Electrical panel movement system

Abstract

An electric panel movement system comprises a motor system, a motor phase comparator circuit, and a microcontroller. The motor system includes a BLDC motor and a rotating shaft configured to rotate in response to the BLDC motor drive. The motor system is configured to adjust the position of a moving part in response to the rotation of the rotating shaft. The motor phase comparator circuit is configured to determine a plurality of first, second, and third BEMF zero-crossing events produced in response to the motor drive. The microcontroller communicates with the motor phase comparator circuit and is configured to determine the rotational position of the rotating shaft based on counting each zero-crossing event corresponding to each of the first, second, and third BEMFs.Consequently, the microcontroller determines the position of the moving part based on the rotational position of the rotating shaft. Figure 3.

Description

Title of the invention: Electrical panel moving system

[0001] Embodiments of the present disclosure relate to the field of vehicle systems, and in particular to an electrical panel moving system.

[0002] The use of brushless technology for the glass roof motor is expected to bring the customer many advantages such as acoustic anti-noise comfort, low radio frequency interference, reduced mass and small packaging volume. However, the use of brushless technology means a higher cost for electronic components compared to a similar brushed motor, especially on the inverter side.

[0003] BRIEF DESCRIPTION

[0004] The present disclosure relates to an electric panel moving system configured to automatically operate a movable panel. The electric panel moving system includes a motor system, a motor phase comparator circuit, and a microcontroller. The motor system includes a BLDC motor and a rotating shaft configured to rotate in response to driving the BLDC motor. The motor system is configured to adjust a position of a movable portion in response to rotation of the rotating shaft. The motor phase comparator circuit is configured to determine a plurality of zero-crossing events of a first back electromotive force (BEMF), a second BEMF, and a third BEMF generated in response to driving the motor.The microcontroller is in signal communication with the motor phase comparator circuit, and is configured to determine a rotational position of the rotating shaft based on counting each zero-crossing event corresponding to each of the first BEMF, the second BEMF, and the third BEMF. The microcontroller determines the position of the moving part based on the rotational position of the rotating shaft and without using position sensors.

[0005] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the microcontroller determines the position of the moving part with an anti-pinch function in accordance with Federal Motor Vehicle Safety Standard (FMVSS) No. 118 (FMVSS118) without using position sensors.

[0006] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the microcontroller enables automatic closing and opening of the movable part based on the position of the movable part.

[0007] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the microcontroller processes BEMF electrical signals representing the first, second, and third BEMFs, filters from the BEMF signals parasitic voltages caused by one or a combination of vibration of the motor system and the BLDC motor, and determines the rotational position of the rotating shaft based on the counted number of zero crossings without using a position sensor.

[0008] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the motor phase comparator circuit includes a comparator including a first input configured to receive the first BEMF and the second BEMF, a second input configured to receive the third BEMF, and an output configured to output a logic signal that transitions between a logic value "0" and a logic value "1" or between a logic value "1" and a logic value "0", either of the transitions indicating the zero crossing event of the first BEMF, the second BEMF, and the third BEMF, respectively.

[0009] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the microcontroller performs operations including determining when the motor is in synchronization or out of synchronization; detecting a demagnetization pulse occurring in a current BEMF of the first BEMF, the second BEMF, or the third BEMF when the motor is out of synchronization; generating a virtual zero crossing pulse in response to detecting the demagnetization pulse, the virtual zero crossing pulse producing the logic signal output of the comparator; and counting the logic signal output resulting from the virtual zero crossing pulse as the zero crossing event of the current BEMF.

[0010] In addition to one or more of the features described above, or as a variant of one of the preceding embodiments, the movable part is a movable panel.

[0011] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the electrical panel moving system further comprises a gear system coupled to the rotating shaft; and a panel regulator comprising a first end coupled to the gear system and a second end coupled to the movable panel.

[0012] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the panel regulator moves the panel in a first direction in response to rotation of the rotary shaft in a first rotational direction and moves the panel in a second direction in response to rotation of the rotary shaft in a second rotational direction. response to rotation of the rotary shaft in a second direction of rotation opposite to the first direction of rotation.

[0013] In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the BLDC motor includes a first alternating current (AC) input configured to receive a first AC voltage having a first phase, a second alternating current (AC) input configured to receive a second AC voltage having a second phase, and an AC DC input configured to receive a third AC voltage having a third phase, wherein the first, second, and third AC voltages are one hundred and twenty (120) degrees out of phase with each other.

