design and fabrication power window apparatus
TRANSCRIPT
DESIGN AND FABRICATION POWER WINDOW APPARATUS
(BOWDEN CABLE TYPE)
AHMAD KAMIL BIN MISKAM
A report submitted in fulfillment of the
requirement for the award of the Diploma
of Mechanical Engineering
Faculty of Mechanical Engineering
University Malaysia Pahang
NOVEMBER 2007
ABSTRACT
The main purpose of this Power window apparatus project is to train final
year student for hands on experience and to work by themseif. The study of
manufacturing is very important in order to ensure that student understand on what
are the needs to do in this project. This project is about designing and fabricating the
Power Window Apparatus for experimental use to help the students in a Automotive
course for easy understanding the basic system of power window and how it works.
This project involves the process of designing the test panel by considering the
shape and also the advantages for student to use in their learning process. After the
design has been completed, it was transformed to the real product by fabricating
process where the design is used for guideline. This project also required analysis to
test the power window operation failure factor. Numerous methods and process
involve in this project for instance joining using welding process. After all the
process had been done, this power window apparatus help us to understand the
fabrication and designing process that involved in this project.
kTJ
ABSTRAK
Tujuan utama projek 'power window apparatus' mi ialah memberi pelajar
pengalaman bekeija dan bekeija dengan sendiri . Pembelajaran di dalam bidang
pembuatan adalah sangat penting untuk memastikan pelajar memahami apa yang
harus dibuat di dalam projek mi. Projek mi adalah mengenai merekabentuk dan
menghasilkan peralatan 'power window' untuk tujuan eksperimen bagi membantu
pelajar di dalam kursus Automotif untuk mudah memahami sistem asas bagi sebuah
'power window' dan bagaimana ia beroperasi. Projek mi melibatkan proses
merekabentuk sebuah 'test panel' dengan mengambil kira bentuk dan juga
kelebihannya dalam membantu para pelajar di dalam proses pembelajaran mereka.
Setelah rekaan yang ingin dihasilkan siap, ia akan ditukarkan kepada produk yang
sebenar di dalam proses penghasilan dimana rekaan tadi akan dijadikan sebagai
panduan. Projek im juga merangkumi analisis keatas faktor kegagalan 'power
window' beroperasi. Banyak cara dan proses yang terlibat dalam proses
penyambungan, sebagai contoh menggunakan proses welding. Setelah kesemua
proses yang terlibat di dalam projek mi selesai, peralatan 'power window' mi
membantu kita memahami proses mereka dan menghasilkan yang terlibat di dalam
projekini.
vi
TABLE OF CONTENT
CHAPTER TITLE PAGE
1 INTRODUCTION 1
1.1 Project Synopsis 1
1.1.1 Specific Project Synopsis 2
1.2 Objective of Final year student 2
1.3 Scope of work 2
1.4 Project planning 3
2 LITERATURE REVIEW 6
2.1 Introduction 6
2. 1.1 Working principle 7
2.1.1.1 The Lifting Mechanism 7
2.1.2 A Basic System 8
2.1.3 An Advanced System 9
vii
viii
2.2 Type of power window 9
2.2.1 Existing Power Windows type 9
2.3 Motors 12
2.3.1 Type of motor 12
2.3.1.1 Direct Current(DC) Motor 12
2.3.1.2 Alternate Current(AC) Motor 13
3 METHODOLOGY 14
3.1. Process flowchart 14
3.1.1. Flow chart description 15
3.1.2. Project Methodology 17
3.1.2.1 Stage One: Study 17
3.1.2.2 Stage Two: Design 17
3.1.2.3 Stage Three: Purchasing 18
3.1.2.4 Stage four: Material Selection 18
3.1.2.5 Stage Five: Fabrication and Modification 18
3.1.2.6 Stage Six: Assembly 19
3.2. Gantt Chart 19
3.2.1. Project schedule 20
4 RESULT AND DISCUSSION 24
4.1 Introduction 24
4.2 Design Specification 25
Ix
4.3 Design Selection 25
4.3.1 Concept Generation and Evaluation 27
4.3.2 Propose Design 28
4.4 Fabrication of the power window test panel 29
4.4.1 Process involve 29
