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IMPROVEMENT DESIGN FOR POWER WNDOW MECHANISM OF CABLE TYPE
MOHD FARHAN BIN MOHD PILUS
Thesis submitted in fulfilment of the requirements
for the award of the degree of
Bachelor of Mechanical Engineering with Automotive Engineering
Faculty of Mechanical Engineering
UNIVERSITI MALAYSIA PAHANG
NOVEMBER 2009
ii
SUPERVISOR’S DECLARATION
I hereby declare that I have checked this project and in my opinion, this project is
adequate in terms of scope and quality for the award of the degree of Bachelor of
Mechanical Engineering with Automotive Engineering.
Signature
Name of Supervisor: MR. ZAMRI BIN MOHAMED
Position: LECTURER
Date: 20 NOVEMBER 2009
iii
STUDENT’S DECLARATION
I hereby declare that the work in this project is my own except for quotations and
summaries which have been duly acknowledged. The project has not been accepted for
any degree and is not concurently submitted for award of other degree.
Signature
Name: MOHD FARHAN BIN MOHD PILUS
ID Number: MH06063
Date: 20 NOVEMBER 2009
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My beloved father, Mr. Mohd Pilus Bin Jaafar,
My loving mother Mrs. Hashimah Binti Md Abu,
Brothers and sisters,
All my friends
May Allah bless all of you
v
ACKNOWLEDGEMENTS
I am grateful and would like to express my sincere gratitude to my supervisor Mr
Zamri Bin Mohamed for his germinal ideas, invaluable guidance, continuous
encouragement and constant support in making this research possible. He has always
impressed me with his outstanding professional conduct, his strong conviction for
science, and his belief that a degree program is only a start of a life-long learning
experience. I appreciate his consistent support from the first day I applied to graduate
program to these concluding moments. I am truly grateful for his progressive vision
about my training in science, his tolerance of my naïve mistakes, and his commitment to
my future career. I also sincerely thanks for the time spent proofreading and correcting
my many mistakes.
My sincere thanks go to all my labmates and members of the staff of the
Mechanical Engineering Department, UMP, who helped me in many ways and made my
stay at UMP pleasant and unforgettable. Many special thanks go to member engine
research group for their excellent co-operation, inspirations and supports during this
study.
I acknowledge my sincere indebtedness and gratitude to my parents for their
love, dream and sacrifice throughout my life. I acknowledge the sincerity of my brothers
and sisters, who consistently encouraged me to carry on my higher studies. I am also
grateful to my fellow colleuges for their sacrifice, patience, and understanding that were
inevitable to make this work possible. I cannot find the appropriate words that could
properly describe my appreciation for their devotion, support and faith in my ability to
attain my goals. I would like to acknowledge their comments and suggestions, which
was crucial for the successful completion of this study.
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ABSTRACT
Power windows system or electric windows is divided in two types. They are cable type
power window system and scissor type power window system. The main function of the
power windows is to raise and lower automobile windows by depressing a button or
switch, as opposed to using a hand-turned crank handle. The system have five
components which are the window, the frame and guide rails, the electric motors and the
door frame. In the cable type, the electric motors that are provided consist of the motor
and a cable driven track that raises and lowers the window. The motor assembly will
need to be fastened to the door frame. These components were reviewed for differences
in shape and construction prior to being assembled to the vehicles. There are difference
specifications for different manufacturers. For this project, power window system of
Proton Gen-2 car was chosen to be benchmarking. Then the parts that always failed will
be defined. The parts will be redesign and the material will be changed. The current and
new parts were design by using SOLIDWORK software in dimensional of Proton Gen-2
car power window system. By using FEA tools that is ALGOR software, the design was
analyzed using constant force. Improvement of power window parts design was
compared based on material used, analysis on Stress Von Mises and displacement,
buying and repairing cost, and others. The new design that will give the lowest value of
Stress Von Mises and displacement will be selected as the improvement part. The
material that will be selected also deal with the value of stress and displacement. The
important result is to improve power window parts in order to enhance the life time of
the system and to give advantages to the car users such as reducing the maintenance
cost.