[0014] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the first AC voltage produces the first BEMF, the second AC voltage produces the second BEMF, and the third AC voltage produces the third BEMF.

[0015] Also provided is a method for adjusting a position of a movable panel without using position sensors. The method includes driving a brushless direct current (BLDC) motor and generating a first back electromotive force (BEMF), a second back electromotive force, and a third back electromotive force generated in response to driving the motor; rotating a rotating shaft of the BLDC motor in response to driving the motor; and adjusting, by the motor system, a position of a movable part in response to rotating the rotating shaft. The method further includes determining, by a motor phase comparator circuit, a plurality of zero-crossing events of the at least one back electromotive force (BEMF).The method further includes determining, by a microcontroller in signal communication with the motor phase comparator circuit, a rotational position of the rotating shaft based on the count of each zero crossing event corresponding to each of the first BEMF, the second BEMF, and the third BEMF; and determining, by the microcontroller, the position of the moving portion based on the rotational position of the rotating shaft. Brief Description of the Drawings.

[0016] The following descriptions should in no way be considered limiting. With reference to the accompanying drawings, like elements are numbered in the same manner:

[0017] [Fig.l] represents a diagram illustrating the three-phase voltages associated with the back electromotive force (BEMF) of a motor included in the electrical panel moving system of [Fig.l] according to a non-limiting embodiment;

[0018] [Fig.2] represents a diagram illustrating the zero crossing points associated with the BEMF according to a non-limiting embodiment;

[0019] [Fig.3] represents a functional diagram of an electrical panel movement system excluding the position sensors according to a non-limiting embodiment;

[0020] [Fig.4] represents a functional diagram of an electronic control unit included in the electrical panel movement system of [Fig.l] according to a non-limiting embodiment;

[0021] [Fig.5] represents a diagram illustrating the demagnetization pulses occurring during the commutation of the motor according to a non-limiting embodiment;

[0022] [Fig.6] represents a flowchart illustrating a method of generating virtual zero crossing pulses following the event of demagnetization pulses in an unsynchronized motor;

[0023] [Fig.7] shows the event of false zero crossings caused by vibrations of a brushless motor and the method for filtering them;

[0024] [Fig.8] represents a flowchart illustrating a method of filtering erroneous zero crossing pulses from the BEMF of an engine according to a non-limiting embodiment; and

[0025] [Fig.9] represents a flowchart illustrating a method of starting an engine without using a position sensor according to a non-limiting embodiment. DETAILED DESCRIPTION

[0026] A detailed description of one or more embodiments of the disclosed apparatus and method is presented herein by way of example and not limitation, with reference to the Figures.

[0027] Sensorless control of brushless motors is commonly used with devices that do not require information about the exact position of the motor, such as fans and pumps. Other applications, however, require information about the rotational position of the motor in order to determine a position of a moving part that is controlled by the rotation of the motor. For example, electrically movable panels for automobiles, such as power windows, sunroofs, sunroofs, etc., use anti-pinch algorithms that require knowledge of the position of the glass panel. Traditionally, position sensors such as Hall effect sensors are used with the power window system to determine the position of the glass panel. The inclusion of Hall effect sensors increases the cost of the system.Therefore, eliminating expensive position sensors is a solution that brings the cost closer to that of a brushed motor. In addition, eliminating position sensors . simplifies the overall design of the engine.

[0028] The various non-limiting embodiments described herein provide an electric panel moving system capable of accurately tracking the rotor position of a brushless motor at all times, from start-up to coasting after stopping, without the use of position sensors. In this manner, the position of a panel (window, sunroof, sunroof, etc.) can be tracked without the use of a sensor to provide various system features such as, for example, a pinch protection feature. In one non-limiting embodiment, the pinch protection feature is performed automatically in accordance with Federal Motor Vehicle Safety Standard (FMVSS) No. 118 (FMVSS118). The pinch protection feature may include, for example, automatically stopping the movement of the moving part and / or automatically reversing the movement of the moving part..

[0029] When a motor rotates, it generates a voltage that opposes the applied voltage or direction of current flow in the motor windings. The opposing voltage is called a "BEMF." In a three-phase brushless DC motor, a three-phase BEMF 10a, 10b, and 10c is produced, in which each phase 10a, 10b, and 10c of the BEMF is out of phase (e.g., 120 degrees) with the other (see [Fig. 1]). A "zero crossing" 12 of each BEMF phase also occurs during one rotation of the motor when the BEMF voltage crosses or passes through zero volts (see [Fig. 2]). This zero crossing 12 occurs when the magnetic field generated by the rotor or armature of the motor aligns with the stator windings so that the induced voltage in the windings drops to zero.

