Electronic Tensioner for Frameless Door Window Regulator
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Solution Overview
Problem
Existing window regulator systems face inaccuracies in window movement due to slack in cables and backlash in mechanical linkages, leading to inconsistent positioning during the 'Short-Drop' process, where the window is lowered below the fully closed position when opening a vehicle door.
Innovation Solution
An electronic tensioner system with a motor, position sensor, and electronic control unit that differentiates motor position and velocity signals to account for freeplay and backlash, ensuring accurate window movement by controlling the motor's power levels to remove slack and maintain precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a motor with cable and mechanical linkages is used to move the window, then the window can be moved between open and closed positions, but slack and backlash in the mechanical components cause inaccurate window positioning
Solution Approach 1:
The patent replaces mechanical tensioning mechanisms with an electronic control system that uses motor control algorithms to compensate for slack and backlash. The electronic control unit processes position sensor data and applies corrective algorithms to eliminate the need for mechanical pre-tensioning devices, thereby improving position accuracy without adding mechanical complexity.
Solution Approach 2:
The system implements a feedback loop where a position sensor continuously monitors the actual window position and feeds this information back to the electronic control unit. The control unit compares the actual position with the commanded position and adjusts motor control signals to eliminate positioning errors caused by cable slack and backlash, achieving accurate positioning through continuous correction.
2Speed
If the window is moved quickly during Short-Drop operation, then response time is improved, but cable slack and mechanical backlash cause inconsistent positioning
Solution Approach 1:
The system performs preliminary positioning actions before the final Short-Drop movement. The electronic control unit first moves the window to a predetermined position above the target, then executes the Short-Drop sequence with controlled acceleration and deceleration. This preliminary positioning ensures that cables are properly tensioned before high-speed movement, eliminating slack-related positioning errors.
Solution Approach 2:
The patent implements dynamic motor control with variable speed profiles during window movement. The electronic control unit adjusts motor torque and speed in real-time based on the window's position and movement phase. During Short-Drop, the system uses accelerated movement followed by controlled deceleration at the target position, optimizing both speed and positioning accuracy through dynamic parameter adjustment.
3Measurement precision
If mechanical tensioners are added to eliminate cable slack, then positioning accuracy is improved, but device complexity and hardware requirements increase
Solution Approach 1:
The patent replaces mechanical tensioning devices with an electronic control system that uses software-based compensation algorithms. The electronic control unit processes position feedback and applies corrective control signals to the motor, eliminating the need for mechanical pre-tensioning springs, adjusters, or other hardware-based tensioning mechanisms while achieving equivalent or superior positioning accuracy.
Solution Approach 2:
The system uses the existing motor and position sensor infrastructure to self-correct positioning errors without requiring additional dedicated tensioning hardware. The electronic control unit leverages the feedback from the position sensor and the motor's inherent control capabilities to automatically compensate for cable slack and backlash, making the system self-regulating without external mechanical assistance.
Data Source
AI summary
A window regulator system for a window coupled to a door and movable between fully open and closed positions and a short drop position and method of operation are disclosed. The system includes rails with window regulator lifter plate assemblies being moveable along the rails by cables. A motor winds the cables to move the window. An electronic control unit detects operation of at least one of a door handle and a latch of the door to identify a short drop request corresponding to the door shut or opened. The electronic control unit ensures that no freeplay exists in the window regulator system to provide accurate movement of the window and controls the motor to selectively raise the window to the fully closed position in response to the door being shut and temporarily lower the window to the short drop position in response to identifying the short drop request.