A power operated actuator mechanism for moving a closure member of a vehicle relative to a vehicle body between an open position and a closed position

Abstract

The present invention relates to a power operated actuator mechanism for moving a closure member of a vehicle relative to a vehicle body between an open position and a closed position. A power closure member actuation system is provided for moving a closure member of a vehicle between an open position and a closed position. The power closure member actuation system includes an external sensor disposed on the closure member and configured to detect movement of the closure member. The power closure member actuation system additionally includes an actuator for moving the closure member and an internal sensor located in the actuator and configured to detect internal movement of the actuator. The power closure member actuation system further includes a controller in communication with the actuator and the internal sensor and the external sensor and configured to use the external sensor on the closure member to detect movement of the closure member to control the actuator to move the closure member. The controller also uses the internal sensor in the actuator to detect internal movement of the actuator to control the actuator.

Description

Cross-references to related applications

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 794,500, filed April 25, 2025. The entire disclosure of the above application is incorporated herein by reference. Technical Field

[0002] This disclosure generally relates to a closing member system for motor vehicles, and more specifically to a power closing member actuation system for moving a closing member, such as a door, relative to the vehicle body between an open position and a closed position. Background Technology

[0003] This section provides background information in connection with this disclosure, which is not necessarily prior art.

[0004] Closing components of a motor vehicle can be mounted to the vehicle body via one or more hinges. For example, a passenger door can be oriented and attached to the vehicle body via one or more hinges to allow for swinging motion about a generally vertical pivot axis. In this arrangement, each door hinge typically includes a door hinge band connected to the passenger door, a body hinge band connected to the vehicle body, and a pivot pin arranged to pivotally connect the door hinge band to the body hinge band and define the pivot axis. It has been recognized that such swinging passenger doors (“swing doors”) have the following problems: for example, when the vehicle is on an inclined surface, the swing door may open too far or swing closed due to the unbalanced weight of the door. To address this problem, most passenger doors have some type of stop or limiting mechanism integrated into at least one of the door hinges to suppress uncontrolled swinging motion of the door by actively positioning and holding it in one or more intermediate travel positions other than the fully open position. In some high-end vehicles, the door hinge may include a stepless door limiting mechanism that allows the door to be opened and held limited at any desired open position. One advantage of passenger doors equipped with door hinges featuring stepless door limit mechanisms is that the door can be positioned and held in any position to avoid contact with adjacent vehicles or structures.

[0005] As a further advancement, powered closing member actuation systems have been developed. Similar to the passenger doors described above, powered closing member systems can be used to automatically swing the passenger door between an open and closed position about its pivot axis to assist a user in moving the passenger door and / or to eject or open the passenger door toward the user. Typically, a powered closing member actuation system includes a powered operating device, such as an electric motor, and a rotary-linear conversion device operable to convert the rotary output of the electric motor into translational movement of the extendable member. In many arrangements, the electric motor and conversion device are mounted to the passenger door, and the distal end of the extendable member is fixedly fastened to the vehicle body. An example of a power-closing member actuation system for a passenger door is shown in International Publication No. WO2013 / 013313, co-owned by Schuering et al. This international disclosure discloses the use of a rotary-linear conversion device having an externally threaded lead screw rotaryly driven by an electric motor and an internally threaded drive nut meshing with the lead screw, and an extendable member attached to the internally threaded drive nut. Therefore, control of the rotational speed and direction of the lead screw results in control of the speed and direction of translational movement of the drive nut and the extendable member, thereby controlling the swing motion of the passenger door between its open and closed positions.

[0006] While this type of powered closed-loop actuation system functions as intended for its purpose, a recognized drawback involves a delay in power-assisted control due to factors such as internal resistance in the powered operating mechanism. This delay adversely affects the user's experience of operating the system.

[0007] In view of the above, there is still a need to develop alternative power closure member actuation systems and corresponding operating methods that address and overcome the limitations and disadvantages associated with known power closure member actuation systems and provide increased convenience and enhanced operational capabilities. Summary of the Invention

[0008] This section provides a general overview of this disclosure, rather than a full disclosure of its entire scope or all its features, aspects and purposes.

[0009] One aspect of this disclosure is to provide a powered closing member actuation system for moving a closing member of a vehicle relative to the vehicle body between an open position and a closed position. The powered closing member actuation system includes an external sensor disposed on the closing member and configured to detect movement of the closing member. The powered closing member actuation system further includes an actuator for moving the closing member and an internal sensor located within the actuator and configured to detect internal movement of the actuator. The powered closing member actuation system also includes a controller that communicates with the actuator, the internal sensor, and the external sensor, and is configured to use the external sensor on the closing member to detect movement of the closing member in order to control the actuator to move the closing member. The controller is also configured to use the internal sensor in the actuator to detect internal movement of the actuator in order to control the actuator.

[0010] In related aspects, the controller is also configured to: stop using external sensors on the closing member to control the actuator when internal movement is detected using internal sensors in the actuator, and start using internal sensors in the actuator to control the actuator when internal movement is detected using internal sensors in the actuator.

[0011] In related aspects, the actuator includes an electric motor operably coupled to an extendable link. An internal sensor in the actuator is configured to detect movement in a kinematic chain disposed between the extendable link and the internal sensor. The kinematic chain includes a flexible element configured to flex in response to a user moving a closing member before the internal sensor detects movement in the kinematic chain. An external sensor is configured to detect movement in the kinematic chain. The controller is further configured to: detect movement in the kinematic chain using the external sensor before using the internal sensor to detect movement in the kinematic chain; control the electric motor of the actuator using the external sensor before the internal sensor detects movement in the kinematic chain; stop using the external sensor to control the electric motor of the actuator after the internal sensor detects movement in the kinematic chain; and start using the internal sensor to control the electric motor of the actuator after the internal sensor detects movement in the kinematic chain.

[0012] Another aspect of this disclosure is to provide a method for controlling the movement of a closing member of a vehicle relative to the vehicle body between an open position and a closed position using a powered closing member actuation system. The method includes the steps of: detecting the movement of the closing member using an external sensor on the closing member to control an actuator to move the closing member. The method also includes the step of: detecting internal movement of the actuator using an internal sensor in the actuator to control the actuator.

[0013] Another aspect of this disclosure is to provide a power-operated closing member actuation system for moving a closing member of a vehicle relative to the vehicle body between an open position and a closed position. The power-operated closing member actuation system includes an actuator coupled to the closing member and the vehicle body and configured to move the closing member relative to the vehicle body. The actuator includes a drive mechanism operably coupled to the closing member and an electric motor coupled to the drive mechanism via a flexible element configured to allow flexure between the drive shaft of the electric motor and the drive mechanism when the closing member is moved by a user. The drive mechanism and the flexible element include a kinematic chain. The power-operated closing member actuation system further includes an external sensor, decoupled from the actuator and coupled to the closing member, and configured to detect movement of the closing member. The power-operated closing member actuation system also includes a controller in communication with the actuator and the external sensor. The controller is configured to use the external sensor to determine that the closing member has been manually moved by a user, including movement achieved by flexure. The controller is also configured to control the actuator to move the closing member based on the user's movement of the closing member detected by the external sensor.

[0014] In related aspects, the drive shaft of the electric motor is capable of rotating about the drive shaft axis, and the power closure member actuation system also includes an internal sensor connected to the drive shaft of the electric motor and communicating with the controller and configured to detect the rotation of the drive shaft. The controller is also configured to use an external sensor to determine that the closure member is manually moved by the user, and to control the actuator to move the closure member in time before detecting the rotation of the drive shaft of the electric motor using the internal sensor in response to the user manually moving the closure member.

[0015] An additional aspect of this disclosure is to provide an actuator for a closing member of a vehicle, the closing member being movable relative to the vehicle body between an open position and a closed position. The actuator includes a drive mechanism operably coupled to the closing member for moving the closing member. The actuator further includes an electric motor including a drive shaft rotatable about a drive shaft axis. The actuator also includes a flexible element coupling the drive shaft of the electric motor and the drive mechanism, and configured to allow deflection between the drive shaft and the drive mechanism when the closing member is moved by a user. The drive mechanism and the flexible element include a kinematic chain.

