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 re manufacturing guidelines, philosophies, and practices.

1. i
A
Project Report
On
“MATERIAL AND STRUCTURE OPTIMIZATION AND
VALUE ENGINEERING APPLIED TO CAR DOOR
WINDOW REGULATOR -- A CASE STUDY”
Submitted By
SARODE JAYESH SUDHAKAR
for the Partial Fulfillment of Master of Mechanical Engineering
-
Guided By
Prof. V. L. FIRAKE
Department of Mechanical Engineering
J.T.Mahajan College of Engineering Faizpur
Dr. Babasahheb Technological University, Lonere (M.S.).
2017 – 2018

2. ii
T.M.E.Society’s
J .T.MAHAJAN COLLEGE OF ENGINEERING
FAIZPUR, DIST. JALGAON.
CERTIFICATE
This is to certify that the Project report entitled ,“ MATERIAL AND STRUCTURE
OPTIMIZATION AND VALUE ENGINEERING APPLIED TO CAR DOOR WINDOW
REGULATOR -- A CASE STUDY”, submitted by Sarode Jayesh Sudhakar for the partial
fulfillment of award of Master Degree in Mechanical Engineering (Machine Design) (Sem-II),
has been accepted under the Dr. Babasahheb Technological University, Lonere (M.S.).
Prof. V. L. FIRAKE Prof. K.K.Chaudhari
(Guide) (P.G. Coordinator)
Prof. D.A.Warke Dr. Nandini Chaudhari
Head, (Principal)
Department of Mechanical Engineering

3. iii
ACKNOWLEDGEMENT
One doesn’t really understand the importance of acknowledgements until one has to write
them. I find myself unable to aptly acknowledge all the help and guidance I received throughout the
course of the preparation of this Project from various quarters. I cannot overstate the importance of
the guidance I received from my guide PROF. V. L. FIRKE , Not only did he guide me in the
choice of the topic but also went out of his way to provide the background study material for the
same. For all this and more, I thank him.
My sincere gratitude goes also to PROF. D.A.WARKE, the Head of the Mechanical
Engineering Department, for the support and encouragement he provides to everyone in this
department. A word of thanks also for all the staff, teaching and non-teaching, because whether it be
a Project or any other student activity, there’s always a contribution from them. Lastly I would like
to thank all my classmates for their support during this Project report.
SARODE JAYESH SUDHAKAR
M.E. Mechanical ( Machine Design)

4. iv
ABSTRACT
The evolution of window regulator technology has led to increased vehicle
occupant comfort and convenience as new systems become available. It also offers a growing
opportunity for the independent Aftermarket. Manual window regulators, while still in use, are
declining steadily. At the other end of the technology spectrum, the most advanced electronic
units feature one-touch comfort function and anti-pinch operations.
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 . Three-dimensional CAD
software (such as CATIA) enables us not only to define kinematical relationships but also to
investigate free traveling on newly developed systems. By dosing so, potential errors can be
minimized in the design phase, so that the costly prototype manufacturing can be prepared most
favorable. The final result is a window regulator more stiffer.
Car window is one of the main parts which are used as protection for passengers
from side collisions. The aim of the project is to analyze the car window regulator with
presently used material steel and replacing with composite materials like Aluminum, Carbon
Epoxy, S-glass epoxy, E-Glass epoxy. Also we are going to reduce weight of the window by
using composite materials replacing with steel. By this we have to reduce the damage
percentage of the car and passenger protection. In this project, the Car window regulator
modeled using parametric modeling software CATIA. CATIA is the standard in 3D product
design, featuring industry-leading productivity tools that promote best practices in design. In
order to define, create and communicate ideas and solutions, the design was modelled in CATIA
software to create the final renders. Once the overall design was defined, materials and
accessories were specified.
This project intends to explore the adoption of Value Engineering (VE) as a value
creation tool. VE relates to a systematic and multi-disciplinary team approach adopted by
organizations which analyze the functional requirements of new and existing products, projects
or services. The aim is to achieve the essential function at the lowest overall cost while

5. v
maintaining customers’ optimum value assurance. 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. It explores each part of the Value engineering job plan for the
successful application of the technique. A case study has been discussed and an analysis has
been carried out by this process to achieve the product optimization. Various tools are used for
the analysis of the product while evaluating the product at different phases. At the end the
results obtained after implementation of this technique are discussed.
A dramatic reduction in environmental impact can be made by product remanufacturing
in which, in contrast to material recycling, the geometrical form of the product is retained and its
associated economical and environmental value preserved. Our 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.
This project details out the analysis of the existing structure and identifies the
drawbacks and explains the process of window system design. Designer from an automobile
engineer faces so many different problems during their work. Some of the major problems in
automobile window are taken as problem for this project and those problems like high weight,
high cost, excessive reinforcements, and water leakage.
The study of manufacturing is very important in order to ensure that student
understand on what are the needs to do in this project. To establish the requirements for the
design, initial studies were performed a literature review, a benchmark of related products
and a study of standard car window designs. After this the final requirements were defined and
the concept generation design phase was begun. In this phase a number of design methods were
applied. The design concepts were systematically evaluated in respect to if, and to what degree,
the concepts met the defined demands and needs of the design. The final concepts were
completed with the demands of the company to obtain the results.
This project is about designing and applying value engineering to the Car Door
Window regulator.

