信昌集團 – 台灣技研處

Hsin Chong Group –

Window Regulator
Door Module
Component
Requirements
CTS
Version 6.0, 12/08/2020
 TABLE OF CONTENTS
1 Overview ............................................................................................................................................. 4
1.1 Change control ............................................................................................................................ 4
1.2 Scope........................................................................................................................................... 4
2 Functional Requirements .................................................................................................................... 4
2.1 Operating Temperature .............................................................................................................. 4
2.2 Operating Voltage for 12V Components ..................................................................................... 5
2.3 Window Regulator Open/Close Movement ................................................................................ 5
2.4 Full Up/Down Stall ...................................................................................................................... 6
2.5 Stopped Glass Support ................................................................................................................ 6
2.6 Window Regulator Operating Sound Quality .............................................................................. 7
2.7 Window Regulator Lifetime Operational Durability .................................................................... 7
3 Safety/Regulatory Requirements ...................................................................................................... 10
3.1 Motor Thermal Characteristics ................................................................................................. 10
3.2 Window Regulator Forced Entry ............................................................................................... 10
3.3 Stall Force.................................................................................................................................. 10
4 Mechanical Requirements ................................................................................................................ 11
Mechanical Loads ................................................................................................................................. 11
4.1 Drop Test................................................................................................................................... 11
4.2 Window Regulator Actuating Range - Stroke ............................................................................ 11
4.3 Window Regulator Actuating Loads - Nominal Torque/Current ............................................... 11
4.4 Window Regulator Rail Yield Stress........................................................................................... 11
4.5 Window Regulator Deflection limit - Rail Y-direction ................................................................ 11
4.6 Door Close Durability ................................................................................................................ 12
4.7 Vibration ................................................................................................................................... 12
4.8 Pull arm tests ............................................................................................................................ 13
4.9 Window regulator on door modules ......................................................................................... 13
Thermal Loads ...................................................................................................................................... 13
4.10 Thermal Shock ........................................................................................................................... 13
4.11 Creep ......................................................................................................................................... 14
4.12 High Temperature and Humidity ............................................................................................... 14
4.13 Low Temperature/Freeze Exposure .......................................................................................... 14
Environment Compatibility ................................................................................................................... 15
4.14 Chemical Resistance .................................................................................................................. 15
4.15 Water Ingress ............................................................................................................................ 17
4.16 Door module water tightness ................................................................................................... 18
4.17 Dust Ingress............................................................................................................................... 18
4.18 Corrosion Resistance Test ......................................................................................................... 18
4.19 Function during water exposure ............................................................................................... 19
4.20 Function during dust exposure ................................................................................................. 19
Material/Coating .................................................................................................................................. 19
4.21 E-coating ................................................................................................................................... 19

Hsin Chong / Inertim Page 2 of 25

 4.22 Localized Grease Application .................................................................................................... 19
4.23 Restricted Materials .................................................................................................................. 20
4.24 Material Compatibility .............................................................................................................. 20
Fastening .............................................................................................................................................. 20
4.25 Free-Play ................................................................................................................................... 20
4.26 Fastening torque/clamp load .................................................................................................... 20
5 Electrical Requirements .................................................................................................................... 21
5.1 Output Hall Signals (to DCU) ..................................................................................................... 21
Connector ............................................................................................................................................. 21
5.2 Packaging of connector on Window Regulator ......................................................................... 21
5.3 Automotive Grade Connector ................................................................................................... 21
5.4 Electrical connector insertion/retention/removal .................................................................... 21
Input Voltage ........................................................................................................................................ 21
5.5 Environmental Test Requirements for Electrical Electronic Components ................................. 21
Electromagnetic Compatibility ............................................................................................................. 23
5.6 EMC ........................................................................................................................................... 23
6 Architectural Requirements/Design Rules ........................................................................................ 23
6.1 Clearance/Dynamic Envelopes .................................................................................................. 23
7 Assembly & Service Requirements.................................................................................................... 23
7.1 Final Assembly Process ............................................................................................................. 23
7.2 Window Regulator Adjustability ............................................................................................... 24
7.3 Fasteners/tape selection ........................................................................................................... 24
7.4 Serviceability ............................................................................................................................. 24
8 Logistics Requirements ..................................................................................................................... 24
8.1 Component Labeling ................................................................................................................. 24
8.2 Pre-Conditioning ....................................................................................................................... 25
8.3 Recyclable Materials Identification ........................................................................................... 25
8.4 Component Packaging .............................................................................................................. 25
9 Component Quality Requirements ................................................................................................... 25
9.1 Dimensions & Tolerances .......................................................................................................... 25
9.2 Inspection Points ....................................................................................................................... 25