[0016] Another aspect of this disclosure is a method for controlling the movement of a closing member of a vehicle relative to the vehicle body between an open position and a closed position using a powered closing member actuation system. The method includes the steps of: providing an actuator with an extendable link for the closing member. Next, providing an internal sensor in the actuator. Additionally, the method includes the step of: providing a kinematic chain between the extendable link and the internal sensor. The method continues with the step of: providing a flexible element as part of the kinematic chain. The method continues with: allowing the flexible element to flex in response to a user moving the closing member before the internal sensor detects movement of the kinematic chain. The next step of the method is: providing an external sensor outside the actuator. The method further includes the step of: detecting the movement of the kinematic chain using the external sensor in time before detecting movement of the kinematic chain using the internal sensor. The method also includes the step of: controlling the electric motor of the actuator using the external sensor before the internal sensor detects movement of the kinematic chain. The method continues with the step of: stopping the control of the electric motor of the actuator using the external sensor after the internal sensor detects movement of the kinematic chain. The method also includes the step of: starting the control of the electric motor of the actuator using the internal sensor after the internal sensor detects movement of the kinematic chain.

[0017] Another aspect of this disclosure is to provide a method for controlling the movement of a closing member of a vehicle relative to the vehicle body between an open position and a closed position using a powered closing member actuation system. The method includes the steps of: detecting the movement of the closing member using a closing member accelerometer on the closing member; the method further includes the step of: using the closing member accelerometer on the closing member to control an actuator to move the closing member; the method further includes the step of: detecting internal movement of the actuator using an internal sensor in the actuator; the method further includes: stopping the control of the actuator using the closing member accelerometer on the closing member when internal movement is detected using the internal sensor in the actuator; and the method further includes the step of: starting to control the actuator using the internal sensor in the actuator when internal movement is detected using the internal sensor in the actuator.

[0018] In a related aspect, the method includes: using an external sensor on the closing member to detect movement of the closing member in order to control an actuator to move the closing member; and using an internal sensor in the actuator to detect internal movement of the actuator in order to control the actuator.

[0019] In this regard, the external sensor is a closed-member accelerometer, and the method further includes the steps of: stopping the use of the closed-member accelerometer on the closed member to control the actuator when internal motion is detected using the internal sensor in the actuator; and starting the use of the internal sensor in the actuator to control the actuator when internal motion is detected using the internal sensor in the actuator.

[0020] In a related aspect, the method further includes the following steps: providing an actuator with an extendable link for the closing member; providing an internal sensor in the actuator; providing a kinematic chain between the extendable link and the internal sensor; providing a flexible element as part of the kinematic chain; allowing the flexible element to flex in response to a user moving the closing member before the internal sensor detects movement of the kinematic chain; providing an external sensor outside the actuator; detecting the movement of the kinematic chain using a closing member accelerometer before using the internal sensor to detect movement of the kinematic chain; controlling the electric motor of the actuator using the closing member accelerometer before the internal sensor detects movement of the kinematic chain; stopping the use of the closing member accelerometer to control the electric motor of the actuator after the internal sensor detects movement of the kinematic chain; and starting the use of the internal sensor to control the electric motor of the actuator after the internal sensor detects movement of the kinematic chain.

[0021] In a related aspect, the method further includes the following steps: when the closing member is moved by a user, using a flexible element of the actuator to allow flexure between the drive shaft of the actuator's electric motor and the actuator's drive mechanism, the actuator being coupled to the closing member and the vehicle body for moving the closing member relative to the vehicle body, the drive mechanism and the flexible element including a kinematic chain; determining, using an external sensor separate from the actuator, that the closing member is manually moved by the user, including movement achieved by flexure; and controlling the actuator to move the closing member based on the user's movement of the closing member detected by the external sensor.

[0022] In a related aspect, the method further includes the steps of: using an external sensor to determine that the closing member is moved manually by the user, and controlling the actuator to move the closing member in time before detecting the rotation of the drive shaft of the electric motor using an internal position sensor in the actuator in response to the user manually moving the closing member.

[0023] According to another aspect, a power-operated actuator mechanism is provided for moving a closing member of a vehicle relative to the vehicle body between an open position and a closed position. The power-operated closing member actuator includes: a motor for extending and retracting an extendable member to move the closing member; a motion chain connecting the extendable member to the motor, the motion chain having a free travel; and an internal sensor located in the actuator and configured to detect internal movement of the actuator when the free travel is eliminated; wherein the free travel allows the extendable member to move during manual movement of the closing member before the free travel is eliminated.

[0024] In this regard, the internal sensors are configured to detect the motor's movement after the idle stroke has been eliminated.

[0025] In a related aspect, the kinematic chain includes a flexible element that provides free travel, wherein the flexible element is configured to flex in response to a user manually moving the door.

[0026] In this context, the flexible element is a belt, where free travel is provided by flexing the belt.

[0027] In related aspects, the internal sensor is configured to detect the motion imparted to the closing member by the user manually moving the closing member, wherein the internal sensor is configured to provide a motion signal to the controller, wherein the motor is electrically connected to the controller and configured to receive a motor signal generated from the motion signal from the controller.

[0028] In related aspects, the internal sensors are configured to detect the motion imparted to the closing member by the user manually moving the closing member when the free travel is eliminated.

[0029] In this regard, the motor is configured to receive an actuation signal generated by the controller before the idle stroke is eliminated.

[0030] In this regard, the motor is configured to receive an actuation signal generated by the controller before the idle stroke is eliminated and before the internal sensors detect internal motion.

[0031] In this regard, the motor is actuated by an actuation signal generated by the controller before the idle stroke is eliminated. The actuation signal is generated based on another motion signal received by the controller from an external sensor.

[0032] In related aspects, the kinematic chain includes: a nut connected to an extendable member; a lead screw threadedly engaged with the nut, the lead screw being configured to cause the nut to translate along the lead screw during rotation of the lead screw; and a flexible belt adapted to rotate the lead screw, the flexible belt being connected to the motor shaft of a motor.

[0033] In a related aspect, a power-operated actuator mechanism for moving a closing member of a vehicle relative to the vehicle body between an open position and a closed position is disclosed, operated by a controller. The controller communicates with an external sensor configured to output an external sensor signal to the controller. The power-operated closing member actuator includes: a motor having a rotatable motor shaft for extending and retracting an extendable member to move the closing member; the motor being configured to receive a command signal from the controller for rotating the rotatable motor shaft; a kinematic chain connecting the extendable member to the motor, wherein the kinematic chain is configured to rotate the motor shaft in response to a user manually moving the door, and wherein the kinematic chain is configured to extend and retract the extendable member in response to the motor receiving the command signal; and an internal sensor located in the actuator, configured to detect internal movement of the motor shaft in response to a user manually moving the closing member and output an internal sensor signal to the controller, wherein the motor is configured to receive a command signal generated by the controller using the external sensor signal for inducing rotation of the motor shaft before the internal sensor detects the internal movement of the motor shaft.

[0034] In a related aspect, the kinematic chain includes a free travel, wherein the motor is configured to receive a command signal generated by a controller using signals from external sensors before the free travel is eliminated, in order to induce rotation of the motor shaft.

[0035] Other applicable fields will become apparent from the description provided herein. The descriptions and specific examples in this invention summary are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0036] The accompanying drawings described herein are for illustrative purposes only, and not for all possible implementations, and are not intended to limit the scope of this disclosure.

[0037] Figure 1 It is a perspective interior view of a closing member of a motor vehicle, wherein various components related to a part of the vehicle body have been removed for clarity purposes only, and the closing member is equipped with a power closing member actuation system according to various aspects of this disclosure;

[0038] Figure 2 The possible movements of the closing member between the open and closed positions are shown, and the amount of movement of the closing member that can be allowed before the sensor of other known actuators detects that the closing member has been moved by the user is illustrated.

