Material And Structure Optimization And Value Engineering Applied To Car Door Window Regulator -- A Case Study

Aim Of Project
In this project automobile window regulator is selected as a case study for
the use of optimization technique in engineering design. This is a project of the
work performed towards the stiffness optimization of an automobile window
regulator.
The aim of the project is to analyze the car window regulator with presently
used material steel and replacing with Plastic if Possible. Also we are going to
reduce weight of the window by using Plastic materials replacing with steel. The
aim is to achieve the essential function at the lowest overall cost while maintaining
optimum value assurance. In this project, the Car window regulator modeled using
software CATIA.
This project intends to explore the adoption of Value Engineering (VE) as a
value creation tool. This project presents the basics of Value Engineering and its
different phases that can be implemented to a window regulator for its
optimization. Value Engineering can improve the product cost by reducing the
unnecessary costs associated with the product.
My long term goal is to postulate and validate design metrics which
effectively and efficiently measure the remanufacturability of given designs. As
well as identifying existing remanufacturing guidelines, philosophies, and practices.
IKSC Knowledge Bridge Pvt. Ltd. 2J T M College of Engg. Faizpur

Content
1 1.1 Introduction (Window Regulator) {Pre-Study}
1.2 Introduction (Value Engineering) {Pre-Study}
2 Literature Review {Value Study} (Information Phase)
3 Conceptual Design (Function Analysis Phase)
4 Mechanical Modeling (Creative Phase)
5 Meshing And Analysis (Evaluation Phase)
6 Improvement (Development Phase)
7 Conclusion (Result Phase)
8 References

1. INTRODUCTION 1.1 Window Regulator (Pre-study)
• Window regulators are
found in vehicle doors and
are used to lower and raise
the window glass car
windows.
• Cable System
• Double Bowden System
• Scissor System

• Bowden System Types of Window Operation
• Manually Operated
• Power Operated

1.2 Value Engineering (Pre-study)
History
The value analysis methodology was started in the late 1940's by Lawrence D. Miles Lawrence D. Miles
started the value analysis methodology in the late 1940’s while working in the purchasing department at General
Electric.

1.2 Value Engineering (Pre-study)
Introduction
Value Engineering is a technique for
determining the manufacturing requirements
of a product/service; it is concerned with its
evaluation and finally the selection of less
costly conditions.
VE is a process for achieving the
optimal result in a way that quality, safety,
reliability and convertibility of every monetary
unit are improved.
Value Engineering is usually applied in
the analysis and design of a service/product.
Fig Product Design Influence

J T M College of Engg. Faizpur IKSC Knowledge Bridge Pvt. Ltd. 8
What Is Value ?
Worth = Product, Delivery, Service, Fast Response, Programs, Merchandising, Credit, Relationship, Accuracy, Reliable
Information, Problem Solving, Technical Assistance, Sales Person/Rep, Cheerfulness, Sympathy
Cost = Price, Problems, Hassle, Time, Confusion, Misunderstanding, Fear, Frustration, Unnecessary Repeat Phone
Calls, Processing Deductions, Returnable Product.
Function = The specific worth that a design/item must perform
Quality = The owner’s or user’s needs, desires, and expectations
Cost = The life cycle cost of the product/project.
Value = The most cost effective way to reliably accomplish a function that will meet the user needs, desires and
expectations.

The Value Methodology

Pre-Study Value Study
Post Study
• Collect Customer Attributes
• Determine Evaluation Factor
• Build Data Models
• Complete Data File
• Determine team composition
STEP 1
Methodology
STEP 2
STEP 3
• A. Information Phase
• B. Function Analysis Phase
• C. Creative Phase
• D. Evaluation Phase
• E. Development phases
• F. Result / conclusion Phase
• Complete Changes
• Implement changes
• Monitor Status

A Information Phase
Complete Data Package
Modify Scope
B Function Analysis Phase
Identify Functions
Classify Functions
Develop Function Models
Establish Function Worth
Cosl Functions
Establish Value Index
C Creative Phase
Create Quantity of Ideas by Function
D Evaluation Phase
Rank and Rate Alternative Ideas
Select Idea for Development
E Development phases
Conduct Benefit Analysis
Complete Technical Data Package
Create implementation Plan
Prepare Final Proposals
F Result / conclusion Phase
Present Oral Report
Prepare written Report

A Information Phase
Step 2 {VALUE STUDY}
In the literature, lots of patents about different types of window regulators can be found. These window
regulators can be grouped into five main headings according to their functioning.
A window regulator mechanism
utilizing rack and pinion
Window regulator mechanism
using pulleys and wires
A different type of window regulator
mechanism using arms

A different window regulator mechanism
using pulleys and wires
Window regulator mechanism utilizing
cross armed mechanism

Exploded view window mechanisms of car door.Exploded view external cover of car door.