Hsin Chong / Inertim Page 3 of 25

 1 Overview

1.1 Change control

REVISION DETAILS DATE

1.0 Initial Release – 08/09/2017

2.0 WIP – Updates to Electrical Spec 04/04/2018

3.0 Updates based on Paco feedback 07/03/2018

4.0 Specific version for customer 14/06/2018

5.0 Specific version for customer 16/11/2018

6.0 Specific version for Human Horizons VX1 19/04/2019

1.2 Scope

This document covers the functional, mechanical and electrical requirements for a door module with a
dual rail, frameless Window Regulator, powered by 1 6-Pin motor and controlled by the Door Control
Unit.

2 Functional Requirements

2.1 Operating Temperature

The operating temperature range for the VX1 Door module &Window Regulator is as follows:

[ºC] RH%
Cold Storage Temperature TCS 5±5 Minimum temperature which the system may
-40 ± 3
experience but, is not expected to operate at
Minimum Temperature TMin -20 ± 3 5±5 Minimum limit value of the ambient
temperature at which the component is
required to operate

Hsin Chong / Inertim Page 4 of 25

 Room Temperature TRTP 23 ± 5 50 ± 20 Ambient room temperature
Operation w/ Humidity 50 ± 3 95 ± 5 High humidity test temperature at which the
THum
component is required to operate
TMax 85 ± 3 5±5 Maximum limit value of the ambient
Maximum Temperature temperature at which the component is
required to operate
Maximum Temperature THT 90 ± 3 5±5 High test temperature at which specific
Retention system components are expected to function
(drain tube retention)
Repaint & Storage Temperature TRPS 105 ± 3 5±5 Maximum temperature which can occur
during repainting, but at which the
component is not operated. Accounts for
high temperature storage and paint booth
exposure

Requirements that follow may just state the abbreviation: e.g. TRTP

2.2 Operating Voltage for 12V Components

Refer to latest HC Environmental Test Requirements_Electrical Electronic Components, for vehicle level
operating voltage range.

The VX1 Window Regulator operating voltage range is as follows:

VDC [V]
Low Voltage VLow 8 Minimum value of the supply which can occur, at which
component can operate with degraded performance
Minimum Operating Voltage VMin 10 Minimum limit value of the supply voltage at which the
component is required to operate
Nominal Operating Voltage VNom 13.5 Nominal supply voltage at the component
Maximum Operating Voltage VMax 16 Maximum limit value of the supply voltage at which the
component is required to operate
High Voltage VHigh 18 Maximum value of the supply which can occur, at
which component can operate with degraded
performance

Requirements that follow may just state the abbreviation: e.g. VNom

2.3 Window Regulator Open/Close Movement

The Window Regulator shall move glass through stroke UP or DOWN in required direction with following
performance targets:
• Move glass smoothly, free from chatter, maintaining parallelism of sliders (+4mm, -0mm)
• Cable movement shall not induce noticeable BSR; anti-rattle sleeves shall be used appropriately
• Ambient, TRTP target speed of 130mm/s +/- 30mm/s, where input voltage is within nominal
range (VLow of 13.5V to VHigh of 15.8V). Use VNom, 14.6V, 0.08Ω
• FNom defined as hanging load of 80N for the Front Regulator & Rear Regulator

Hsin Chong / Inertim Page 5 of 25

 • Exceed 95mm/s at -30°C, TLow with FMax hanging loads of 100N
• Do not exceed 200mm/s and/or cause excessive stall noise at 85°C/45% RH, 15.8V

2.3.1 Component Exposure to Cold Storage/Paint Repair

The Window Regulator

• Shall function (no speed targets) at Cold Storage Temperature
• Shall function (no speed targets) at Paint Repair Temperature

2.3.2 Component Exposure to unusual 12V loading

The Window Regulator

• Shall function (with no speed targets) at degraded bus voltages VLow/VHigh
• Shall resume normal function after exposure to unusual 12V loading (per cases in HC Electronic
Environmental Test Requirements Spec)

2.4 Full Up/Down Stall

The Window Regulator shall support glass through full up and down stall loads over life:
• Rail material and thickness shall be evaluated to support lifetime hard stop stalls
• Cable movement and slider stops during stall shall not induce noticeable BSR for the customer;
anti-rattle sleeves shall be used appropriately