[0039] Figure 3 An example actuator is shown that allows for faster detection of the motion of a closed member in response to an external force compared to other known actuators according to various aspects of this disclosure;

[0040] Figure 4 According to various aspects of this disclosure, when a user applies force to the closing member, the connection with the closing member... Figure 3 A simplified diagram of the actuator; and

[0041] Figures 5 to 7 The illustration shows the steps of a method for controlling the movement of a vehicle's closing member relative to the vehicle body between an open position and a closed position using a power closing member actuation system according to various aspects of this disclosure. Detailed Implementation

[0042] In the following description, details are set forth to provide an understanding of this disclosure. In some instances, certain circuits, structures, and techniques have not been described or shown in detail so as not to obscure this disclosure.

[0043] In general, at least one exemplary embodiment of a power-operated closure member actuation system and method of operation constructed in accordance with the teachings of this disclosure will now be disclosed. Exemplary embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in the art. Numerous examples of specific details, such as specific components, devices, and methods, are set forth to provide a thorough understanding of embodiments of this disclosure. It will be readily understood by those skilled in the art that specific details are not required, exemplary embodiments may be implemented in many different forms, and none should be construed as limiting the scope of this disclosure. In some exemplary embodiments, well-known processes, well-known device structures, and well-known techniques are described in detail.

[0044] First refer to Figure 1 The passenger door 12 of the example motor vehicle 10, also referred to as the exemplary closing member 12, is shown as pivotally mounted to the body 14 of the motor vehicle 10 via an upper door hinge 16 and a lower door hinge 18. According to this disclosure, a powered closing member actuation system 20 is integrated into the pivotal connection between the first passenger door 12 and the body 14. According to a preferred configuration, the powered closing member actuation system 20 typically includes a power-operated actuator mechanism or actuator 22 fixed within the cavity of the passenger door 12.

[0045] Each of the upper door hinge 16 and the lower door hinge 18 includes a door-mounted hinge component and a body-mounted hinge component that are pivotally connected to each other via hinge pins or posts. The door-mounted hinge component is hereinafter referred to as the door hinge band, while the body-mounted hinge component is hereinafter referred to as the body hinge band. Although the powered closing member actuation system 20 is shown only as associated with the front passenger door 12, those skilled in the art will recognize that the powered closing member actuation system can also be associated with any other closing member of the vehicle 10, such as a door or liftgate.

[0046] The power closing member actuation system 20 is operable to pivot the door 12 relative to the vehicle body 14 in a controllable manner between an open position and a closed position. An actuator 22 is coupled to the closing member (e.g., door 12) and the vehicle body 14. The actuator 22 is configured to move the closing member 12 relative to the vehicle body 14.

[0047] In other known conventional actuators (i.e., variations of actuator 22), minute movements or deflections of the closing member 12 in response to external forces are not readily detected. Examples of such other known actuators are described in U.S. Patent Application No. 2018 / 0238099, which is incorporated herein by reference, and may include an extendable link (e.g., movable via a lead screw) Figure 3 The extendable link 21), the lead screw is driven by an electric motor (e.g., via a transmission). Typically, it is desirable for tactile controls or power actuators (e.g., actuator 22) to reduce slack / tilt in the actuator to ensure that any sensing at, for example, the motor shaft directly senses the movement of the closing member 12. In other known actuators of this kind, the transmission connection and other couplings between the motor shaft and the connection to the body 14 are designed to reduce slack or tilt. However, the transmission of other known actuators has internal forces resisting the movement of the closing member 12, resulting in the use, for example, of Hall sensors (e.g., those measuring the rotation of the electric motor shaft in response to the movement of the closing member 12). Figure 3 The Hall sensor 64 detects the delay between haptic / servo-assisted activation of other known actuators. An illustrative example of haptic / servo-assisted activation is shown and described in U.S. Patent Application Publication No. US20220243521A1 entitled “A Power Closure Member Actuation System,” the entire contents of which are incorporated herein by reference. Figure 2The illustration shows the range 23 of angular movement of the closing member 12 between the open and closed positions, and also illustrates the amount of movement of the closing member 12 that can be permitted by the sensor before it is detected by the user in other known actuators (indicated by reference numeral 23). Thus, the closing member 12 can flex due to the user without imparting rotation to the closing member 12 about the hinge axis of hinges 16, 18, resulting in the extension member or extension link extending / retracting. This causes the user to potentially sense the movement of the closing member 12 due to flexing, and therefore the user may sense the resistance of the actuator. Thus, due to the reverse driving force of the actuator, what happens, for example, is that when the user initially moves the closing member 12, due to the internal resistance of the actuator, the closing member 12 will flex before the sensor detects the movement (e.g., the internal resistance of the actuator is able to hold the extension member to allow some flexing in the closing member 12). Once the sensor finally detects the movement and any force-assisted control is activated, this may result in a delay in the control of the haptic assist motor and some sudden / unnatural assistive sensations for the user.

[0048] Figure 3 An example actuator 22 is shown, which allows for faster detection of the response to an external force 25 compared to other known actuators. Figure 4 The movement of the closed member 12. Figure 3 The actuator 22 includes a kinematic chain for converting the rotation of the electric motor 36 to extend and retract the extendable member to open and close the closing panel, respectively. The kinematic chain connecting the extendable member to the motor is configured with a free travel. As used herein, "free travel" refers to the relative movement permitted by the elastic or compliant deformation of a flexible element before the movement of the motor is transmitted to the extendable member, and the relative movement permitted by the elastic or compliant deformation of a flexible element before the movement of the extendable member is transmitted to the motor. Free travel can also be provided by a gap occupied after a limited amount of movement between components, as non-limiting examples, such as by a pin moving in an enlarged slot configuration, a transmission with spacing between teeth, tension in a cable, elastic deformation in a plastic component, bending in an elastic element such as a spring, or play between a connector and / or rod or other part and the component. Free travel allows a limited range of movement of the input motion to the kinematic chain before the free travel is eliminated and the input motion drives the output. Upward input motion may not drive the output motion before the free travel is eliminated. For example, the motion source for the input to the kinematic chain can be the motion of one of the rotary motors or the motion of the extendable component, which does not produce an output motion proportional to or immediately proportional to the motion of the other rotary motor or the extendable component until the idle stroke is eliminated.

[0049] Figure 3 The actuator 22 includes a housing 27 and a drive mechanism 28 operably coupled to the closing member 12. The actuator 22 includes an electric motor 36 for driving a kinematic chain, illustratively shown as having the drive mechanism 28 and a flexible element 30. The flexible element 30 is configured to provide free travel by allowing flexure between the drive shaft 32 of the electric motor 36 and the extendable member 21 of the drive mechanism 28 when the closing member 12 is moved by a user. The drive mechanism 28 and the flexible element 30 illustratively provide a kinematic chain 34 between the extendable member 21 and the motor 36; however, by way of non-limiting example, the drive mechanism 28 and the flexible element 30 may include other intermediate components, such as planetary gear trains, additional linkages, and clutches. The actuator 22 includes an electric motor 36, a kinematic chain 34 with free travel, and an internal sensor 64 configured to detect internal movement only after the free travel has been eliminated.

[0050] Return to reference Figure 1 The powered door closure actuation system 20 further includes an external sensor 86, which is separate from the actuator 22 and coupled to the door closure 12 and configured to detect movement of the door closure 12. Depending on a particular aspect and as detailed below, the external sensor 86 may be a door closure accelerometer 86. The external sensor 86 may be located at a position on the door closure accelerometer 86. The external sensor 86 may be provided as part of a door control module, or as part of a door latch, or as part of the actuator 22, which is configured to control other components of the door, such as window regulators and side mirrors, and the door latch. The powered door closure actuation system 20 also includes a controller 50, which is coupled to the actuator 22 and communicates with other vehicle systems (e.g., a body control module) and also receives vehicle power from the vehicle 10 (e.g., from the vehicle battery 53). The controller 50 also communicates with the external sensor 86. The controller 50 is configured to use the external sensor 86 to determine that the door closure 12 has been manually moved by a user, including movement achieved by flexure. The controller 50 is also configured to control the actuator 22 to move the closing member 12 based on user movement of the closing member 12 detected by an external sensor 86. The external sensor 86 is another sensor in addition to the internal sensor 64.

