MOTOR CONTROL FOR POWERED CLOSURE WITH ANTI-PINCH

Abstract

A controller system is provided for a motorized moveable striker assembly on a vehicle door or window. The assembly includes a striker on the door post which is moveable by an electric motor between extended and retracted positions. A latch on the door releasably engages the striker. Switches in the latch sends signals to the controller to actuate the motor. After the latch is engaged, the controller retracts the striker from the extended position to fully close the door. When the latch is disengaged from the striker, the latch switch sends a signal to controller to actuate the motor so as to extend the striker from the retracted position to the extended position as to prepare for the next door closing. Anti-pinching control and temperature compensation is also provided.

Claims

1. An electronic controller assembly for a motorized striker of a vehicle door or window closure, the striker being adapted to be moved by a motor between extended and retracted positions and adapted to engage and disengage a rotary latch on the vehicle door or window closure, the electronic controller assembly comprising: switches on the rotary latch to sense the position and generate signals corresponding to the rotary latch position; and a microprocessor operatively connected to the switch to actuate the striker motor in response to the signals.

2. The electronic controller assembly of claim 1 wherein the switch is a reed-type micro-switch.

3. The electronic controller assembly of claim 2 wherein the micro-switch is magnetically activated.

4. The electronic controller assembly of claim 1 wherein the switch is magnetically activated.

5. The electronic controller assembly of claim 1 wherein the microprocessor monitors electrical parameters of the striker motor.

6. The electronic controller assembly of claim 5 wherein the microprocessor automatically reverses the motor to extend the striker if the electrical parameters exceed a pre-designed limit.

7. The electronic controller assembly of claim 5 wherein the electrical parameters include supply voltage and current draw.

8. The electronic controller assembly of claim 1 wherein the microprocessor is hard wired to the striker motor and to the switches.

9. The electronic controller assembly of claim 1 wherein the microprocessor has reverse input protection.

10. The electronic controller assembly of claim 1 further comprising a thermistor operatively connected between the motor and the microprocessor.

11. The electronic controller assembly of claim 1 wherein the controller assembly is capable of monitoring the ambient temperature.

12. A method of controlling movement of a motorized striker on a vehicle door or window closure frame for retracting and extending a vehicle door or window closure relative to the door or window closure frame when a latch assembly on the door or window closure is engaged by the striker, the method comprising: sensing a position of the latch assembly relative to the striker by a plurality of switches on the latch assembly; generating signals corresponding to the latch assembly positions; sending the signals to a controller on the closure frame whereby the controller actuates the striker motor in response to the signals to extend or retract the striker; automatically reversing the direction of the striker motor if a pinch situation is detected.

13. The method of claim 12 further comprising magnetically activating the switches.

14. The method of claim 12 further comprising automatically extending the striker when electrical parameters exceed predetermined limits.

15. The method of claim 12 further comprising monitoring electrical parameters indicative of a closure obstruction or mechanical failure.

16. The method of claim 15 wherein the electrical parameters are customizable and configurable to different and specific closure requirements.

17. The method of claim 12 further comprising monitoring overheating of the motor.

18. The method of claim 12 further comprising monitoring current to and from the motor as well as the speed of the motor.

19. The method of claim 18 wherein a pinch situation is detected when the current consumed by the motor reaches a configurable threshold that compensates for ambient temperature or the speed of the motor reaches a different configurable threshold that compensates for ambient temperature.

20. The method of claim 19 wherein the direction of the motor is automatically reversed when a pinch situation is detected.

Description

DESCRIPTION OF THE DRAWINGS

[0036] FIG. 1 is a perspective exploded view of the overall assembly with a hoop striker, with a first embodiment of the pivot plate, mount plate and drive motor.

[0037] FIG. 2 is a front plan view of the cinching door mechanism with cover hidden.

[0038] FIG. 3 is a rear plan view of the cinching door mechanism with motor hidden.

[0039] FIG. 4 is a perspective exploded view of the overall assembly with the hoop striker and longitudinal loading rivet with an alternative pivot plate.

[0040] FIG. 5 is a rear perspective exploded view of the overall assembly with the hoop striker attached to the pivot plate.

[0041] FIG. 6 is a detail view of FIG. 5 showing details of the sensor retention plate and extended/retracted sensors.

[0042] FIG. 7 is a schematic view of the striker and the latch assembly controller.

[0043] FIG. 8 is a front perspective of an alternative embodiment that has motor directly placed under the mechanical assembly with striker bolt shown in retracted position, shown exploded.

[0044] FIG. 9 is a perspective exploded view of an alternative embodiment shown with the striker in retracted position.

[0045] FIG. 10 is another perspective exploded view of the embodiment shown in FIG. 9.

[0046] FIG. 11 is an exploded perspective of an alternative embodiment of a self-contained assembly module with a remote drive motor and controller.

[0047] FIG. 12 is an enlarged view taken along line 12. 12 of FIG. 11.

