轎車雨刮器結(jié)構(gòu)設(shè)計(jì)【說明書+CAD+PROE】
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附 錄A
Windshield Wiper
Background
Windshield wipers are used to clean the windshield of a car so that the driver has an unobstructed view of the road. A typical wipe angle for a passenger car is about 67 degrees. The blades are 12-30 in (30-76 cm) long with lengths increasing in 2-in (5-cm) increments.
History
The history of the windshield wiper began with the invention of the automobile. Most transportation vehicles did not have wipers. Horse-drawn carriages and trucks moved at slow speeds, and glass was not needed to protect the driver or passengers or to act as a windbreak.
The first windshield wipers were brushes. Inventor J. H. Apjohn came up with a method of moving two brushes up and down on a vertical plate glass windshield in 1903. In the same year, Mary Anderson devised a swinging arm that swept rain off the windshield when the driver moved a lever located inside the car. Anderson patented her invention of the mechanical windshield wiper in 1905, and it became standard equipment by 1913. Electric motors were not used yet to power automobile essentials or accessories, and Anderson's device had a drawback. Without another power source, a driver had to use one hand to move the lever. The driver's other hand steered the car (with either a wheel or steering tiller) and worked the stick-mounted gear shift and brake grips standing on the floor of the car or outside the driver's side on the running board.
Rubber strips replaced brushes as the cleaning tools on wipers in 1905. Unfortunately, the hazardous need for drivers to wipe windshields while driving was not eliminated until 1917. The solution was to use an electric motor to move a single wiper with a long rubber blade back and forth. Hawaiian dentist Dr. Ormand Wall invented the automatic wiper by placing an electric motor in the top center of the windshield so the wiper arced down over the hood of the car in a semi-circular or rainbow shape. Wipers were one of the first electrical devices in automobiles after the electric starter was developed in 1912. Most wipers on cars before 1930 were paired and hung down from the top of the windshield. They were moved to the base of the windshield as electrical systems became more complicated.
Windshield washers were added to the wiper on/off levers, and these required spray nozzles in front of the windshield, a tank for washer fluid in the engine compartment, and electrical connections to coordinate these operations. In 1962, Bob Kearns invented the intermittent wiper with intervals and speeds that the driver could change. The advent of electronic systems with fuses and circuit breakers to operate, regulate, and coordinate electrical components expanded the possibilities for more diverse wipers. Wipers were added to headlights in the 1980s, requiring connections between the lighting and wiper systems. In the 1990s, microsensors were built into windshields to detect rain on the windshield, activate the wipers, and adjust speed and intermittent use for the amount of rain.
Raw Materials
The manufacturer purchases all of the parts from companies that specialize in fabricating parts from aluminum and steel, rubber blades, plastic bushings for the linkages, and the motors. Windshield wipers and windshield wiper systems (with motors) are different assemblies; some manufacturers make both, and others produce wipers only.
The connecting and drive links and the pivots that move the wipers are made of galvanized steel. Galvanization is the process of applying zinc coating to steel to protect it from corrosion. Drive arms for boats and vehicles used in the marine industry are made of stainless steel that resists damage from salt water. The wiper suspension and claws are also galvanized steel. The galvanizing zinc coating is easier to paint than uncoated steel. Steel is also the material in the small parts of wipers, such as washers, screws, nuts, springs, and brackets.
The blade frame is made from aluminum. The blades are made of natural rubber or synthetic compounds. Some rubber blades are composites of soft rubber on the wiping edge (the squeegee surface) and firm rubber that supports the wiping edge in the rest of the blade.
Other materials that comprise parts of windshield wipers are rubber for washers in the pivots and plastic bushings that line holes for connecting parts of the linkage. The wiper suspension is typically painted black. If the wiper manufacturer also builds wiper systems, motors are purchased from subcontractors. The motors are contained in steel housings and include permanent magnet motors wound with copper wire. Each housing has connections for the electrical wires that are part of the vehicle and wiring harnesses are furnished specific to operating the wipers. Each motor also contains one or more electronic circuits depending on the sophistication of the system that the motor controls.