[0030] Back electromotive force (BEMF) signals can be used in sensorless brushless motor control systems to determine whether the system is in synchronization or out of synchronization. When in synchronization (e.g., in sync), the BEMF signals are consistent and predictable as the rotor aligns with the stator magnetic fields. This consistency allows the control system to accurately discern rotor position and generate precise commutation, resulting in efficient motor operation and achieving the desired torque and speed. In contrast, when the motor is out of synchronization (e.g., out of sync), the BEMF signals become erratic and distorted, making it difficult for the control system to accurately determine rotor position.In this condition, commutation is out of synchronization, resulting in inefficient motor performance, reduced torque, increased vibration, and the potential for erratic behavior or motor stalling.

[0031] Achieving synchronization depends on the reliability and consistency of the BEMF signals, which are the primary source of information about the position of rotor for sensorless control systems. Maintaining a consistent relationship between the rotor and stator magnetic fields ensures accurate signal interpretation and proper motor function. However, rapid or large deviations in rotor position can disrupt the quality of the BEMF signal, making it more difficult for the control system to maintain synchronization.

[0032] In one or more non-limiting embodiments, the electrical panel moving system uses back electromotive force (BEMF) to determine and track the rotational position of the motor shaft without using position sensors. The electrical panel moving system described herein is also capable of filtering out spurious pulses called "demagnetizing pulses" from the BEMF. In this manner, a more accurate rotational position of the motor (e.g., rotor or motor shaft) can be obtained.

[0033] With respect to [Fig. 3], an electric panel moving system 100 is illustrated according to a non-limiting embodiment of the present disclosure. The electric panel moving system 100 comprises a motor system 102 configured to move a movable part 110, and an electronic control unit (ECU) 120. According to a non-limiting embodiment, the movable part 110 comprises an adjustable panel 112 supported in a frame 113. The adjustable panel 112 is configured to move in a first direction and a second direction opposite the first direction such that it can be moved between a fully open position and a fully closed position (end stop). The panel 112 may include, for example, a window, a glass roof, a sunroof, a movable cover, etc.

[0034] The motor system 102 includes a brushless direct current (BLDC) motor 104, a rotating shaft 106 configured to rotate in response to driving the motor 102, and a gear system 107 coupled to the rotating shaft 106. The BLDC motor 104 includes a first alternating current (AC) input 105a configured to receive a first AC voltage having a first phase, a second AC input 105b configured to receive a second AC voltage having a second phase, and a third AC input 105c configured to receive a third AC voltage having a third phase. The first, second, and third AC voltages are out of phase with each other. In at least one non-limiting embodiment, for example, the first, second, and third AC voltages are one hundred twenty (120) degrees out of phase with each other.

[0035] The gear system 107 is configured to transmit rotational motion of the motor shaft 106 to adjust a panel regulator 114 (or armature). A portion of the panel regulator 114 is coupled to the gear system 107, while a second portion of the panel regulator 114 is coupled to the panel 112. Accordingly, the panel regulator 114 moves the panel 112 in the first direction in response to rotation of the rotary shaft 106 in a first rotational direction and moves the panel 112 in the second direction in response to rotation of the rotary shaft 106 in a second rotational direction opposite the first rotational direction. In one or more non-limiting embodiments, the gear system 107 is implemented as a worm drive comprising a worm 109 coupled to a worm gear 110. It should be noted, however, that other gear systems may be implemented without departing from the scope of the present invention.

[0036] The electronic control unit (ECU) 120 is configured to control the engine system 102. The ECU 120 includes a first AC output 121a configured to output the first AC voltage, a second AC output 121b configured to output the second AC voltage, and a third AC output 121c configured to output the third AC voltage. A non-limiting embodiment of the ECU 120 is illustrated in [Fig. 4]. The ECU 120 includes a power bridge inverter 124 and a microcontroller 122. The power bridge inverter 124 includes a power supply 125 for providing a DC voltage and a plurality of switches 128a, 128b, 128c, 128d, 128e, and 128f (collectively referred to as switches 128a-128f). Switches 128a to 128f operate to convert the DC voltage into the first AC voltage, the second AC voltage, and the third AC voltage.According to a non-limiting embodiment, a first pair of switches 128a and 128b is connected to the first AC output 121a to deliver the first AC voltage, a second pair of switches 128c and 128d is connected to the second AC output 121b to deliver the second AC voltage, and a third pair of switches 128e and 128f is connected to the third AC output 121c to deliver the third AC voltage.