[0051] As described above and continue to refer to Figure 3The drive shaft 32 of the electric motor 36 is rotatable about the drive shaft axis 35, and the power closure member actuation system 20 also includes an internal sensor 64 located in the actuator 22 and coupled to the drive shaft 32 of the electric motor 36. The internal sensor 64 communicates with the controller 50 and is configured to detect rotation of the drive shaft 32 (i.e., internal movement of the actuator 22). The internal sensor 64 is configured to provide a motion signal to the controller 50, which uses the motion signal to generate a corresponding motor control signal to be provided to the electric motor 36, based on the detected internal motion. Therefore, according to other aspects of this disclosure, the controller 50 is also configured to use an external sensor 86 to determine that the closure member 12 has been manually moved by a user, and to control the actuator 22 to move the closure member 12 before the internal sensor 64 detects rotation of the drive shaft 32 of the electric motor 36 in response to the user manually moving the closure member 12. In this way, the internal sensor 64 detects motor movement only after the idle stroke has been eliminated. Therefore, controller 50 is configured to use an external sensor 86 on the closing member 12 to detect movement of the closing member 12 in order to control actuator 22 to move the closing member 12. Controller 50 is also configured to use an internal sensor 64 in actuator 22 to detect internal movement of actuator 22 in order to control actuator 22. According to other aspects, controller 50 is further configured to stop using the external sensor 86 on the closing member 12 to control actuator 22 when internal movement is detected using the internal sensor 64 in actuator 22. Controller 50 is also configured to start using the internal sensor 64 in actuator 22 to control actuator 22 when internal movement is detected using the internal sensor 64 in actuator 22. When the internal sensor 64 detects internal movement, controller 50 stops control based on the external sensor 86 and switches control to the internal sensor 64.

[0052] More detailed and still refer to Figure 3The drive mechanism 28 includes a lead screw 13 extending between a first lead screw end 38 and a second lead screw end 40, and rotatable about a lead screw axis 42 parallel to and spaced apart from the drive shaft axis 35. The lead screw 13 defines a lead screw pulley 43 at the first lead screw end 38, and has external threads 44 defined on the lead screw 13 in a threaded region 46 extending from the lead screw pulley 43 to the second lead screw end 40. The drive mechanism 28 also includes a nut, illustratively shown as a ball nut 48, configured to move along the threaded region 46 of the lead screw 13 in response to rotation of the lead screw 13, and including a ball 49 that is captured and rotatable within the ball nut 48. The ball 49 defines a lead screw bore 54 through which it passes. Ball bearing 49 is arranged annularly around lead screw 13, and lead screw hole 54 defines internal thread 55 that engages with external thread 44 of lead screw 13. Actuator 22 also includes extendable link 21 extending from a first link end 57 attached to ball nut 48 to a second link end 59 connected to closing member 12. Extendable link 21 extends along link axis 65, which is parallel to and spaced from lead screw axis 42. Extendable link 21 can move linearly along link axis 65 in response to movement of ball nut 48 along lead screw 13 during rotation of lead screw 13, thereby moving closing member 12. End stop 67 is attached to extendable link 21 and configured to abut against housing 27 to limit axial movement of extendable link 21. Connector 69 for electrically connecting actuator 22 to vehicle 10 is also provided.

[0053] Continue to refer to Figure 3The kinematic chain 34 also includes a planetary gearbox 68, which is coupled to and driven by the drive shaft 32 of the electric motor 36, and configured to rotate the drive pulley 70 about a pulley axis 73 parallel to and spaced apart from the lead screw axis 42 (and coaxial with the drive shaft axis 35). According to one aspect and as shown, the flexible element 30 is a belt 30 extending around the drive pulley 70 and the lead screw pulley 43 and between the drive pulley 70 and the lead screw pulley 43. The belt 30 is configured to cause simultaneous rotation of the lead screw pulley 43 and the drive pulley 70 while providing flexure between the drive shaft 32 and the lead screw 13. The flexure in the pulley 43 illustratively provides idle travel. This belt drive allows for a reduction in the size of the actuator 22. For example, the electric motor 36 can be aligned on the lead screw 13, and the planetary gearbox 68 includes planetary gears aligned with the drive shaft axis 35, unlike the offset worm gear engaging the nut tube. Therefore, although such deflection in the kinematic chain 34 is generally undesirable, it can now be used to eliminate deflection of the closure member 12 without detection to provide a smooth transition for tactile control. While the flexible element 30 is described herein as a belt, it should be understood that the flexible element 30 can be some other type of linkage that allows deflection, such as, but not limited to, spring-loaded or biased members. In other embodiments, the flexible element 30 can be any compliant torque transmission element capable of providing free travel.

[0054] Therefore, the electric motor 36 is operably coupled to the extendable link 21. An internal sensor 64 in the actuator 22 is configured to detect movement in the kinematic chain 34 disposed between the extendable link 21 and the internal sensor 64. Similarly, the kinematic chain 34 includes a flexible element 30 configured to flex in response to movement of the closing member 12 by a user prior to the internal sensor 64 detecting movement in the kinematic chain 34. An external sensor 86 is also configured to detect movement of the closing member corresponding to movement in the kinematic chain 34. Therefore, according to various aspects of this disclosure, the controller 50 is further configured to detect movement of the kinematic chain 34 using the external sensor 86 before using the internal sensor 64 to detect movement in the kinematic chain 34. The controller 50 is also configured to control the electric motor 36 of the actuator 22 using the external sensor 86 before the internal sensor 64 detects movement in the kinematic chain 34. Additionally, the controller 50 is configured to stop controlling the electric motor 36 of the actuator 22 using the external sensor 86 after the internal sensor 64 detects movement in the kinematic chain 34. The controller 50 is also configured to initiate control of the electric motor 36 of the actuator 22 using the internal sensor 64 after the internal sensor 64 detects movement of the kinematic chain 34. Therefore, flexing allows the movement of the closing member 12 to be recorded by an external sensor 86 on the closing member 12, which is highly sensitive to the movement of the closing member 12. This flexing has lower resistance than the reverse drive force of the actuator 22's transmission. Therefore, a more sensitive response time is provided before haptic control is activated when the movement of the closing member 12 is used, and the user does not have to resist the reverse drive of the transmission before a sudden motor control initiation. The closing member 12 also does not flex. Furthermore, a drive mechanism 28 with some slack / tilt can be used to generate some elastic deformation in the actuator 22 to allow the accelerometer 86 to detect the movement of the closing member 12 before the internal Hall sensor 64 detects rotation of the drive shaft 32 of the electric motor 36. Therefore, the actuation signal generated by the controller 50 is used by the electric motor 36 to control rotation before the free travel is eliminated, which can provide increased response time in power-assisted support for users who manually move the door 12. The accelerometer 86 provides a motion signal to the controller 50, which generates a motor actuation signal to be provided to and received by the electric motor 36. Therefore, the electric motor 36 can receive the actuation signal generated by the controller 50 using the accelerometer signal 86 before the free travel is eliminated.

[0055] As discussed, the power closure member actuation system 20 includes at least one closure member feedback sensor or internal sensor 64. The internal sensor 64 is used to determine at least one of the position, velocity, and attitude of the closure member. Thus, at least one closure member feedback sensor 64 detects signals from the actuator 22 by counting the revolutions of the electric motor 36, detecting the absolute position of the extendable member 21, or detecting signals from the door 12 (e.g., as an example, an absolute position sensor regarding door limits) that can provide position information to the controller 50. The feedback sensor 64 communicating with the controller 50 is part of a feedback system or motion sensing system for directly or indirectly detecting door movement, such as by detecting changes in the velocity and position of the closure member or its associated components. For example, the motion sensing system can be hardware-based (e.g., a Hall sensor unit, associated circuitry) for detecting movement of a target, such as on the closure member (e.g., on a hinge) or on the actuator 22 (e.g., on a motor shaft), and / or the motion sensing system can be software-based (e.g., using code and logic to execute a pulse counting algorithm), for example, executed by the controller 50. Other types of position, velocity, and / or orientation detectors, such as accelerometers and induction-based sensors, can be used without restriction.