6. vi
CONTENT
Sr. No. Title Page No.
1 1.1 Introduction (Window Regulator) {Pre-Study} 01
1.2 Introduction (Value Engineering) {Pre-Study} 08
2 Objectives 17
3 Conditions And Limitations 17
4 Literature Review {Value Study} (Information Phase) 18
5 Conceptual Design (Function Analysis Phase) 28
6 Mechanical Modeling (Creative Phase) 41
7 Meshing And Analysis (Evaluation Phase) 46
8 Improvement (Development Phase) 51
9 Conclusion (Result Phase) 54
10 References 55

7. 1
1. INTRODUCTION
1.1 WINDOW REGULATOR (PRE-STUDY)
What Is a Window Regulator?
 Window regulators are found in vehicle doors and are used to lower and raise
the car windows.
 One of the standard properties of cars is the capability to open windows
of side doors. As a result, the need of a device that opens windows of car doors
arose with the invention of cars. This device which is used to raise or lower the
window of the car door is called a window regulator.
 Window regulators are components that make it possible to lower and raise
the window glass in a vehicle .
 Necessity of Power Window- To minimize human effort to operate window
Power Window Regulator exactly does?
The power window system allows each of the door windows to be
raised and lowered electrically by actuating a switch on the trim panel of each
respective door.
They are one of the most commonly used parts of the car, since people are
always lowering or raising their windows. Because their continued use, window
regulators are prone to wearing down and breaking. A window regulator can be manually
operated by a hand crank or power operated by an electric motor. Window regulators use
either a cable or a gear to expand or retract the mechanism.
Power window regulators may be equipped with an option specific to the vehicle
such as “Anti-pinch” and/or “1– touch“ feature.
Anti–pinch: This feature prevents an object from becoming lodged or pinched by
the window. If an object is preventing the window from completing the up cycle the
regulator senses the obstruction and reverses the window.
1-touch: This feature allows the operator to either raise or lower the window by
pushing a control once instead or holding it for the full cycle. The instillation of a window

8. 2
regulator (manual or power) requires the removal of the door interior trim panel. The
removal of this panel often causes damage to the retaining clips, handle bezel or even the
vapor barrier.
The evolution of window regulator technology has led to increased vehicle
occupant comfort and convenience as new systems become available. It also offers a
growing opportunity for the independent Aftermarket. Manual window regulators, while
still in use, are declining steadily. At the other end of the technology spectrum, the most
advanced electronic units feature one-touch comfort function and anti-pinch* operations.
Types of Technology
Powered window regulators are supplied in four distinct technologies, each employing a
slightly different method to achieve a similar result:
Cable System
 Cable these days is a marginal technology, used mainly in rear doors and
industrial vehicles
 Cable attached to one side of the slider, making it more efficient in one direction
 Used mainly on hgvs and older vehicles
Bowden System - this is the most commonly used technology
 this is the most commonly used technology

9. 3
 Cable attached to both sides of the slider
 Used mainly on 4 or 5 door vehicles and rear windows where the glass is smaller
Double Bowden System
 Double Bowden – the latest and most innovative technology
 Similar to the Bowden system but uses two sliders allowing large windows to be
raised or lowered evenly
 Used mainly on 3 door vehicles and front doors
Scissor System

10. 4
 Scissor – used predominantly in Japanese and Vauxhall vehicles
 A motor operates a gear wheel to raise and lower the window using a scissor
action
 Fitment within doors can be problematic compared with Bowden systems
Types of Window Operation
Manually Operated Power Operated
Comfort Function
A simple test for this function is whether or not the window regulator is
activated by one touch of the switch. A window regulator without this function will
require the user to maintain pressure on the switch to raise or lower the window.

11. 5
Comfort function-specified units utilize a variety of connector types and these
should be checked to ensure a correct replacement. While they might look similar, they
can use 4, 6 or 8 pins, and work in three quite distinct ways:
Connector Type 1 - A unique central unit controls all of the comfort functions
within the vehicle, by sending impulses to the motors on each of the window regulators.
Connector Type 2 - A more complex technology, each of the window regulator
motors in the vehicle has an internal electronic chip. A unique connector allows these
functions to communicate with a central unit.
Connector Type 3 - This is similar to Connector Type 2 but utilises an electronic
protocol code which protects the system. Exclusivity on these protocols rests with the
VM.
It is also worth remembering that a vehicle could employ three different types of
window regulator – for example, it might conceivably have a driver’s door with
one-touch comfort function, a passenger door with standard function, and rear doors with
manual window regulators.
Replacement
Reasons for failure are various and include:
- Accident damage
- Part wear or malfunction
- High ambient temperature causes rubber seal expansion and strain on the motor
- Non-use/corrosion of rear doors
The most commonly replaced part within the system is the mechanism. This has built-in
adaptability and can be used with a variety of different motors including those fitted with
a one touch comfort function.
Doors are one of the major components in a car which provide easy access for
passengers into the car. With the growing demand on car styling, comfort,
safety and other systems integration (window regulator, latch, speaker, motor and
electronics) in the door, designing this system is a great challenge to engineers. Door
system mainly consists of window glass, window regulator assembly, door latch, sealing
and structural components of the door assembly. Traditionally these parts were designed,

12. 6
manufactured and procured separately. A door module is an assembly of functional
elements mounted onto a carrier plate. Unlike conventional door systems, where the
window regulator assembly was directly attached to the door inner panel, the door
module comprises of a carrier plate with window regulator assembly, glass motor and
speaker. The window regulator consists of a motor assembly, one or two rails to guide the
glass motion, cursor or glass clamps to support the glass, and mechanisms to move the
glass up and down. The window regulator, speaker, and other wire harnesses are mounted
on the carrier plate using bolts, rivets, and clips. Detailed figure of door
module assembly is shown in Figure 1. The carrier plate is bolted to the inner
panel. This module approach helps the car makers in reducing
assembly time and hence cost. Thus, design and manufacture of door modules
is very important.
Fig. Door module
A door module should perform the following functions
 Window regulatory function
 Latch function
 Speaker function
 Sealing function
A door module offers several advantages over conventional door systems. Some
important advantages include
 Higher structural strength