[0048] FIG. 13 is an opposite perspective exploded view of the embodiment shown in FIG. 11.

[0049] FIG. 14 is an exploded view of the cinching power striker detail of the embodiment of FIGS. 11 and 13, without the full lengths of the mounting plate and connecting rod.

[0050] FIG. 15 is a perspective view of the assembly shown in FIG. 11 with the drive link disconnected and secured so as to disable to power of the striker function in the case of motor out of power, controller or other mechanical failure, to allow the operator to still use the vehicle door, with the striker rotated and secured in the retracted position.

[0051] FIG. 16 is an electrical schematic for the control system of the present invention.

[0052] FIG. 17 shows the striker in an extended position.

[0053] FIG. 18 shows the striker in a retracted position.

[0054] FIG. 19 shows the striker, latch, motor and controller of the present invention.

[0055] FIG. 20 is a state flow diagram that shows the process by which the system operates.

DETAILED DESCRIPTION OF THE INVENTION

[0056] The following part list describes the components and their functions, using reference numerals corresponding to the drawings.

1. Mount plateprovides mounting surfaces for all cinching mechanism parts and provides mounting and mounting adjustment details for mounting to the vehicle.
2. Glideisolates the moveable pivot plate 3 from the mounting plate 1 to reduce friction and wear.
3. Pivot Plateprovides a base with a mounting surface for moveable apparatus, also has a pivot rivet mounting hole 67, and a pivot plate drive hole 58.
4. Torque Wheelhouses a magnet 14 for positional sensing, provides a drive feature for the motor interface, and a drive feature for a link that connects the torque wheel to the pivot plate 3.
5. Link Adjustment Screwprovides positive retention between the adjustable link components.
6. Driven Linkattaches to the pivot plate 3 via the drive rivet 9 and interfaces with the drive link 7 through the link adjustment screw 5.
7. Drive Linkattaches to the torque wheel 4 via the torque wheel drive pin 24 and interfaces with the driven link 6 through the link adjustment screw 5.
8. Pivot Rivetretains the pivot plate 3 and the glide 2 to the mount plate 1, and allows the pivot plate 3 and the glide 2 to pivot via the pivot rivet pivot shoulder 59.
9. Drive Rivetretains the driven link 6 to the pivot plate 3, drives the pivot plate 3 and glide 2 on through the drive rivet guide shoulder 60, and retains surface contact between the pivot plate 3, the glide 2 and the mount plate 1 through the pivot rivet retention head 62.
10. Drive Motorprovides rotational motion and torque to the torque wheel 4 to drive the mechanism. The motor is electric, and preferably rotates 360, though a reversible motor can also be used.
11. Cover Screwretains the cover 17 to the mount plate 1.
12. Cover Screwretains the cover 17 to the mount plate 1.
13. Motor Mount Screwretains the sensor retention plate 19 and the drive motor 10 to the mount plate 1.
14. Magnetprovides a magnetic field to be sensed by the extended/retracted position sensor.
15. Striker mount screwretains the striker apparatus 16 to the pivot plate 3.
16. Hoop Strikerprovides a latch retention surface for latching the occupant door.
17. Covercovers all moveable part and retains the drive link 7 and the torque wheel 4 and maintains their contact.
18. Extended/Retracted Position Sensorprovides positional feedback by sensing the magnet 14 and opening or closing a circuit internal to itself that a cinching striker controller input can verify.
19. Sensor Retention Plateprovides for positive positional placement of the extended/retracted sensor 18, provides wire routing features, and location for a wire retaining zip tie 20 to be secured.
20. Wire Retaining Zip Tieused to retain the wires and the connector 21 to the sensor retention plate 19.
21. Wire Connectorused to connect the cinching door mechanism electrically to a cinching door mechanism controller, receives wiring from the drive motor 10 and the extended sensor 28 and the retracted sensor 27. (FIGS. 1 and 3.)
22. Vertical adjustment slotson the mount plate 1 and allows for the cinching door mechanism to be adjusted vertically on a vehicle mounting location. (FIG. 2)
23. Extension/Retraction adjustment slotin the driven link 6 and allows a place for the link adjustment screw to pass through and provides adjustment limits. (FIG. 2)
24. Torque wheel drive pinmates with the drive link drive hole 50 to provide a place for an interface to the drive link 7 and the torque wheel 4 (FIG. 4).
25. Magnet pocketprovides a place for the magnet 14 to be attached to the torque wheel 4 (FIG. 3).
26. Arcuate Drive Rivet Slotin the mount plate 1 to provide sliding guide for the drive rivet 9 to pass through the mount plate 1, thus allowing the drive rivet head to be on the back side of the mount plate 1 so as to retain the pivot plate 3 and the glide 2 to the mount plate 1 (FIG. 3).