[0056] The powered closure member actuation system 20 further includes at least one non-contact obstacle detection sensor 66, which can form part of a non-contact obstacle detection system connected, for example, electrically connected to the controller 50. The controller 50 is configured to determine whether an obstacle has been detected using at least one non-contact obstacle detection sensor 66 (e.g., using a non-contact obstacle detection algorithm), and can, for example, stop the movement of the closure member in response to determining that an obstacle has been detected. The non-contact obstacle detection system can also be configured to calculate the distance from the closure member to an object or obstacle, or to a user who is an object or obstacle, or to the door 12. For example, the non-contact obstacle detection system can be configured to perform time-of-flight calculations using a radar-based sensor 66 to determine the distance, or, for example, characterize an object as a user or a human based on the reflectivity of the object determined using the radar-based sensor 66 and the system, compared to a non-human object. The non-contact obstacle detection system can also be configured to determine when an obstacle has been detected, for example, by detecting reflected waves from radar emitted from the obstacle sensor 66, indicating an object, obstacle, or user. The non-contact obstacle detection system can also be configured to determine, for example, when an obstacle is not detected by the absence of a radar reflection emitted from the obstacle sensor 66, indicating an object, obstacle, or user. Operation and examples of at least one non-contact obstacle detection sensor 66 and system are discussed in U.S. Patent Application No. 2018 / 0238099, which is incorporated herein by reference.

[0057] Figure 4When the user applies force 25 to the closing member 12, the connection with the closing member 12 is... Figure 3 A simplified diagram of actuator 22 is shown. Motor teeth and friction 26 are illustrated. Door hinges 16, 18 and body 14 may also flex. Therefore, the force 25 applied by the user causes the closing member 12 to flex (shown in dashed lines). As shown, the belt 30 also flexes (according to belt stiffness K), thereby allowing the lead screw 13 to rotate and the motor shaft 32 of the electric motor 36 to rotate in response to the force 25 applied by the user to the closing member 12. Therefore, the force 25 applied by the user is detected more quickly by the internal sensor 64.

[0058] As discussed, an external sensor 86 (such as an accelerometer) is also connected to the controller 50 to detect the tilt of the vehicle 10. The vehicle tilt sensor or external sensor 86 outputs a tilt signal corresponding to the tilt of the vehicle 10, and the controller 50 is also configured to receive the tilt signal and adjust the command signal to the actuator 22 accordingly. Although the vehicle tilt sensor 86 can be separate from the controller 50, it should be understood that the vehicle tilt sensor 86 can also be integrated into the controller 50 or another control module, such as, but not limited to, the body control module 52.

[0059] The controller 50 is also configured to perform at least one of an initial boundary condition check prior to the generation of the command signal to the actuator 22 and a boundary check during the generation of the command signal. Such boundary checks prevent the movement of the closing member and the operation of the actuator 22 from exceeding a number of predetermined operational limits or boundary conditions.

[0060] Return to reference Figure 1 For example, controller 50 may also be coupled to vehicle latch 83. Additionally, controller 50 may include or be coupled to a memory device 92 having at least one storage location for storing at least one stored motion control parameter associated with the movement of a control closing member (e.g., door 12). Memory device 92 also stores door motion parameters (e.g., door limit profiles and pop-out profiles) that can be modified by the original equipment manufacturer (OEM).

[0061] The controller 50 is also coupled to a latch 83, which includes a tether motor for pulling the closing member 12 to the closed position. The latch 83 also includes, for example, multiple primary and secondary ratchet position sensors or switches that provide feedback to the controller 50 regarding whether the latch 83 is in the primary or secondary latch position.

[0062] Similarly, a vehicle tilt sensor 86 (such as an accelerometer or slew rate meter) is also coupled to the controller 50 for detecting the tilt of the vehicle 10. The vehicle tilt sensor 86 outputs a tilt signal corresponding to the tilt of the vehicle 10, and the controller 50 is also configured to receive the tilt signal and accordingly adjust the command signal to the actuator 22. This adjustment may, for example, include adjusting the motion command so that the door 12 moves at the same speed and motion profile as if the door 12 were moving on level terrain. Therefore, the actuator 22 can move the door 12 such that the motion profile when tilted (e.g., the relationship between speed and door position) is the same as or follows the motion profile as if the vehicle were not tilted. In other words, when the vehicle 10 is tilted or not tilted, the user does not detect a visual difference in the relationship between speed and position in the appearance of the door movement. Alternatively, the command signal may be adjusted accordingly to move the door 12 to apply a resistance similar to that detected by the user as if the door 12 were moving on level terrain. Therefore, actuator 22 can move door 12 such that the force required for the user to move door 12 when it is tilted is the same as the force required for the user to move door 12 when vehicle 10 is not tilted. In other words, whether vehicle 10 is tilted or not, the user experiences the same reaction resistance against the user's input force on door 12.

[0063] The controller 50 includes a processor or other computing unit 110 that communicates with the memory device 92. Therefore, the controller 50 is coupled to the memory device 92, which stores a plurality of motion parameters of a powered closing member, which are used by the controller 50 to control the movement of a closing member (e.g., door 12). The plurality of motion parameters of the powered closing member include a closing member model and a plurality of closing member component profiles. The memory device 92 may also store boundary conditions (e.g., a plurality of predetermined operating limits) used for boundary checks to prevent movement of the closing member and operation of the actuator 22 from exceeding the plurality of predetermined operating limits or boundary conditions.

[0064] Return to reference Figure 1The computing unit 110 may be connected to a compass 300. The compass 300 may be formed as a microchip device, such as Honeywell's 3-axis digital compass HMC5843, and in one possible configuration is provided as part of the computing unit 110. Alternatively, the compass 300 may be mounted at other locations on the door 12. For example, the compass 300 may be mounted on the same printed circuit board as other electronics forming the computing unit 110. Thus, the compass 300 is configured to detect changes in the orientation of the door 12 relative to a magnetic field, and particularly relative to magnetic north. The orientation of the compass 300 can be read by the computing unit 110, for example, after detecting that the vehicle was stationary before changing orientation, such as by detecting when the vehicle has moved to park (P). In known power-operated door systems, when the door 12 is in the closed position, Hall effect counting in the power door actuator 22 is used as a means of determining the door's position. Using a positioning device such as compass 300 provides a way to determine the door position independently of an absolute positioning device associated with power actuator 22, and in the event of a power outage when door 12 is open, which causes the power system to lose the position of the door angle detected by the absolute positioning device. Therefore, there is no need for Hall sensors, for example, located in actuator 22 or on door hinges 16, 18, and there is no need to store the position of the door angle in system memory. Eliminating sensors in drive unit 22 allows for a reduction in the size of actuator 22 and the elimination of wiring extending into and out of drive unit 22. Other types of compass devices that are not dependent on magnetic fields, such as a gyrocompass, can also be used to determine the position of door 12 when the compass 300 is described by referring to a detected magnetic field to determine a constant reference point on Earth. Other types of inertial-based devices can also be used to determine the position of door 12 without using external reference input. Therefore, controller 50 is configured to receive either a motion input associated with the power-assisted mode (i.e., assisting the user in moving the closing member 12 with some force in response to an ongoing input / force from the user, making it easier for the user to move the closing panel 12) or an automatic mode initiation input associated with the automatic mode (i.e., automatically moving the closing member 12 in response to a one-time input from the user). Controller 50 is then configured to send a command signal to actuator 22 based on this user input (e.g., a motion input or an automatic mode initiation input) and multiple power-assisted closing member motion parameters to change the actuator output force acting on the closing member 12 to move the closing member 12. Controller 50 also monitors and analyzes the historical operation of the power-assisted closing member actuation system 20 and adjusts the multiple power-assisted closing member motion parameters accordingly.