13. 7
 Better sealing against water vapor and hence door modules are called “Sealed
Carrier Systems”
- Better noise insulation
- Dry side mounting of motor and door electronic Components
- Weight savings and hence cost savings due to reduced sheet metal on the
door inner panel Reduced original equipment assembly operations as the module is
directly bolted to the door inner panel
With the growth of the automotive industry, automotive suppliers spend much
effort on the design of window regulators. At first, window regulators are used manually
for a long time. The user generally opened and closed the window of the door by turning
a handle. Later, like other man-powered mechanisms, manual operation is replaced with
automatic functioning. Window regulators are powered with electric motors as a result
windows are raised and lowered automatically.
No matter what type of a power source is used, window
regulators require mechanisms to function. Because, as known mechanisms are basis of
all mechanic devices. Hence, different types of mechanisms are utilized resulting
different types of window regulators. The reason for using different mechanism types
may be cost, operation, assembly, production, etc.

14. 8
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. Faced with a lack of strategic
materials, the company asked Miles to identify new materials to reduce costs. He, then,
gradually put into place a rigorous work plan which yielded reductions of 40 %.

15. 9
I. 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.
In fundamental terms, VE is an organized way of thinking or looking at an item
or a process through a functional
Is an intensive, interdisciplinary problem solving activity that focuses on
improving the value of the functions that are required to accomplish the goal, or
objective of any product, process, service, or organization.

16. 10
What Is Value ?
Value is the lowest price you must pay to provide a reliable function or service (L.
D. Miles)
“The ratio of Function to Cost”
Where,
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.

17. 11
Why & When to Apply Value Engineering ?
 Value Engineering is used to determine the best design alternatives for Projects.
 Value Engineering is used to reduce cost on existing Projects.
 Value Engineering is used to improve quality, increase reliability and availability,
and customer satisfaction.
 Value Engineering is also used to improve organizational performance.
 Value Engineering is used to improve schedule
 Value Engineering is used to reduce risk
 Value Engineering is a powerful tool used to identify problems and develop
recommended solutions.
Fig Product Design Influence

18. 12
AREAS OF APPLICATION
Value Analysis has been successful in several domains:
 Defense
 Automotive
 Aeronautical
 Software development
 Water treatment
 Civil engineering
It has also proven very effective in "soft" areas such as:
 Client services
 Work processes
 Information Systems
 Organizational development
Value Engineering Job Plan:
 Information Phase
 Gather, compile and review information
 Finalize scope
 Function Analysis Phase
 Identify functions
 Classify functions
 Function models
 Establish function worth
 Cost functions
 Establish functional rating system
 Functional Analysis System Technique (FAST) Diagram
 Select functions for study
 Evaluation Phase
 Evaluate ideas for adequacy & feasibility (rating and ranking)

19. 13
 Select ideas with best potential
 Determine advantages and disadvantages
 Evaluate costs
 Development Phase
 Benefit analysis
 Insure functionality, adequacy, compatibility and feasibility
 Identify impacts, risks and barriers to adoption
 Implementation plan
 Presentation Phase
 Present proposals to decision makers
 Overcome resistance to adoption
 Obtain commitments for implementation
 Implementation
 Complete changes
 Implement changes
 Monitor status
 Feedback
PRINCIPLES OF THE METHODOLOGY
Value analysis is a systematic and creative method to improve competitiveness. It
is aimed at satisfying user needs by means of a specific procedure for
invention (or modification) which is functional (the purpose), economic (what it costs),
and multidisciplinary (how).
In other words, value analysis identifies the activities necessary for a process to
develop a product or service, and finds the most economic way to accomplish it. This
method permits the effective identification of that part of process cost which does
not contribute to ensure process quality.
The improvement of a process must never put into jeopardy the quality of a
product, especially in terms of the safety and reliability of a product. Value analysis can

20. 14
make an existing process profitable or optimize the effectiveness and the profitability of
a process at the time of its design.

21. 15
THE VALUE METHODOLOGY

22. 16
THE VALUE METHODOLOGY
The VM Job Plan covers three major periods of activity: Pre-Study, the Value
Study, and Post-Study. All phases and steps are performed sequentially. As a value study
progresses new data and information may cause the study team to return to earlier phases
or steps within a phase on an iterative basis. Conversely, phases or steps within phases
are not skipped.
 PRE-STUDY
 VALUE STUDY
A. Information Phase
B. Function Analysis Phase
C. Creative Phase
D. Evaluation Phase
E. Development phases
F. Presentation / Result / conclusion Phase
 POST STUDY
Now I Have Applied All the Phases to the Same Project Car door
window regulator.

23. 17
2. OBJECTIVES
The two main aims of this project are to:
- Add a window and its mechanism on each door with the ability to go up and
down.
- To modify size and elements of the doors And window for better access to the
automobile.
3. CONDITIONS AND LIMITATIONS
The restraints defined at project start were:
- The mechanism that provides the up/down movement would be a manual crank.
The company established as priority to keep the car style, hence a power window
with a motor would not suit this aspiration.
- In the development of the window lifter and changes of the car doors, the
materials are limited to those the company currently uses
- The final design is limited in respect to how far in the design process the
project reaches. This is since the company rather requires a general design on a
conceptual design solution level, and do not expect detailed designs of each part.
This is because the final idea from this project then is to be introduced in the
company’s own design process.
- The task of making the door larger is restricted since the available space for
expansion is only some centimeters. The door can grow to the edge of the
windscreen.
- The project has to be done in the software CATIA since many company works
with this software.
- The materials and productions processes were discussed. The materials used in the
production must be readily available, easily fabricated, and of the required
properties. They must also resist the oxidation by rainwater, and the
corrosion by dust and corrosive agents.
- The frontal edge of the door has a different angle than on a normal car, and it must
be kept in order to keep the design style of the car