2.5 Stopped Glass Support

The Window Regulator shall support glass in any X, Y, Z-axis stopped position through stroke:
• Slider to glass interface shall not have unintended movement/shakiness or BSR, with shakiness
defined as: 0.3gs of chatter on leading edge of glass (B-Pillar top corner)
• Slider to glass set (relative position fixed after adjustment) shall not alter

This requirement applies for:

• Temperature range between TMin to TMax
• Lifetime vibration and door open/close loading
• FNOM loads on Regulator of hanging load of 100N for the Front Regulator & hanging load of 80N
for the Rear Regulator

2.5.1 Component Exposure to Abusive Door Slams

The regulator shall support glass in any X, Y, Z-axis stopped position through stroke during abusive door
slams:
• Slider to glass set (relative position fixed after adjustment) shall not alter
• Noticeable shakiness OK as long as component does not incur damage
• Regulator attachment to sheetmetal is not weakened (see Fastening & Mechanical
Requirements for limits)

2.5.2 Component Exposure to Blowout

Hsin Chong / Inertim Page 6 of 25

 The regulator shall support glass in any X, Y, Z-axis stopped position through stroke in the event of
blowout on glass (at the B-Pillar header corner or mid-pillar):
• Slider to glass set (relative position fixed after adjustment) shall not alter
• Blowout (represented by a 40N pull force perpendicular to the glass, on 3/4 UP glass) causes
<5mm of glass deflection, as measured from the maximum deflection point

2.6 Window Regulator Operating Sound Quality

During the Window Regulator's operation, operational noise heard shall be <9 sones. Revise target to
max of 11 sones after initial data collection if necessary.
• Measured with microphone 20 inches away from center of window regulator motor
• No undesirable/noticeable BSR (cable rattle, spring rattle, cable ticks)

Operational sound data collected shall be in dB or sones (in .wav files). Conduct loudness vs. time and
loudness vs. frequency analysis with sampling rate no less than 48kHz.

This requirement applies for:

• Temperature and humidity range between TMin to TMax
• China dust exposure directly on rails of Window Regulator

2.7 Window Regulator Lifetime Operational Durability

The Window Regulator must endure 1 lifetime of operational cycles without its performance degrading
by more than 20% or incurring physical damage:
• <20% degradation to Window Regulator Movement requirement
• <20% degradation (~2 sones increase) to Window Regulator Operating Sound Quality
requirement
• no physical damage or noticeable shakiness to meet Window Regulator Support requirement
• no physical damage due to repeated stalls to meet Window Regulator Full Up/Down Stall
requirement
• Cable slackness shall remain acceptable, as measured on the self-adjustment feature (Measure
self-trapping for target)

The Window Regulator shall be installed as close to vehicle condition as possible, with hanging loads.
1 Lifetime of Window Regulator Operational Cycles is as follows:
• 28 000 cycles, where 1 cycle consists of:
o 1 Full Drop: From Full-Up Hard Stop, WR travels full-down to stall for 0.5s, then full-up
again to Full-Up Hard Stop position, also stalling for 0.5s
o 3 Smoker's Gap Drops: From Full-Up Hard Stop stalling, WR travels down and up for
approximately 1.0s three times with stops at both upper and lower positions for 0.5s.
The first two times of travel up will not hit Hard Stop, and the 3rd time will do and stall
for 0.5s.
o 1 Short Drop: From Full-Up Hard Stop stall, WR travels down 0.15 seconds, stops for
0.5s, and travels full-up to Hard Stop position.
• Appropriate rest time between cycles for motor cooling needs

Hsin Chong / Inertim Page 7 of 25

 Include applicable vehicle and system features to the component operational life:
• input voltage range is varied per following breakdown (refer to Operating Voltage
Requirement):
o 50% of all cycles at VNom
o 25% of all cycles at VHigh
o 25% of cycles at VLow
• tune wiring resistance between voltage source and regulator to represent vehicle conditions
• temperature cycling is included per following breakdown (refer to Operating Temperature
Requirement):
o 50% of all cycles at TRTP
o 20% of all cycles at THum
o 5% of cycles at THigh
o 20% of cycles at TLow
• hanging loads per following breakdown:
o 75% of all cycles at FNom/Nominal use case
▪ hanging load of 80N for the Front & Rear Regulator
o remainder of cycles at FMax
▪ hanging load of 100N for the Front & Rear Regulator
• Arizona/China dust and/or salt water is applied to the upper pulley area of the rails at least
every 1700-2000 cycles, where
o dust application is defined as a pressure duster spray of 0.2g ± 0.1g of Arizona Dust (SAE
J726b fine) or China Dust (50/50 blend of JIS Z8901 Class 8 Test Dust & SiO2)
o only one type of dust is applied at a time (e.g. alternate applications for 50/50
breakdown) using a pressure duster, from a distance of 300mm to movable WR parts