27. Retracted Sensor Positionsenses the magnet 14 to tell the cinching door mechanism controller to stop motion that mechanism is retracted (FIG. 3).
28. Extended Sensor Positionsenses the magnet 14 to tell the cinching door mechanism controller to stop motion that mechanism is extended (FIG. 3).
29. Longitudinal loading rivetretains an upper part of the pivot plate 3 to the mount plate 1 when longitudinal load is placed on the striker device 16, 35.
30. Longitudinal loading slotin the pivot plate 3 to provide a place for interface of the pivot plate 3 to the longitudinal loading rivet 29.
31. Lower vertical adjustment slotone of the slots 22 in the mount plate 1 to provide interface for the mounting fastener, and to allow for vertical adjustment of the cinching mechanism.
32. Upper vertical adjustment slotone of the slots 22 in the mount plate 1, to provide interface for mounting the fastener, and to allow for vertical adjustment of the cinching mechanism.
33. Link adjustment indicatorson the drive link 7 to provide finite adjustment indicators for the driven link 6.
34. Link adjustment markon the drive link 7 to provide a finite adjustment indication alignment mark for the drive link 7.
35. Striker boltalternative striker interface that can be mounted on the pivot plate 1 in place of a hoop striker 16.
36. Sensor retention plate pocketU-shaped channel in the sensor retention plate 19 that accepts the extended sensor 28 and retracted sensor 27. (FIG. 6.)
37. Torque wheel pivot guide shaftprovides a bearing surface for torque wheel 4 to rotate about and takes side loading. (FIG. 5.)
38. Torque wheel bearing surfaceprovides a bearing surface for the torque wheel 4 to rest against the mount plate 1. (FIG. 5.)
39. Hoop striker latch retention surfacelocation where latching the device attaches the door to the cinching door mechanism. (FIG. 4.)
40. Pivot rivet mounting holepivot hole in the glide 2 that the glide pivots about, and maintains the relationship between the pivot plate 3 and the mount plate 1. (FIG. 5.)
41. Sensor retention barbprotrusion in the sensor retention plate sensor pocket 36 that retains the extended sensor 28 and the retracted sensor 27. (FIG. 6.)
42. Wire routing pathchannel created under the sensor retention plate 19 for wire routing. (FIG. 4.)
43. Drive rivet retention slotslot that controls the drive rivet 9 and allows for the drive rivet 9 to move the pivot plate 3 on the mount plate 1. (FIG. 4.)
44. Striker mount screw access holeallows for access to the striker mount screw 15 through the mount plate 1. (FIG. 4.)
45. Wire routing pathpath between the wire retaining zip tie 20 and the sensor retention plate 19.
46. Driven link adjustment retention featureprovides a tooth featured surface on the driven link that locks the driven link 6 to the drive link 6 when the link 7 adjustment screw 5 is tightened.
47. Drive link adjustment retention featureprovides a tooth featured surface that locks the driven link 6 to the drive link 7 when the link adjustment screw 5 is tightened.
48. Link adjustment screw mounting holethreaded hole in the drive link 7 that receives the link adjustment screw 5 and allows the link adjustment screw 5 to be threaded into the drive link 7.
49. Driven link mounting holereceives the drive rivet 9 to retain and drive the pivot plate 3 and the glide 2 through the drive rivet retention slot 43. (FIG. 4.)
50. Drive link drive holereceives the torque wheel drive pin 24 on the torque wheel 4 which allows the torque wheel 4 to drive the drive link 7. (FIG. 4.)
51. Sensor FaceFace of the extended/retracted sensor 18 that is oriented near the magnet 14 to sense the magnetic field. (FIG. 6.)
52. Torque wheel center drivereceives the motor drive shaft 53 to transfer rotation and torque to the torque wheel 4. (FIG. 5.)
53. Motor drive shafttransfers rotation and torque from the drive motor 10 to the torque wheel 4 to drive the cinching door mechanism. (FIG. 4.)
54. Motor mounting holesthreaded holes that allow for the motor mount screw 13 to be threaded into the motor 10. (FIG. 4.)
55. Motor mounting holesclearance hole in the mount plate 1 that allow for the motor mount screw 13 to pass through and align the drive motor 10 to the mount plate 1, also retains the drive motor 10 so it can pass rotation and torque to the torque wheel 4. (FIG. 4.)
56. Cover mounting holesholes in the mount plate 1 that accept the cover screw 11, 12. (FIG. 4.)
57. Striker mounting holesholes in the pivot plate 3 that allow the striker mount screw 15 to pass through and attach the striker apparatus 16, 35. (FIG. 4.)
58. Pivot plate drive holeaccepts the drive rivet 9, and more specifically, the drive rivet guide shoulder 60 and drives the pivot plate 3. (FIG. 4.)
59. Pivot rivet pivot shoulderfits into the pivot rivet pivot hole 72 and allows rotational motion between the mount plate 1, the pivot plate 3, and the glide 2. (FIG. 4.)