[0065] The controller 50 is configured to receive an automatic mode activation input and, in response to receiving the automatic mode activation input or an input motion command, enter automatic mode to output a command signal. The automatic mode activation input can be a manual input on the closing member itself or an indirect input to the vehicle (e.g., a closing member switch 58 on the closing member, a switch on the smart key 60, etc.). Thus, for example, the automatic mode activation input could be, for example, the result of a user or operator operating a switch (e.g., closing member switch 58), making a gesture near the vehicle 10, or holding the smart key 60 near the vehicle 10. It should also be understood that other automatic mode activation inputs are contemplated, such as, but not limited to, the proximity of a user detected by a proximity sensor. Such power-assisted mode and automatic mode operation are discussed in U.S. Patent Application No. 2025 / 0059815, which is incorporated herein by reference.

[0066] Figures 5 to 7 The illustration shows the steps of a method for controlling the movement of the closing member 12 of the vehicle 10 relative to the vehicle body 14 between an open position and a closed position using a powered closing member actuation system 20. First, refer to... Figure 5 Furthermore, according to various aspects of this disclosure, the method includes step 500: using an external sensor 86 on the closing member 12 to detect movement of the closing member 12 in order to control the actuator 22 to move the closing member 12. The method also includes step 502: using an internal sensor 64 in the actuator 22 to detect internal movement of the actuator 22 in order to control the actuator 22.

[0067] Similarly, the external sensor 86 can be a closed-member accelerometer 86. Therefore, see specific references. Figure 6 Furthermore, according to other aspects, the method further includes step 600: using a closing member accelerometer 86 on the closing member 12 to detect the motion of the closing member 12. Next, step 602 uses the closing member accelerometer 86 on the closing member 12 to control the actuator 22. Additionally, the method includes step 604: using an internal sensor 64 in the actuator 22 to detect internal motion of the actuator 22. The method continues to step 606: when internal motion is detected using the internal sensor 64 in the actuator 22, the use of the closing member accelerometer 86 on the closing member 12 to control the actuator 22 is stopped. The method further includes step 608: when internal motion is detected using the internal sensor 64 in the actuator 22, the use of the internal sensor 64 in the actuator 22 to control the actuator 22 is started.

[0068] According to another aspect and specifically referring to Figure 7The method further includes step 700: providing an actuator 22 with an extendable link 21 for the closing member 12. Next, step 702 provides an internal sensor 64 in the actuator 22. Additionally, the method includes step 704: providing a kinematic chain 34 between the extendable link 21 and the internal sensor 64. The method continues with step 706: providing a flexible element 30 as part of the kinematic chain 34. The method continues with step 708: allowing the flexible element 30 to flex in response to a user moving the closing member 12 before the internal sensor 64 detects movement of the kinematic chain 34. The next step of the method is 710: providing an external sensor 86 outside the actuator 22. The method further includes step 712: detecting the movement of the kinematic chain 34 using a closing member accelerometer 86 before the internal sensor 64 detects movement of the kinematic chain 34. The method further includes step 714: controlling an electric motor 36 of the actuator 22 using the closing member accelerometer 86 before the internal sensor 64 detects movement of the kinematic chain 34. The method continues with step 716: after the internal sensor 64 detects movement of the kinematic chain 34, the use of the closed member accelerometer 86 to control the electric motor 36 of the actuator 22 is stopped. The method further includes step 718: after the internal sensor 64 detects movement of the kinematic chain 34, the use of the internal sensor 64 to control the electric motor 36 of the actuator 22 is started.

[0069] According to another aspect, the method further includes the step of: when the closing member 12 is moved by a user, using the flexible element 30 of the actuator 22 to allow flexure between the drive shaft 32 of the electric motor 36 of the actuator 22 and the drive mechanism 28 of the actuator 22, the actuator 22 being coupled to the closing member 12 and the vehicle body 14 for moving the closing member 12 relative to the vehicle body 14, the drive mechanism 28 and the flexible element 30 including a kinematic chain 34. Additionally, the method includes the step of: determining, using an external sensor 86 separate from the actuator 22, that the closing member 12 is manually moved by the user, including movement achieved by flexure. The method further includes the step of: controlling the actuator 22 to move the closing member 12 based on the user's movement of the closing member 12 detected by the external sensor 86.

[0070] In addition, according to other aspects of this disclosure, the method may further include the steps of: determining, using an external sensor 86, that the closing member 12 is manually moved by a user, and controlling the actuator 22 to move the closing member 12 in time before detecting the rotation of the drive shaft 32 of the electric motor 36 using an internal position sensor in the actuator 22 in response to the user manually moving the closing member 12.

[0071] Therefore, the powered closure member actuation system 20 disclosed herein, which uses an actuator 22 including a flexible element 30, offers numerous advantages. Even before any rotation of the motor 36 occurs, the controller 50 predicts the activation of haptic control (i.e., control of the actuator 22 in powered assist mode) by observing the acceleration of the closure member 12. More specifically, as discussed above, the use of a driven actuator 22 facilitates flexure or “system flexibility,” which helps generate acceleration of the closure member 12 that can be detected using a G-sensor or an external sensor 86 before the electric motor 36 begins its reverse-drive rotation. Thus, the assist mode can begin with a lower load provided by the user and has a more gradual transition, resulting in a more pleasant user experience.

[0072] However, it will be apparent that changes may be made to the description and illustration herein without departing from the scope defined in the appended claims. The foregoing description of embodiments has been provided for illustrative and descriptive purposes. The foregoing description is not intended to be exhaustive or limiting of this disclosure. Elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and can be used in chosen embodiments, even if not specifically shown or described. Elements or features of a particular embodiment may also vary in many ways. Such variations are not considered to depart from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

[0073] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may also be intended to include the plural forms unless the context clearly indicates otherwise. The terms “comprising,” “including,” “containing,” and “having” are inclusive and thus specify the presence of stated features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or combinations thereof. Unless specifically indicated as the order of performance, the method steps, processes, and operations described herein should not be construed as requiring them to be performed in the particular order discussed or illustrated. It should also be understood that additional or alternative steps may be employed.

[0074] When an element or layer is referred to as “on another element or layer,” “joined to,” “connected to,” or “attached to” another element or layer, the element or layer may be directly on, joined to, connected to, or attached to the other element or layer, or there may be intermediate elements or layers present. In contrast, when an element is referred to as “directly on another element or layer,” or “directly joined to,” “directly connected to,” or “directly attached to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0075] Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or portions, these elements, components, regions, layers, and / or portions should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another element, component, region, layer, or segment. Unless clearly indicated by the context, terms such as “first,” “second,” and other numerical terms used herein do not imply any order or sequence. Therefore, without departing from the teachings of the exemplary embodiments, the first element, first component, first region, first layer, or first segment discussed below may be referred to as a second element, second component, second region, second layer, or second segment.

[0076] For ease of description, spatially related terms such as “inside,” “outside,” “below,” “below,” “lower,” “above,” “upper,” “top,” “bottom,” etc., are used herein to describe the relationship between one element or feature and another element or feature as shown in the figures. Spatially related terms may be intended to include different orientations of the device in use or operation other than those depicted in the figures. For example, if the device in the figures is flipped, the element described as “below” or “below” to another element or feature will then be oriented “above” to that other element or feature. Thus, the example term “below” can include both above and below orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially related descriptions used herein shall be interpreted accordingly.