Design
Windshield wipers are designed and made to clear water from a windshield. Most cars have two wipers on the windshield, and they may have one on the rear window and one on each headlight. The wiper parts visible from outside the car are the rubber blade, the wiper arm holding the blade, a spring linkage, and parts of the wiper pivots. The wiper itself has up to six parts called pressure points or claws that are small arms under the wiper. The claws distribute pressure from the wiper along the back of the blade. This is described as a balance beam with a suspension system, where the wiper is the beam and the claws are the suspension components. The claws keep the blade flexed against the windshield to distribute even pressure to clean the glass all along the blade. More claws usually distribute the pressure better and are suited to large or highly curved windshields.
Although the rubber is the familiar part of the blade, the blade actually includes a metal strip called a blade frame with a slot along the length of the frame and replacement holes in the frame. The replacement holes provide access for replacing the rubber blade with a refill. The blade on its aluminum frame can also be changed as a unit.
The standard two windshield wipers are usually operated as a single-motor, tandem scheme with one wiper on the driver's side and one positioned near the middle of the windshield that moves across the passenger's view. The wipers are secured to pivots. A wiper and pivot are mounted on brackets at both ends of a long rod called the connecting link, and, as the force from the motor pushes on the driver's end of the connecting link, it in turn moves the other wiper. The connecting link is attached to another long rod called the drive link near the wiper motor. A slender spring linkage ties the pivot to the drive link to return the wiper to its resting or park position, hug the wiper close to the windshield, and keep it attached to the car if the links are damaged.
Between the motor and the drive link, a linkage system consisting of a cam (another short rod) and pivot, a gear output shaft, and a worm gear controls the force of the motor delivered to the drive arm. The worm gear slows the speed of the motor while multiplying its torque (force). The gear allows a small motor to produce enough force to move the blades across the glass. This description is based on using a single motor to drive both wipers. If one motor powers each wiper, more links are needed to move the two wipers together in a so-called unitized motor system.
This multiplied force is required to accelerate the blades from being stopped at both
Windshield wiper systems.
ends of their movement, to resist the friction of the rubber against the glass, to resist the friction of the rubber on dirt on the glass, and to oppose wind pressure on the windshield.
Quality Control
During assembly, the workers observe the conditions of the parts during their work, but their only specific quality control activity is to check the operation of the motors by turning them on to make sure they start and by listening to the sounds they make as indications of performance.
The last inspection is performed when the assemblies are complete and before the wipers and systems are packed. The manufacturing director or final quality control inspectors look at the general appearance of the assemblies, confirm that the wipers have been sized and angled correctly for their sweep, and check that the assemblies are in the park position. The director or inspectors also check to see that the correct accessories are ready to be packed with the assemblies.
Byproducts/Waste
Small quantities of steel and aluminum scraps from trimmings or rejected or damaged parts are collected in bins and sold to salvage dealers who, in turn, sell them to metal manufacturers who melt the scrap down for recycling. Packaging from received parts is also collected and recycled.
The Future
As of 2002, windshield wipers and wiper systems are evolving because of changes in automobiles and other vehicles, technical improvements, and consumer demand. Wiper blades are as much as 30 in (76 cm) long, creating more resistance as they clean the windshield. Night-vision screens for windshields are in development, and these also increase resistance and change the dimensions needed for wipers. Blades are being improved with increasingly flexible rubber, so-called "boots" that fit around the blades to keep out ice and snow, and nonstick coatings on the squeegee edges of the blades to keep oil and wax from adhering and aging them.
Motor systems are also being increased in voltage to power longer wipers and more accessories. Engineers are investigating fully automated systems that do not require any actions by drivers to start and stop wiper systems. Inventors expect the capabilities of the rain-detecting sensors available in the late 1990s to widen to prompt the wipers to clean dirty windshields with no rain, for example. Windshield wipers are among most reliable automotive devices—the design life of a wiper system is 1.5 million wipes.