60. Drive rivet guide shoulderfits into drive rivet retention slot 43 to control movement of the pivot plate 3 and the glide 2, and passes through the drive rivet retention slot 43, the glide rivet drive hole 69, and the pivot plate drive hole 58. (FIG. 4.)
61. Drive rivet retention headmaintains contact with the mount plate surface to retain contact of the mount plate 1, the glide 2, and the pivot plate 3. (FIG. 4.)
62. Pivot rivet retention headmaintains contact with the mount plate surface to retain contact of the mount plate 1, the glide 2, and the pivot plate 3. (FIG. 4.)
63. Wire routing retention zip tie mounting holesaccess holes in the sensor retention plate 19 that allow the wire retaining zip tie 20 to be looped through to retain wires. (FIG. 3.)
64. Torque wheel pivot guide boreaccepts the torque wheel pivot guide shaft 37 to provide a bearing surface for side load of the torque wheel 4. (FIG. 6.)
65. Longitudinal load rivet mounting holeaccepts the longitudinal loading rivet mount shoulder 87 to fasten the longitudinal loading rivet 29 to the mount plate 1. (FIG. 4.)
66. Driven link guide slotprovides for perimeter support of the driven link 6 so that the driven link 6 is not allowed to rotate about the link adjustment screw 5. (FIG. 4.)
67. Pivot rivet mounting holeaccepts the pivot rivet mount shoulder 85 and affixes the pivot rivet 8 to the pivot plate 3. (FIG. 4.)
68. Striker mount screw access holeallows for access to the striker mount screw 15 through the glide 2. (FIG. 4.)
69. Glide rivet drive holeaccepts the drive rivet 9, and more specifically the drive rivet guide shoulder 66 and drives the glide 2. (FIG. 4.)
70. Sensor retention plate collarfits into the mount plate sensor retention plate bore 71 to locate the sensor retention plate 19 and transfer bearing load from the torque wheel 4 through the torque wheel pivot guide shaft 37 and the torque wheel pivot guide bore 64. (FIG. 4.)
71. Mount plate sensor retention plate boreaccepts the sensor retention plate collar 70 to locate the sensor retention plate 19 and transfer bearing load from the torque wheel 4 through the torque wheel pivot guide shaft 37 and the torque wheel pivot guide bore 64. (FIG. 4.)
72. Pivot rivet pivot holeaccepts the pivot rivet pivot shoulder 59 to allow rotational movement between the mount plate 1, the glide 2, and the pivot plate 3. (FIG. 4.)
73. Cover hold down surfaceholds the torque wheel 4 and drive link 7 in place by maintaining contact with the drive pin hold down surface 80 and the drive link hold down surface 79. (FIG. 5.)
74. Hoop striker mounting holeaccepts the striker mount screw 15 to attach the hoop striker 6 to the pivot plate 3. (FIG. 5.)
75. Cover screw mounting holesaccepts the cover screws 11, 12 to attach the cover 17 to the mount plate 1. (FIG. 5.)
76. Pivot plate clearance cutoutallows for cinching door mechanism mount screw to stand proud of the mount plate 1 and not interfere with the pivot plate 3 movement. (FIGS. 4 and 5.)
77. Rear sensor retention plate motor mounting surfaceprovides a bearing clamp surface for the motor mounting surface 82 to mount the drive motor 10 against. (FIG. 6.)
78. Front sensor retention plate mounting surfaceprovides a bearing clamp surface for the sensor retention plate 19 to mount to the mount plate 1. (FIG. 4.)
79. Drive link hold down surfacemaintains contact with the cover hold down surface 73 to hold the drive link 7 in place. (FIG. 4.)
80. Drive pin hold down surfacemaintains contact with the cover hold down surface 73 to hold the torque wheel 4 in place. (FIG. 4.)
81. Glide clearance cutoutallows for cinching door mechanism mount screw to stand proud of the mount plate 1 and not interfere with the glide 2 movement. (FIG. 4.)
82. Motor mounting surfaceprovides a bearing clamp surface for the sensor retention plate 19 to mount to the motor 10. (FIG. 4.)
83. Striker bolt latch retention surfacea location where the latching device attaches the door to the cinching door mechanism.
84. Latchlatching mechanism which interfaces with the hoop striker latch retention surface 39 to hold the door in place with respect to the hoop striker 16 and the pivot plate 3 movement.
85. Pivot rivet mount shoulderFits into the pivot rivet mounting hole 67 to locate and retain the pivot plate 3 and the glide 2 to the mount plate 1. (FIG. 4.)
86. Drive rivet mount shoulderFits into the driven link mounting hole 49 to locate and maintain the pivot plate 3, the glide 2, and the mount plate 1 contact, and to drive the pivot plate 3 and the glide 2. (FIG. 4.)
87. Longitudinal loading rivet mount shoulderFits into the longitudinal load rivet mounting hole 65 to retain the longitudinal loading rivet 29 to the mount plate 1. (FIG. 23.)
88. Latch switchprovides feedback to the controller that the latch is in the primary and fully latched position and in the unlatched and fully open position.