4.4.1.1 Measuring process 30
4.4.1.2 Cutting process 30
4.4.1.3 Drilling process 31
4.4.1.4 Welding process 32
4.4.1.5 Finishing process 33
4.4.1.6 Assembly process 33
4.5 Analysis 34
4.5.1 Experiment result 34
4.5.2 Calculation methods 37
5 CONCLUSION AND RECOMMENDATION 41
5.1 Introduction 41
5.2 Project Problem 41
5.3 Recommendation 42
5.4 Future Work 42
5.5 Conclusion 43
REFERENCES 44
APPENDICES 45
LIST OF FIGURES
FIGURE TITLE PAGE
1.0 Power window work 7
1.1 Motor direction 8
1.2 Wiring system window going up on driver control 10
1.3 Wiring system window going down 11
1.4 Wiring system window going up on passenger control 11
1.5 Wiring system window going down 12
2.0 Three of the most popular GM motors 13
2.1 Two popular Ford motors 13
3.0 Project Flow Chart 15
3.1 Gantt chart of Power window Project 19
4.0 Sketching design A 25
4.1 Sketching design B 26
4.2 Sketching design C 26
4.3 Sketching design D 26
4.4 Sketching design E 26
4.5 Datum concept 26
4.6 Propose design on Solidworks 26
4.7 Measuring process 30
XI:
4.8 Cutting process 30
4.9 Cut the sheet metal using shear machine 31
4.10 Drill the holes using drilling machine 31
4.11 MIG welding machine. 32
4.12 Welding the test panel frame 32
4.13 Finished welding the test panel frame 32
4.14 Finishing test panel frame 33
4.15 Assembled test panel frame 33
4.16 Experiment apparatus 34
4.17 Graph analysis for voltage versus max load 36
4.18 Graph analysis for power versus max load 36
4.19 Distance between starting point and pivot point 37
4.20 Graph analysis for required power versus max load 40
LIST OF TABLES
TABLE TITLE
PAGE
Table 4.0 Result of the experiment
35
Table 4.1 Calculation result 39
xli
LIST OF APPENDICES
APPENDIX TITLE
PAGE
A Machine and tools
45
B Material used
47
C Solidworks drawing 48
xli'
CHAPTER 1
INTRODUCTION
1.1 Project synopsis
This project concerned on design a test panel of a power window, fabricate and
test the platform as an experiment apparatus. In order to fabricate the test panel, this
project required a lot of machining process in mechanical such as metal cutting, and
grinding. This project also required a skills in manufacturing process such as MIG
welding to joint the parts and etc. Basically the main processes that involved in this
entire power window apparatus project are the fabrication of the frame panel, the base
and the T beams ,assembly the panel frame and the wiring of motor on the power
window system.
1.1.1 Specific Project Synopsis
My project title is Design and Fabrication Power Window Apparatus (Burden
Cable type).Panel will work to test the power window failure factor and easy to
understand how power window work. This project also involved the analysis of the
cable strength, durability and the adjustment of the system itself. It is fabricated as an
experiment Equipment/Material to assist the learning process of automotive class in
Faculty of Mechanical Engineering. Overall, this project will acquire the skills of
design, analysis, fabrication and testing.
1.2 Objectives of Project
(i) To design the power window test panel.
(ii) To fabricate the power window test panel.
(iii) To test the test platform as an experiment apparatus.
13 Scope of Work
Fabrication of the power window test panel requires special coordinated scope
Of work. As this is a new project, special scopes of works have to be determined so that
the main objective and goal can be achieved.
3
These scopes help the team to be focused and knew about his or hers job. These
scopes are:
(i) Literature Review: Valuable data are searched and gathered. Considering
the design of the test panel in terms of its complexity and method to
produce.
(ii) Sketching & Designing: Sketching and designing using Solid works
software in creating the design of the test panel for power window
(Bowden cable type only).
