Pulley Assembly Module Plate Integration
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Solution Overview
Problem
Current pulley assemblies for window regulator systems require complex assembly processes, are heavy, and costly, while also facing challenges in supporting large forces and maintaining durability and performance.
Innovation Solution
A pulley assembly design featuring a base element with a finger and stepped area, integrated with a module plate, utilizing a clip-in mechanism with support surfaces to securely attach the pulley assembly, reducing manufacturing steps and weight, and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fastening elements (screws or stepped pins) are used to attach the pulley assembly to the guide rail, then the assembly can support large forces and bending moments, but the manufacturing process becomes more complex and requires more assembly steps
Solution Approach 1:
The base element is integrally formed as a single piece that combines the mounting structure with the force-bearing features. The finger portion and stepped area are part of the same continuous structure, eliminating the need for separate fastening elements and reducing assembly steps while maintaining strength to support large forces and bending moments.
Solution Approach 2:
The base element serves multiple functions simultaneously: it provides structural support, acts as a mounting interface for the pulley assembly, and engages with the guide rail through the finger and stepped area. This multi-functional design replaces multiple separate components with a single integrated element that performs all necessary functions.
2Reliability
If traditional fastening elements and multi-step assembly processes are used, then the pulley assembly can be securely attached, but the manufacturing cost and weight increase
Solution Approach 1:
The base element is integrally formed as a single piece that combines the mounting structure with the force-bearing features. The finger portion and stepped area are part of the same continuous structure, eliminating the need for separate fastening elements and reducing assembly steps while maintaining strength to support large forces and bending moments.
Solution Approach 2:
The base element's geometry itself provides the attachment mechanism. The finger portion engages with the guide rail structure and the stepped area provides positioning and securing features, eliminating the need for separate fastening elements. The design uses its own structural features to achieve secure attachment without additional components.
Data Source
AI summary
A window regulator assembly for a motor vehicle includes a pulley assembly with integrated module plate for redirecting a cable. The pulley assembly includes a base element and a cable pulley rotatably coupled with the base element. The base element has a pair of fingers and a stepped area for engaging with an integrated module plate. The integrated module plate has a pulley assembly receiving site for placing the pulley assembly. The pulley assembly receiving site of the integrated module plate has at least one aperture, a slot and a mating portion for easily engaging with the pulley assembly. The mating portion includes a third support surface for supporting the edge of the stepped area of the base element.