Window Regulator Cable Routing for Frameless Door Stability
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Solution Overview
Problem
Window regulators for frameless automotive doors face challenges in providing stability and cost-effectiveness, as they need to manage window movement without frames and must be optimized for reduced manufacturing costs while maintaining strength and adjustability.
Innovation Solution
A window regulator design featuring a pair of guide rails with cursors and a motor-driven cable system, including a cable drum and pulleys, that ensures stable window movement and is optimized for reduced manufacturing costs through the use of hollow guide rails and cursors with multiple contact points for stability and materials like polyoxymethylene and nylon for durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a window regulator is designed for a frameless door assembly to provide window stability in all directions, then window stability and movement control are improved, but manufacturing cost increases
Solution Approach 1:
The window regulator is divided into two separate guide rails (first guide rail and second guide rail) with individual cursors for each, rather than using a single integrated guide structure. This segmentation allows for simplified manufacturing of individual components while collectively providing comprehensive window stability in all directions through the coordinated action of both guide rails
Solution Approach 2:
The cable sheaths are nested within the hollow guide rail structures, with the first cable sheath extending from the first guide rail to the housing, and the second cable sheath extending from the second guide rail to the housing. This nesting eliminates the need for separate cable protection structures, reducing part count and manufacturing cost while maintaining structural integrity
2Device complexity
If the housing is not mounted to the lower end of the first guide rail, then device complexity and manufacturing cost are reduced, but structural support may be compromised
Solution Approach 1:
The second guide rail serves a dual function: it provides guidance for the second cursor while also serving as a mounting structure for the housing. The housing is mounted to the lower end of the second guide rail, eliminating the need for a separate mounting bracket or attachment mechanism. This multi-functionality reduces device complexity and part count while maintaining adequate structural support through the robust second guide rail
3Reliability
If cable sheaths are extended to prevent cable wear and extend cable life, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The cable sheaths are nested within the hollow guide rail structures, with the first cable sheath extending from the first guide rail to the housing, and the second cable sheath extending from the second guide rail to the housing. This nesting eliminates the need for separate cable protection structures, reducing part count and manufacturing complexity while providing adequate protection against cable wear through the structural integrity of the guide rails
Solution Approach 2:
The guide rails serve multiple functions: providing mechanical guidance for the cursors, structural support for the cable sheaths, and protection against cable wear. This multi-functionality eliminates the need for dedicated cable protection structures, reducing device complexity while maintaining cable life through the protective effect of the guide rail enclosures
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 provides stable and cost-effective window regulation for frameless doors by reducing manufacturing costs and maintaining structural integrity, allowing for efficient movement and adjustment of windows while preventing undesired movement.
Implementation Method 1
a cable tensioner associated with the first cable sheath
Implementation Method 2
a pulley is rotationally mounted to each of the first feature of the first guide rail, the second feature of the second guide rail, the first feature of the second guide rail and the second feature of the second guide rail
Data Source
AI summary
A window regulator, including: a first guide rail; a first cursor slidably mounted to the first guide rail; a second guide rail spaced from the first guide rail; a second cursor slidably mounted to the second guide rail; a housing that is not mounted to a lower end of the first guide rail or the second guide rail; a motor mounted to the housing and operably coupled to the first cursor and the second cursor such that operation of the motor will cause the first cursor to slide along the first guide rail and second cursor to slide along the second guide rail; a cable drum rotationally mounted to the housing, the cable drum being operably coupled to the motor and a first cable secured to the cable drum at one end and the first cursor at another end; a second cable secured to the cable drum at one end and the second cursor at another end; a third cable secured to the first cursor at one end and the second cursor at another end; a first cable sheath surrounding the first cable that extends from a first feature of the first guide rail to the housing; a cable tensioner associated with the first cable sheath; a second cable sheath surrounding the second cable that extends from the housing to a second feature of the second guide rail; and a third cable sheath surrounding the third cable that extends from the a second feature of the first guide rail to a first feature of the second guide rail, wherein the window regulator is configured for raising and lowering a window of a frameless door assembly of a vehicle.