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ABSTRAK
Tingkap automatik atau tingkap elektrik terbahagi kepada dua jenis iaitu tingkap
automatik jenis kabel dan tingkap automatik jenis gunting. Fungsi utama tingkap
automatik adalah untuk menurun dan menaikkan cermin tingkap kereta dengan menekan
butang atau suis, sebagai tukaran menggunakan pemutar pegangan engkol. Terdapat
lima komponen dalam sistem tingkap automatik iaitu cermin tingkap, bingkai dan rel
pembimbing, motor elektrik dan bingkai pintu. Pada tingkap automatik jenis kabel,
motor elektrik yang disediakan terdiri daripada motor dan trek pembimbing kabel yang
menaik dan menurunkan cermin tingkap. Motor yang dihimpunkan dengan bingkai
pintu perlu diketatkan. Sebelum dipasang kepada kenderaan, komponen-komponen ini
diterima dalam bentuk yang berbeza-beza. Pengeluar berbeza akan mengeluarkan
spesifikasi yang berbeza. Untuk projek ini, sistem tingkap automotik Proton Gen-2
telah dipilih untuk dijadikan tanda aras. Kemudian bahagian-bahagian yang selalu rosak
akan ditakrifkan. Bahagian-bahagian tersebut akan direka bentuk semula dan
penggunaan bahan akan ditukar. Reka bentuk bahagian lama dan baru direka
menggunakan perisian SOLIDWORK berdasarkan ukuran sistem tingkap automatik
Proton Gen-2. Dengan menggunakan perisian FEA iaitu perisian ALGOR, reka bentuk
bahagian dianalisa menggunakan daya yang kekal. Penambahbaikan bentuk bahagian
tingkap automatik dibandingkan dengan berdasarkan pada penggunaan bahan, analisa
pada Stress Von Mises dan regangan, pemasangan, kos pembelian dan pembaikian, dan
lain-lain. Penambahbaikan bentuk yang akan menghasilkan nilai Stress Von Mises dan
regangan yang paling rendah akan dipilih sebagai bentuk yang baru untuk komponen.
Pemilihan bahan juga akan bergantung kepada nilai Stress Von Mises dan regangan
yang dihasilkan. Kepentingan keputusan adalah untuk menambahbaikan bahagian
tingkap automatik kereta dengan menambahkan jangka hayat dan untuk memberi lebih
keuntungan kepada penguna-penguna kereta seperti mengurangkan kos
penyelenggaraan.
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TABLE OF CONTENTS
Page
SUPERVISOR’S DECLARATION ii
STUDENT’S DECLARATION
DEDICATION
iii
iv
ACKNOWLEDGEMENTS v
ABSTRACT vi
ABSTRAK vii
TABLE OF CONTENTS viii
LIST OF TABLES xi
LIST OF FIGURES xii
LIST OF ABBREVIATIONS xv
CHAPTER 1 INTRODUCTION
1.1 Introduction 1
1.3 Problem Statement 2
1.3 Objective 2
1.4
1.5
1.6
Project Scope
Significance of project
Limitation
3
3
3
CHAPTER 2 LITERATURE REVIEW
2.1 Power window system 4
2.2 Power window control 5
2.3 Circuit operation
2.3.1 Obstacle-Sensing window
6
7
2.4
2.5
Power window motor
Model-based design of a power window system
10
1 × ENTER (1.5 line spacing)
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CHAPTER 3 METHODOLOGY
3.1 Introduction 13
3.2 Project Background 13
3.2.1 Project flow chart 14
3.3 Benchmark power window cable type design 15
3.4 Designing current and new parts of the system 17
3.5
3.6
Design analysis
3.5.1 Upper joint design analysis
3.5.2 Carrier plate design analysis
Comparison result
20
20
22
23
CHAPTER 4 RESULTS AND DISCUSSION
4.1 Benchmark activity 24
4.2 Improvement design of upper joint part 26
4.3 Improvement design of carrier plate part 30
4.4 Force calculation
4.4.1 Force calculation on B
4.4.2 Upper joint force calculation
4.4.3 Carrier plate force calculation
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36
37
40
4.5
4.6
Design analysis
4.5.1 Upper joint analysis
4.5.1.1 Discussion
4.5.2 Carrier plate analysis
4.5.2.1 Discussion
New design selected
40
40
45
46
51
53
CHAPTER 5 CONCLUSION AND RECOMMENDATIONS