[0077] Components of the exemplary apparatus, systems, and methods employed according to the illustrated embodiments may be implemented at least partially as digital electronic circuits, analog electronic circuits, or as computer hardware, firmware, software, or a combination thereof. These components may be implemented as a set of instructions executed by a processing device, for example, as a computer program product, such as a computer program, program code, or computer instructions tangibly implemented in an information carrier or machine-readable storage device to be executed by or control the operation of a data processing device such as a programmable processor, microprocessor, computer, or multiple computers. The term "controller" as used herein refers to any combination of such computers, processors, microchip processors, integrated circuits, or any other elements, whether single or multiple, capable of carrying a program for performing the functions, methods, and flowcharts provided herein. A controller may be a single such element located on a printed circuit board along with other electronic components. Alternatively, a controller may exist remotely from other element systems described herein. For example, but not limited to, at least one controller may be programmed in a vehicle's onboard computer located inside a door, latch, or other location within the vehicle. A controller may also exist in multiple locations or comprise multiple components.

[0078] The instruction list, such as a computer program, can be written in any form of programming language, including compiled or interpreted languages, and can be deployed in any form, including as a standalone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. The computer program can be deployed to execute on one computer or on multiple computers located at a single station or distributed across multiple stations and interconnected via a communication network. Furthermore, the functional programs, code, and code segments used to implement the illustrative embodiments can be readily interpreted by a skilled programmer in the art to which the illustrative embodiments pertain as being within the scope of the claims executed in the illustrative embodiments. The method steps associated with the illustrative embodiments can be performed by one or more programmable processors executing computer programs, code, or instructions to perform functions (e.g., by manipulating input data and / or generating output). For example, the method steps can also be performed by a dedicated logic circuit system such as a FPGA (Field-Programmable Gate Array) or ASIC (Application-Specific Integrated Circuit), and the apparatus of the illustrative embodiments can be implemented as said dedicated logic circuit systems.

[0079] The various illustrative logic blocks, modules, algorithms, steps, and circuits described in conjunction with the embodiments disclosed herein can be implemented or performed by a general-purpose processor, a digital signal processor (DSP), an ASIC, an FPGA or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but alternatively, as an example, the processor may be any conventional processor, microcontroller, or state machine. The processor may also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a combination of multiple microprocessors, a combination of one or more microprocessors with a DSP core, or any other such configuration.

[0080] By way of example, processors suitable for executing computer programs include both general-purpose microprocessors and special-purpose microprocessors, as well as any type of digital computer and one or more processors. Typically, a processor receives instructions and data from read-only memory or random access memory, or both. The basic components of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Typically, a computer will also include or be operatively coupled to one or more mass storage devices, such as magnetic disks, magneto-optical disks, or optical disks, for receiving data from or transferring data to them, or both. Information carriers suitable for implementing computer program instructions and data include all forms of non-volatile memory, including, as examples, semiconductor memory devices such as electrically programmable read-only memory or ROM (EPROM), electrically erasable programmable ROM (EEPROM), flash memory devices, and data storage disks (e.g., magnetic disks, internal hard disks or removable disks, magneto-optical disks, and CD-ROM and DVD-ROM disks). Processors and memory may be supplemented by or incorporated into a dedicated logic circuit system.

[0081] Those skilled in the art will understand that information and signals can be represented using any of a variety of different processes and techniques. For example, data, instructions, commands, information, signals, bits, symbols, and chips that may be mentioned throughout the above description can be represented by voltage, current, electromagnetic waves, magnetic fields or particles, light fields or particles, or any combination thereof.

[0082] Those skilled in the art will also understand that the various illustrative logic blocks, modules, circuits, algorithms, and steps described in connection with the embodiments disclosed herein can be implemented as electronic hardware, computer software, or a combination of both. To clearly illustrate this interchangeability between hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether this functionality is implemented as hardware or software depends on the specific application and design constraints imposed on the system as a whole. Those skilled in the art may implement the described functionality in different ways for each specific application, but such implementation decisions should not be construed as causing a departure from the scope of the claims exemplified by the illustrative embodiments. Software modules may reside in random access memory (RAM), flash memory, ROM, EPROM, EEPROM, registers, hard disks, removable disks, CD-ROMs, or any other form of storage medium known in the art. An exemplary storage medium is coupled to a processor such that the processor can read information from and write information to the storage medium. Alternatively, the storage medium may be an integral part of the processor. In other words, the processor and storage medium may reside in an integrated circuit or be implemented as discrete components.

[0083] Computer-readable non-transitory media include all types of computer-readable media, including magnetic storage media, optical storage media, flash memory media, and solid-state storage media. It should be understood that software can be installed in and sold with a central processing unit (CPU) device. Alternatively, software can be obtained and loaded into a CPU device, including through physical media or distribution systems, such as from a server owned by the software creator or from a server not owned by the software creator but used by the software creator. For example, software can be stored on a server for distribution via the Internet.

[0084] The embodiments of this disclosure can be understood with reference to the following numbered paragraphs:

[0085] 1. A power-operated actuator mechanism for moving a closing member of a vehicle relative to the vehicle body between an open position and a closed position, the power-operated closing member actuator comprising:

[0086] Motors are used to extend and retract extendable members to move closed members.

[0087] A kinematic chain, which connects an extendable component to a motor, has a free stroke; and

[0088] An internal sensor, located within the actuator, is configured to detect internal movement of the actuator when the idle stroke is eliminated;

[0089] The free travel allows the extendable member to move during the manual movement of the closing member before the free travel is eliminated.

[0090] 2. The power-operated actuator mechanism according to paragraph 1, wherein the internal sensor is configured to detect the motion of the motor after the idle stroke has been eliminated.

[0091] 3. The power-operated actuator mechanism according to paragraph 1, wherein the kinematic chain includes a flexible element providing idle travel, wherein the flexible element is configured to flex in response to manual movement of the door by a user.

[0092] 4. The power-operated actuator mechanism according to paragraph 3, wherein the flexible element is a belt, and wherein the idle stroke is provided by flexing the belt.

[0093] 5. The power-operated actuator mechanism according to paragraph 1, wherein an internal sensor is configured to detect motion imparted to the closing member by manual movement of the closing member by a user, wherein the internal sensor is configured to provide a motion signal to a controller, wherein a motor is electrically connected to the controller and configured to receive a motor signal generated from the motion signal from the controller.

[0094] 6. The power-operated actuator mechanism according to paragraph 5, wherein the internal sensor is configured to detect the motion imparted to the closing member by the user manually moving the closing member when the idle stroke is eliminated.

[0095] 7. The power-operated actuator mechanism according to paragraph 6, wherein the motor is configured to receive an actuation signal generated by the controller before the idle stroke is eliminated.

[0096] 8. The power-operated actuator mechanism according to paragraph 1, wherein the motor is configured to receive an actuation signal generated by the controller before the idle stroke is eliminated and before the internal motion is detected by the internal sensor.

[0097] 9. The power-operated actuator mechanism according to paragraph 1, wherein the motor is actuated by an actuation signal generated by a controller before the idle stroke is eliminated, the actuation signal being generated based on another motion signal received by the controller from an external sensor.

[0098] 10. The power-operated actuator mechanism according to paragraph 1, wherein the kinematic chain includes:

[0099] Nut, the nut is connected to an extendable member;

[0100] A lead screw, threadedly engaged with a nut, configured to cause the nut to translate along the lead screw during rotation; and

[0101] A flexible belt, suitable for rotating the lead screw, is connected to the motor shaft of the motor.

[0102] 11. A power-operated closing member actuation system for moving a closing member of a vehicle relative to the vehicle body between an open position and a closed position, the power-operated closing member actuation system comprising:

[0103] An external sensor is mounted on the closed member and configured to detect the movement of the closed member.

[0104] Actuator, an actuator is used to move a closed member;

[0105] An internal sensor, located within the actuator, is configured to detect internal movements within the actuator;

[0106] The controller communicates with the actuator, internal sensors, and external sensors. The controller is configured to:

[0107] External sensors on the closing member are used to detect the movement of the closing member, in order to control the actuator to move the closing member.

[0108] The internal motion of the actuator is detected by internal sensors in the actuator in order to control the actuator.

