Mechanical Design and Production

Faculty of Engineering
Cairo University
𝟐𝒏𝒅 Year Mechanical Engineering
MPD-2130 Machine Design

Windshield Wiper
Mechanism
Submitted to/ Dr. Mohamed El-Shazly
Associate Professor of Mechanical Design
 MPD-2130 Machine Design
Windshield Wiper Mechanism

Table of Contents
Names: ............................................................................................................................................ 1
Introduction: ................................................................................................................................... 2
1. Shaft Design: ............................................................................................................................... 4
2. Lever Design: ............................................................................................................................... 6
3. Welding Calculations: ................................................................................................................. 7
4. Working drawings: ...................................................................................................................... 8
4.1. Shaft: .................................................................................................................................... 8
4.2. Lever 1: ................................................................................................................................. 9
4.3. Lever 2: ............................................................................................................................... 10
4.4. Bearing: .............................................................................................................................. 11
5. Construction drawing: ............................................................................................................... 12

Names:

Name Sec B.N. Code

1. Eslam Amr Saleh Refaai 2 6 9210217
2. Eslam Mohamed Waheed Morsi 2 8 9210221
3. Eslam Mohamed Yehia Farid 2 9 9210222

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 MPD-2130 Machine Design
Windshield Wiper Mechanism

Introduction:
Windshield wiper blades are responsible for keeping your windshield clean. They work like a
squeegee; in a back-and-forth motion they wipe water, snow, wiper fluid, and other liquids or
debris off the windshield. Windshield wipers are operated by an electric motor. The electric
motor is attached to a worm gear, which transmits the necessary force to a long rod that sets
the wiper arms in motion. The worm gear can generate the force required to move the wipers as
fast as they need to move. The arms move the actual windshield wiper blades. The blades are
made of rubber and must apply enough pressure to the windshield to remove all moisture
without any streaks. The arms attach to the middle of each wiper blade, and each wiper blade
has several arms that distribute the pressure onto the windshield evenly. Windshield wipers are
basically the same on every car. They have two pivot points (one on the driver’s side and one in
the middle of the windshield) that work together to remove moisture. This is called the tandem
system, and it provides the most coverage to clean the area of the windshield through which the
driver looks out. There are other systems that are used; these include the single arm system
(used on Mercedes vehicles) in which a single arm (controlled) system extends and retracts as it
moves, and the opposed system that has pivot points on opposite ends of the windshield, and
the wipers move in the opposite direction. Windshield wipers operate at several different
speeds. There is usually a slow and a fast setting, along with several intermittent settings.

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 MPD-2130 Machine Design
Windshield Wiper Mechanism

A windshield wiper mechanism for a truck shown in the figure below. A F1 force is
applied to lever 1 by an adjacent link. The reaction force, F2, on lever 2 is transmitted
to another link.
Let the distance, d, between elements is 20.0 mm.

Using windshield wiper motor of:

Power 50Watt
No. of cycles 55Rpm

2𝜋𝑁
𝑃 =𝑇∗𝜔=
60
120𝑃 ∗ 103 50 ∗ 60 ∗ 103
𝑇= = = 8681 𝑁. 𝑚𝑚
2𝜋𝑁 2𝜋 ∗ 55

Lever 1&2 having the same torque [ 𝑇 = 8681 𝑁. 𝑚𝑚]

𝐹1 ∗ 60 = 𝐹2 ∗ 40 = 8681
𝐹1 = 145𝑁 & 𝐹2 = 217𝑁

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 MPD-2130 Machine Design
Windshield Wiper Mechanism

1. Shaft Design:
∑ 𝐹𝑍 = 0
Y
𝐶𝑍 + 𝐴𝑍 + 145 + 217 = 0 𝑨𝒚
∑𝑀𝐴 = 0
145 ∗ 20 + 217 ∗ 60 = −40𝐶𝑍 A 𝑪𝒚
𝐶𝑍 = −398𝑁 & 𝐴𝑍 = 36𝑁 B
Z
∑𝐹𝑦 = 0 𝑨𝒛 C
T
𝐶𝑦 = 0 & 𝐴𝑦 = 0 𝑭𝟏
D
𝑪𝒛
X
𝑭𝟐 T
(X-Z) Plane
145N 217N
𝟐𝟎𝒎𝒎 𝟐𝟎𝒎𝒎
398N 𝟐𝟎𝒎𝒎
36N A B D
C
8681N.mm 8681N.mm

181
36

SFD

217 𝑀𝑎𝑥 𝑀𝑜𝑚𝑒𝑛𝑡 @𝐶

= 4340𝑁. 𝑚𝑚
4340
𝑇𝑜𝑟𝑞𝑢𝑒 @𝐶
= 8681𝑁. 𝑚𝑚
720

BMD

8681
TMD

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 MPD-2130 Machine Design
Windshield Wiper Mechanism

Assume for shaft:

Material AISI 1065 Carbon Steel

Safety factor 3
𝑆𝑦 490Mpa
𝑆𝑈𝑡 635Mpa

❖ For static design:

Using Distortion Energy Theory (DET):
1 1
3 3
32 ∗ 𝑛𝑠 3 32 ∗ 3 3
𝑑=[ ∗ √𝑀 2 + 𝑇 2 ] = [ ∗ √43402 + ∗ 86812 ] = 8.15𝑚𝑚
𝜋 ∗ 𝑆𝑦 4 𝜋 ∗ 490 4

Take d=9mm

❖ For fatigue design:

𝑚𝑎𝑥
𝑀𝑚𝑖𝑛 = ±4340𝑁. 𝑚𝑚
𝑚𝑎𝑥
𝑇𝑚𝑖𝑛 = +8681𝑁. 𝑚𝑚
𝑀𝑚 = 0 & 𝑀𝑎 = 4340𝑁. 𝑚𝑚
𝑇𝑎 = 0 & 𝑇𝑚 = 8681𝑁. 𝑚𝑚
𝑆𝑒 = 𝐾𝑓 𝐾𝑠 𝐾𝑟 𝐾𝑡 𝑆 ` 𝑒

▪ 𝐾𝑓 = 𝑒 ∗ 𝑆𝑈𝑡 𝑓 = 4.51 ∗ 635−0.265 = 0.82

▪ 𝐾𝑠 = 1.248 ∗ 𝑑 −0.112 = 1.248 ∗ 9−0.112 = 0.98
▪ 𝐾𝑟 = 𝐾𝑡 = 1
▪ 𝑆 ` 𝑒 = 0.5 ∗ 𝑆𝑈𝑡 = 0.5 ∗ 635 = 317.5𝑀𝑝𝑎
𝑆𝑒 = 0.82 ∗ 0.98 ∗ 317.5 = 255𝑀𝑝𝑎
1
3
2 2
32 ∗ 𝑛𝑠 𝑆𝑦 𝑆𝑦
𝑑=[ ∗ √(𝑀𝑚 + ∗ 𝐾𝑓 ∗ 𝑀𝑎 ) + (𝑇𝑚 + ∗ 𝐾𝑓𝑠 ∗ 𝑇𝑎 ) ]
𝜋 ∗ 𝑆𝑦 𝑆𝑒 𝑆𝑒
1
3
2
32 ∗ 3 490
=[ ∗ √( ∗ 4340) + (8681)2 ] d=9mm
𝜋 ∗ 490 255

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 MPD-2130 Machine Design
Windshield Wiper Mechanism

2. Lever Design:
Assume for lever:

Material AISI 1080 Carbon Steel

Safety factor 3
𝑆𝑦 585Mpa
𝑆𝑈𝑡 965Mpa

Y
Assume rectangular cross section area.

t=0.25x X

For lever 2:
𝑀 = 𝐹 ∗ 𝐿 = 217 ∗ 40 = 8681𝑁. 𝑚𝑚

𝑀𝑦 ∗ 𝑋 8681 ∗ 0.5𝑥 208344 𝑆𝑦 583

𝜎= = = = = = 10𝑚𝑚
𝐼𝑌 1 4 𝑥3 𝑛𝑠 3
∗ 0.25 ∗ 𝑥
12

For safety:
𝑥 = 12𝑚𝑚 (𝑊𝑖𝑑𝑡ℎ)
𝑡 = 0.25𝑥 = 3𝑚𝑚 (𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠)

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 MPD-2130 Machine Design
Windshield Wiper Mechanism

3. Welding Calculations:
Designing for lever 2 as it has max force:

Electrode E70XX
Safety factor 3
𝑆𝑦 393Mpa
𝑆𝑈𝑡 482Mpa
𝑆𝑠𝑦 0.5 ∗ 𝑆𝑦 = 196.5𝑀𝑝𝑎

𝐹2 𝐹2 217 10.855
𝜏𝑣 = = = =
0.707 ∗ ℎ ∗ 𝐿 0.707 ∗ 𝜋 ∗ 𝑑 ∗ ℎ 0.707 ∗ 𝜋 ∗ 9 ∗ ℎ ℎ

𝑇∗𝑟 𝑇∗𝑟 8681 ∗ 4.5 96.5

𝜏𝑇 = = = =
0.707 ∗ ℎ ∗ 𝐽𝑈 𝜋 ∗ 𝑑3 𝜋 ∗ 93 ℎ
0.707 ∗ ℎ ∗ 0.707 ∗ ℎ ∗ 4
4

107.355 𝑆𝑠𝑦 196.5

𝜏𝑎𝑏𝑠 = 𝜏𝑣 +𝜏 𝑇 = = =
ℎ 𝑛𝑠 3
ℎ = 1.639𝑚𝑚

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 MPD-2130 Machine Design
Windshield Wiper Mechanism

4. Working drawings:
4.1. Shaft:

8
 MPD-2130 Machine Design
Windshield Wiper Mechanism

4.2. Lever 1:

9
 MPD-2130 Machine Design
Windshield Wiper Mechanism

4.3. Lever 2:

10
 MPD-2130 Machine Design
Windshield Wiper Mechanism

4.4. Bearing:

11
 MPD-2130 Machine Design
Windshield Wiper Mechanism

5. Construction drawing:

12