Hsin Chong / Inertim Page 8 of 25

 o salt water application is defined as a 10ml spray of 50g ± 5g salt (NaCl) solution in
distilled water

The Window Regulator must endure and additional lifetime of operational cycles and be functional at
the end (degraded performance OK).

Example of durability cycle with temperature and dusting:

Reference contact:

Hsin Chong / Inertim Page 9 of 25

 3 Safety/Regulatory Requirements

3.1 Motor Thermal Characteristics

Provide thermal limits of the system to HC:

• Temperature rise rate given Power (I*V) input
• Depletion rate for rest time
• Temperature limit for shutoff

These factors should allow the motor to perform for 2 operational lifetimes without damage.
Data for can be collected with thermocouple implemented on motors.

HC software shutoff implementation example:

3.2 Window Regulator Forced Entry

The Window Regulator shall move <15mm when a 735N load is directly applied onto the component
across the two sliders.

3.3 Stall Force

Spec the motor and system loads so that stall force into header, as measured 25mm from its full closed
position is <270N at 13.5V/0.08Ω, in case of anti-pinch software failure.

Hsin Chong / Inertim Page 10 of 25

 4 Mechanical Requirements

Mechanical Loads

4.1 Drop Test

the door module form a height of 500 mm onto a hard concrete surface at the following orientations:
Horizontal with dry side down.
Horizontal with dry side up.
Vertically on forward edge.
Vertically on rearward edge.

Evaluate the door module after each drop looking for any damage.

The Window Regulator must function correctly even if it was accidentally dropped from a height of 1m
during handling or installation onto a hard surface.

The sample is dropped with the test surface and impact surface parallel to each other and in all 6 axes
(x, -x, y, -y, z, -z). The impact surface is usually a concrete surface.

4.2 Window Regulator Actuating Range - Stroke

The Window Regulator Stroke (from hard stop to hard stop) shall have a tolerance of +1.5mm -0mm.
Over life, cable slackness shall be corrected for by the tensioner to maintain stroke length.

4.3 Window Regulator Actuating Loads - Nominal Torque/Current

At TRTP, VNom and nominal loads (80N for Front & Rear Regulator), the Window Regulator working Torque
target is 5-6Nm. Provide expected nominal current draw to HC based on motor selection.
• Variation of 15% OK
• All conditions being same, 15 consecutive cycles later, current draw should not exceed 15A

4.4 Window Regulator Rail Yield Stress

The maximum stress seen on the Window Regulator Rails (worst case: stall load at VHigh, THigh) shall not
exceed 70% of the material's yield stress.

4.5 Window Regulator Deflection limit - Rail Y-direction

In Y-direction, the window regulator rails shall deflect:

• <1.5mm during stall
• <0.5mm during UP/DOWN movement with load

Conduct CAE evaluation before final rail material and thickness selection. Verify during durability testing.

Hsin Chong / Inertim Page 11 of 25

 4.6 Door Close Durability

The Window Regulator must withstand the Power Door System's lifetime panel open/close slam
loading without its performance degrading or undergoing physical damage. Undesirable buzz, squeaks
and rattles should not develop. Endurance of the component is defined by:

• No physical damage or noticeable shakiness to meet Window Regulator Support requirement

• Subjective/Jury BSR evaluations during and/or after vibration endurance
• Regulator attachment to sheet metal is not weakened

1 Lifetime of Powered Door System Operational Cycles is defined as:

• 1 lifetime, NDoors = 85 000 cycles of powered open/close cycles
• 8500 abusive slam cycles

Regulator position is varied per following breakdown:

• 33% of all cycles at Full Up
• 33% of all cycles at mid-stroke
• 33% of all cycles at Full Down

4.7 Vibration

There shall be no malfunctions or breakage/mechanical damage of the component when subjected to

vibration load.

At TRTP and for VLow, VNom and VHigh component must function correctly under following conditions:
Frequency Sweep
Acceleration m/s2 Time/Sweep #Sweeps/Axes #Axes Total
(Hz) Type
10mm p-p
5-15
Displacement limited
15-25 54 Sweeps
44.1 (4.5gs) Log 20mins 18 3
25-100 18.0hours
19.6 (2gs)
100-200
4.9 (0.5gs)

The component can also be tested as per the test procedures listed in ISO-16750-3, Section 4.1.2.4 - Test
IV - Passenger car, sprung masses (vehicle body).

OR:

Hsin Chong / Inertim Page 12 of 25

 The Window Regulator must withstand 1 lifetime/150 000 customer equivalent miles of vibration
loading without its performance degrading or incurring physical damage. Undesirable buzz, squeaks and
rattles should not develop. Performance of the component is defined by:
• <20% degradation (~2 sones increase) to Window Regulator Operating Sound Quality
requirement
• no physical damage or noticeable shakiness to meet Window Regulator Support requirement
• Subjective/Jury BSR evaluations during and/or after vibration endurance

4.8 Pull arm tests

The door system incl. a stiff dummy of the inner pull cup bracket has to be assembled to a door or gauge
and fixed on a stiff rig. The deformation of the pull cup fixation points has to be recorded in form of a
graph.

No cracks or malfunction.

100N applied in Y direction, elastic deformation not exceed 2mm

200N applied in Y direction, not exceed tensile strength of material

4.9 Window regulator on door modules

Window regulators mounted on door modules must provide hard attachments to the door module
within 25,4 cm of the upper and lower window regulator centreline attachments to ensure that at full
up window stall the door module panel deflection is less than 1 mm in any direction.

Thermal Loads

4.10 Thermal Shock

The Window Regulator must be immune to thermal fatigue that is caused by rapid temperature
changed, without exhibiting any breaks, fractures, cracks, deformations or other failure modes that affect
performance.

Check performance of the Window Regulator against following functional requirements:

• Window Regulator Open/Close Movement
• Window Regulator Full Up/Down Stall
• Window Regulator Stopped Glass Support
• Window Regulator Operating Sound Quality

The component should be installed and loaded as close to vehicle condition as possible and subject to
1. Freezing component until thermally stable at -30°C
2. Partial soak the frozen system with 40°C water
3. Repeat steps (1) and (2) for a total of 4 thermal shocks
4. Heat the system until thermally stable at 65°C
5. Partial soak the heated system with 10°C water
6. Repeat steps (4) and (5) for a total of 4 thermal shocks

Hsin Chong / Inertim Page 13 of 25

 4.11 Creep

The Window Regulator must endure high load, high temperature (creep inducing) conditions without
exhibiting any breaks, fractures, cracks, deformations (affecting performance) or other failure modes
that affect function. In FEA, all load carrying plastic (pulleys, sliders) should have yield strength that
exceeds applied stress at appropriate contact areas.

Check performance of the Window Regulator against following functional requirements:

• Window Regulator Open/Close Movement
• Window Regulator Full Up/Down Stall
• Window Regulator Stopped Glass Support
• Window Regulator Operating Sound Quality

Component should be subject to creep inducing conditions for a minimum of 1000 hours, in half day
cycles. 1 cycle is comprised of:
• Application of 650N load for 12 hours at TMax
• Relief and functional operation twice at TRTP, VNom, FNom (80N for Front & Rear Regulator)
• Thermal Shock of all plastic sub-components with water (2s) at TRTP
• Monitoring critical load carrying areas for initial cracking, fatigue or deformation

The component must endure an additional 500 hours of creep cycles and be functional at the end
(degraded performance OK).

4.12 High Temperature and Humidity

The component shall withstand exposure to high temperature and humidity:

• THum, min 336 hours exposure (14 days)

• TMax, min 168 hours exposure (7 days)
• TRPS, min 120 hours exposure (5 days) if applicable

The component shall operate as functionally required during and after the high temperature/humidity
exposure (Performance degradation OK for non-safety critical items). Components shall also be free
from deformation, cracks, breakage, color changes, blister, wall thinning, softening & separation.

Rubber components shall not exceed any applicable shrinkage or expansion limits.

4.13 Low Temperature/Freeze Exposure

The component shall withstand exposure to -40°C and ice build-up (up to 3mm on Class A surfaces):

• TMin, min 48 hours exposure (2 days)

• For water spray application onto component at TMin or TLow, min 1 hour soak for freeze to occur

Hsin Chong / Inertim Page 14 of 25

 The component shall operate as functionally required during and after the low temperature/freeze
exposure (Performance degradation OK for non-safety critical items). Components shall also be free
from deformation, cracks, breakage, color changes, blister, wall thinning, softening & separation.
Components shall not exceed any applicable shrinkage or expansion limits.

Environment Compatibility

4.14 Chemical Resistance

The component shall withstand exposure to the various chemicals and contaminants it might contact
during its lifetime. Refer to ISO 16750-5 for chemical selection.

The performance/response of the component shall not be affected by exposure/contact with the
various chemicals. Class A components shall also be free from deformation, cracks, breakage, color
changes, blister, wall thinning, softening & separation.

Hsin Chong / Inertim Page 15 of 25

Hsin Chong / Inertim Page 16 of 25
 4.15 Water Ingress

Class A/Exposed parts are required to be protected from water per ISO 20653, IP code rating 9K – water
jet stream.

Connectors/parts that are not directly exposed to exterior should meet IP 67 or equivalent.

Hsin Chong / Inertim Page 17 of 25

 4.16 Door module water tightness

Complete door is required for this test.

Apply water to the glass in angle of 15 degrees to nominal alignment by using 5 nozzles over the glass
length with an opening angle of 25° in a distance of 200mm to the glass. The water pressure shall be
approx. 470 kPa with closed nozzle. With open nozzle (full flow), the water pressure shall be
approximately 60 kPa. No wetting agent shall be added to the water which shall have a temperature of
5°C to 25°C.
The water jet should hit the glass about 200mm above the belt line.
Test to be performed at ambient.
The water flow at the shower nozzle shall be approx. 15 l/min.
Test duration 10 minutes per alignment.

No water may leak in through the door module

No water may leak between the door module and door
Single drops can occur through a rivet
Water is not allowed to drop at/into electrical components

4.17 Dust Ingress

Class A/Exposed parts are required to be protected from dust per ISO 20653, IP code rating 6 – dust
tight.

Connectors/parts that need to be sealed to the dust should meet IP 67 or equivalent:

• Per IEC 60528: IP 6X, part placed into chamber with 2kg/m 3 suspended dust
• 20 operational cycles at VNom between 6s application of dust, then pause 15min for 5hrs

4.18 Corrosion Resistance Test

The component shall withstand cyclical corrosion testing and pass functional checks after the salt spray
exposure. It shall not exhibit visible rust (red on zinc treated steel or white corrosion on aluminum, zinc
alloys or magnesium).

A Class-A component shall withstand 70 cycles, with 4 sprays per cycle.

A Class-B or Closures wet-side component shall withstand 45 cycles, with 1 spray per cycle.

The component shall be tested as follows:

Hsin Chong / Inertim Page 18 of 25

 4.19 Function during water exposure

The component shall operate as functionally required during and after exposure to lifetime water events
(rain, car wash, water flow/drainage through sheet metal).

4.20 Function during dust exposure

The performance/response of the component shall not be affected by exposure to dust it might contact
during its lifetime. Mechanical components shall function normally during and after exposure.
Components shall also be free from deformation, cracks, breakage, color changes, blister, wall thinning,
softening & separation.

China dust shall be used in testing instead of (or in addition to) Arizona dust.

Material/Coating

4.21 E-coating

E-coat shall have a minimum thickness of

• 12μm for Interior usage

4.22 Localized Grease Application

Localized grease application (rails, springs, drum housing) shall be specified in drawing. Control plan
must ensure it cannot be applied outside areas. Packaging shall be designed to help contain grease
during shipment to Final Assembly.

Grease quantity shall be:

• 2g per rail, with >75% coverage
• >2g in drum
• >2g in tensioner
• 1g in other applicable close fit/interference parts (rivets etc.)

Hsin Chong / Inertim Page 19 of 25

 Material spec of grease must be shared and approved by HC Packaging/Manufacturing prior to FESO
milestone.

4.23 Restricted Materials

Do not use materials on the following directives:

• China: GB/T 30512-2014
• EU: Commission directive (EU) 2016/774

4.24 Material Compatibility

Materials that contact each other within the component and to external interfaces (like sheet metal)
shall be compatible to avoid BSR, corrosion, etc.
• Glass/Laminated Glass Bracket to Slider
• Slider hard stop to Rail/Hinge
• Pulley-cable-rivet
• Hinges/studs to rail
• Studs to sheet metal

Fastening

4.25 Free-Play

Sub-components attached with fasteners or close fits shall be checked for free-play (no unintended
movement) or BSR:
• Motor to drum housing interface after assembly at nominal torque
• Drum housing to cable spring fit
• Drum housing to cable tensioner fit
• Cable conduits to cable terminals

4.26 Fastening torque/clamp load

The Window Regulator attachment points (to sheet metal and to glass) shall have well defined assembly
torques that serve its attachment type, required clamp load and lifetime joint loading. Torques must be
defined during CATIA & illustration releases for:
• Bolt for Sliders to Glass
o half torque pre-adjustment in X-direction (sliding plastic slider against aluminum back)
o full torque after adjustment
• Nut for Top Rail Studs to sheet metal
o half torque pre-adjustment
o full torque after adjustment
• Nut for Bottom Rail Studs to sheet metal
o half torque pre-adjustment
o full torque after adjustment
• Slider adjustment set screws for adjustment in Z-direction
• Screws for Drum housing to sheet metal

Hsin Chong / Inertim Page 20 of 25

 5 Electrical Requirements

5.1 Output Hall Signals (to DCU)

Regulator shall output hall signals to DCU for full vehicle operating range of T Min to THigh, VMin to VMax.

5.1.1 Component Exposure to unusual 12V loading

Exposure to unusual 12V input (see Input Voltage specs) shall not affect hall signal output capability of
the motor.

Connector

5.2 Packaging of connector on Window Regulator

Connector must be oriented on the regulator such that it can be easily accessed by operator after
Window Regulator installation in the door.

5.3 Automotive Grade Connector

• Interface connectors shall be appropriate for automotive use by complying to USCAR or

equivalent standard.
• Specify dry side or wet side depending on usage and packaging location.
• Provide completed EDCS sheet to HC Electrical team.

5.4 Electrical connector insertion/retention/removal

• The force to insert the harness side connector onto the component shall be ≤ 50N at TRTP
• The force to remove the connector (pull along connector axis) with the lock tab in locked
position shall be ≥ 100N at TRTP. Electrical function should not be affected.
• The force to disconnect the connector shall be ≤ 100N at TRTP

Input Voltage

5.5 Environmental Test Requirements for Electrical Electronic Components

Refer to HC Environmental Test Requirements_Electrical Electronic Components Rev B.pdf.

If part has limitations to meet this specification, escalate to HC Electrical team.

For Section 3 of Environmental Test Spec, the Window Regulator will be classified as a non-critical,
convenience function (Code E as specified by Table -1, ISO 16750-2).

Applicable supply voltage for tests for Code E: Non-critical and convenience function
• Minimum Supply Voltage 10V

Hsin Chong / Inertim Page 21 of 25

 • Maximum Supply Voltage 16V

Summary of Low Voltage Electrical tests applicable to the Window Regulator:

Section Name Applicable? Functional Class

Requirements

3.1 DC Supply Voltage Apply to all ECU powered by 12V bus Class A

3.2 Parasitic current Applicable if device draws current when <0.1mA

Vehicle is “asleep” (ie. it is a direct
battery feed)

3.3 Over Voltage Apply to all ECU powered by 12V bus For Code B – Class B

For Code E – Class C

3.5 Pulse superimposed Apply to all ECU powered by 12V bus Class A
voltage

3.6 Slow decrease and Apply to all ECU powered by 12V bus Class C (unless agreed
increase of supply voltage upon by HC and
Supplier)

3.7 Momentary drop in supply Apply to all ECU powered by 12V bus For Code B --(unless
voltage agreed upon by HC and
Supplier)

3.8 Power supply interruption Apply to all ECU powered by 12V bus Class C

3.11 Open circuit test – Single Apply to all Device Class C

line

3.12 Open circuit test – Apply to all Device Class C

multiple line

3.13 Intermittent short to Apply to all Device Class C

Battery and Ground

3.14 Continuous short to Apply to all Device Class C

Battery and Ground

3.16 Overload Protection Apply to device with Load circuits Class C for Electronically
Protected, Class D is
Fuse Protected, Class E
is unprotected.

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 ISO 16750-1: Class Definitions

• Class A: All Functions as designed during after and after the test
• Class B: All function performs as design during the test. However, one or more of them may go
beyond the specified tolerance. All functions return automatically to within normal limits after
the test. Memory function shall remain class A.
• Class C: One or More functions do not perform as designed during test, but returns
automatically to normal operation after the test.
• Class D: One or more functions do not perform as designed during the test and do not return to
normal operation after the test until the device/system is reset by simple “operator/user” action
• Class E: One or more functions do not perform as design during and after the test and cannot be
returned to proper operation without replacing the device/system

Electromagnetic Compatibility

5.6 EMC

Refer to HC EMI EMC Requirements_Electrical Electronic Components Rev A.pdf. If part has limitations
to meet this specification, escalate to HC Electrical team.

6 Architectural Requirements/Design Rules

6.1 Clearance/Dynamic Envelopes

Clearance between:
• moving to moving parts >15mm
• moving to static parts >10mm
• static to static parts >5mm

Create following envelopes and approve exceptions/intrusions prior to PESO milestone:

• Static envelope of glass for all adjustment positions (in X and Y per RSS stack-ups)
• Dynamic envelope of glass with 10mm clearance around static envelope
• Dynamic envelope of sliders with 10mm clearance around all inboard/outboard adjusted full-
stroke sweeps
• Static envelope of rails with 5mm clearance around all inboard/outboard adjusted rails

Update envelopes any time the glass/rail drop or geometry is updated.

7 Assembly & Service Requirements

7.1 Final Assembly Process

HC requires the Window Regulator to be installed into the door at Final Assembly as such:

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 • in a doors off process
• with 1 station for part install
• fasteners poke-yoked; tools minimized
• ergonomically, repeatedly

In order to meet system assembly process time, HC requires installation of Window Regulator into door
complete, in 77s. This time requirement is for 1 door. This includes:
• Placement of Window Regulator in door
• Fastener soft starts on the rails
• Final torques on the motor

Complete Manufacturing Virtual Assessment/Build Process checklist by FESO signoff.

7.2 Window Regulator Adjustability

In order to meet system requirements, the glass should be adjustable (through regulator interface) by at
least 2.5mm in X, Z and Y (at beltline) based on RSS stack-up. Allow Y pre-load adjustment as well of >
8mm.

7.3 Fasteners/tape selection

Select fasteners and torques based on System-level communization strategy.

Get sign-off from HC Manufacturing for all selected fasteners before release.

7.4 Serviceability
Complete Serviceability Virtual Assessment/checklist by Tooling Kick OFF.

8 Logistics Requirements

8.1 Component Labeling

Where applicable, the manufacturer's assembly identification shall appear on each part, including the
line number and/or facility where duplication exists.

The label shall also include the following information:

• Part Number
• Part Name/Description
• Revision Number
• Traceability Information
• Any other labels per Regulatory Requirement (e.g. FMVSS 205 for Safety glass)

All samples used for testing purposes shall be externally or visibly marked in a permanent manner for
identification and traceability purposes during the initial inspection process.

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 ALSO Requested for VX1 program:
• Paint dots or other visual marker for RH, LH differentiation
• Paint dots or other visual marker for Front, Rear differentiation

8.2 Pre-Conditioning
Pre-conditioning represents a component's exposure to the environment during shipment (from Tier 1
to OEM, and/or from final assembly to customers). Components must not exhibit performance loss due
to pre-conditioning.

8.3 Recyclable Materials Identification

All plastic parts shall be marked for material identification in accordance with ISO 1043-1

8.4 Component Packaging

Submit packaging proposal to HC Packaging team by 90 days prior to MRD. HC will review and approve
or request changes.

9 Component Quality Requirements

9.1 Dimensions & Tolerances

All the assemblies/ components provided by the supplier must meet dimensions and tolerances as
agreed upon in assembly drawing. The datum scheme for the components and/or assemblies shall be
decided up based on inputs from the manufacturing team (for assembly) and the supplier (based on
manufacturing process). The supplier is also responsible for providing the individual component
drawings identifying all the dimensions and tolerances of the individual parts.

9.2 Inspection Points

The component or assembly's critical spots for inspection must be identified and called out on the
drawings. The inspection points shall be decided on between the Human Horizons and HC's lead
engineers with inputs from the quality team and the manufacturing team. The component shall be
inspected in the free-resting state with the help of locators (without any additional clamps causing any
deformation).

• Supplier must follow HC PPAP approval process.

• Supplier should perform 6 Piece CMM inspection for every 1000 parts produced
• Cp and Cpk = 1.67 or greater (during initial off-tools and PPAP runs)
• Cp and Cpk = 1.33 or greater (following PPAP runs)

Refer to HC Quality Specs for full package

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