100. Controller

[0057] 102. Motor Assemblydraws/retracts the door or window
104. Door Latchengages/interacts with the striker
106. Strikerengages/interacts with the door latch

[0058] In operation, the striker of the embodiment shown in FIGS. 1-7 is in an extended position when the door is open and the latch is disengaged or open. When the door is closed, the latch engages the striker, which is detected by the switch, which in turn sends a signal to the controller to actuate the motor. The motor rotates the torque wheel, which in turn moves the drive link and driven link, so as to pivot the pivot plate and thereby retract the striker approximately 1. This retraction movement of the striker pulls the door tight to provide an enhanced seal between the door and the door frame. When the latch is released or disengaged from the striker by operation of the interior or exterior door handle to open the door, the switch in the rotary latch sends a signal to the controller to actuate the motor, which in turn rotates the torque wheel which moves the drive link and driven link, so as to pivot the pivot plate and thereby extend the striker approximately 1, in preparation for the next closing of the door.

[0059] The torque wheel can be rotated 360 by the motor, or in the case of a reciprocating motor the torque wheel is oscillated 180 , so as to extend and retract the striker.

[0060] The distance that the striker is moved by the motor can be adjusted or fine-tuned by changing the extent of overlap between the drive link 7 and the driven link 6. The links 6, 7 have overlapping teeth 46, 47 to secure the links in a desired position via the link adjustment screw 5.

[0061] The motor 10 is connected to a power supply of the vehicle independently of the rotary latch. Therefore, in case of a power failure, the latch can still be operated in a normal manner to open and close the vehicle door. Thus, a person cannot be locked in or locked out of the vehicle due to a lack of power to the motor, such as a dead battery.

[0062] The alternative embodiment shown in FIG. 8 is a compact design that uses a motorized wheeled pin to move a striker bolt between door open and door closed positions. When the latch is closed on the striker, the wheeled pin moves the striker bolt between door open and door closed positions. When the latch is closed on the striker, the wheeled pin then pulls the striker into the door closed position. On release of the latch, the wheeled pin returns the striker to the door open position. Assembly allows adjustment for alignment of the body-mounted striker with the door-mounted latch jaws.

[0063] When compared to the embodiments of FIGS. 1-7, the compact design of FIG. 8 reduces the space claim for the cinching mechanism by over 50% while increasing available striker travel by 25%. The compact design also adds separate vertical and horizontal adjustability of the striker relative to the door structure of the vehicle. The compact design greatly reduces the number of necessary components.

[0064] The embodiment shown in FIGS. 11-14 is a way to remotely drive a vehicle door striker with an over center mechanism that is mounted on a mount bracket along with the drive motor, cam, drive rod and controller. The package can contain all items fully assembled and the timing of the cinch mechanism in relationship to the motor and inboard/outboard sensors can be adjusted before being sold to the customer. Customer striker adjustability is built in, but does not affect the operational travel of the motor, cam, sensors, and over center striker mechanism. In the case of an electrical failure there has been a pin provided so that the rod could be disconnected from the cam on the motor and bolted solid to the mount frame to maintain the striker inboard position.

Overall System Operational Description

[0065] A controller 100 drives a motor assembly 102 that draws (retracts) the door striker 106 into a closed position, and likewise will open (extend) the striker mechanism 106 when the door handle is opened, utilizing magnetically activated reed type micro-switches as controller inputs, to determine position of the latch 104 and the striker 106.

[0066] The door latch 104 contains a first magnetically activated switch which provides input to the controller that the latch is in primary position (engaged the striker). The controller 100 will actuate the motor 102 to retract the striker mechanism 106, drawing the door to a closed position. A second magnetically activated switch will detect when the striker/latch mechanism 106/104 has reached the mechanically set closed position. The process for opening the door is similar in operation, except in the opposite direction.

[0067] The door cinching assembly provides anti-pinch and a motor reversing feature by monitoring motor supply voltage, current draw and latch/striker state switch status; these parameters will provide the necessary inputs to the controller circuitry, providing the method for automatic motor 102 (latch/striker) reversal if switch detection or motor drive current, exceed system design limits. Exceeding the system design detection limits could result from a mechanical failure or obstruction of the door.

Mechanical System Details

[0068] The preferred mechanics of the present invention include: [0069] Closing force: 100-150 lbs. [0070] Speed of closure: total dwell time to open, time to close 3-5 seconds each direction +/0.5 sec Mechanical Advantage: 2:1 [0071] Motor Torque required achieving closing force: 80-120 in lbs. [0072] Rotation: must be able to rotate CW & CCW. Both directions are needed for latch extension/retraction and motor mechanism reversing in the event of a pinched situation. [0073] End of stroke status: system must maintain static position at ends of travel (not back driven, by mechanical jarring) End of stroke status could be the same input from either latch extended or retracted switch.

[0074] Examples of a rotary latch for the present invention is described in Applicant's pending application Ser. No. 15/068,221, which is incorporated herein by reference in its entirety.