24. 18
4. LITERATURE REVIEW
VALUE STUDY (Information Phase)
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. These are screw driven window regulators, window regulators utilizing rack
and pinion, window regulators comprising lazy tong mechanisms, window
regulators using pulleys and window regulators using arms.
Screw driven window regulators use power screws to raise and lower windows.
One the early patents belongs to Kraemer in 1928. In this design, the window is attached to
the nut of the power screw. Power screw is driven with a handle with actuating gears. In
Figure, a describing drawing of the patent is given.
Figure An early screw driven window regulator mechanism
Another example of screw driven window regulator mechanism is patented
from Szkodzinski in 2016 In this patent, power screw extends through a radius of
curvature of the window. Power screw is connected to hollow axle of the electric motor

25. 19
like a nut. Also, the window is attached to the electric motor, in that manner the window
and electric motor go together along the power screw. A drawing from the patent is shown
in Figure
Figure Another example of screw driven window regulator mechanism
Another type of window regulator mechanisms employs racks and pinions to provide
translation for windows. An early example belongs Bell and Schoenleber patented in
1920 . In this patent, the power from the handle is transmitted to rack to and pinion
pair trough gears and chains. With rack and pinion, the window is raised and lowered
A different patent belongs to Rietdijk taken in 2008. In this design, window is
attached to the electric motor. Window regulator is operated by an electric motor driving
rack and pinion with a gear set.
Another group of window regulator mechanisms utilizes lazy tong mechanisms
to obtain translational motion of the window. An early example is patent of Eckey
taken in 1914. In this patent, a handle drives the lazy tong mechanism with gears. Also,
window is connected to the tip of lazy tong mechanism, by this way window is raised or

26. 20
lowered through the window frame. A describing drawing of this patent is given in Figure
Figure A window regulator mechanism utilizing rack and pinion
A further example is patent of Walters taken in 1989. In this design, the window is
connected to tip of the lazy tong mechanism. The motion of the window
is obtained by a lazy tong mechanism which is driven by an electric motor with a
power screw.
A different group of window regulators employs pulley and wires to
obtain the translational motion of the window. One of the early patents of this type
belongs to Cousinard in 1921. In this patent, window moves along the window frame by
pulleys and wires. In addition, pulleys are powered by a manual handle. A drawing of this
patent is given in Fig.
Another example is a patent belonging to Kuki, Isomura, Suzumura, Sakakibara
and Ishihara taken in 1991. In this patent, window is attached to a bracket moving on a
guide rail which is fixed to car door. The motion of this bracket on guide rail is supplied
by a pulley and wire mechanism connected to an electric motor. A
describing drawing of this patent is shown in Figure.. In another patent belonging to

27. 21
Medebach, two guide rails are used with brackets. Again, these brackets are attached to
window and move with a different pulley and wire mechanism.
Figure A window regulator comprising a lazy tong mechanism
Fig Window regulator mechanism using pulleys and wires

28. 22
Fig. A different window regulator mechanism using pulleys and wires
the arm is rotated with a gear set one of which attached handle. In Figure, a describing
drawing of this patent is shown.
Last group of window regulators utilizes arms to operate the mechanism. There
are lots of patents about different types of window regulators comprising arms. An early
example is a patent of Seegers & Sohn taken in 1922 [10]. In this patent, window is raised
or lowered using an arm with a slider at the tip. A slide attached to the window guide to a
Another early patent belongs to Paul taken in 1932. This patent is similar to patent
Seegers but utilizes two arms with slides. Arms are rotated with rack and pinion
mechanism. The mechanism is operated with a handle attached to a gear set. A drawing of
this patent is presented in Fig.

29. 23
Figure. A window regulator mechanism utilizing an arm
Fig A window regulator mechanism using two arms

30. 24
A different example is a patent of Ternstedt Manufacturing Company taken in
1937. In this patent, a cross armed or a scissor mechanism is used.
Window is attached to slide of the mechanism and moves along window frame.
Mechanism is driven with a handle with a gear set. A drawing from this patent is given in
Fig.
An improved version of previous one is a patent belonging to Dupuy taken in
1993. In this patent, window is raised or lowered also with a cross armed mechanism in a
window frame. However, arms in this mechanism are angled. This cross armed
mechanism is driven using an electric motor with a gear set. In Fig, a
drawing of this patent is given.

31. 25
Fig Window regulator mechanism utilizing cross armed mechanism

32. 26
A different example is a patent of Kriese taken in 2005. The window is moved with
a different type of mechanism comprising more than two arms. The movement of the
mechanism is provided with an electric motor connected to a gear set. A
describing drawing of the patent is given in Figure
Figure A different type of window regulator mechanism using arms
Cardan Motion
The Cardan motion plays an important role in the design process, because synthesis of
window regulator mechanism is carried out using Cardan motion. First, some
basic definitions are presented to use the Cardan motion in synthesis.
During a planar motion of a moving reference frame in which angular acceleration
is not equal to zero, instantaneously there exists a point on the plane
having zero velocity relative to a fixed reference frame. This point is called
instantaneous center. During this motion, instantaneous center defines two

33. 27
curves, one in the fixed reference frame and the other in the moving reference
frame. The curve defined in the fixed reference frame is called fixed centrode
and the curve defined in the moving reference frame is called moving centrode.
These two centrodes are tangent to each other for all conditions. In addition, for special
motions these two centrodes take shape of a circle. For this case, the motion for which
fixed centrode radius is twice as the moving centrode radius is called Cardan motion, and
these circles are called Cardan circles. As a general case, any point on moving frame
describes an ellipse. As a special case of Cardan motion, any point on the moving
centrode describes a line passing through center of the fixed centrode
Figure Cardan motion for a centric slider-crank mechanism
One of the known special mechanisms for which Cardan motion occurs is a
centric slider-crank mechanism having equal crank and coupler lengths
Cardan motion occurs for the coupler link of this mechanism. In this case, Point A is the
center of fixed centrode and point B is the center of the moving centrode. These two
circles are tangent at point T. Point D taken on the moving centrode, describes an exact
line passing through the center of the fixed centrode (Point A).

