Window Regulator Pulley Bracket With Stress Distribution Unit
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Solution Overview
Problem
Window regulators in vehicles experience stress concentration and creep rupture in pulleys, pulley shafts, and rails due to cable tension, leading to durability issues and assembly challenges.
Innovation Solution
A window regulator design featuring a guide rail, pulley bracket, and stress distribution unit that includes a fixing unit with upper and lower end locking structures, a stress support portion, and an accommodation mechanism to distribute stress and prevent separation of the cable, thereby minimizing stress concentration and improving assemblability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables are tensioned to raise and lower the window glass, then the window regulator can perform its lifting function, but stress concentration occurs in the pulleys, pulley shafts, and guide rail leading to creep rupture
Solution Approach 1:
A stress distribution unit is introduced as an intermediary component between the pulley shaft and the guide rail. This unit includes a stress distribution member that distributes the concentrated stress from the pulley shaft over a larger area of the guide rail, preventing stress concentration and creep rupture while allowing the cable tension to effectively raise and lower the window glass
Solution Approach 2:
The stress distribution unit is pre-installed on the guide rail before the pulley shaft is assembled. This preliminary action ensures that when the cable tension is applied, the stress is already distributed through the pre-positioned stress distribution member, preventing creep rupture before it can occur
2Reliability
If multiple separate fastening members are used to secure the pulley bracket to the guide rail, then the assembly is more secure, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
Multiple separate fastening members are merged into a single integrated fixing unit. This fixing unit includes a fixing member that simultaneously performs multiple fastening functions, securing the pulley bracket to the guide rail at multiple points with a single component, thereby reducing assembly complexity while maintaining secure attachment
Solution Approach 2:
The fixing unit is designed as a multi-functional component that simultaneously serves as a mounting bracket, a fastening mechanism, and a stress transfer element. This universal component replaces multiple specialized fasteners, simplifying the assembly process while ensuring secure attachment of the pulley bracket to the guide rail
3Stability of the object's composition
If the pulley bracket is rigidly fixed to the guide rail, then the assembly is more stable, but stress concentration increases at the fixed points
Solution Approach 1:
The fixing unit is designed with non-uniform stress distribution characteristics, concentrating flexibility at specific localized points while maintaining rigidity at other areas. The stress distribution unit creates localized compliance zones that allow stress to be distributed rather than concentrated at fixed points, maintaining overall assembly stability while reducing peak stress
Data Source
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AI summary
The present invention relates to a window regulator, and includes a guide rail provided inside a door, a pulley bracket that is fixed to the guide rail and to which a pulley that changes a moving direction of a cable is axially coupled, and a stress distribution unit configured to distribute a stress applied to the pulley.