System Modes

[0075] FIG. 16 shows the electrical schematic for the control system. The controller 100 and cinch mechanism provide two primary functions or modes of operation. First, the primary function of the cinch mechanism is to provide the ability for the door to open and close at a specified rate, thereby assuring the door seal is properly loaded in the closed position. Second, the controller 100 allows for auto-reversing of the direction the door is moving during the close cycle. The controller 100 monitors the current consumed by the motor 102 and reverses the motor 102 direction if a specified current level is detected.

Normal/Typical Operation

[0076] The following illustrates normal operation of the system. FIG. 19 shows the striker 106, latch 104, motor 102, and controller 100 of the system.

[0077] When a door that is utilizing the disclosed system is closed, the striker 106 is retracted, the motor 102 is off, and after a specified period of time the controller 100 enters a sleep mode during which it draws a low current. A typical specified period of time before the controller 100 enters sleep mode is 8 seconds, but alternative times could be utilized.

[0078] When a user opens the door handle, the primary latch opens. A change of state in the latch sensor (as particularly shown in FIGS. 17 and 18 appearing on the right side of component 104 in FIG. 17 there are two wires that connect to a small cylinder, which is the latch sensor) triggers the controller 100 to wake up from sleep mode and for the motor 102 to be powered to move the striker 106. If the controller 100 is in sleep mode, it wakes up from sleep mode within a specified period of time. The typical specified period of time in which the controller 100 wakes up is within 100 milliseconds, but alternative amounts of time could be utilized. Motor 102 current draw is continuously monitored while the controller 100 is waking up from sleep mode. The motor 102 is then powered to move the striker 106 to the extended position.

[0079] FIG. 17 shows the striker 106 in an extended position. Inputs sent to the controller 100 are debounced via software so false state changes do not cause unwanted striker 106 movement. The motor 102 rotates both clockwise and counterclockwise to move the striker 106 to the extended (out) and retracted (in) positions. When the striker 106 is extended, the motor 102 stops, and after a specified period of time, the controller 100 enters a sleep mode during which it draws a low current.

[0080] When the user pushes the door shut, the primary latch 104 closes. A change of state in the latch sensor triggers the motor 102 to be powered to move the striker 106 to the retracted position. When the striker 106 is retracted, the motor 102 stops and after a specified period of time the controller 100 enters into a sleep mode during which it draws low current. FIG. 18 shows the striker 106 in a retracted position.

[0081] Any and all anomalies of the current, force requirements, or travel profile shall be handled per FMVSS 118 if applicable and any other regulatory requirements. No electrical or software calibration shall be required once the assembly leaves the supplier facility. Electronic controller units and electrical components shall be interchangeable without any mechanical, electrical, or software calibrations.

[0082] As FIG. 16 shows, the controller 100 includes a Striker Retract Switch (SW1), a Striker Extend Switch (SW2), and a Door Latch Switch (SW3). FIG. 20 provides a detailed illustration of the state flow diagram of the system. When power is applied to initialize the system, the system either enters a retracted state, an extended state, or remains idle. When the system is initialized, if SW3 is requesting retraction and SW1 is fully retracted, then the system is in a retracted state and the controller 100 then enters sleep mode after a specified time period of inactivity, preferably about 8 seconds. Alternatively, when the system is initialized, if SW3 is requesting extension and SW2 is fully extended, the system is in an extended state and the controller 100 then enters sleep mode after a period of inactivity, preferably about 8 seconds. Finally, if neither of the above conditions are met when the system is initialized, the system remains idle.

[0083] Further in view of FIG. 20, when the controller 100 is in sleep mode, if SW3 changes state, the controller 100 wakes up and the system becomes idle. From the idle position, the controller 100 can then enter sleep mode after a time period of inactivity, preferably about 8 seconds. Alternatively, from the idle position, the system can either enter the retracting or extending mode. When the system is idle, if SW3 has changed state and is requesting retraction, SW1 is not fully retracted, and the voltage is normal, then the system begins retracting. When the system is idle, if SW3 changes state and is requesting extension, SW2 is not fully extended, and the voltage is normal, then the system begins extending.

[0084] Further in view of FIG. 20, when the system is in the retracting state, it has three options: (1) it can enter the retracted state, (2) it can enter the idle state, or (3) is can enter the extending state. From the retracting state, if SW3 is requesting retraction and SW1 is fully retracted, then the system enters the retracted state. Alternatively, from the retracting state, if SW3 changes state or the voltage is invalid or low, then the system enters the idle state. Alternatively, from the retracting state, if the motor 102 current meets a specified threshold (usually greater than or equal to 4 amps), then the system enters the extending state. When the motor 102 current meets the specified threshold (usually greater than or equal to 4 amps) that means a pinch situation is detected. When the striker 106 is retracting and a pinch situation is detected (based on the motor 102 current), the motor 102 reverses direction, thereby extending the striker 106. This is the anti-pinch auto-reverse feature.

