PWM

DFMEA of power window Motor

Proprietary of VEM technologies pvt ltd. Hyderabad , india

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Objective

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To prepare Design Failure Mode & Effects Analysis For Power Window Motor

Proprietary of VEM technologies pvt ltd. Hyderabad , india

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Team members

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M.Viswanatha Reddy T.Laxmi Narayana CHV Rama Rao N.Nanja Reddy R.Balaji Singh

KVR Varma

Proprietary of VEM technologies pvt ltd. Hyderabad , india

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Product Overview

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Application: Used in automobile (car) power window application to raise / down the window glass

Function: When motor is input powered, dc motor rotates and drives the worm gear assembly and shaft with the required torque. This mechanism is capable to rotate in CW and CCW direction based on window travel requirement
Proprietary of VEM technologies pvt ltd. Hyderabad , india
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Product Requirements
Product requirements are identified in the following three ways End User requirements Customer (OEM) requirements Product requirements

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1. End user requirements: 1.1 Window opening 1.2 Window Closing 1.3 Safety trip after closing 1.4 Safety trip after opening 1.5 Life of product
2. OEM 2.1 2.2 2.3 2.4 requirements Mounting requirements Wiring harness Life of product Reliability of product

3. Product requirements 3.1 CTQs of function 3.2 CTQs of process 3.3 CTQs of DFMA
Proprietary of VEM technologies pvt ltd. Hyderabad , india
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Probable Design failure modes

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Problems are listed based on power window lifter failures only

1. 2. 3. 4. 5. 6.

Window is not closing (lifting) /opening (down) More noise while closing / opening. Load is not taking (stopping by keeping hand). Jerk while opening / closing. Tripping of motor Less life / Durability

Proprietary of VEM technologies pvt ltd. Hyderabad , india

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Failure-1

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1. Window is not closing (lifting) /opening (down)

1. Function : Is to lift/down the window glass of car. 2. Failure mode: Window is not closing (lifting) / Opening (down) 3. Effect : Inconvenience and lack of safety 4. Cause: 1. Worm slip over knurling due to less interference 2. Centre distance between gear and worm (slipping) 3. Gear tooth broken due to less strength

Proprietary of VEM technologies pvt ltd. Hyderabad , india

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Failure-2
2. More noise while closing / opening.

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1. Function : Less noise (50dB) while operating 2. Failure mode: More noise while closing / opening 3. Effect : Inconvenience and less life 4. Cause: 1. Cogging torque at armature (due to no skew) 2. Burr on Worm or Gear teeth 3. Dust at Bearings and armature 4. Unbalance in armature winding

Proprietary of VEM technologies pvt ltd. Hyderabad , india

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Failure-3
3. Load is not taking (stopping by keeping hand).

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1. Function : To raise the window with 6 kg load 2. Failure mode: Load not taking (stopping by keeping hand) 3. Effect : Some times window cannot lift. 4. Cause: 1. Less output Torque due to less magnetic flux of magnet 2. Less output torque due to friction at bearings (dimensions) 3. Less Torque between Worm & shaft knurling.

Proprietary of VEM technologies pvt ltd. Hyderabad , india

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Failure-4
4. Jerk while opening / closing.

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1. Function : Smooth operation of window up / down 2. Failure mode: Jerk while opening and closing 3. Effect : Noise and inconvenience 4. Cause: 1. Few Gear tooth wornout 2. Worm tooth damage 3. Coupling plate slipping due to more play or more stack play

Proprietary of VEM technologies pvt ltd. Hyderabad , india

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Failure-5
5. Intermediate stop (Tripping of motor)

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1. Function : Safety trip after full travel of window. 2. Failure mode: Intermediate stop 3. Effect : Inconvenience & Lack of safety

4. Cause: 1. Due to wrong PTC from vendor (mixup) 2. Window travel obstruction due to external factors 3. Overheat at motor due to less winding at armature (due to miss operation)

Proprietary of VEM technologies pvt ltd. Hyderabad , india

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Critical failures identification

DFMEA
Item/ Process Step Potential Failure Mode Potential Effect(s) Of Failure Inconvenience & lack of safety SEV Potential Cause(s) Of Failure Worm slip over knurling CD b/w gear & worm (slipping) Gear tooth broken due to less strength More noise while closing/opening Inconvenience & Less life 5 Cogging torque at armature Burr on worm or gear teeth Dust on bearings & armature Unbalance in armature winding OCC Current Controls DET

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RPN

Window is not closing / opening

100% functional test (factor of safety > 2) CD critical control Gear material chosen for high strength (PBT-40% GF) Providing skew for armature 100% inspection Two stage arc cut and visual control Demagnetization till cap assy Less unbalance on OD (100% balancing)

3 3

96 96

4 2

48

80

120

4 4

3 3

60 60

Proprietary of VEM technologies pvt ltd. Hyderabad , india

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PWM
Load is not taking Window cant lift 8 Less O/P torque due to less magnetic flux 3 100% inspection of magnetic flux 3 72

Less O/P torque due to friction at bearing

Oil less bush with turbine 90 Oil

96

Less torque b/w worm & Shaft Knurling Jerk while opening / closing Noise & convenience 5 Few Gear tooth worn-out Worm tooth damage Coupling plate slipping due to more play or more stack play Intermediate stop Inconvenience & lack of safety 7 Due to wrong PTC from vendor (mix-up) Window travel obstruction due to external factors Overheat at motor due to less winding at armature (due to miss operation)

More interference & knurling pitch More tooth in contact Process handling (strength factor >2) Circlip at end and more bush guiding Steel based instead of copper base (resistance) Gasket at cap to avoid water and dust entry Performance robustness to 2% winding variation

72

2 3

3 3

30 45

30

63

63

63

Proprietary of VEM technologies pvt ltd. Hyderabad , india

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PWM

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Proprietary of VEM technologies pvt ltd. Hyderabad , india

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