Cable Controls Case Studies

Case Studies by Industry:

Automotive Cable Customization

Seat Control Module
Status Quo

Previous system used three handles. One for recline, another for folding and a third for tumble/kneel.

Need

One handle to provide flip, fold, tumble and recline.

Challenge
  • Mechanism travel variation
  • Release force variation
  • Child release under 20N
Result
  • Integrated 1-handle system
  • Energy Storage
  • Central tolerance control
  • 20N push-button release
Powered Sliding Door
Status Quo

Up to 1990, all sliding van side doors were manually opened and closed.

Need

Powered, cable-based system to offer consumers a powered sliding doors.

Challenge
  • “Cable destroyer” routing
  • 500 lb loads
  • Durability
  • Environment
Result
  • Innovative conduit jacket
  • High durability
  • High efficiency
  • High reliability
Powered Sliding Window
Status Quo

Power rear sliding window systems ran at speeds below the OEM's specifications.

Need

Design a power drive system that meets the OEM specification at a lower cost.

Challenge
  • Increase operational speed
  • Meet difficult specifications
  •  Lower costs
Result
  • New motor drive system
  • Achieved specifications
  • Lowered costs
Powered Adjustable Pedals
Status Quo

Generic fixed pedal location in vehicles did not accommodate all drivers

Need

Make foot pedals adjustable to accommodate all drivers and address rumored government mandates

Challenge
  • Increase travel speed
  • Meet difficult specifications
  • Lower costs
  • Lower noise level
Result
  • Developed specifications for new product and developed a flexshaft and tube to achieve noise, vibration and durability requirements
Lumbar Cable
Status Quo

At the time, there was no lumbar controls in vehicles

Need

Provide powered and manual lumbar control that met packaging constraints.

Challenge
  • High static loads
  • Crash spike loads
  • Low efforts
Result
  • Developed conduit and end fittings to meet high spike loads and high tensile loads during life of part.
Door Cables
Status Quo

During crash, existing designed door rods would bend resulting in unintended latch release.

Need

New crash regulations mandate doors remained closed in vehicle crash.

Challenge
  • No base specifications
  • Cold weather requirements
  • High side loads and cycle life
  • Durability requirements
Result
  • Identified strand construction for environmental specs and developed new birdcage conduit that met 2,000N side loads
Seat Handle Control
Status Quo

Previous system used three straps, pulled sequentially. There was no interlock and
the seats were not removable.

Need

Actuator for 3rd row seat to flip, fold, tumble and remove seat.

Challenge
  • Timed release mechanism
  • Handle to carry 25kg seat
  • 1-million pieces/year
Result
  • Integrated 1-handle system
  • Integrated interlocks
  • In-process defect checking for 15-features , 9-functions and 3 part tracking checks
Pull-pull HVAC Cable
Status Quo

Electronic actuated HVAC controls provided the smooth 'feel' that customers desired, but were expensive to produce

Need

Mechanical system that 'feels' digital, with high quality required to enter the market.

Challenge
  • High quality expectation
  • High volume and efficiency
  • Support global production
Result
  • Provided, highly efficient consistent part with regional support to each customer location

Office Cable Customization

Tilt Control
Status Quo

Multiple handles used to adjust office chair seat cushion and tilt.

Need

VA/VE to lower costs and improve feel

Challenge
  • Variable operating effort
  • Reduce costs
Result
  • Safe and easy to use design at a lower cost
Lumbar Control
Status Quo

Lumbar adjustment is out of reach and positioned on back of chair making it difficult to use and visually unappealing.

Need

Design remote lumbar adjustment mechanism that is within easy reach.

Challenge
  • Improved ergonomics
  • Improve 'look and feel'
  • Secure position adjustment
Result
  • Innovative clutch design
  • Ergonomic improvement
  • Cosmetically appealing
  • 'Feels good' to consumers
Chair Lumbar
Status Quo

Existing system had a problem with back-driving clutch, resulting in high warranty costs.

Need

Increased reliability, Infinite adjustability, and reduce warranty claims.

Challenge
  • New reliable clutch needed
  • Limited packaging space
  • No objectionable noise
Result
  • Designed new clutch utilizing a unique spring material that eliminated back-drive and produced zero noise.
Adjustable Arms
Status Quo

Arms on office chairs were fixed in place. Customer had been unable to devise a solution for this need.

Need

Design a single point actuated, synchronized arm height adjustment.

Challenge
  • Meet or beat fixed budget
  • 300-lb arm load
  • Non-visible mechanism
Result
  • Created a unique, non-visible solution that met the 300-lb load and came in 90% below the budget. Lever on one arm simultaneously and equally adjusted both arms
Friction Plate Assembly
Status Quo

Customer was experiencing 2000-PPM and high labor costs to adjust and securely lock seat-back within any range of movement.

Need

Increase quality and lower VA/VE costs.

Challenge
  • Clutch slippage requirements
  • Identify VA/VE oppuortunities
Result
  • 0-PPM
  • Global sourcing of parts
  • Designed and built in-process checking
Pneumatic Cable
Status Quo

Airy suspension seat created aesthetic challenge.

Need

Robust function and Aesthetic harmony.

Challenge
  • Innovative use of clear molded in color Polycarbonate materials
  • Clean and simple aesthetics with robust functionality.
Result
  • Highly aesthetic clean appearance handle that operates every time.

Aerospace Cable Customization

Over-ride cables
Status Quo

Cable and lever system over-rides motor to release and allow seat to be moved into flight position . High efforts cause injury to users.

Need

Safe and easy to use design and to lower costs.

Challenge
  • High efforts
  • Design 'hold open' feature
Result
  • Designed new actuator that is low in effort and is safe to use with an integrated hold-open feature.
Inertia Cables
Status Quo

Inertia release in current aircraft seating had high effort required to actuate and low durability.

Need

Improved design to increase durability, reduce effort in use and reduce cost.

Challenge
  • Confined packaging space
  • High effort to overcome
  • Poor available routing
Result
  • Designed integrated guide tube and attachment components that reduced assembly time and increased efficiency. 

Defense Cable Customization

Quick Release
Status Quo

Existing and varied systems took too long to reassemble in the field, putting soldiers at risk.

Need

Generic vest cable system that allows for release and reassembly in 30-seconds.

Challenge
  • Achieve 100% reliability for the sequential release of multiple points at zero weight gain
Result
  • Collaborated on specifications to innovate a new system that is 100% realiable and can be released and reassembled in under 30 seconds.

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