[0085] Further in view of FIG. 20, when the system is in the extending state, it has three options: (1) it can enter the extended state, (2) it can enter the idle state, or (3) the controller 100 can enter sleep mode. From the extending state, if SW3 is requesting extension and SW2 is fully extended, then the system enters the extended state. Alternatively, from the extending state, if SW3 changes state and is now requesting extension, SW2 is not fully extended, and voltage is normal, then the system enters the idle state. Alternatively, from the extending state, if the motor current reaches a particular threshold (usually greater than or equal to 6 amps), then the controller 100 enters sleep mode.

Exception to Normal Operation

[0086] The system includes modes of operation other than normal operation. The system includes several safeguards against any potential malfunctions. For example, if the extend or retract commanded motion fails, the system is designed to allow the motor 102 to turn continuously in clockwise or counterclockwise motion without any mechanical interference. If the commanded striker 106 position (extend or retract) is not reached within a certain number of pulses of the motor 102 hall effect sensor, the motor 102 shall stop. If the motor 102 hall effect sensor does not indicate movement after the motor 102 is commanded to move to a position, within a specified period of time, the motor 102 shall be commanded to stop. If the system fails, or there is a power failure, the striker 106 can be mechanically moved striker to the retracted position, and, therefore, the door will operate as a standard door. FIG. 15 shows an example of the system operating under the condition of system failure due to power failure, motor 102 failure, controller failure, or mechanical failure. FIG. 15 shows that in the event of system failure, the striker 106 can be moved to the retracted position and a user can still open and close the door. FIG. 15 shows the drive link 7 disconnected, thereby disabling the power that allows the striker 106 to be moved automatically. The system allows the striker 106 to be moved to the extended position and stop if the pinch force limit is equal to or greater than a set limit. If motor stall is detected, the power to the motor 102 shall be removed over a set current limit.

Controller System Requirements

[0087] The requirements and system configuration for a preferred embodiment of the present invention are based on the following: [0088] a) Vehicle electrical power is supplied to the controller; and the controller supplies motor control/monitoring and electrical power. [0089] b) The system is hard-wired and does not rely upon any RF type of communication. [0090] c) Micro-controller shall be of 32 bit based architecture. [0091] d) Controller current consumption: Active: Controller overhead (TBD) plus requirements to drive motor assembly. The design plan based on an exemplary motor assembly: [0092] External Inputs to controller: All inputs to the controller shall have reverse input protection. [0093] Power (VBatt) [0094] Ground [0095] Latch state switch Retract state switch Extend state [0096] Motor Position/PWM [0097] 2 Spare inputs; TTL level [0098] Internal Inputs to Controller: [0099] Motor drive current detection [0100] Thermistor (heat sense of motor drive semi-conductors) [0101] Controller Output: [0102] Two wire motor drive, through control FET devices (non mechanical relay system) 2 spare outputs; Positive TTL levels. [0103] General Electrical/Environmental Specifications: [0104] Operating temp 40 to 85 C [0105] Input Voltage: 9-16 VDC [0106] Cinch motor reverse response time: 500 mS. [0107] The reverse response time is the time to transition motor drive direction. [0108] System reaction time: 100 mSec. [0109] The system reaction time is the transition time from controller sleep mode to full active mode. [0110] Sleep Mode: [0111] Quiescent current: 100 u [0112] Motor Power Drive circuitry: [0113] 5 Amps; continuous drive [0114] 10 Amps; intermittent

[0115] The motor drive shall be monitored by a semi-conductor device specifically designed to monitor current flow, and preferably, no resistive methods should be utilized.

System Electrical Block Diagram

[0116] FIG. 16 is a representation of the controller functionality to be structured, based on the preferred mechanical design described above.

[0117] The mechanical design two magnetically activated end of travel (extend and retract) reed type switches and one latch switch. The extend and retract reed switches are contained in the same mechanism and the latch switch is located in the door mounted latch assembly.

Software/Firmware Considerations

Continual Characterization Mode

[0118] Due to variations with individual doors, door seals, fit/installation at point of manufacture and mechanical/material wear over time under normal usage, a Continual Characterization mode is provided to account for the mechanical variations. These variations may have an effect on electrical current draw by the striker motor mechanism and door as it contacts the frame door seal. The Continual Characterization Mode will function by storing, motor draw current, motor drive voltage and motor timing, in NVM (non-volatile memory), the most recent 5 door cycles; open/close, (close would be by the cinching latch drawing in normal operation).

[0119] The Continual Characterization Mode then will have established a normal operating range, considering material characteristics, mechanical and general wear over time. The Continual Characterization Mode will operate automatically, without the need for operator involvement or any special configuration set-up.

Operational Considerations

[0120] Operational conditions shall provide a safe, reliable and robust system.

[0121] For example, there may be instances where the motor needs to reverse (automatically) and one (1) instance where the motor drive mechanism will slow its operation:

A. Position Sense

[0122] The latch draw is approximately 25 mm. If a current spike is detected before the normal expected peak the motor will reverse direction of travel to the extended (door open) position.