[0037] The microcontroller 122 includes a memory configured to store software instructions and a processor configured to execute the software instructions to perform various operations, including, but not limited to, motor position calculation, gate driver switching management, and anti-pinch management. The microcontroller 122 further includes an output 125 configured to output a timing control signal that activates and deactivates the plurality of switches 128a-128f according to a timing sequence. In a non-limiting embodiment, the timing sequence activates and deactivates the first pair of switches 128a and 128b, the second pair of switches 128c and 128d, and the third pair of switches 128e and 128f one hundred and twenty (120) degrees out of phase with each other.In this manner, the first pair of switches 128a and 128b generates the first AC voltage, the second pair of switches 128c and 128d generates the second AC voltage, and the third pair of com- . Mutators 128e and 128f generate the third AC voltage.

[0038] As described herein, the ECU 120 determines the rotational position of the motor shaft 106 and whether the motor is in synchronization (e.g., in sync) or out of synchronization (e.g., out of sync) based on the BEMF produced by the motor 104. Still referring to [Fig. 2], the ECU 120 includes a motor phase comparator circuit 130 configured to determine a first BEMF associated with the first AC voltage, a second BEMF associated with the second AC voltage, and a third BEMF associated with the third AC voltage. The motor phase comparator circuit 130 includes a first phase input 134a, a second phase input 134b, a third phase input 134c, and a comparator 132.The first phase input 134a is connected to the first AC output 121a and receives the first BEMF, the second phase input 134b is connected to the second AC output 121b and receives the second BEMF, and the third phase input 134c is connected to the third AC output 121c and receives the third BEMF.

[0039] The comparator 132 comprises a first input 136a, a second input 136b and an output 138. The first input 136a is connected to both the first phase input 134a and the second phase input 134b, while the second input 136b is connected only to the third phase input 134c.

[0040] Accordingly, output 138 outputs a logic value “0” if the sum of 134a and 134b is less than 134c, or outputs a logic value “1” if the sum of 134a and 134b is greater than 134c. The change in the logic output of the BEMF comparator will be interpreted by the microcontroller as a zero crossing event.

[0041] Although only one comparator 132 is illustrated, it should be understood that the motor phase comparator circuit 130 may include three individual comparators, each comparator being associated with a corresponding phase of the BEMFs, e.g., the first BEMF, the second BEMF, and the third BEMF. In one or more non-limiting embodiments, the comparators include internal or external hysteresis for robustness of sensitivity to noise. The BEMF comparators may also be suitably tuned to be both robust with respect to noise, and sensitive enough to detect rotations at the lowest motor speeds. Accordingly, the logic states (0 / 1) of the three comparators are used to count a number of zero-crossing events of the BEMFs, and then to determine the motor shaft rotations based on the number of zero-crossing events counted.In this way, the position of the movable part 110, for example the panel 112. .

[0042] In some cases, the commutation of the motor 104 in conjunction with the inverter 124 may produce spurious pulses. These spurious pulses are referred to herein as "degaussing pulses", 14a, 14b and 14c, which may appear in the first BEMF, second BEMF and third BEMF, as shown, for example, in [Fig.5]. Demagnetizing pulses are generally undesirable because they can cause erroneous detection in comparator 132, thus causing drift in the position estimate of motor shaft 106.

[0043] Referring to [Fig. 6], a method of generating virtual zero crossing pulses to avoid inaccuracies caused by the degaussing pulse event is illustrated according to a non-limiting embodiment. At operation 600, commutation (N) of the motor occurs and a determination is made at operation 602 as to whether commutation stops. When commutation stops, the first, second, and third AC voltages associated with the three phases of the motor 104 are turned off. At operation 606, a time-out period occurs to filter the degaussing pulse. After the time-out period, the microcontroller (122) determines the current logic state (a) (Xstate(N)) of the next BEMF phase (e.g., U, V, W) that should undergo a zero crossing; and (b) the current logic state (Ystate(N)) of the BEMF phase (e.g., U, V, W) following the next zero-crossing phase.For example, when the switching sequence order is UVW and the next phase for which a zero crossing is expected is phase U, operation 610 is a comparison of the current BEMF logic state of phase U (Ustate(N)) with the previous BEMF logic state recorded for phase U (Ustate(Nl)). When the BEMF logic state of phase U of BEMF has changed (e.g., Ustate(N) Ustate(Nl)), then a position pulse is generated, and the next operation 614 is the comparison of the current BEMF logic state of phase V of BEMF (Vstate(N)) with the previous BEMF logic state recorded for phase V of BEMF (vstate(Nl)). .