(iii) Fabrication: Fabricate and produce the test panel by using all necessary
manufacturing process such as welding, cutting, grinding and etc.
(iv) Testing: Test the design system that works like an actual power window.
(v) Analysis: Analysis the power window failure factor according to:
(1) Load (attached the load at the regulator).
(ii) Surface contact (effected by door structure part).
It is the time where the soft skill e.g. punctuality, self discipline, time
management and problem solving been practices because the project is highly depends
on the effectiveness of all the skill as much as the knowledge the student has learn.
1.4 Project planning
This project began with investigation and research literature review via internet,
reference books, supervisor and other relevant academic material that related to this
project. To make this project more accurate and suitable, I study more about related
4
topic and spent more than two weeks doing a literature review. Every week,
improvement of knowledge needed to make sure this project will be completed very
well.At the same week I do some schedule management for this project which
included schedule management. This is done using Microsoft Office Project using Gantt
chart system. This also takes a week to accomplish.
Then, discuss with supervisor about the title and continue detail research about
the power window (Bowden cable type). After research already finish, decision making
a design should be applied to choose a design that suitable among engineering student.
The sketching of the model takes about 1 week to be done. The sketching done
using manual sketched at A4 size paper and the engineering drawing is done using
Solidwork software. The sketching of the design are detail discussed and the best design
that suits are selected. The design are selected based on concept selection that have been
learned in the Industrial Design subject.
The next task is preparation of progress for mid-presentation and progress report
writing, both of these tasks takes two more week to be done. After that comes the
progress presentation week and progress report submission. On this particular week I
have to prepare the speech for the presentation and double checked the presentation
slide and report that has to be submitted. The student also receives a comment and
correction from the supervisor about the presentation.
The next week is the fabrication week where the project parts start to be
fabricated. The frame panel, T base and other parts are fabricated according to the
selected design. The fabrication process is schedule to finished by two week but
because of fabrication process is have a lot of part to cutting and fabricated, then this
process is scheduled to take about four weeks.
5
Next the assembly process of power window regulator and motor on the test
panel that already finished, then testing and analysis, correction, and finishing of the
model. This task scheduled to take time about two weeks.
Next task is the final report writing and final presentation preparation. This take
about three week to complete. The report is done with the supervisor's guidance. Due to
all problems, the project the management has agreed to extend the time to submit the
report and the presentation. All the task is scheduled to take about sixteen weeks
overall.
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
Power windows or electric windows are automobile windows which can be
raised and lowered by depressing a button or switch, as opposed to using a hand-turned
crank handle. The power moonroof, a transparent, retractable sunroof, may be
considered as an extension of the power window concept. The first electric power
windows were introduced around 1946 by Lincoln. These are driven by a small electric
motor inside the door and have come to be universal in the industry. Prior to that date,
in the few vehicles offering this feature, the windows were driven by hydraulics or off
the engine vacuum. In the 1950s, electric power was also applied to the tailgate
window, in many station wagons. In a typical installation, there is an individual switch
at each window and a set of switches in the driver's door, so the driver can operate all
the windows. However, some models have used switches located in the center console,
where they are accessible to all the occupants. In this case, the door-mounted switches
can be omitted.
2.1.1 working Principle
7
2.1.1.1 The Lifting Mechanism
Figure 1.0 :Power window work
This cool device is the heart of a power-window system. The window lift on
most cars uses a really neat linkage to lift the window glass while keeping it level. A
small electric motor is attached to a worm gear and several other spur gears to create a
large gear reduction, giving it enough torque to lift the window.
The linkage has a long arm, which attaches to a bar that holds the bottom of the
window. The end of the arm can slide in a groove in the bar as the window rises. On
the other end of the bar is a large plate that has gear teeth cut into it, and the motor turns
a gear that engages these teeth. The same linkage is often used on cars with manual
windows, but instead of a motor turning the gear, the crank handle turns it. In the next
section we'll learn about some of the neat features some power windows have, including
the child lockout and automatic-up.
8
MOTOR
Figure 1.1: Motor direction
2.1.2 A Basic System
On this system, the power is fed to the driver's door through a 20-amp circuit
breaker. The power comes into the window-switch control panel on the door and is
distributed to a contact in the center of each of the four window switches. Two contacts,
one on either side of the power contact, are connected to the vehicle ground and to the
motor. The power also runs through the lockout switch to a similar window switch on
each of the other doors.
When the driver presses one of the switches, one of the two side contacts is
disconnected from the ground and connected to the center power contact, while the other
one remains grounded. This provides powerto the window motor. If the switch is
pressed the other way, then power runs through the motor in the opposite direction.
2.1.3 An Advanced System
On some cars, the power windows work in a completely different way. Instead
of the power for the motor going through the switches directly, the switches are
connected to one of the many electronic modules in the car (the average car contains
25). Some cars have one in the driver's door, as well as a central module called the body
controller. Cars that have lots of controls on the door are more likely to have a setup
like this. Some cars have the power-window, power-mirror, power-lock and even
power-seat controls all on the door. This would be too many wires to try to run out of
the door. Instead of trying to do that, the driver's door module monitors all of the
switches. For instance, if the driver presses his window switch, the door module closes
a relay that provides power to the window motor. If the driver presses the switch to
adjust the passenger-side mirror, the driver's door module sends a packet of data onto
the communication bus of the car. This packet tells the body controller to energize one
of the power-mirror motors.
2.2 Type of power window
2.2.1 Existing Power Windows type
Automatic Up/Down - The automatic-down feature is fairly common on cars
with power windows. You tap and release the down switch and the window goes all the
way down. This feature uses a circuit that monitors the amount of time you hold the
switch down. If the switch is down for less than about half a second, the window will go
all the way down until it hits the limit switch. If you hold the switch down for longer
than that, the window will stop when you release the button. Automatic-up windows are
less common.
10
The problem with automatic-up windows is that if anything gets in the way of
the window, such as a child, the window has to stop moving before it hurts the child.
One way that car makers control the force on the window is by designing a circuit that
monitors the motor speed. If the speed slows, the circuit reverses the power to the motor
so the window goes back down.
Window Control From Outside - On the Volkswagen in the TV commercial, the
windows can be lowered by inserting the key in the driver's door, turning and holding it.
This feature is controlled by the driver's door module, which monitors a switch in the
door lock. If the key is held turned for more than a set amount of time, the driver's door
module lowers the windows.
Courtesy Power-On - Some cars maintain the power to the window circuit after
you turn your car off, which saves you from having to stick your key back in the
ignition if you forget to roll your window up. The power-window circuit will have a
relay on the wire that provides the power. On some cars, the body controller keeps this
relay closed for an extra minute or so. On other cars, it stays closed until you open a
door.
n
a a
A simple power-window circuit
Figure 1.2: Wiring system during window going up on driver control.
A simple power-window circuit
Figure 1.3: Wiring system during window going down on driver control.
Lack
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o N a0 2OO1 I trw;
A simple power-window circuit
Figure 1.4: Wiring system during window going up on passenger control.
11
12
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A simple power-window circuit
Figure 1.5: Wiring system during window going down on passenger control.
23 Motors
23.1 Type of motor
23.1.1 Direct Current(DC) Motor
The modem DC motor was invented by accident in 1873, when Zenobe
Gramme connected a spinning dynamo to a second similar unit, driving it as a motor.
The classic DC Motor has a rotating armature in the form of an electromagnet. A rotary
switch called a commutator reverse the direction of the of the electric current twice
every cycle.
13
Figure 2.0 Three of the most popular GM motors
23.11 Alternate Current(AC) Motor
In the induction Motor, the field and armature were ideally of equal field
strengths and the field and armature cores were of equal sizes. The total energy supplied
to operate the device equal the sum of energy expended in the armature and field coils.
--
- . ( --4\_ j -: --------J - - -- -
It -
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Figure 2.1 : Two popular Ford motors
CHAPTER 3
METHODOLOGY
33. Process Flowchart
In fabrication of the project, there is a planning of the overall progress to assure
the project can be finish on schedule.