Cairo University

Faculty of engineering: Mechanical Department

MDP 2130 – Machine Design 1

Windshield Wiper Mechanism

(Mini Project 1)
By
Yousef Hossam Shapan | Sec: 6 | 9220980
Yousef Adel Abd-Elmoneim | Sec: 6 | 9220991
Yousef Magdy Mounir | Sec: 6 | 9221003

Supervised by:
Prof. Mohamed Elshazly
Contents
Introduction ................................................................................................................................... 2
Mechanism Design ........................................................................................................................ 3
Springs Chosen............................................................................................................................ 3
Wiper Chosen .............................................................................................................................. 3
Motor Chosen .............................................................................................................................. 4
Initial Calculations ...................................................................................................................... 5
Lever Design ............................................................................................................................... 7
Comments.................................................................................................................................... 7
Connection chosen ........................................................................................................................ 8
CAD Design ................................................................................................................................... 9
Shaft Drawing ............................................................................................................................. 9
Lever 1 Drawing........................................................................................................................ 10
Lever 2 Drawing........................................................................................................................ 11
Assembly Drawing .................................................................................................................... 12
References .................................................................................................................................... 13

Page 1 of 14
Introduction
This is a windshield wiper mechanism design project. A windshield
wiper is a device used to remove rain, snow, ice, washer fluid, water, or
debris from a vehicle's front window. Almost all motor vehicles,
including cars, trucks, buses, and trains are equipped with one or more
such wipers, which are usually a legal requirement.
A wiper generally consists of a metal arm; one end pivots and the other
end has a long rubber blade attached to it. The arm is powered by a
motor, often an electric motor, although pneumatic power is also used
for some vehicles. The blade is swung back and forth over the glass,
pushing water, other precipitation, or any other impediments to visibility
from its surface. The speed is usually adjustable on vehicles made after
1969, with several continuous rates and often one or more intermittent
settings. Most personal automobiles use two synchronized radial-type
arms, while many commercial vehicles use one or more pantograph
arms.
For this mechanism, we have used AISI 1050 to manufacture the main
shaft. We have chosen AISI 1050 because of its high workability and
machinability. We needed a high-strength material for the levers, so we
chose AISI 304 stainless steel.

Page 2 of 14
Mechanism Design

Springs Chosen

Wiper Chosen

WT22
Length: 550mm

Page 3 of 14
Motor Chosen

Power Chosen= 50W

Angular Velocity=
55RPM
Efficiency= 75%

Page 4 of 14
Initial Calculations
Coefficient of friction between rubber and dry glass 0.9
Fn= spring force + weight of lever Standard spring force = 120N,

⸫𝐹𝑛 = 120 + 0 = 120N

⸫𝐹1 = 0.9 * 120 = 108N
neglect weight of lever.
⸪𝑃𝑚𝑜𝑡𝑜𝑟 = T * 𝜔
Assume that 𝜔 = 55 rpm
Then 𝑇 = F * d = 108 * 60 = 6480 N.mm
2𝜋∗55
⸫𝑃𝑚𝑜𝑡𝑜𝑟 = 6.48 * = 36𝑊
60
Let 𝑃𝑚𝑜𝑡𝑜𝑟 𝑊
⸪Standard efficiency for V = 12v and I = 5 to 10 amp is 75 %
⸫Shaft output power is 0.75 * 50 = 37.5 watt
2π∗55
37.5 = 𝑇𝑜𝑢𝑡 * 𝑇out = 6.511 = 𝐹 * 𝑑
60

6.511
⸫𝐹 1 = F1 =108.52 , let F1 = 110N
60∗10−3

From torque equilibrium:

𝟏𝟏𝟎∗𝟔𝟎
𝐹1 * 60 = F2 *40 𝐹2 = = 165N
𝟒𝟎
165
Free body diagram:
S.F.D
∑ 𝑀𝐴 = 0 𝐹1 * 20 + F2 * 60 = Rc * 40 -27.5

-137.5
= 261.25
∑𝐹𝑦 = 0 𝐹1 + 𝐹2 + 𝑅𝐴 =
⸫𝑅𝐴 = 23.75𝑁
⸫𝑅𝑐 = 302.5N ⸫𝑅A = 27.5N B.M.D

From bending moment diagram: -550

Critical section is C. ⸫𝑀max = 3.3 𝑁. 𝑚 -3300

xxxxxxxxxxxxxxxxxxx 𝑇max = 6.6𝑁. 𝑚

Page 5 of 14
Shaft Design
The critical section occurs at point “c”.
𝑑
𝑀∗ 33613.524
σx = 2
𝑑4
=
𝜋∗ 64 𝑑3