[0044] In operation 610, a determination is made whether (Xstate(N)) is equal to (Xstate(Nl)). When the rotor position has not changed from the BEMF perspective (e.g., (Xstate(N)) is equal to (Xstate(Nl))), the method proceeds to operation 618 and continues to stop the motor. However, when the rotor position has changed from the BEMF perspective (e.g., (Xstate(N)) is not equal to (Xstate(Nl)), a position pulse is generated in operation 612. In operation 614, a determination is made whether (Ystate(N)) is equal to (Ystate(Nl)).

[0045] Still referring to [Fig.6], the method determines whether the rotor position has increased by a first amount, for example one-sixth of an electrical cycle (for example, Xstate(N) is not equal to Xstate(Nl) but Ystate(N) is not equal to Ystate(Nl)), or whether the rotor position has increased by a second amount, for example, one-third of an electrical cycle (for example, Xstate(N) is not equal to Xstate(Nl) and Ystate(N) is equal to Ystate(Nl)). When Xstate(N) is not equal to Xstate(Nl) but Ystate(N) is not equal to Ystate(Nl)), the position is compensated by 1 position pulse. When, for example, Xstate(N) is not equal to Xstate(Nl) and Ystate(N) is equal to Ystate(Nl)), the position is however compensated by 2 position pulses.

[0046] Referring to operation 614, when (Ystate(N)) is equal to (Ystate(Nl)), the method proceeds to operation 618 and continues to stop the motor. However, when (Ystate(N)) is not equal to (Ystate(Nl)), a position pulse is generated at operation 616, and the method continues to stop the motor at operation 618.

[0047] When the motor commutation is not stopped in operation 602, the voltage associated with the next phase (e.g., U, V, W) that is expected to undergo a zero crossing is turned off in operation 620. In operation 622, a timeout period elapses before proceeding to operation 624 and setting the current logic state (Xstate(N)) of the next phase (e.g., U, V, W) that is expected to undergo a zero crossing to the current logic state of the BEMF associated with the voltage turned off in operation 620. In operation 626, a determination is made whether (Xstate(N)) is equal to (Xstate(N1)). When (Xstate(N)) is equal to (Xstate(Nl)), the method returns to operation 624 and sets the current logic state (Xstate(N)) of the next phase (e.g., U, V, W) that should undergo a zero crossing to the current logic state of the BEMF associated with the voltage turned off in operation 620.However, when (Xstate(N)) is not equal to (Xstate(Nl)), a position pulse is generated at operation 628 and the next switching (N+l) is initiated, i.e., "N" is set to "N+l".

[0048] In some cases, the shaft 106 may vibrate during motor shutdown due to cogging torque, shaft oscillation, and / or chatter occurring throughout the motor system 102. As shown in [Fig. 7], for example, the vibrations may create unwanted pulses 16 in the BEMF, which in turn contribute to false zero-crossing detections by the comparator circuit 130. As also shown in [Fig. 7], these unwanted vibration zero-crossing pulses are characterized by very rapid activations followed by a longer sequence without activation.

[0049] According to a non-limiting embodiment, the power movable panel system 100 is configured to filter unwanted vibration pulses using a dedicated method that can be used when the motor 104 is not being driven. As shown in [Fig. 7], a valid zero crossing pulse 18 can be generated after waiting for a period of time referred to herein as a "dead time" 20 that occurs after a raw zero crossing 22. The dead time 20 can be initially defined as a percentage of the last commutation time of the motor 104, and the raw zero crossing 22 can be the output generated by the comparator circuit 130. In at least one non-limiting embodiment, the valid zero crossing 18 is generated only if no other raw zero crossing 22 has been detected during a given dead time 20. When a zero crossing is detected during the dead time 20, the dead time 20 restarts from that point. According to a non-limiting embodiment, the duration of the dead time 20 is set so as to be proportional to the time between two previous valid zero crossings 18.