5.1 Conclusion 54
5.2 Recommendations 55
x
REFERENCES 56
APPENDICES 57
A Material properties 57
B Gantt chart 58
xi
LIST OF TABLES
Table No. Title Page
4.1 Results of upper joint analysis 43
4.2
4.3
Results of carrier plate analysis
New design selected
49
53
xii
LIST OF FIGURES
Figure No. Title Page
2.1 A power window system 5
2.2 Typical power window circuit 7
2.3 The infrared sensor for a smart window system 8
2.4 Direct drive motor 9
2.5 Motor use a rack-and-pinion gear set 9
2.6 A V Diagram of the System Design and Realization Process 11
3.1 Flowchart of project 14
3.2 Proton Gen-2 rear door power window system 15
3.3 Current upper joint design 16
3.4 Current carrier plate design 16
3.5 Current upper joint design 17
3.6 New upper joint design 1 17
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
New upper joint design 2
Current carrier plate design
New carrier plate design 1
New carrier plate design 2
Current upper joint design analysis
New upper joint design 1 analysis
New upper joint design 2 analysis
Current carrier plate design analysis
New carrier plate design 1 analysis
New carrier plate design 2 analysis
18
18
19
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21
21
22
22
23
xiii
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
4.25
Parts in the rear door Proton Gen-2 power window
Upper joint of rear door Proton Gen-2 power window
Carrier plate of rear door Proton Gen-2 power window
Current design of upper joint – front view
Current design of upper joint – side view
Current design of upper joint – rear view
New design 1 of upper joint – front view
New design 1 of upper joint – side view
New design 1 of upper joint – rear view
New design 2 of upper joint – front view
New design 2 of upper joint – side view
New design 2 of upper joint – rear view
Current design of carrier plate – front view
Current design of carrier plate – side view
Current design of carrier plate – rear view
New design 1 of carrier plate – front view
New design 1 of carrier plate –side view
New design 1 of carrier plate –rear view
New design 2 of carrier plate – front view
New design 2 of carrier plate – side view
New design 2 of carrier plate – rear view
Dimension of the system
Free body diagram of the system
Current design stress analysis
New design 1 stress analysis
24
25
25
26
27
27
28
28
29
29
30
30
31
31
32
32
33
33
34
34
35
35
36
40
41
xiv
4.26
4.27
4.28
4.29
4.30
4.31
4.32
4.33
4.34
4.35
4.36
4.37
4.38
4.39
New design 2 stress analysis
Current design displacement analysis
New design 1 displacement analysis
New design 2 displacement analysis
Stress Von Mises of upper joint design
Displacement of upper joint design
Current design stress analysis
New design 1 stress analysis
New design 2 stress analysis
Current design displacement analysis
New design 1 displacement analysis
New design 2 displacement analysis
Stress Von Mises of carrier plate design
Displacement of carrier plate design
41
42
42
43
44
45
46
47
47
48
48
49
50
51
xv
LIST OF ABBREVIATIONS
3D Three dimension
AISI America Iron and Steel Institute
CAE Computer-aided engineering
FEA Finite element analysis
FYP Final year project
UMP Universiti Malaysia Pahang
UTS Ultimate tensile strength
CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION
Power window or electric window system is a part of an automotive element
which locates at the door of vehicle. The purpose of power window system is to raise
and lower door glass by depressing a switch in order to replace the use of hand-turned
crank handle. Power window system is made up of driver motor, electronic power and
control system.
Power window system is divided in two types. They are cable type power
window system and scissors type power window system. The main functions for both of
them are for raising and lowering the automobile windows using a dc motor. For this
project, the focus is to the cable type power window system. The cable type has four
components consisted of electric motor, railing, cable, and switch. The mechanism
works by using the cable to raise and lower the glass. The window glass is attached at
the carrier plate and the cable is located on the railing surface. Motor is use to rotate the
cable in order to move the window up and down using a gear attached to the motor and
the cable.
This design project covers the improvement of the cable type system. The
improvement is based on the parts design, material used and load testing. The load
testing is using Algor, a Finite Element Analysis (Fea) software. Analysis using
software to test the design on this project.
2
1.2 PROBLEM STATEMENT
Power window system is one of the common components that are built in a car.
It is not a compulsory component but more to accessory component which can help
user. The current power window system in Proton Gen-2 rear door is the cable type
system. The common complaints from the customers are:
(i) Frequent problem cause by window jammed.
(ii) Glass drops during down operation.
(iii) Cable that be use is easier to snap.
(iv) The slider hook easy to break causes the cable cannot move smoothly.
(v) Rough sound when glass reaches top position.
(vi) All above issues cause premature failure of power window and reflects
high repair cost.
The problems arise from components that are easy to damage or broken. For
example, the pulley that is used is easy to cracks or broken. This makes the cable get out
from the pulley. The pulley is also only mounted on the railing by using one riveting pin
and causes the pulley easy to disengage from the railing. The riveting cable guide
cracks or broken causes the cable not able to move smoothly. The slider hook is easy to
break, this makes the window detaches from the railing. So, the window cannot be
pulled up or down. These entire causes make the power window cannot be used in a
longer than normal period. So, the users have to spend some money in order to replace
the power window system after a couple of years.
1.3 OBJECTIVE
The main objective of this project is to improve the design of cable type system.
It will be designed using Solidwork and Catia Software. Another main objective is to
analyze the current and improvement design using Finite Element Analysis Software.
The design will be analyzed in ALGOR software. Another objective is to make the
design simpler and to increase the life time of the system.
3
1.4 PROJECT SCOPE
Study the current design of mechanical parts for cable type power window
system. Proton Gen-2 rear door power window is selected as the benchmark design.
Design and improve the current design using Solidwork. Make the analysis using CAE
(ALGOR) software.
1.5 SIGNIFICANCE OF PROJECT
The significance of this project is to reduce the problem that user of Proton Gen-
2 faced. The new parts design will help reducing the maintenance cost of the user in
order to maintain their power window system in a good condition. The planning is to
make a new part which can be used for a long time without any failure. So, the user can
use the system in their Proton Gen-2 without faced any problem and can spend their
money for other usage.
1.6 LIMITATION
During this project, some limitations occurred. One of them is not many
references about the cable type power window system. This gave difficulty for me to
research the background. However, another alternative is by using the books from
University Malaysia Pahang (UMP) library. Other limitation is, three dimensional (3D)
scanner was under maintenance. In order to continue with the project, normal
measurement was implemented.
CHAPTER 2
LITERATURE REVIEW
2.1 POWER WINDOWS SYSTEM
The purpose of power windows system is to raise and lower windows. The
systems do not vary significantly from one model to another. The major components of
a typical system are the master control switch, individual window control switches, and
the window drive motors (Erjavec 2005).
They can be operated by both a master control switch located beside the driver
and additional independent switches for each electric window. Some power window
systems use a lockout switch located on the driver’s control to prevent operation of the
power windows from the independent switches. Power window are designed to operate
only with the ignition switch in the “on” (run) position. This safety feature of power
windows should never be defeated. Some manufacturers use a time delay for accessory
power after the ignition switch is turned off. This feature permits the driver and
passengers an opportunity to close all windows or operate other accessories for about 10
minutes or until a vehicle door is opened after the ignition has been turned off
(Halderman and Mitchell, 2003).
Most power window systems use permanent magnet electric motors. It is
possible to run a PM motor in reverse direction simply by reversing the polarity of the
two wires going to the motor. Most power windows motors do not require that the
motor be grounded to the body (door) of the vehicle. The ground for all the power
windows is most often centralized near the driver’s master control switch. The up-and-
down motion of the individual window motors is controlled by double-people, double-
5
throw (DPDT) switches. These DPDT switches have five contacts and permit battery
voltage to be applied to the power window motor and to reverse the polarity and
direction of the motor (Halderman and Mitchell, 2003).
Figure 2.1: A power window system
2.2 POWER WINDOW CONTROL
The window is controlled manually by means of a rocker switch. For a greater
convenience, power window can be linked to a central or decentralized closing system
which, when the vehicle is locked, closes the windows automatically or sets them to a
predefined partially open position for a ventilation purposes when the windows are
6
closed, a force limitation device comes into effect. The device serves to prevent human
limbs from being caught by the closing window. In Germany, paragraph 30 of the St
V20 (Road traffic Licensing Regulations) stipulates that the force limitation device must
be effective when the window is moving upwards within a range of 200 to 4mm from
the upper edge of the window aperture (Gilles and Barbara, 2002).
The power window drive units include integral Hall-effect sensors to monitor
motor speed during operation. If a reduction in speed is detected, the motor’s direction
of rotation is immediately reversed. The window closing force must not exceed 100N at
a spring rate of 10N/mm. The unit automatically overdrives the force limitation function
immediately before the window enters the door seal, allowing the motor to run to its end
position and permitting complete closure of the window. The window position is
monitored over its entire range of movement. Electronic control may be dispersed
among the individual power window motors in order to reduce the complexity of the
wiring. Future decentralized electronics will be networked via bus interfaces (LIN bus/
CAN bus). The advantages offered are fault diagnosis for the electronics and further
reduction of the amount of wiring (Robert Bosch Gmbh 2006).
2.3 CIRCUIT OPERATION
Typically a permanent magnet motor operates each power window. Each motor
raises or lowers the glass when voltage is applied to it. The direction that the motor
moves the glass is determined by the polarity of the supply voltage. Voltage is applied
to a motor when any UP switch in the master switch assembly is activated. The motor is
grounded through the DOWN contact. Battery voltage is applied to the motor in the
opposite direction when any DOWN switch in the master switch assembly is activated.
The motor is then grounded through the master switches UP contact (Schwaller 1999).
The operation of the individual window switches is much the same. When the
UP switch is activated, voltage is applied to the window’s motor. The motor is grounded
through the DOWN contact at the switch and the DOWN contact at the master switch.
7
When the DOWN switch in the window switch is activated, voltage is applied to the
motor in the opposite direction. The motor is grounded through the UP contact at the
window switch and the UP contact in the master switch. This runs the motor in the
opposite direction (Erjavec 2005).
Each motor is protected by an internal circuit breaker. If the window switch is
held too long with the window obstructed or after the window is fully up or down, the
circuit breaker opens the circuit (Erjavec 2005).
Figure 2.2: Typical power window circuit
2.3.1 OBSTACLE-SENSING WINDOWS
This feature is available on some vehicles and prevents the window from closing
if something is in the way, such as fingers. On some systems, if the window is closing
and contacts something, the window will reverse and open fully. Other systems do not
require direct contact with an obstacle. Rather, they rely on infrared sensors. When the
8
light beams are broken by the presence of an obstacle, the window will reverse and go
down (Schwaller 1999).
Figure 2.3: The infrared sensor for a smart window system
2.4 POWER WINDOW MOTOR
Power window have a mechanism that are driven by electric motor. There are
two types of system in use. The available installation space assumes a prominent place
among the criteria applied in determining which system to install. The types of power
window that always be use are rod linkage regulator mechanism and flexible cable
mechanism. For a rod linkage regulator mechanism, the drive motor pinion engages
with a quadrant gear, which is connected to a rod linkage. The use of this type window
regulator mechanism is decreasing. For a flexible cable mechanism, the drive motor
turns a cable reel, which operates a flexible cable mechanism (Chapman 1999).
9
Figure 2.4: Direct drive motor
Figure 2.5: Motor use a rack-and-pinion gear set