Pulley Rivet Design for Window Regulator Joint Strength
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Solution Overview
Problem
Window regulator systems, particularly those using cable-driven pulleys, face premature joint failure due to forces involved in operation and installation, necessitating a stronger and more streamlined fastening solution.
Innovation Solution
A pulley rivet system with a retaining lip and retainer portion is used to secure the pulley to the rail, preventing separation and ensuring a strong connection through a fastener, which is installed within both the pulley and rail apertures, enhancing the structural integrity and stability of the window regulator assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fastening methods are used to attach pulleys to rails, then the design is simpler, but the joint strength is insufficient and premature failure occurs due to cable tension forces
Solution Approach 1:
The fastening system is divided into distinct functional segments: the pulley aperture, rail aperture, retaining lip, and retainer portion. Each segment performs a specific function in the fastening process, allowing the system to achieve high strength through specialized design of each component rather than a single complex fastener
Solution Approach 2:
The pulley rivet is nested within both the pulley aperture and rail aperture, creating a layered fastening structure. The retaining lip engages with the pulley surface while the retainer portion engages with the retaining surface, with the rivet body positioned within both apertures to provide structural integration
2Reliability
If a stronger fastening system is implemented to withstand cable tension forces, then joint reliability improves, but the installation and design complexity increases
Solution Approach 1:
The pulley rivet combines multiple fastening functions into a single integrated component. It simultaneously provides structural support through the rivet body positioned in both apertures, retention through the retaining lip engaging the pulley surface, and anchoring through the retainer portion engaging the retaining surface, eliminating the need for multiple separate fastening elements
Solution Approach 2:
The fastening system employs a composite structural approach where the pulley rivet integrates different functional portions (retaining lip, retainer portion, rivet body) within a single component, creating a composite fastening solution that combines multiple mechanical engagement methods to achieve high reliability
3Ease of manufacture
If the pulley rivet structure is simplified for easier manufacturing, then production cost decreases, but the ability to inhibit separation under cable tension forces is reduced
Solution Approach 1:
The pulley rivet is designed with segmented functional portions (retaining lip, retainer portion, rivet body) that can be manufactured using standard forming processes. Each segment serves a specific purpose, allowing for efficient manufacturing through conventional techniques while maintaining the overall structural integrity and connection strength
Solution Approach 2:
The pulley rivet utilizes parameter changes in its geometry, with the retaining lip and retainer portion configured to engage with corresponding surfaces. The hole dimension and positioning are optimized to accommodate fasteners while maintaining structural strength, allowing manufacturing with standard tolerances and processes
Data Source
AI summary
A component for a window regulator system of a vehicle closure panel including: a rail having a rail aperture extending between a first side of the rail and a second side opposite the first side, the rail aperture having a retaining surface associated with the rail aperture; a pulley for mounting adjacent to the first side, the pulley having a pulley aperture with a pulley surface opposite the first side; a pulley rivet having a rivet body including a retaining lip for engaging with the pulley surface and a retainer portion for engaging with the retaining surface, the rivet body configured for receipt in both the pulley aperture and the rail aperture when installed, the rivet body having a hole for receiving a fastener for fastening the rail to a panel via the pulley rivet; wherein, when installed, the rivet body is positioned within the pulley aperture and within the rail aperture, such that engagement between the retaining lip and the pulley surface inhibits separation of the pulley from the rail while engagement of the retainer portion with the retaining surface inhibits separation of the pulley rivet from the rail aperture.