[0050] Referring to [Fig. 8], a method of filtering erroneous zero crossing pulses from the BEMF of the motor 104 using dead times 20 as described above is illustrated according to a non-limiting embodiment. At operation 800, a determination is made as to whether a zero crossing of the BEMF (e.g., U phase, V phase, or W phase) has occurred. When a zero crossing has not occurred, the method returns to operation 800. However, when a zero crossing has occurred, a dead time period (e.g., dead time 20) discussed herein is initiated. At operation 804, a determination is made as to whether the dead time has elapsed. When the idle time has elapsed, a determination is made whether an oscillation flag 806 is set to true, indicating detected oscillation or vibration of the motor.When the wobble flag is not set to true, the wobble flag is set to false in operation 808, indicating that motor wobble or vibration was not detected, and the method returns to operation 800 to continue monitoring for the event of a zero crossing.

[0051] When the dead time has not elapsed during operation 804, a determination is made as to whether a zero crossing of the BEMF is detected during operation 810. When a zero crossing of the BEMF is detected, the wobble flag is set to true during operation 812, indicating that motor wobble or vibration is detected and the method proceeds to initiating the dead time period (e.g., dead time 20) during operation 802. However, when a zero crossing is not detected during operation 810, the method returns to operation 804 and continues to monitor whether the dead time period has elapsed. The method may then continue as described herein to filter out erroneous zero crossing pulses from the BEMF of the motor 104 using the dead times 20.The filtered BEMF signals (e.g., first, second, and third BEMF signals) can then be used to determine the position of the moving portion 110 based on the rotational position of the rotating shaft 106 without using a position sensor.

[0052] As described herein, the power movable panel system 100 described herein can determine the rotational position of the motor (e.g., the motor shaft 106) without using position sensors. Since the position sensors are excluded, the The mobile power panel system 100 performs a method of starting the motor 104 without using a position sensor as illustrated in [Fig. 9]. At operation 900, a determination is made as to whether a motor acceleration mode is activated. The purpose of the acceleration sequence is to increase the motor speed sufficiently so that BEMF pulses can be confidently detected. Since no BEMF pulses are observed when the motor speed is low, the position management during the acceleration sequence is effectively open loop and is different from closed loop position management.The strategy considers several use cases: acceleration phase ends and BEMF pulses are confirmed, acceleration ends and BEMF pulses are not confirmed, acceleration is stopped but BEMF pulses are confirmed, acceleration is stopped but BEMF pulses are not confirmed.

[0053] When the acceleration mode is enabled, the method proceeds to operation 902 to monitor the acceleration time. When the acceleration mode is not enabled, the acceleration mode is initiated in operation 901, and a determination is made in operation 902 as to whether an acceleration time has elapsed. The acceleration time is set to a time where, when the time has elapsed, the motor is running at a speed at which the BEMF pulses can be detected by the comparator circuit (e.g., comparator circuit 130). The acceleration time and frequency slope may be set according to the specifications of the motor. When the acceleration time has elapsed, a determination is made in operation 904 as to whether a zero crossing of the BEMF has occurred. When a zero crossing has not occurred, the motor is stopped in operation 906.However, when a zero crossing has occurred, a closed-loop mode is invoked during operation 908. In a non-limiting embodiment, closed-loop mode refers to a switching mode in which commutation of the motor 104 is performed based on feedback from the BEMF comparator outputs. Open-loop mode (e.g., acceleration) differs from closed-loop mode because commutation does not take into account feedback from the BEMF comparator outputs.

[0054] However, when the acceleration time has not elapsed during operation 902, a determination is made as to whether a zero crossing of the BEMF occurred during operation 910. When a zero crossing has not occurred, the rotational position of the motor is not updated. However, when a zero crossing has occurred, a rotational position of the motor is compensated based on the number of commutations made before and including the last zero crossing that occurred.