附 錄B
雨 刷
背景
雨刷是專門用來清潔車輛上的擋風(fēng)玻璃,這樣司機(jī)就可以清晰地看到前方的道路了。乘務(wù)車上的雨刷一般傾斜角度大約在67度。雨刮片長(zhǎng)度一般在12-30英尺左右(即30-76 cm)，長(zhǎng)度增量在2英尺(即5cm)左右。
歷史
擋風(fēng)玻璃的雨刷起始于發(fā)明汽車的時(shí)期。當(dāng)時(shí)大多數(shù)運(yùn)輸工具都沒有雨刷，馬車和卡車都是以很慢的速度移動(dòng),所以就不需要玻璃來保護(hù)司機(jī)和乘客或充當(dāng)一個(gè)擋風(fēng)物。
第一個(gè)雨刷采用是的毛刷。在1903年，發(fā)明者J. H. Apjohn突然有了一個(gè)想法,就是在垂直的擋風(fēng)玻璃上面上下移動(dòng)兩把刷子。同年,瑪麗·安德森發(fā)明了一種擺動(dòng)手臂可以把擋風(fēng)玻璃上的雨水清除，這種裝置是通過司機(jī)移動(dòng)一個(gè)設(shè)置在車內(nèi)的杠桿來操作的。1905年，安德森把她發(fā)明的機(jī)械擋風(fēng)玻璃刮申請(qǐng)了專利,到了1913年這種機(jī)械裝置成了運(yùn)輸工具上面的標(biāo)準(zhǔn)使用設(shè)備。當(dāng)時(shí)還沒有采用電動(dòng)機(jī)來驅(qū)動(dòng)重要設(shè)備及配件,因此安德森的設(shè)備有一個(gè)缺點(diǎn)。由于沒有別的電源驅(qū)動(dòng),駕駛司機(jī)不得不騰出一只手來擺動(dòng)車內(nèi)的杠桿。而此時(shí)司機(jī)的另一只手需要來開車(握著方向盤輪或掌著車舵柄)，還需要控制工作換檔桿和制動(dòng)鉗控制桿，這些桿有可能在汽車內(nèi)的地板上也可能處在靠近司機(jī)那一邊的車外，而做這些動(dòng)作時(shí)車輛是在行駛中的。
到了1905年，橡膠密封條取代了刷子成為擋風(fēng)玻璃的清洗工具。不幸的是,一直到1917年，需要司機(jī)一邊開車一邊清潔擋風(fēng)玻璃的這種危險(xiǎn)行為才被廢除了。而解決的辦法就是要通過使用一個(gè)電動(dòng)機(jī)驅(qū)動(dòng)來回移動(dòng)一個(gè)裝有塑料雨刮片的雨刷。夏威夷的牙醫(yī)Ormand發(fā)明的自動(dòng)雨刮器是把電動(dòng)機(jī)放置在擋風(fēng)玻璃頂部的中心處，這樣雨刷按照半圓形或彩虹的形狀掃過車子的前殼。當(dāng)1912年電力發(fā)動(dòng)機(jī)被發(fā)明出來后，雨刷成為最早一批使用在車輛上面的電氣裝備。大多數(shù)汽車雨刷在1930年以前是成對(duì)使用的并且豎直懸掛在擋風(fēng)玻璃的頂端。當(dāng)電力系統(tǒng)可以被設(shè)計(jì)得更加復(fù)雜后，雨刷就被移動(dòng)到擋風(fēng)玻璃上的底部。
在雨刮的開/關(guān)杠桿上添加了擋風(fēng)玻璃刮墊圈,這就要求在擋風(fēng)玻璃在前設(shè)置噴嘴, 然后在發(fā)動(dòng)機(jī)艙里面安置儲(chǔ)液罐,并且還需設(shè)置電路連接線路以協(xié)調(diào)這些操作.在1962年, Bob Kearns發(fā)明了一種司機(jī)可以自主改變運(yùn)動(dòng)間隔和速度的間歇式雨刮器。后來出現(xiàn)了一種電子系統(tǒng),它內(nèi)部可以添加保險(xiǎn)絲和繼電器來操作,調(diào)節(jié),協(xié)調(diào)電器元件部分，從而使擴(kuò)展雨刷的多樣性得以實(shí)現(xiàn)。到了20世紀(jì)80年代，人們把雨刷添加到前燈上,不過這需要把照明系統(tǒng)和雨刮系統(tǒng)連接起來。當(dāng)發(fā)展到了20世紀(jì)90年代,人們?cè)趽躏L(fēng)玻璃上面應(yīng)用了微型傳感器，來檢測(cè)下在擋風(fēng)玻璃上的雨水,從而激活雨刷,并根據(jù)雨量來調(diào)節(jié)速度和運(yùn)動(dòng)間隔時(shí)間。
原材料
制造商所有的零件都是從專業(yè)從事某行業(yè)的公司購買來的，其中有從事鋁和鋼精密零件制造的公司、橡膠雨刮片公司、連桿塑料襯套公司以及專門生產(chǎn)電動(dòng)機(jī)的公司。擋風(fēng)玻璃上的雨刷和雨刷系統(tǒng)(裝配有電動(dòng)機(jī))是不同的組件;有些制造商同時(shí)生產(chǎn)這些,但有的只是生產(chǎn)雨刷而已。
控制移動(dòng)雨刷的連桿和驅(qū)動(dòng)桿，以及樞軸都是由鍍鋅鋼制造的。鍍鋅就是把鋅電鍍到鋼得表面以保護(hù)鋼鐵不受腐蝕。船和車輛驅(qū)動(dòng)臂用于船舶工業(yè)用不銹鋼做的抵抗傷害從鹽水。雨刷的懸架和鉗也是用鍍鋅鋼制造的。鍍有涂層的鋼鐵表面比未鍍鋅涂層的鋼鐵剛?cè)菀淄科?。鋼也是制造雨刷小部件的主要材?比如墊圈,螺母、螺栓、彈簧和托架。
雨刮片的框架是用鋁制造的，而雨刮片本身是以天然橡膠或合成物為材料制作的。有的橡膠雨刮片是用軟橡膠和硬橡膠共同構(gòu)成，把在軟橡膠固定在擦刮板的邊緣(刮板的表面)，而硬橡膠則構(gòu)成了雨刮片其余部分并支撐著擦刮板的邊緣。
組成雨刷其他部分的材料有制作樞軸里墊圈的橡膠和制作連接桿件部分的孔的塑料軸襯。一般懸架系統(tǒng)會(huì)被涂成很明顯的黑色。如果雨刷制造商也同時(shí)制造雨刷系統(tǒng)，那么電動(dòng)機(jī)將也從這個(gè)供應(yīng)商這里購買。而這些電動(dòng)機(jī)都會(huì)被包在鐵箱里面,包括用銅絲繞制的永磁電機(jī)。每個(gè)殼體一般都已經(jīng)連接了電線,這些電線都是此交通工具的一部分，通過安裝特定的的電線束來操作雨刷。根據(jù)電動(dòng)機(jī)所控制的線路的復(fù)雜程度，每臺(tái)電機(jī)內(nèi)部還會(huì)包含一個(gè)或更多的電子電路。
設(shè)計(jì)
雨刷是設(shè)計(jì)用來從擋風(fēng)玻璃上清除雨水。大多數(shù)汽車擋風(fēng)玻璃上的有兩個(gè)雨刷,一個(gè)在后窗另一個(gè)在前照燈處。從外部可以看得出車上的雨刷是橡膠的雨刮片,雨刷臂支撐著雨刮片,彈簧連桿以及雨刷的樞軸部分。雨刷本身由六個(gè)部分構(gòu)成，它們被稱為壓力點(diǎn)或爪,是在雨刷下面的小型機(jī)械臂。爪在雨刮片的背部沿著雨刮片為雨刷分散壓力。這可以被描述為一種懸掛梁平衡系統(tǒng),在這里面雨刷是梁、爪子是懸臂部分。爪子可以使雨刮片很靈活在擋風(fēng)玻璃上通過分散壓力來沿著雨刮片清潔玻璃。爪子越多就可以越有效地分散壓力,就越適合大型和曲線明顯的擋風(fēng)玻璃。
盡管人們對(duì)于雨刮片上的橡膠部分很熟悉,但是事實(shí)上雨刮片還包括金屬槽，被稱作雨刮片框架，而沿框架的長(zhǎng)度和更換洞框架的框架。更換孔可以用來更換完好的橡膠雨刮片。當(dāng)然也可以把雨刮片和框架替換成一體的。
標(biāo)準(zhǔn)雙雨刷電機(jī)通常是由一個(gè)電動(dòng)機(jī)驅(qū)動(dòng)的，并且串聯(lián)起來，使一個(gè)雨刷在司機(jī)那邊,另一個(gè)位置靠近擋風(fēng)玻璃的中央而工作在乘客的視線前方。樞軸固定住雨刷。刮水器和樞軸安裝在支架的兩端,作為推動(dòng)力量從電機(jī)驅(qū)動(dòng)的連接,反過來移動(dòng)其他雨刷。連接起來是連接到另一個(gè)長(zhǎng)棍稱為驅(qū)動(dòng)連接在雨刮器電機(jī)等。用細(xì)長(zhǎng)的彈簧連接刮臂與驅(qū)動(dòng)支點(diǎn)之間,使刮桿能和擋風(fēng)玻璃緊密接觸,并保持一定的壓力使擋風(fēng)玻璃不至于損壞。
在馬達(dá)和驅(qū)動(dòng)連接之間，存在一個(gè)連接系統(tǒng)組成的一個(gè)凸輪(另一個(gè)短桿)和支點(diǎn),輸出軸,齒輪,蝸輪傳動(dòng)控制的動(dòng)力驅(qū)動(dòng)電機(jī)送到他們的手臂。這個(gè)蝸輪延緩了馬達(dá)的速度并成倍增加其轉(zhuǎn)矩(力量)。齒輪允許一個(gè)小型電機(jī)產(chǎn)生足夠的壓力來移動(dòng)雨刮片,清掃玻璃。這種描述是基于使用單個(gè)電動(dòng)機(jī)驅(qū)動(dòng)兩哥雨刮器。如果一個(gè)人配用電機(jī),是需要移動(dòng)更多連結(jié)在一起的兩個(gè)雨刷電機(jī)系統(tǒng)一個(gè)所謂的電動(dòng)機(jī)系統(tǒng)。
成倍增加的力需要用來加速運(yùn)動(dòng)到兩端的雨刮片防止運(yùn)動(dòng)停止,還需要用來抵消的摩擦橡膠與玻璃窗之間的摩擦力、抵消的摩擦橡膠與玻璃上的灰塵之間的摩擦力,并且還要抵消擋風(fēng)玻璃反向風(fēng)壓力。
質(zhì)量控制
在組裝期間,工人們會(huì)觀察各零件的工作狀況,但是他們質(zhì)量控制方法只是簡(jiǎn)單的檢查打開電源后電動(dòng)機(jī)是否運(yùn)轉(zhuǎn)，并且通過聽電動(dòng)機(jī)運(yùn)轉(zhuǎn)時(shí)候的聲音來判斷運(yùn)轉(zhuǎn)的狀況。
最后一道檢驗(yàn)工作是在配件制造完成,但還沒有把雨刷系統(tǒng)組裝起來的時(shí)候。生產(chǎn)指導(dǎo)員或者質(zhì)量控制檢測(cè)員一般都是看看配件的外觀，確認(rèn)雨刷的尺寸和傾斜角是清潔時(shí)需要的正確尺寸并且還要檢查配件是在要組裝的位置上。在指導(dǎo)員或檢測(cè)員也要檢查看看這些合格的配件是否可以組裝了。
副產(chǎn)品和廢料的
擋風(fēng)玻璃的雨刷系統(tǒng)
有一些多余的或者廢棄了的以及損壞了的部件上面的鋼材和鋁材下腳料，它們會(huì)被收集在垃圾桶里,然后賣給了那些收廢品的，這些人接下來會(huì)繼續(xù)倒賣給金屬制造商,制造商會(huì)把金屬熔化了以便回收利用。零部件上的包裝也可以被收集和回收利用。
走勢(shì)
到了2011年,由于汽車以及其他交通工具的改進(jìn)，技術(shù)改進(jìn),以及消費(fèi)者的需求，雨刷和雨刷系統(tǒng)也正在不斷得到改進(jìn)。雨刮片長(zhǎng)達(dá)76厘米,當(dāng)它們?cè)趽躏L(fēng)玻璃上工作時(shí)會(huì)產(chǎn)生很多的阻力?，F(xiàn)在正在改進(jìn)擋風(fēng)玻璃上的夜視屏，這也會(huì)增加雨刷工作時(shí)的阻力并且會(huì)需要改變雨刷的尺寸。橡膠的柔韌性日益增加引起雨刮片也不斷改進(jìn),所謂最適合雨刮片可以把冰雪抵擋在外面,在刮板邊緣的不粘涂料可以避免油漬和蠟液附著和使雨刮器老化。
電機(jī)系統(tǒng)的電壓也在不斷增加以提供充足的能量驅(qū)動(dòng)雨刷以及其他的配件。工程師們正在檢測(cè)全自動(dòng)化的控制系統(tǒng)可行性,這一系統(tǒng)將不需駕駛員任何行動(dòng)來開始和停止雨刷系統(tǒng)。發(fā)明家們期待雨水探測(cè)感應(yīng)器可以在20世紀(jì)90年代末改善性能,從而可以在沒有雨水的情況下清潔擋風(fēng)玻璃上的污漬。例如，雨刷是最可靠的汽車裝置之一，它的設(shè)計(jì)壽命可達(dá)150萬次擦拭動(dòng)作。
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