34. 28
5. CONCEPTUAL DESIGN
Function Analysis Phase
Introduction
In the conceptual design stage, different concepts should be generated and then
the best concept should be selected to satisfy design needs. At the selection
of best concept, the evaluation of created concepts is performed subjective by its
nature. Therefore, conceptual design is another critical stage of the study.
In this chapter, firstly the created concepts are presented in concept development
and presentation. Afterwards, concept evaluation criteria are defined. Lastly,
the best concept is selected among created concepts using concept evaluation
criteria. The procedure followed in this chapter is a simpler version of the
conceptual design .
Concept Development and Presentation
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
The first developed concept is the screw-driven window regulator mechanism.
In this concept, the motion of the window is provided by a power-screw mechanism.
The screw is fixed to the car door. In addition; the nut is attached to the power screw
with a casing and driven by an electric motor through a gear set. Electric motor and gear
set are secured in a casing. The rotation of nut is free in the casing. Furthermore, the
window is rigidly attached to the casing of the nut and guided through the window
frame. Therefore, as the nut is driven by the motor, the window makes a translational
motion through the window frame.
An illustrative sketch of Concept I is given in Figure. Nowadays, car doors are
manufactured in a curved shape. Thus, the window should make a curved motion in the
window frame. So, the screw is illustrated in a curved manner.

35. 29
Figure An illustrative sketch of Concept I
Concept II
Figure A descriptive sketch of Concept II

36. 30
The second concept is operated by a rack and pinion. In this concept, the rack is
fixedly connected to the car door. The pinion is attached to the rack in a casing to secure
the connection between them. Furthermore, the pinion is driven by a gear set powered
by an electric motor which is also connected to the casing. In addition, the window is
also rigidly connected to the casing. Thus; as the pinion is rotated, the window makes a
translational motion along the rack.
In Figure, a descriptive sketch of the Concept II is given. Note that, the rack
should be also in a curved shaped in the side view to provide the aforementioned curved
motion of the window.
Concept III
Third concept is utilizing wire and pulleys. In this concept, a wire is attached to
the main pulley which is rotated by an electric motor. This electric motor is connected to
the car door chassis. In addition, the wire is also connected to a bracket moving on a
carriage which is fixed to the car door chassis. Furthermore, the window is rigidly
attached to the bracket. So, when the main pulley is rotated, the bracket is pulled along
the carriage with the help of two additional pulleys.
An explanatory sketch of the Concept III is shown in Figure Note that,
the carriage should be also in a curved shaped in the side view to provide the aforesaid
curved motion of the window.
Concept IV
Fourth concept comprises an arm type mechanism. In this concept, an arm is
rigidly connected to a gear which is driven by a pinion. A slider is attached to the tip of
the arm and connected to a moving slide. The window which is guided
through the window frame is fixed to moving slide. In addition to these, the pinion is
operated by an electric motor. Therefore; as the pinion is rotated by the
electric motor, the window makes a translational motion through the window frame.
An illustrative sketch of Concept IV is given in Figure. Note that, the arm can
bend to provide the abovementioned curved motion of the window.

37. 31
Figure An explanatory sketch of Concept III
Figure An illustrative sketch of Concept IV

38. 32
Concept V
The last concept utilizes a cross armed or a scissor mechanism. The input link of
the cross armed mechanism is fixed to a gear which is driven by a pinion. The window is
rigidly attached to the moving guide of the cross armed mechanism and guided in the
window frame. In addition, the pinion is driven using an electric motor. Therefore, as the
input link is operated, the window makes a translational motion through the
window frame.
In Figure, a descriptive sketch of the Concept II is given. Note that; as in Concept
IV, arms can bend to provide the curved motion of the window.
Figure 2.5 A descriptive sketch of Concept V

39. 33
Concept Evaluation Criteria
After concept development is completed, the next step is clarifying concept
evolution criteria. Concept evaluation criteria can be chosen among a variety
of technical, economic, technical, etc. aspects. However, these criteria must be selected
such that differences between concepts can be observed during the evaluation process.
Chosen evaluation criteria are small number of components, low complexity of
components, low complexity of concept, long service life, regular force transmission, low
noise operation, simple assembly and low space utilization.
Small number of components is mainly a cost criterion since number of
components directly affects the overall cost of the product. If the product
consists of higher number of components, more materials will be used in the
manufacturing stage of the product.
Low complexity of components also affects cost of the product. Because, complex
components necessitate using different production techniques resulting in a costly
manufacturing stage. In addition, operational problems may occur because
of complex components.
Low complexity of concept influences functioning and design process of the
product. Because, complex designs demand complex sub-functions and
assemblies which may cause a worse functioning of the design. Long service life
directly affects maintenance cost of the product. Furthermore, regular force
transmission influences functioning and maintenance of the product. Because, undesired
force transmission may cause higher reaction forces resulting high wear of components.
Lastly, simple assembly and low space utilization influences assembly stage of the
product.