[0055] As described herein, a mobile power panel system 100 includes a motor system 102 with a brushless direct current (BLDC) motor 104 and a rotating shaft 106 configured to rotate in response to driving the BLDC motor 104, wherein the motor system 102 is configured to adjust a position of a moving part 110 in response to rotation of the rotating shaft 106. A motor phase comparator circuit 130 is in signal communication with the motor system 102. The motor phase comparator circuit 130 is configured to determine a plurality of zero-crossing events of a first back electromotive force (BEMF), a second BEMF, and a third BEMF produced in response to driving the motor 106. A microcontroller 122 is in signal communication with the motor phase comparator circuit 130.The microcontroller 122 is configured to determine a rotational position of the rotary shaft 106 based on the count of each zero-crossing event corresponding to each of the first BEMF, the second BEMF, and the third BEMF. The microcontroller 122 determines the position of the movable portion 110 based on the rotational position of the rotary shaft 106 without using a position sensor. According to at least one non-limiting embodiment, the microcontroller 122 is configured to automatically close and open the movable portion 110 based on the position of the movable portion 110 determined according to the rotational position of the motor shaft 106. The automatic automotive control operation includes an anti-pinch detection operation, which may automatically stop the movement of the movable portion 110 and / or reverse the movement of the movable portion 110.

[0056] The term "approximately" is intended to include the degree of error associated with the measurement of the particular quantity based on the equipment available at the time the application is filed. For example, "approximately" may include a range of ±8%, 5%, or 2% of a given value.

[0057] The terminology used herein is for the sole purpose of describing particular embodiments and is not intended to limit the present disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It is further understood that the terms "comprises" and / or "comprising," when used in this specification, indicate the presence of given features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups of such features, integers, steps, operations, elements components, and / or groups thereof.

[0058] Although the present disclosure has been described with reference to exemplary embodiment(s), those skilled in the art will understand that various modifications may be made and that equivalents may be substituted for elements thereof without departing from the scope of this disclosure. Furthermore, numerous modifications may be made to adapt a particular situation or particular material to the teachings of this disclosure without departing from the essential scope thereof. Accordingly, it is intended that this disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this disclosure, but that this disclosure will include all embodiments falling within the scope of the claims.

Claims

Claims

1. An electrical panel moving system comprising: a motor system comprising a brushless direct current (BLDC) motor and a rotating shaft configured to rotate in response to driving the BLDC motor, the motor system being configured to adjust a position of a moving part in response to rotation of the rotating shaft; a motor phase comparator circuit in signal communication with the motor system, the motor phase comparator circuit being configured to determine a plurality of zero crossing events of a first back electromotive force (BEMF), a second BEMF, and a third BEMF generated in response to driving the motor;and a microcontroller in signal communication with the motor phase comparator circuit, the microcontroller configured to determine a rotational position of the rotating shaft based on counting each zero crossing event corresponding to each of the first BEMF, the second BEMF, and the third BEMF, wherein the microcontroller determines the position of the moving portion based on the rotational position of the rotating shaft.;

2. The electrical panel moving system of claim 1, wherein the microcontroller is configured to automatically close and open the moving portion based on the position of the moving portion.

3. The electric panel moving system of claim 2, wherein the automatic automotive control operation is an anti-pinch detection operation, the anti-pinch detection operation comprising at least one of automatically stopping the movement of the moving part and reversing the movement of the moving part.

4. The electrical panel moving system of claim 1, wherein the microcontroller processes BEMF electrical signals representing the first, second, and third BEMFs, filters from the BEMF signals parasitic voltages caused by one or a combination of vibration of the motor system and the BLDC motor, and determines the rotational position of the rotating shaft based on the counted number of zero crossings without using a position sensor.

5. The electrical panel moving system of claim 4, wherein the motor phase comparator circuit comprises: a comparator comprising a first input configured to receive the first BEMF and the second BEMF, a second input configured to receive the third BEMF, and an output configured to output a logic signal that transitions between a logic value "0" and a logic value "1" or between a logic value "1" and a logic value "0", either of the transitions indicating the zero crossing event of the first BEMF, the second BEMF, and the third BEMF, respectively.

6. The electrical panel moving system of claim 5, wherein the microcontroller performs operations including: determining when the motor is in synchronization or out of synchronization; detecting a degaussing pulse occurring in a current BEMF of the first BEMF, the second BEMF, or the third BEMF when the motor is out of synchronization; generating a virtual zero crossing pulse in response to detecting the degaussing pulse, the virtual zero crossing pulse producing the logic signal output of the comparator; and counting the logic signal output resulting from the virtual zero crossing pulse as the zero crossing event of the current BEMF.