𝑑
𝑇∗2 33613.524
τxy = 𝜋 4 =
𝑑 𝑑3
32

σ𝑥 σ 2
2
σ1,σ2 = ± √( 𝑥 ) + 𝜏𝑥𝑦
2 2

33613.524 33613.524 2 33613.524 2

= ± √( ) +( )
2𝑑3 2𝑑3 𝑑3

33613.524 √5 33613.524
= ± ( )
2𝑑3 2 𝑑3
54387.824 −20774.30031
⸫ σ1 = , σ2 = 0 , σ3 =
d3 d3

33613.524 2
√ 33613.524 2 ( 𝑑 3 )
√5⁄ (33613.524)
𝜏𝑚𝑎𝑥 = ( ) + = 2
𝑑3 4 𝑑3
𝑆𝑦
|σ1 − σ3 | = 2𝜏𝑚𝑎𝑥 <
𝑛𝑠
54387.824 20774.30031 340
+ <
d3 d3 3
𝑑3 > 663.195
𝑑 > 8.721𝑚𝑚
We took 𝒅 = 𝟏𝟓𝒎𝒎 𝒇𝒐𝒓 𝒓𝒊𝒈𝒊𝒅𝒕𝒚

Page 6 of 14
Lever Design
Assuming
Thickness = 4mm
ns = 3
⸪ M =6.6 N.m
𝑀𝑐 d0 1
⸫ σb = 𝑐= , I = 𝑡(d03 – di3)
𝐼 2 12
1
6600∗2∗d0 σ𝑦
σb = 1 σ𝑏 ≤
∗4∗(d03 – 153 ) 3
12

𝑑0 = 18.18014𝑚𝑚 σ𝑦 = 205𝑀𝑝𝑎 AISI304 stainless steel

We took 𝒅𝟎 = 𝟐𝟎𝒎𝒎.

Comments
We assumed that the shaft has a constant cross section therefore no stress
concentration was considered in the calculations.
A way to obtain the required results is to take a standard power of motor which
runs the windshield wiper mechanism then get F1, but it’s not the best solution as
its reversed engineering.
So, we took the 2nd assumption which is: friction between rubber and glass
especially dry as it would be worst case multiplied by normal force on glass will be
F1 then get power of motor needed and take standard power.
The results match a standard wiper in the market as shown in page 3 with
assumptions for the missing information which can be considered as a valid usable
design with some improvements we can apply at the end of the course.

Page 7 of 14
Connection chosen
We chose the interference fit to connect the levers to the shaft for several
reasons. Firstly, an interference fit ensures a secure and rigid connection
between the levers and the shaft, minimizing any potential play or
movement during operation. This helps maintain the precise motion
transmission required for effective wiper arm movement. Secondly, the
interference fit provides increased torque transmission capabilities,
allowing the wiper motor to transfer its rotational force efficiently to the
wiper arms without slippage or power loss. Additionally, the interference
fit helps to distribute the load evenly across the contact surfaces,
reducing the risk of localized stress concentrations that could lead to
premature wear or failure. By selecting an interference fit between the
levers and the shaft, the windshield wiper mechanism can achieve
reliable and robust performance, enhancing the overall effectiveness and
longevity of the wiper system.

Page 8 of 14
CAD Design
Shaft Drawing

Page 9 of 14
Lever 1 Drawing

Page 10 of 14
Lever 2 Drawing

Page 11 of 14
Assembly Drawing

Page 12 of 14
References
1) Coefficient of Friction:
The friction coefficient for the dry rubber-glass contact (squares) and... | Download
Scientific Diagram (researchgate.net)
2) Hella Wiper Blades For Trucks Catalogue:
https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&ved=2ah
UKEwj6nsOcwpSCAxVvVqQEHREqBa8QFnoECAsQAQ&url=https%3A%2F%
2Fwww.hella.com%2Ftruck%2Fassets%2Fmedia_global%2F813_Wiperblades_Tr
uck_Brochure_HELLA_EN.pdf&usg=AOvVaw1l514K43TlI34pb0I7G4Tp&opi=8
9978449
3) DMKE high torque electric worm gear reducer dc motor:
DMKE high torque electric worm gear reducer dc motor 12v 24v - worm gear
motor - Brushless DC motor manufacturer|DMKE motor (dmkmotor.com)
4) Fit tolerances and applications:
Fit tolerances and applications - mec Engineering Spreadsheets (mec-engineering-
spreadsheets.com)

Page 13 of 14