40. 34
Demand
(D)
or wish (W)
Requirements Measurements or means
D Doors that offer good visibility and
comfort
Add a window on the door.
D Windows that can be removed
when
desired
Add a crank based mechanism to the
door to manually move the
window up and down.
D Avoid glass window vibration Prevent excessive vibration of
the
glass in case of closing the door with
the window completely lowered.D Hermetic closure Create a good closure between
the
door, the glass window, the canvas of
the folding roof and the surrounding
element of the car body.D Easier and more comfortable car
ingress/egress
Make the car doors larger at relevant
places.
D Clean the water on the window
surface
Possibility to add rubbers on the edge
of the door that sweep the water and
dust out of the door interior.
D Keep the door opened when desired A mechanism would be created to
keep the door opened.
D Use corrosion resistant elements Create a dry area for mechanism or
elements with its own cover to
isolate from moisture.
D Keep protection and safety To not compromise or modify door
safety with the window changes.
D Offer easy handling of the door Consider different positions and
designs of handles and hinges.
W Good aesthetics Create a design that keeps the current
car style.
W Use materials and production
processes established at the
company
Aim to use materials and production
processes that the company
usually uses.
W Use recyclable materials Aim to use recyclable materials as
much as possible.
W Ease of assembly (during
manufacture)
Aim to use a design with a good
assembly in the manufacture process.
W Easy up/down glass movement Window regulator guides
should
facilitate the effort.

41. 35
Table 1 Value scale used for the evaluation of concepts
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
Table 2 Assigned weights to concept evaluation criteria
After Analyzing if above Table concept 3 is the best alternative Among all
concept so, I have chosen it for further Improvement.
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

42. 36
Concept 3 In Details
Due to its complexity, for the development, the door is usually divided into three
distinct parts: outer cover, mechanisms and inside cover (door panel).
External cover The external cover is the exterior of the door, usually made
entirely of steel and is composed of the outermost zone (sheet metal) and the inner zone
(frame).
Figure Exploded view external cover of car door.
- Internal frame: is the innermost part of the frame. Where some mobile
elements are joined in the architecture of door DTM (Door Trim Module)
- Waist reinforcement: consists of two parts (exterior and interior) and serves to
provide rigidity to the waist area. This rigidity is necessary, firstly, to ensure the safety
of the occupant in case of a side impact and, secondly, to guarantee no deformation and
the space necessary for the glass to be raised and lowered without any friction or
interference with the bodywork.

43. 37
- Frame-waist reinforcement: This is the piece that gives consistency to the
area of the door frame. It is the area with less mass and therefore weaker.
- Rear mirror reinforcement: is the part responsible for giving consistency to
the junction of the door mirror.
- Protection bar: This is the main piece that ensures no intrusion of any external
element inside the passenger compartment in a lateral collision. It is a piece of steel
welded to the inner frame.
- Hinges: These two parts have to support the full weight of the door when it is
open, and allows the opening and closing movement.
- Guide: This is a piece that has two main functions: to guide the glass in its up
and down movement, and to prevent excessive vibration of the glass in case of closing
the door with the window completely lowered.
- External cover: is the outermost part of the door. Its main function is to cover
the interior pieces with an attractive design to the user. Its design has to achieve good
aerodynamic performance. Also it has to avoid noise when the vehicle is moving at high
speed.
* Mechanisms
This area of the door includes both mechanisms as well as sealing elements,
covers, cables, etc., which are situated between the external cover or even outside of the
sheet such as the mirror. Shown in Figure, the Exploded view window mechanisms of
car door.
- Window: It is the piece of glass covering the window area bounded by the
rubber sweeps and window guide.
- Window guide: It guides the up / down movement of the glass. This provides
an airtight seal in order to avoid entry of water in the carrier. It is a rubber element with
aluminum grafts that confers rigidity to the piece.

44. 38
Figure 2.3: Exploded view window mechanisms of car door.
- Weather strip: The part fixed to the outer sheath prevents as far as possible the
entry of moisture and dust into the door (dry zone). In addition, it is to acoustically
isolate the interior and restrict vibration of the glass.
- Rubber sweeps: assembled between the external cover and glass, whose main
function is to prevent the ingress of water and dirt from the outside into the wet area of
the door. It also restricts the vibration of the glass.
- Foams: are placed in areas where noise is generated due to wind flow when the
car is moving. They are also used to cushion the collisions between parts
caused by vibration.
- Window regulator (mechanism). This is the set pieces that make possible the
up / down movement of the glass pressing a button or using a manual
crank. The mechanical part consists of four main parts.
- Window regulator guides: are the rails that hold the glass to move it.
- Regulator carriage: they are clipped on the two lower holes of the glass and
also attached to the Bowden cables.
-Bowden cables. Responsible for transmitting the force of the electric motor or

45. 39
manual crank to the regulator carriage. They are made of steel with a polymer coating
-Electric motor: powered by the car battery, provides the necessary strength to
raise and lower the glass. A different option is a crank with which
the movement is provided manually as the Figure.

46. 40
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.