B. Peak Load

[0123] A power characterization can be determined and programmed into the controller.

C. Change in Logic Throughout Transfer Operation

[0124] This will be tied to the Position sensor; if the slope of the current increases by X% within Y number of motor revolutions, the motor will reverse.

D. Motor Drive Circuitry Overheating Step Back (Internal to Controller)

[0125] Temperature (thermistor) monitoring of the motor drive circuitry (FET's) shall provide input to micro-controller/firmware indicating an overheating condition. If an overheating condition is detected, the controller will reduce the amount of drive resource to the motor, thereby slowing the mechanical operation, but not stopping completely. The controller will continue in the step back mode, until the originating overeating condition is normalized.

Firmware Version

[0126] Firmware shall have provisions that the following are configurable and adjustable to allow for integration/configuration to other door configurations platforms: This can be accomplished through a UART-Terminal configuration, or similar. Configurable settings shall be implemented, such that source code changes/re-compiling is not required.

[0127] The firmware is configurable to incorporate the following provisions: the retract current detection level for setting the anti-pinch limit will vary with motor position input; the extend current detection level is a hard limit to prevent mechanical damage; source voltage monitoring; motor pulse count for extend; motor pulse count for retract; peak current; and motor drive current.

Drive Current Detection, Motor Speed, and Auto-Reversing

[0128] The controller shall monitor drive current continuously during movement operations. If, during the extend drive function the motor drive current reaches a predetermined and configurable limit, then the controller 100 shall command the motor 102 to stop. If, during the retract drive function the drive current or motor speed reaches certain configurable limits based on position, voltage, and ambient temperature, then the controller 100 shall command the motor 102 to reverse direction toward the extended position and stop once the extended position is achieved. This is another representation of the anti-pinch auto-reverse feature. In addition to motor current, the speed (RPM) of the motor 102 can be used to detect a pinch situation. A pinch situation is detected if the speed of the motor 102 reaches a configurable threshold. If the slope of the drive current increases by a particular percentage within a particular number of motor revolutions, then the motor 102 will reverse in direction.

[0129] The controller 100 shall use additional motor position and speed (RPM) information, provided by the motor position sense Hall-Effect output, to determine allowable speed reduction limits to differentiate between normal closing speeds, and abnormal closing speeds. An abnormal or quick speed reduction will indicate that an object has obstructed the door's closing path. The force on the on an object in the door will never exceed 100 Newtons. When the controller 100 determines the speed is abnormal or abrupt the controller 100 will command the motor 102 to reverse and move the striker to the extend position. Several factors that can affect speed reduction limits include: variations in door seal loading, variations in system voltage, variations in ambient temperature, and variations in anti-pinch force limits due to changes in the mechanical advantage associated with the striker movement.

[0130] Several conditions can cause the mechanism to reverse the direction of the motor 102 when no obstacle is actually present in the closure path. Extreme cold weather can cause erratic or no operation due to the added resistance in the mechanism caused by grease viscosity in the mechanism. Additionally, the door gaskets can become stiffer and the motor 102 can experience slower speed due to cold ambient temperature. The controller 100 can monitor the ambient temperature to adjust the reverse algorithm so that at lower temperatures the motor will not reverse without an object in the doors closing path.

Motor

[0131] An example of a striker motor is; Bosch AHC 12V 0 390 203 045. This motor has position PWM output, which shall be used as an input to the microcontroller circuitry. The output is a PWM duty cycle based on motor armature rotation

Standards and Regulations

[0132] The system (mechanical and electrical) shall meet the requirements of customers, such as commercial vehicle manufactures in the agriculture/construction and heavy truck industries.

[0133] Both tactile and motor-controlled anti-pinch systems are used today as standard protection systems that avert the danger electric door and window openers present. Should an object (organic or in-organic) interfere or become trapped within the opening while the door or window is closing; the anti-pinch systems cause the automatic movement to come to a halt.

[0134] The FMVSS 118, CMVSS 118 and 74/60/EEC standards and directives establish the requirements for power operated window, partitions and roof panel systems, their purpose being to prevent injury arising from trapping situations. They give a description of not only how the systems run but the operating requirements, the test pieces, readings and test set up. Should an object get trapped while the automatic closing function is being carried out, a reversal must come about before the trapping force has reached 100 N. This requirement is verified using a semi-rigid cylindrical test rod, from 4 to 200 mm in diameter. This test rod is put through the opening from the inside of the vehicle, normally at a right angle, in such a way that its cylindrical surface contacts all parts of the frame of the opening component.

[0135] The present invention also meets these standards: [0136] SAE Documents.

[0137] The below listed SAE documents are listed, for reference purposes. 2004-01-1108

Anti-pinch protection for power operated features
2009-01-0637 Anti-pinch direct sensor solutions

[0138] The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives.