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HISTORY OF WINDOW REGULATOR OR HAND CRANK WINDOW

Window regulators are components that make it possible to lower and raise the window glass in a vehicle at will. In some cases, the regulator is manual, requiring a person to operate the movement of the regulator using a hand crank. More commonly today, a window regulator is an automated device that is activated by pressing a toggle switch or a button found on the arm rest of the car door closest to the window. With most vehicles, an automated window regulator system is configured so the driver can control the movement of all windows in the car or truck. This effectively allows drivers to adjust front and back seat windows without using the controls situated by each of the passenger windows in the vehicle. Most makes and models continue to have individual controls situated near each window, allowing passengers to open or close the nearest window without calling on the driver to handle the task. Prior to the middle of the 20th century, a window regulator was usually operated using a hand crank. The cranks were situated at a convenient location along the door panel, making it easy for anyone seated near the window to simply grab the crank and turn it clockwise or counter-clockwise in order to open and close the window. As the hand crank was turned, a plate supporting the glass window would lower or raise the window into the desired position. The construction of the crank made it possible to position the window so it was fully closed or open, or opened at a level that was to the liking of the passenger or driver. By the 1960s, the power window regulator was gaining widespread attention. Rather than operating the mechanism with a hand crank, this new innovation made it possible to open and close car windows be moving a switch or pressing a button on a control console. Originally, this feature was offered as an extra or luxury item on many makes and models. However, by the end of the 1970s, most vehicle manufacturers considered the inclusion of power windows to be a standard feature. Over time, the rear window regulator came into common usage. Along with the windows situated near the seating area for the driver and passengers, the ability to raise and lower the rear window of an SUV, minivan, or station wagon became desirable to consumers. This option was also considered a factory extra at one time but now is usually included as a basic feature of vehicles sold today. As with any type of mechanical component, a window regulator does sustain wear and tear after years of repeated usage. The origin of the problem with a power window regulator is usually based in the small motor that controls the movement of the window. When the motor begins to wear out, the regulator may not respond as efficiently to the press of a button. Often, replacing the motor will restore full functionality. However, there are situations where the issue with the regulator is more complex than simply a worn motor. When this is the case, replacement of the entire regulator may be necessary. Depending on the make and model of the vehicle, replacing an electric window regulator can be quite costly.

(Reference : http://www.wisegeek.com/what-is-a-window-regulator.htm)

HISTORY OF POWER WINDOW

Power windows or electric windows (American English) as well as electric or power window lifts (British English) are automobile windows which can be raised and lowered by depressing a button or switch, as opposed to using a hand-turned crank handle. Packard introduced the first power windows (along with automotive air-conditioning systems) in the 1940 Packard 180 series. This was a hydro-electric system. In 1941, the Ford Motor Company followed quickly with power windows on the Lincoln Custom (only the limousine and seven-passenger sedans). Cadillac had a straight-electric divider window (but not side windows) on their series 75 limousines immediately prior to World War II. Power assists originated in the need and desire to move convertible body-style tops up and down by some means other than human effort. The earliest power assists were vacuumoperated and were offered on Chrysler Corporation vehicles, particularly the lowcost Plymouth convertibles in the late 1930s. Shortly before World War II, General Motors developed a central hydraulic pump for working convertible tops. This system was introduced on 1942 convertibles built by GM. Previously, GM had used a vacuum system which did not have the power to handle increasingly larger and complex (four side-windows vs. only two) convertible top mechanisms. The June and July 2010 issues of "The Self-Starter", the official magazine of the International Cadillac-LaSalle Club, contain references to the use of various types of power window mechanisms in pre-WWII specially modified Cadillac sedans. These Cadillac-built (as opposed to private coachbuilder) models used three types of power mechanisms - straight electric, straight vacuum (much as the power antenna mechanisms used on Cadillacs through 1955) and the soon-to-be-standard electro-hydraulic system. The July 2010 edition also references a 1941 specially modified Cadillac Model 6219 four-door sedan built for the Chairman of the GM Board, Alfred P. Sloan, that had power window mechanisms, although the type is not specified. Chief Engineer of the Buick Division, Charles A. Chayne, "...had introduced an electrically controlled hydraulic system into the 1946 Buick convertibles that provided fingertip operation of the top, door windows, and front seat adjustment". Apparently Chayne was a pioneer in these types of systems. These systems were based on major hydraulic advances made in military weapons (tanks, aircraft) in preparation for World War II. The "Hydro-Lectric" system (windows, front seat adjustment and convertible top) was standard on 1947 model year. It was probably standard on some 1946 convertible models. Despite the fact that no specific documentation has been found in sales literature (on internet searches), the January 2011 issue of "The Self-Starter", the official magazine of the CadillacLa Salle Club, lists a 1946 model 6267D Convertible for sale with "hydraulic windows".

However, a 1946 Buick Convertible advertised on eBay had roll-up windows, indicating a production change after introduction. This appears to confirm that the accessory (including the electro-hydraulic front bench seat and convertible top) were available on post-war Cadillac models or at least shortly after introduction of the 1946 models.. The seat and window assist system was nor available on GM closed cars (standard on some Cadillac Series 75 models). The full system was standard only on the high-end GM convertibles made by Oldsmobile, Buick, and Cadillac. It was only available as a package; that is, power assisted windows, front seat and convertible top (where applicable). This feature can be identified in 1948 and later General Motors model numbers with an "X" at the end, such as the 1951 Cadillac Sixty Special sedan, model 6019X. Ford also had a similar electro-hydraulic system on higher-end convertibles Mercury and Ford Sportsman convertibles (with wood trim) were equipped with power windows on four windows from 1946 through 1948. (Mercury and Lincoln) by 1951. These systems were used by other luxury car models (Imperial and Packard) until Chrysler introduced the allelectric operation on the 1951 Imperial. General Motors also followed with full electric operation in 1954. This included four-way and then six-way seats, which were introduced in 1956. Chevrolet introduced the oddity of power front windows (only) in the 1954 model. Ford also introduced full four-door power windows in sedans in 1954. Electrically-operated vent windows were available as early as 1956 on the Continental Mark II. The 1960s Cadillac Fleetwood came standard with power front and rear vent windows, in addition to standard power side windows, for a total of eight power window controls on the driver's door panel. Modern heavy-duty highway tractors frequently have an option for power window controls; however, these are generally what is referred to as "straight air". That is, the compressed air system used for air brakes is also used for the windows. These types of trucks have long used compressed air cylinders for seat height adjustment. In a similar fashion to the electro-hydraulic system, the compressed air is merely released to lower the window and/or seat. The compressed air is then admitted to the respective cylinder to raise the window or seat. In a typical auto/light truck installation, there is an individual switch at each window and a set of switches in the driver's door or a-frame pillar, so the driver can operate all the windows. These switches took on many different appearances, from heavy chrome plate to inexpensive plastic. However, some models like Saab and Holden 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.

OPERATION OF POWER WINDOW

Power windows are usually inoperable when the car is not running as the electrical system is not "live" once the ignition has been turned off. The Hydro-Lectric system; however, could lower the windows at rest, since pressure from the hydraulic system was merely released to lower the window. Raising the windows required the pump to operate (at a fairly high noise level) and introduce pressure at each cylinder. These hydraulic systems also required pressure lines to each cylinder (door, seat and top) and tended to leak. Many modern cars have a time delay feature, first introduced by Cadillac in the 1980s, called retained accessory power. This allows operation of the windows and some other accessories for ten minutes or so after the engine is stopped. Another feature is the expressdown window, which allows the window to be fully lowered with one tap on the switch, as opposed to holding the switch down until the window retracts. Many luxury vehicles during the 1990s expanded on this feature, to include express-up on the driver's window, and recently, some manufacturers have added the feature on all window switches for all passengers convenience. This is done by activating the switch until a "click" response is felt. Power windows have become so common that by 2008, some automakers eliminated hand cranks from all models. So many vehicles have power windows that some people no longer understand the (formerly) common sign from another driver of using their hand to simulate moving a window crank to indicate that they wish to speak with someone (stopped at a light or in a parking lot). The 2008 Audi RS4 sold in Europe, however, still has roll-up windows for the rear doors although its counterpart sold in the USA has power windows for all doors.

SAFETY OF POWER WINDOW

Power windows have come under some scrutiny after several fatal accidents in which children's necks have become trapped, leading to suffocation. Some designs place the switch in a location on a hand rest where it can be accidentally triggered by a child climbing to place his or her head out of the window. To prevent this, many vehicles feature a driver-controlled lockout switch, preventing rear-seat passengers (usually smaller children) from accidentally triggering the switches. This also prevents children from using them as toys and pets riding with their heads out windows from activating the power window switch. Starting with the 2008 model year, U.S. government regulations required automakers to install power window controls that are less likely to be accidentally activated by children. However, the rules do not prevent all potential injuries to a hand, finger, or even a child's head, if someone deliberately holds the switch when the window is closing. In 2009, the U.S. auto safety administration tentatively decided against requiring all cars to have automatic

reversing power windows if they sense an obstruction while closing. Proposed requirements concern "one-touch" up window systems, but most vehicles with this feature already have automatic-reversing. The federal government made a written contract that all automakers should make the lever switches (as opposed to the rocker and toggle switches) standard on all new vehicles by 1 October 2010.

(Reference : http://en.wikipedia.org/wiki/Power_window)

HOW POWER WINDOW WORK? The Lifting Mechanism Let's start with the lifting mechanism. 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. An important feature of power windows is that they cannot be forced open the worm gear in the drive mechanism takes care of this. Many worm gears have a self-locking feature because of the angle of contact between the worm and the gear. The worm can spin the gear, but the gear cannot spin the worm -- friction between the teeth causes the gears to bind.

Figure 1 : Window lifting up mechanism at work, with inset of motor and gear reduction

Figure 2 : Window lifting down mechanism at work, with inset of motor and gear reduction

Figure 1 and Figure 2 shows 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.

The Wiring and Switches Car doors are wired in many different ways, depending on which features are incorporated. We'll go through the wiring on a basic system -- one that allows the driver to control all four windows on the car and can lockout the controls on the other three individual windows.

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.

Figure 3 : A simple power window circuit

On the figure 3, 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 power to the window motor. If the switch is pressed the other way, then power runs through the motor in the opposite direction.

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.

Interesting Features 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. 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 carmakers 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, 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.

Automotive Power Window System Description and Functions

1. Description The power window system is the system to open and close the windows by switch operation. The power window motor rotates when the power window switch is operated. The power window motor revolution is then changed to up-and-down motion by the window regulator to open or close the window. 2. The power window system includes the following functions: Manual open/close function One touch auto open/close function Window lock function Jam protection function Key-off power window function

3. Reference Some models have the driver door key cylinder linked function. 4. Function i. Manual open/close function When the power window switch is pushed or pulled halfway, the window opens or closes until the switch is released. ii. One touch auto open/close function When the power window switch is pushed or pulled fully, the window fully opens or closes. 5. Hint Some models have only auto open function and some models have auto open/close function for the drivers window only. iii. 3.Window lock function When the window lock switch is turned on, the opening and closing of all windows except the drivers window is disabled. iv. Jam protection function

This function automatically stops the power window and moves it downward about 50 mm if foreign matter gets caught in the window during one touch auto close operation. v. Key-off power window function This function allows the operation of the power window system for approximately 45 seconds after the ignition switch is turned to the ACC or LOCK position, if the drivers door is not opened. 6. Reference Driver door key cylinder linked function. This function opens and closes the window according to the operation of the driver door key cylinder and wireless door lock.

(Reference : http://youronlinemechanic.com/automotive-power-window-system-decription-and-functions/)

Power Window Manual and One Touch Auto Open and Close Function

1. Manual Open/Close Function When the ignition switch is in the ON position and the drivers power window switch is pulled halfway, a manual UP signal is input to the IC and the following change occurs:

Tr: ON UP relay: ON DOWN relay: ground circuit As a result, the drivers power window motor revolves in the UP direction. When the switch is released, the UP relay turns off and the motor stops. When the drivers power window switch is pushed halfway, a manual DOWN signal is input to the IC and the following change occurs:

Tr: ON UP relay: ground circuit DOWN relay: ON

As a result, the drivers power window motor revolves in the DOWN direction.

HINT: Some models are equipped with a PTC thermo-sistor or circuit breaker in order to prevent excess current to the motor.

2. One Touch Auto Open/Close Function When the ignition switch is in the ON position and the drivers power window switch is pulled fully, an auto UP signal is input to the IC. As the IC has a timer circuit and the circuit maintains ON condition for a maximum of 10 seconds when the auto UP signal is input, the drivers power window motor continues to revolve even after the switch is released. The power window motor stops if the drivers window completely closes and the IC detects motor lock from the signals from the speed sensor and limit switch of the power window motor or the timer circuit turns off. Auto close operation can be stopped by pushing the drivers power window switch halfway for opening.

(Reference function/)

http://youronlinemechanic.com/power-window-manual-and-one-touch-auto-open-and-close-

Power Window Jam Protection Function

Window jam is detected by two components: the limit switch and the speed sensor in the power window motor. The speed sensor changes the motor speed to a pulse signal. Jam is detected from the change in the pulse wavelength. With the dead band of the ring gear, the limit switch distinguishes the change of the pulse signal wavelength in the case of jam and that in the case when the window is fully closed.

1. Operation When the power window master switch receives the signal that notifies of a jam from the power window motor, it turns off the UP relay, turns on the DOWN relay for about one second and opens the window about 50 mm in order to prevent the window from closing further. CAUTION: The jam protection function operation can be tested by inserting an object (such as a hammer handle) between the window and frame. When the window is almost shut, the jam protection function does not activate. Therefore, testing with hands may cause injury. Some older models do not have the jam protection function. 2. Resetting The power window motor needs to be reset (to the initial position of the limit switch) in the following cases: The window regulator and power window motor are disconnected. The window regulator is activated when the windows are not mounted. Any operation to change the window fully shut position is performed, for example in case of door glass run replacement. How to reset (in the case of Corolla (NZE12#)) Connect the power window motor and power window master switch to the wire harness of the vehicle. Turn the ignition switch to the ON position and operate the power window master switch to run the power window motor idly in the UP direction for four seconds or more (between 6 and 10 cycles of revolution).

(Reference : http://youronlinemechanic.com/power-window-jam-protection-function/)

MONITORING VEHICLE POWER WINDOWS USING A REED SENSOR

Introduction

Power windows have been improving their performance over the years and now use Reed Sensors to control the motors as they reach their end limits. Also, if an object impedes the windows progress slowing the windows progress, this slowdown must be detected, particularly when going in the closing position. This is particularly important if ones arm or hand is between the top of the window and door. Reed Sensors have been an excellent choice capable of accomplishing all three requirements in a reliable manner.

Power Windows End Points Are Reliably Controlled By Reed

Sensors

Power windows have undergone dramatic changes in the controls. Originally the end limits were controlled by mechanical limit switches that were subject to the environment, which would eventually effect their reliability over the useful life of the window. If ones hand got caught between the window and the door, there was no way to sense this condition. Of course this resulted in some severely pinched and broken fingers. The designer developed away to sense when the motor slowed down which caused a surge in the current flow to the motor. This surge occurred when the window reached its end limits or when an object showed resistance to window movement. This approach improved the reliability and now detected the existence of a hand impeding the window from shutting. This approach had some flaws particularly when subjected to temperature extremes and used many costly electronic components. Designers finally discovered a clever way to solve all the problems associated with power windows in an economical way using MEDERs reed sensors. MEDERs reed sensors use hermetically sealed reed switches that are further packaged in strong high strength plastic, which virtually eliminates any environmental effects on their reliability particularly over the temperature extremes. The magnet is mounted on the motor and two reed sensors are mounted in a convenient manner detecting each rotation of the motor. Using two reed switches allows the designer to determine the direction of motor and therefore the direction of the window movement. The design of the motors used slow their rotation once they encounter any resistance. This is immediately sensed by the reed sensors showing the change in rotation speed, which in turn sends a signal to the electronics turning off the motor. In this way the end limits are reliably detected as well as the detection of any resistance to the window movement before it reaches its end limits. MEDERs sensors are packaged for surface mounting as well as through hole mounting. Also, MEDER has cylinder packages and well as screw fastening packages having lead wires for remote attachment to the electronics.

(References : http://www.meder.com/us_power-windows40.html)

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