47. 41
6. MECHANICAL MODELING
CREATIVE PHASE
1 INTRODUCTION
CATIA V5 is mechanical design software, addressing advanced process centric
design requirements of the mechanical industry. With its feature based design
solutions, CATIA proved to be highly productive for mechanical assemblies and
drawing generation. CATIA, with its broad range if integrated solutions for all
manufacturing organization. CATIA is the best solution capable of addressing the
complete product development process, from product concept specification through
product service in a fully integrated and associative manner. CATIA mechanical
design solutions provide tools to help you implement a sophisticated standard based
architecture.
CATIA V5 is totally compliant with windows presentation standards. CATIA
V5 provides a unique two way interoperability with CATIA version4 data. As an
open solution, CATIA includes with the most commonly used data exchange
industry standards. CATIA V5 extends the power of leading edge engineering
practices to include relation design, which results in,
 Higher Quality design
 More opportunities for innovation
 Fewer engineering changes
CATIA V5 users access the highest productivity for specific advanced processes with
focused solutions.
 Sketcher
 Part design
 Assembly design
 Wireframe and surface design
 Drafting
 Real
 SKETCHER

48. 42
CATIA sketcher tools initially drafts a rough sketch following the shape of the
profile. The objects created are converted into a proper sketch by applying geometric
constraints and dimensional constraints. These constraints refine the sketch according
to a rule. Adding parametric dimensions further control the shape and size of the
feature. Pad, groove, slot etc., are used as one of the feature creation tools to convert the
sketcher entity into a part feature.
PART DESIGN
The CATIA V5 is a 3D parametric solid modeler with both part and assembly
modeling abilities. You can use CATIA to model simple parts and then combine them
into more complex assemblies. With CATIA, you design a part by sketching its
component shapes and defining their size, shape, and inter relationships. By
successively creating these shapes, called features, you can construct the part.
 The general modeling process-
 Planning concept of designing
 Creation of base feature
 Completion of other features
 Analyzing the part design
 Modifying the design as necessary

49. 43
Fig Part Windows carriage Plate
ASSEMBLY DESIGN
CATIA assembly design gives the user the ability to design with user controlled
associability. CATIA builds individual parts and subassemblies into an assembly in a
hierarchical manner according to the relationships defined by constraints. As in part
modeling, the parametric relationships allow you to quickly update an entire assembly
based on a change in one of its parts.
The general assembly process-
 Layout the assembly
 Based on design follow either top down or bottom up
 Analyze the assembly
 Modifying the assembly

50. 44
DRAFTING
Drawings and documentation are the true products of design because they guide
the manufacture of a mechanical device. CATIA automatically generate associative
drafting from 3D mechanical designers and assemblies. Associability of the drawings
to the 3D master representation enables to work concurrently on designs and drawings.
CATIA enriches Generative Drafting with both integrated 2D interactive functionality
and a productive environment for drawings dress-up and annotation.

51. 45

52. 46
7. MESHING AND ANALYSIS OF CARRIER PLATE
Evaluation Phase
MESH GENERATION:
In the finite element analysis the basic concept is to analyze the structure, which
is an assemblage of discrete pieces called elements, which are connected, together at a
finite number of points called Nodes. Loading boundary conditions are then applied to
these elements and nodes. A network of these elements is known as Mesh. Symmetry
Conditions
FINITE ELEMENT GENERATION:
The maximum amount of time in a finite element analysis is spent on generating
elements and nodal data. Pre processor allows the user to generate nodes and elements
automatically at the same time allowing control over size and number of elements.
There are various types of elements that can be mapped or generated on various
geometric entities.
The elements developed by various automatic element generation capabilities
of pre processor can be checked element characteristics that may need to be verified
before the finite element analysis for connectivity, distortion-index etc. Generally,
automatic mesh generating capabilities of pre processor are used rather than defining
the nodes individually. If required nodes can be defined easily by defining the
allocations or by translating the existing nodes. Also on one can plot, delete, or search
nodes. The finite element method is numerical analysis technique for obtaining
approximate solutions to a wide variety of engineering problems. Because of its
diversity and flexibility as an analysis tool, it is receiving much attention in almost
every industry It is not possible to obtain analytical mathematical solutions for many
engineering problems. An analytical solutions is a mathematical expression that gives
the values of the desired unknown quantity at any location in the body, as consequence
it is valid for infinite number of location in the body. For problems involving complex
material properties and boundary conditions, the engineer resorts to numerical methods
that provide approximate, but acceptable solutions.

53. 47
The finite element method has become a powerful tool for the numerical
solutions of a wide range of engineering problems. It has been developed
simultaneously with the increasing use of the high- speed electronic digital computers
and with the growing emphasis on numerical methods for engineering analysis. This
method started as a generalization of the structural idea to some problems of elastic
continuum problem, started in terms of different equations..
If the physical system under consideration exhibits symmetry in geometry, material
properties, and loading, then it is computationally advantageous to model only a
representative portion. If the symmetry observations are to be included in the model
generation, the physical system must exhibit symmetry in all of the following:
Geometry, Material properties, Loading, Degree of freedom constraints.
A three-dimensional finite element mesh of the structure contains tetrahedral
elements with nodes.
MESH BOUNDARY CONDITIONS
Entity Size
Nodes 2953
Elements 8270

54. 48
Material 1 ( Steel )
Analysis
1. Force Applied on Force 100N
Fig Force Applied on Force 100N
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

55. 49
2. Force Applied 100N Carrier Plate With Meshing
Fig Force Applied 100N Carrier Plate With Meshing
3. Stress on plate 100N, Result -- (2.42x10^7Pa)
Fig Stress on plate 100N, (2.42x10^7Pa)

56. 50
4. Translational displacement 100N, Result--(0.000887mm)
Fig Translational displacement 100N, (0.000887mm)
5. Stresses And Translational Displacement
Fig stresses and translational displacement

