum into the linear motion needed to move the closure while maintaining proper cable tension. The pulleys serve as intermediate contact points that guide the cables through their routing paths, ensuring reliable tension control without requiring complex direct cable routing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively manages closure movement while optimizing space and reducing manufacturing costs, ensuring reliable operation with reduced complexity and increased flexibility in usage modes.
Implementation Method 1
a cable drum positioned within the volume and driven by a motor
Implementation Method 2
a first tension pulley positioned within the volume proximate the first exit opening, a second tension pulley positioned within the volume proximate the second exit opening
Data Source
AI summary
A door cable pulley system for use with a motor vehicle having a closure movable between an open and closed position. The door cable pulley system includes a first tension pulley, a second tension pulley, a cable drum driven by a motor, and a pair of drive cables. The first drive cable includes a first end coupled to the cable drum and a second end coupled to the closure, where the first drive cable extends from the cable drum, passes over the first tension pulley, and exits the body through the second exit opening. The second drive cable includes a first end coupled to the cable drum and a second end coupled to the closure, where the second drive cable extends from the cable drum, passes over the second tension pulley, and exits the body through the first exit opening.