[0109] 12. The power-operated closure member actuation system according to paragraph 11, wherein the controller is further configured to:

[0110] When internal movement is detected using the internal sensor in the actuator, the use of external sensors on the closing member to control the actuator is stopped, and

[0111] When internal motion is detected using the internal sensors in the actuator, the actuator is controlled using the internal sensors in the actuator.

[0112] 13. The power closure member actuation system according to paragraph 12, wherein the actuator includes an electric motor operably coupled to an extendable link, an internal sensor in the actuator is configured to detect movement in a kinematic chain disposed between the extendable link and the internal sensor, the kinematic chain including a flexible element configured to flex in response to a user moving the closure member prior to the internal sensor detecting movement of the kinematic chain, an external sensor is configured to detect movement of the kinematic chain, and the controller is further configured to:

[0113] In terms of time, the movement of the kinematic chain is detected using external sensors before the movement of the kinematic chain is detected using internal sensors.

[0114] The electric motor of the actuator is controlled by an external sensor before the internal sensor detects the movement of the kinematic chain.

[0115] After the internal sensors detect movement in the kinematic chain, the use of external sensors to control the actuator's electric motor is stopped; and

[0116] After the internal sensors detect the movement of the kinematic chain, the electric motor of the actuator is controlled using the internal sensors.

[0117] 14. A method for controlling the movement of a closing member of a vehicle relative to the vehicle body between an open position and a closed position using a powered closing member actuation system, the method comprising:

[0118] The movement of the closed member is detected by an external sensor on the closed member, and an actuator is controlled to move the closed member; and

[0119] The internal motion of the actuator is detected by internal sensors in the actuator in order to control the actuator.

[0120] 15. The method according to paragraph 14, wherein the external sensor is a closed-member accelerometer, and the method further comprises the following steps:

[0121] When internal motion is detected using the internal sensors in the actuator, the use of the closing member accelerometer on the closing member to control the actuator is stopped; and

[0122] When internal motion is detected using the internal sensors in the actuator, the actuator is controlled using the internal sensors in the actuator.

[0123] 16. The method according to paragraph 15 further includes the following steps:

[0124] Provide an actuator with an extendable link for the closed component;

[0125] Internal sensors are provided in the actuator;

[0126] Provide a kinematic chain between the extendable link and the internal sensor;

[0127] Provide flexible elements as part of the kinematic chain;

[0128] This allows the flexible element to flex in response to a user moving a closed member before the internal sensors detect the movement of the kinematic chain.

[0129] Provide external sensors outside the actuator;

[0130] In terms of time, the motion of the kinematic chain is detected using a closed-member accelerometer before the internal sensors are used to detect the motion of the kinematic chain.

[0131] Before the internal sensors detect the motion of the kinematic chain, the electric motor of the actuator is controlled by a closed-member accelerometer.

[0132] After the internal sensors detect the motion of the kinematic chain, the use of the electric motor controlling the actuator via the closed-member accelerometer is stopped; and

[0133] After the internal sensors detect the movement of the kinematic chain, the electric motor of the actuator is controlled using the internal sensors.

[0134] 17. The method according to paragraph 14 further includes the following steps:

[0135] When the closing member is moved by the user, the flexible element of the actuator allows for deflection between the drive shaft of the actuator's electric motor and the actuator's drive mechanism. The actuator is coupled to the closing member and the vehicle body to move the closing member relative to the vehicle body. The drive mechanism and the flexible element include a kinematic chain.

[0136] External sensors, separate from the actuator, are used to determine whether the closed member is moved manually by the user, including movement achieved by flexure; and

[0137] The actuator is controlled to move the closing member based on the user's movement of the closing member detected by external sensors.

[0138] 18. The method according to paragraph 17 further includes the steps of: determining, using an external sensor, that the closing member is manually moved by a user, and controlling the actuator to move the closing member in time before detecting rotation of the drive shaft of the electric motor using an internal position sensor in the actuator in response to the user manually moving the closing member.

[0139] 19. A power-operated actuator mechanism, operated by a controller, for moving a closing member of a vehicle relative to the vehicle body between an open position and a closed position, the controller communicating with an external sensor configured to output an external sensor signal to the controller, the power-operated closing member actuator comprising:

[0140] A motor having a rotatable motor shaft, the motor being used to extend and retract an extendable member to move a closed member, the motor being configured to receive a command signal from a controller for rotating the rotatable motor shaft.

[0141] A kinematic chain, which connects an extendable member to a motor, wherein the kinematic chain is configured to rotate the motor shaft in response to a user manually moving the door, and wherein the kinematic chain is configured to extend and retract the extendable member in response to a command signal received by the motor; and

[0142] An internal sensor, located in the actuator, is configured to detect the internal movement of the motor shaft in response to manual movement of the closing member by the user and to output an internal sensor signal to the controller.

[0143] The motor is configured to receive a command signal generated by the controller using signals from external sensors before the internal sensors detect the internal movement of the motor shaft, in order to cause the motor shaft to rotate.

[0144] 20. The power-operated actuator mechanism according to paragraph 19, wherein the kinematic chain includes a free stroke, wherein the motor is configured to receive a command signal generated by a controller using external sensor signals for causing rotation of the motor shaft before the free stroke is eliminated.

Claims

1. A power-operated actuator mechanism (22) for moving a closing member (12) of a vehicle (10) relative to a vehicle body (14) between an open position and a closed position, the power-operated actuator mechanism (22) comprising: A motor (36) is used to extend and retract the extendable member (21) to move the closed member (12); A motion chain (34) connecting the extendable member (21) to the motor (36), the motion chain (34) having a free stroke; and An internal sensor (64) is arranged in the actuator mechanism (22) and configured to detect internal movement of the actuator mechanism (22) when the idle stroke is eliminated; The empty travel allows the extendable member (21) to move during manual movement of the closing member (12) before the empty travel is eliminated.

2. The power-operated actuator mechanism (22) according to claim 1, wherein, The internal sensor (64) is configured to detect the movement of the motor (36) after the idle stroke is eliminated.

3. The power-operated actuator mechanism (22) according to claim 1, wherein, The kinematic chain (34) includes a flexible element (30) that provides the free travel, the flexible element (30) being configured to flex in response to a user manually moving the closing member (12).

4. The power-operated actuator mechanism (22) according to claim 3, wherein, The flexible element is a strip (30), and the free travel is provided by flexing the strip (30).

5. The power-operated actuator mechanism (22) according to claim 1, wherein, The internal sensor (64) is configured to detect the movement of the closing member (12) caused by the user manually moving the closing member (12) and to provide a motion signal to the controller (50), wherein the motor (36) is electrically connected to the controller (50) and configured to receive a motor control signal generated by the controller (50) based on the motion signal.

6. The power-operated actuator mechanism (22) according to claim 5, wherein, The internal sensor (64) is configured to detect movement of the closing member (12) by the user when the empty stroke is eliminated.

7. The power-operated actuator mechanism (22) according to claim 6, wherein, The motor (36) is configured to receive an actuation signal generated by the controller (50) before the idle stroke is eliminated.

8. The power-operated actuator mechanism (22) according to claim 1, wherein, The motor (36) is configured to receive an actuation signal generated by the controller (50) before the idle stroke is eliminated and before the internal sensor (64) detects the internal movement of the actuator mechanism (22).

9. The power-operated actuator mechanism (22) according to claim 1, wherein, The motor (36) is actuated by an actuation signal generated by the controller (50) before the idle stroke is eliminated. The actuation signal is generated based on motion signals received by the controller (50) from an external sensor (86).

10. The power-operated actuator mechanism (22) according to claim 1, wherein, The kinetic chain (34) includes: Nut (48), said nut (48) is connected to said extendable member (21); A lead screw (13) is threadedly engaged with the nut (48) and configured to cause the nut (48) to translate along the lead screw (13) during rotation of the lead screw (13); and A flexible belt (30) adapted to rotate the lead screw (13) is connected to the motor shaft (32) of the motor (36).

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