57. 51
8. IMPROVEMENT / DEVELOPMENT PHASE
At the beginning of the design process, it was necessary knowing the problem of
current design to understand the requirements that required. The literature study was one of
the main problems from the beginning of this thesis. To find related information was quite
difficult. The work in the Section study of a standard car door window regulator was very
useful in this project for understanding the performance, materials and components of a car
door. As well as the function analysis was very helpful to establish the initial project
specifications.
The project had to be done in the software CATIA. It took some time that would
have been spent on the implementation of the report. As the project progressed, the
solution space seemed to be more limited. Perhaps the biggest contribution of the work was
in choosing and proposing ideas within the window and its mechanisms.
Several methods were used for the development of the concept generation:
benchmarking, and concept classification tree using decomposing by user needs. After
these methods several concepts were selected among some ideas thanks to the Concept
combination table. Perhaps, more ideas could have been generated applying different and
more methods, but the lack of time due to first stages of the project caused a more direct
search of concepts. The final stage of the design process is the realization of the final
design concept. This is not strictly in this thesis due to the final choices will be taken into
the companies own design process before the manufacturing because of factors outside the
control of this project.
The product development and preliminary application of VE/VA technique is a
powerful tool for product cost optimization which attacks on product design, procurement,
production inventory, product assembly process, product manufacturing stages, etc. Prior
involvement of VAVE techniques during concept and design stage of new product phases
reduces the overall lifecycle time and reduces product cost, wastage (lean),
increase product reliability, high customer satisfaction, etc. resulting in better and optimal
techniques and methodologies for product cost optimization. A case study has been
conducted to optimize the cost of a sub- assembly of automotive component. The
cumulative effect on the cost saving for the large lots will result into considerable amount

58. 52
of saving. It not only saves or optimized the product cost but also plays a great role in the
overall organization profit margin. Consequently, the implementation of VE/VA
techniques is planned into the major areas of automotive Product design and development
across the organization.
The project suggests the material selection in combination with structural
optimization procedure. Employing the well-developed techniques we organized them in
one system that allows solving the problem of material selection based on structural
optimization including mechanical analysis of a component. In other words, the optimal
material choice according to the constructed system is based on the best potential of each
material-candidate in mechanical behavior under given load and boundary conditions.
Other parameters such as recyclability, manufacturability, etc., can be also included into
consideration, if available.
Detailed strength analyses are not carried out during the detailed
design stage because forces acting on the links of the mechanism are relatively small.
But, to improve the design, detailed strength analyses can be
performed. Optimization study for detailed strength analyses can be made considering
weights of the linkages of the window regulator mechanism. In this manner, overall weight
of the mechanism can be reduced. Analysis of the internal logistics of the company under
consideration has shown large potential of production optimization in respect of material
flow and, consequently, minimization of the costs involved in it.
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.

59. 53
Material and Structure Optimization
Fig. Modified Carrier Plate ( 6 Holes )
Material 2 ( Plastic)
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
Weight before holes Weight after holes Percentile reduction in weight
200gm 188gm 6%

60. 54
9. CONCLUSION
In the Case Study discussed above we see how the cost of a product is
minimized by applying the Value Engineering Methodology. Value Engineering is
the systematic application of recognized techniques by a multi-disciplined team
which identifies the function of a product or services; establishes a worth for
that function; generates alternatives through the use of creative thinking; and
provides the needed functions to accomplish the original intent of the project,
reliably and at the lowest life-cycle without sacrificing project requirements for safety,
quality, operations, maintenance and environment. Various worksheets are
developed and thorough analysis is done to attain a concrete solution. With the use of
VAVE technique, the product cost has been optimized with around 6% reduction
Comparison of the results of the materials selection according to different
approaches (via the material indices and the compound objective function) showed that the
optimal material choice depends on the formulation of the problem as well as on the
applied criteria and method. In addition, the possibility to use Plastic in automobile
structures was examined in comparison with the conventional (steel, aluminum alloy) and
non-conventional (metallic and synthetic fiber composites) materials based on the given
case study.
• 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 door 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.

61. 55
10. REFERENCES
1) Automotriz. (2015). Partes de la puerta de un coche [ONLINE] Available at:
<http://www.automotriz.biz/coches/cars-trucks-autos/other-autos/112630.html>
[Accessed 9 April 2015].
2) Cabello, J., Márquez, F., Pérez J.M., & Verdier, C. (2009). Industrial Design
Methodology / Metodología del diseño industrial. 1st ed. Málaga: SPICUM
servicio de publicaciones.
3) Cross, N. (2008). Engineering design methods: strategies for product design. 3rd ed.
Chichester: Wiley.
4) EHow En Español. (2015). Partes de la puerta de un coche [ONLINE] Available at:
5) <http://www.ehowenespanol.com/partes-puerta-coche-lista_319708/> [Accessed
12April 2015].
6) Krolczyk, G.; Legutko, S.; Krolczyk, J.; Tama, E. Materials Flow Analysis in the
Production Process-Case Study. // Applied Mechanics and Materials. 474(2014),
pp. 97-102. DOI: 10.4028/www.scientific.net/AMM.474.97
7) Starbek, M.; Menart, D. The optimization of material flow
8) Venkateswaran, J., and Son, Y., 2005, Production and Distribution Planning for
Dynamic Supply Chains Using Multi-resolution Hybrid Models, Simulation
(submitted).
9) Access to success: Value Engineering, Mani Mala, Advancements & Futuristic
Trends In Mechanical
10)Kraemer, W. L., Window Opener, Patent No: US1695691A, 1928.
11)Szkozinski, A., Direct Drive Vehicle Window Regulator, Patent No:
CA2510712A1, 2006.
12)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
13)http://www.value-engineering.com/consulting.htm
14)http://www.wordiq.com/definition/Value_engineering
15)http://en.wikipedia.org/wiki/Value_engineering
16)http://www.nab.usace.army.mil/whatwedo/ValueEngineering.html