7. The electrical panel moving system of claim 1, wherein the moving portion is a moving panel.

8. The electrically powered panel moving system of claim 1, further comprising: a gear system coupled to the rotating shaft; and a panel regulator comprising a first end coupled to the gear system and a second end coupled to the movable panel, wherein the panel regulator moves the panel in a first direction in response to rotation of the rotating shaft in a first rotational direction and moves the panel in a second direction in response to rotation of the rotating shaft in a second rotational direction opposite the first rotational direction.

9. The electrical panel moving system of claim 8, wherein the BLDC motor comprises a first alternating current (AC) input configured to receive a first AC voltage having a first phase, a second alternating current (AC) input configured to receive a second AC voltage having a second phase, and an AC input configured to receive a third AC voltage having a third phase, the first, second, and third AC voltages being one hundred and twenty (120) degrees out of phase with each other.

10. The electrical panel moving system of claim 9, wherein the first AC voltage produces the first BEMF, the second AC voltage produces the second BEMF, and the third AC voltage produces the third BEMF.

11. A method of operating an electrical panel moving system, the method comprising: driving a brushless direct current (BLDC) motor and generating a first counter electromotive force (BEMF), a second BEMF, and a third BEMF generated in response to driving the motor; rotating a rotary shaft of the BLDC motor in response to driving the motor; adjusting, by the motor system, a position of a moving part in response to rotating the rotary shaft; determining, by a motor phase comparator circuit, a plurality of zero-crossing events of the at least one counter electromotive force (BEMF);determining, by a microcontroller in signal communication with the motor phase comparator circuit, a rotational position of the rotary shaft based on counting each zero-crossing event corresponding to each of the first BEMF, the second BEMF, and the third BEMF; and determining, by the microcontroller, the position of the moving portion based on the rotational position of the rotary shaft.;

12. The method of claim 11, which further comprises performing, by the microcontroller, automatic closing and opening of the movable part based on the position of the movable part.

13. The method of claim 12, wherein the automatic automobile control operation is an anti-pinch detection operation, the anti-pinch detection operation comprising at least one of automatic stopping of the movement of the moving part and reversing the movement of the moving part.

14. The method of claim 11, further comprising: processing, by the microcontroller, BEMF electrical signals representing the first, second, and third BEMFs; filtering the BEMF signals of stray voltages caused by one or a combination of vibration of the motor system and the BLDC motor; and counting, by the microcontroller, each zero-crossing event corresponding to each of the first BEMF, the second BEMF, and the third BEMF to determine a counted number of zero crossings.

15. The method of claim 13, wherein counting each zero-crossing event comprises: providing, at a first input of a comparator, the first BEMF and the second BEMF; providing, at a second input of the comparator, the third BEMF; and outputting, from an output of the comparator, a logic signal that transitions between a logic value "0" and a logic value "1" or between a logic value "1" and a logic value "0", either of the transitions indicating the zero-crossing event of the first BEMF, the second BEMF, and the third BEMF, respectively.

16. The method of claim 15, further comprising: determining, by the microcontroller, when the motor is in synchronization or out of synchronization; detecting, by the microcontroller, a demagnetization pulse occurring in a current BEMF of the first BEMF, the second BEMF, or the third BEMF when the motor is out of synchronization; generating, by the microcontroller, a virtual zero-crossing pulse in response to detecting the demagnetization pulse, the virtual zero-crossing pulse producing the logic signal output of the comparator; and counting, by the microcontroller, the logic signal output resulting from the virtual zero-crossing pulse as the zero-crossing event of the current BEMF.

17. The method of claim 11, wherein the movable portion is a movable panel.

18. The method of claim 11, further comprising: coupling a gear system to the rotating shaft; coupling a first end of a panel regulator to the gear system and coupling a second end of the panel regulator to the movable panel; and moving the panel regulator in a first direction to adjust the position of the panel in a first direction in response to rotation of the rotating shaft in a first rotational direction and moving the panel regulator to adjust the position of the panel in a second direction in response to rotation of the rotating shaft in a second rotational direction opposite the first rotational direction.

19. The method of claim 18, wherein the BLDC motor comprises a first alternating current (AC) input configured to receive a first AC voltage having a first phase, a second alternating current (AC) input configured to receive a second AC voltage having a second phase, and an AC DC input configured to receive a third AC voltage having a third phase, the first, second, and third AC voltages being one hundred and twenty (120) degrees out of phase with each other.

20. The method of claim 19, wherein the first AC voltage produces the first BEMF, the second AC voltage produces the second BEMF, and the third AC voltage produces the third BEMF.

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