Direct-Drive Roller Blind Wire Lead for Noise-Free Pulley Alignment
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Solution Overview
Problem
Direct driven roller blind assemblies in vehicles face issues with a large angle between the tensioning wire and the wire pulley, leading to noise, rattling, and potential wire dislodgment due to improper positioning within the winding groove, which is exacerbated by the packaging constraints of the roof system.
Innovation Solution
A pivotable wire lead with a guiding arm and wheel is introduced to control the angle between the tensioning wire and the wire pulley, ensuring proper alignment and positioning within a predetermined range, using a guiding arm and wheel to manage the tensioning wire's path onto and off the pulley.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the wire pulley and drive motor are packaged next to the winding tube to create a direct driven roller blind assembly, then noise and vibration are reduced and operating behavior is improved, but the roller blind assembly becomes wider than conventional roller blind assemblies
Solution Approach 1:
The wire pulley is integrated into the winding tube structure, with the pulley positioned at the outer end of the winding tube. This nesting approach allows the wire pulley to share the same spatial envelope as the winding tube, eliminating the need for additional lateral space that would be required if the pulley were mounted separately on the assembly housing.
2Area of stationary object
If the roller blind assembly is packaged within a separate space inside the inner area of other roof components to maintain a wider daylight opening, then the daylight opening is wider in the transversal direction, but a large step is created in the longitudinal direction between the tensioning wire and wire pulley
Solution Approach 1:
The wire pulley is positioned at the outer end of the winding tube, utilizing the longitudinal dimension of the winding tube rather than consuming additional lateral or vertical space. This dimensional repositioning allows the tensioning wire to engage with the pulley at a location that minimizes the longitudinal step while maintaining adequate transversal daylight opening.
3Reliability
If a large distance in the longitudinal direction is used to mitigate the large angle between the tensioning wire and wire pulley, then the angle is reduced, but the distance is bound by the dimensions of the vehicle
Solution Approach 1:
The wire pulley is designed with a curved surface featuring a spiral-shaped winding groove that wraps around the pulley circumference. This curvature allows the tensioning wire to follow a controlled path around the pulley, maintaining a consistent engagement angle as the wire winds or unwinds, thereby preventing the wire from rattling or falling off even within limited longitudinal space.
4Object-generated harmful factors
If the tensioning wire makes a large angle with the wire pulley, then the wire may not be properly positioned within the winding groove, leading to noise, rattling, and potential wire dislodgment, but reducing the angle requires precise packaging constraints
Solution Approach 1:
A guiding arm with a guiding wheel at its end is introduced as an intermediary component between the tensioning wire and the wire pulley. The guiding arm is pivotally connected to the frame and positioned such that its guiding wheel controls the path of the tensioning wire as it engages with the wire pulley. This intermediary guiding mechanism ensures that the tensioning wire approaches the wire pulley at a controlled, small angle, preventing the wire from rattling or dislodging while accommodating typical vehicle packaging constraints without requiring excessive precision.
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 solution effectively reduces the angle between the tensioning wire and the wire pulley to a controlled range, preventing noise and dislodgment, ensuring smooth operation and secure handling of the blind screen.
Implementation Method 1
a pivotable wire lead is provided at an end portion of the guide rail closest to the winding tube, wherein the pivotable wire lead comprises a guiding arm, a guiding wheel at an end of the guiding arm near the wire pulley, and a pivot joint at another end of the guiding arm, wherein the guiding arm is curved such that when pivoting about the pivot joint, the guiding wheel moves such that an angle at which the tensioning wire runs to and from the wire pulley is limited to a controlled/pre-determined range
Data Source
AI summary
A roller blind assembly comprises a pivotable wire lead for guiding a tensioning wire with a controlled angle from and onto a wire pulley. A roof assembly comprises such a roller blind assembly, while and a vehicle comprises said roof assembly.