Drive Wire Tensioning Method for Window Regulator Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional window regulator manufacturing methods and drive wire tension applying methods are inefficient, increasing the number of manufacturing steps and causing time loss due to the complex process of applying tension to the drive wire.
Innovation Solution
A method that involves fixing one end of the drive wire to the drive drum, temporarily placing the other end in a temporary placement portion on the drum housing, and applying tension by moving it to an engaging portion on the drive drum using a motor unit, allowing for efficient tension application by winding the drive wire around the drum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tension is applied to the drive wire by pulling the wire end from the first portion to the second portion of the drive drum using equipment or hand, then the drive wire is properly tensioned, but the number of manufacturing steps increases and efficiency deteriorates
Solution Approach 1:
The drive drum automatically winds the drive wire to apply tension, eliminating the need for external equipment or manual pulling. The system uses its own rotational capability to perform the tensioning function, thereby reducing manufacturing steps and improving efficiency while ensuring proper tension is applied to the drive wire
Solution Approach 2:
The patent replaces the manual or equipment-based mechanical pulling system with an automated winding mechanism. The drive drum's rotation automatically winds the drive wire, substituting complex external tensioning equipment with a simpler integrated winding action that reduces manufacturing complexity
2Productivity
If the drive wire is temporarily placed in a temporary placement portion on the drum housing and then moved to the engaging portion by winding, then the number of manufacturing steps is reduced, but the positioning precision requirement increases
Solution Approach 1:
The temporary placement portion acts as an intermediary structure that facilitates the transition of the drive wire from a temporary state to the final engaged state. This intermediate structure enables automated winding while maintaining positioning accuracy, allowing the system to reduce manufacturing steps without sacrificing precision
Solution Approach 2:
The drive wire is preliminarily positioned in the temporary placement portion before the final winding operation. This preliminary action prepares the wire for automated tensioning, ensuring that when the winding begins, the wire is already in the correct starting position, thereby maintaining precision while enabling automation
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
This method significantly reduces the number of manufacturing steps and enhances efficiency in applying tension to the drive wire, improving the overall production process.
Implementation Method 1
a drive drum around which the drive wire is wound
Data Source
AI summary
The method includes a step of fixing the other end of the drive wire to the drive drum; a step of temporarily placing one end of the drive wire in a temporary placement portion provided on the drum housing; and a step of applying tension to the drive wire by moving the one end of the drive wire to an engaging portion provided on the drive drum after canceling the placed state of the one end of the drive wire in the temporary placement portion by pulling a portion of the drive wire on the one end side thereof by winding a portion of the drive wire on the other end side thereof by the drive drum with the one end of the drive wire placed in the temporary placement portion.