B Function Analysis Phase
Literature survey constitutes the background for concept development. Therefore, five different
concepts are created based on types of window regulator mechanisms found in the literature survey.
Concept I
An illustrative sketch of Concept I
Concept II
A descriptive sketch of Concept II
Concept III
An explanatory sketch of Concept III

Concept IV
An illustrative sketch of Concept IV
Concept V
A descriptive sketch of Concept V

Points Meaning
0 Absolutely useless solution
1 Very inadequate solution
2 Weak solution
3 Tolerable solution
4 Adequate solution
5 Satisfactory solution
6 Good solution with few drawbacks
7 Good solution
8 Very good solution
9 Solution exceeding the requirement
10 Ideal solution
Value scale used for the evaluation of concepts Assigned weights to concept evaluation criteria
Evaluation Criterion Concept 1 Concept 2 Concept 3 Concept 4 Concept 5
Small Number of Components 4 5 6 5 6
Low Complexity of Components 6 5 6 4 5
Low Complexity of Concept 7 6 7 5 3
Long Service Life 4 5 7 6 5
Regular Force Transmission 3 4 8 5 4
Low Noise Operation 3 4 9 6 5
Simple Assembly 6 3 8 5 4
Low Space Utilization 5 4 8 4 3
Total Points 38 36 59 40 35
After Analyzing if above Table concept 3 is the best alternative
Among all concept so, I have chosen it for further Improvement.

In these window regulator the regulator carriage plate has a scope to further
improvements so from onwards in these project specially focused on regulator carriage plate only.

C Creative Phase
Mechanical Modeling
Part Windows carriage Plate Drafting

D Evaluation Phase
Meshing And Analysis Of Carrier Plate
Boundary Conditions
Material 1 ( Steel )
Material Steel
Young's modulus 2e+011N_m2
Poisson's ratio 0.266
Density 7860kg_m3
Coefficient of thermal expansion 1.17e-005_Kdeg
Yield strength 2.5e+008N_m2
Force Applied on Force 100N

Stress on plate 100N, Result -- (2.42x10^7Pa)
Stresses And Translational Displacement 0.000887mm

E Improvement / Development Phase
By removing unnecessary material with control on following parameters
1. Reduce the weight as more as possible.
2. No reduce in strength of a part.
3. Maintain a stress of part in a permissible limit.
4. If Possible replace a metal material by Thermoset Plastic material.
5. Find out a more functional design which has no maintenance & corrosion free.
Remove extra material- To reduce the weight of plate without hampering
strength and center of gravity of plate, 6 holes are created which are along the
circumference of the point of center of gravity.

Material and Structure Optimization
Fig. Modified Carrier Plate ( 6 Holes )
Weight before holes Weight after holes Percentile reduction in weight
200gm 188gm 6%
Material Plastic Polyamides
Young's modulus 3.2e+009N_m2
Poisson's ratio 0.36
Density 1120 kg_m3
Coefficient of thermal
expansion
1.49e-4 strain/°C
Material 2 ( Plastic)

F Result / conclusion (Phase)
•By making hole in carriage plate weight reduction is up to 6%
•The study helped in designing plastic door window regulator module plate
for car body application using Plastic Polyamides material, topology and
shape optimization techniques.
•Final design of the plastic module is 40% lesser in weight with improved
structural, properties compared to existing steel door module plate.
•The design and analysis methodology adopted here to design plastic door
module plate to replace existing steel door module plate can be adopted to
design and analysis plastic parts to replace semi structural automotive parts
currently made from steel.

References
• Cross, N. (2008). Engineering design methods: strategies for product
design. 3rd ed. Chichester: Wiley.
• Dod 4245.8-H Value Engineering March 1986 [6] Val u e E n g i n e e
r i n g w h i t e p a p e r , www.kpitcummins.com
• http://www.value-engineering.com/consulting.htm
• Starbek, M.; Menart, D. The optimization of material flow
• Cabello, J., Márquez, F., Pérez J.M., & Verdier, C. (2009). Industrial
Design Methodology / Metodología del diseño industrial. 1st ed.
Málaga: SPICUM servicio de publicaciones.

Material And Structure Optimization And Value Engineering Applied To Car Door Window Regulator -- A Case Study

More Related Content

What's hot (20)

Similar to Material And Structure Optimization And Value Engineering Applied To Car Door Window Regulator -- A Case Study (20)

More from Jayesh Sarode (11)

Recently uploaded (20)

Material And Structure Optimization And Value Engineering Applied To Car Door Window Regulator -- A Case Study