Calibration system and method for electronic parent installation check system

The child safety system addresses inconsistent harness tension in safety seats by using a tension sensor and indicator lights with optical cables, ensuring accurate calibration and feedback for proper tensioning.

WO2025049167A9PCT designated stage expired Publication Date: 2026-01-29INDIANA MILLS & MANUFACTURING INC
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Patent Information

Application Number
PCT/US2024/043026
Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
Priority Date
2023-08-25
Filing Date
2024-08-20
Publication Date
2026-01-29

AI Technical Summary

Technical Problem

Existing child safety seats face challenges in achieving consistent harness tension properties due to manufacturing and tolerance issues, leading to potential injuries from improperly tensioned harnesses or discomfort from overly tight harnesses.

Method used

A child safety system with a tension sensor and indicator lights that remotely illuminate through optical cables, adaptable to existing harness adjusters, and a calibration mode initiated by unusual input sequences, eliminating the need for additional equipment.

Benefits of technology

Ensures accurate harness tension calibration under real-world conditions, enhancing safety and comfort by providing visual and auditory feedback on proper tensioning.

✦ Generated by Eureka AI based on patent content.

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Abstract

A seat monitoring system (100) for a child safety seat includes a harness (155), buckle (145), buckle sensor (180), and tension sensor (120). The buckle sensor (180) monitors the status of the buckle (145). A harness adjuster (170) adjusts tension of the harness (155). The tension sensor (120) monitors the tension to the harness (155). An output device (185) is located on the buckle (145). The output device (185) provides the status of the buckle (145) and tension of the harness (155). A calibration technique has been developed to calibrate the tension sensor (120) while installed on the seat and without the need for specialized switches or ports.
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Description

[0001] CALIBRATION SYSTEM AND METHOD EOR ELECTRONIC PARENT

[0002] INSTALLATION CHECK SYSTEM

[0003] CROSS REFERENCE TO RELATED APPLICATIONS

[0004] This application claims the benefit of US Patent Application Number 63 / 578,696, filed August 25, 2023, which is hereby incorporated by reference.

[0005] BACKGROUND

[0006] Child safety seats are now commonly used and have saved countless lives. Child restraint harnesses are normally used in child safety seats to safely hold the seat occupant in place, but if the harness is not properly tensioned, injuries may occur. Due to tolerance and / or manufacturing issues, obtaining consistent harness tension properties within and between seats can be difficult.

[0007] Thus, there is a need for improvement in this field.

[0008] SUMMARY

[0009] A unique child safety system has been developed to address the previously mentioned issues as well as other issues. Among other things, the system is configured to sense the tension being applied to a harness. I f the tension of the harness is too low, the harness may not properly restrain the seat occupant during an accident. Conversely, the harness can become uncomfortable if the harness is too tight. In one version, one or more indicator lights indicate whether the proper tension in the harness was achi eved and / or the amount of tension in the harness. In one example, the indicator lights are remotely illuminated through one or more liber optic cables or other light conduits. Having the indicator lights remotely illuminated avoids the need of having complex and bulky electronics within the cramped space of the belt buckle. The tension sensor is configured to be readily adaptable to existing harness adjuster systems. The tension sensor is able to be placed underneath the seat. A harness adjuster strap of the harness adjuster is then routed over the tension sensor without needing to be severed or otherwise redesigned.

[0010] A unique harness tension calibration technique has also been developed. Preexisting or common inputs are used to initiate the calibration mode. The calibration mode is started by a sequence of unlikely events occurring in the existing inputs for the system. For instance, the harness can be buckled and unbuckled multiple times within a relatively short time period. As an example, the harness is buckled and / or unbuckled four (4) times within a five-second period to initiate the calibration mode, and in another example, the harness is buckled and / or unbuckled five (5) times within a fifteen-second period to initiate the calibration process. This helps to eliminate the need for special equipment, such as extra switches, buttons, or ports, in order to calibrate harness tension. This also allows the tension sensor unit to be calibrated after the unit is installed in the child safety seat which in turn helps to enhance calibration accuracy under real-world conditions.

[0011] The systems and techniques as described and illustrated herein concern a number of unique and inventive aspects. Some, but by no means all, of these unique aspects are summarized below.

[0012] Aspect 1 generally concerns a system. Aspect 2 generally concents the system of any previous aspect including a smart buckle system.

[0013] Aspect 3 generally concerns the system of any previous aspect including a child safety seat.

[0014] Aspect 4 generally concents the system of any previous aspect including a seat assembly.

[0015] Aspect 5 generally concerns the system of any previous aspect including a seat back.

[0016] Aspect 6 generally concents the system of any previous aspect including a seat bottom.

[0017] Aspect 7 general ly concerns the system of any previous aspect including a restraint system.

[0018] Aspect 8 generally concerns the system of any previous aspect including a harness.

[0019] Aspect 9 generally concerns the system of any previous aspect in which the harness includes one or more belts.

[0020] Aspect 10 generally concerns the system of any previous aspect including a buckle.

[0021] Aspect 11 generally concents the system of any previous aspect in which the harness includes one or more latch plates.

[0022] Aspect 12 generally concerns the system of any previous aspect in which the latch plates include a tongue.

[0023] Aspect 13 generally concerns the system of any previous aspect in which the latch plates are coupled to the belts.

[0024] Aspect 14 generally concerns the system of any previous aspect in which the latch plates are configured to be detachably secured to the buckle.

[0025] Aspect 15 generally concerns the system of any previous aspect in which the restraint system includes a harness adjuster. Aspect 16 generally concerns the system of any previous aspect in which the buckle includes a release button configured to release the latch plates from the buckle.

[0026] Aspect 17 generally concerns th e system of any pre vi ous aspect in which th e harness adjuster is configured to adjust tension of the harness.

[0027] Aspect 18 generally concerns the system of any previous aspect in which the harness adjuster includes a harness adjuster strap.

[0028] Aspect 19 generally concerns the system of any previous aspect in which the harness adjuster includes a cam buckle configured to secure the harness adjuster strap.

[0029] Aspect 20 generally concern s th e system of any pre vious aspect in which th e restrain t system includes a splitter plate.

[0030] Aspect 21 generally concerns the system of any previous aspect in which the splitter plate connecting the harness adjuster strap to the harness.

[0031] Aspect 22 generally concerns the system of any previous aspect in which the splitter plate connects the harness adjuster strap to the belts.

[0032] Aspect 23 generally concerns th e system of any pre vi ous aspect in which th e seat monitori ng system.

[0033] Aspect 24 generally concerns the system of any previous aspect including a controller.

[0034] Aspect 25 generally concerns the system of any previous aspect in which the controller includes a processor.

[0035] Aspect 26 generally concerns the system of any previous aspect in w hich the controller includes memory. Aspect 27 generally concerns the system of any previous aspect in which the memory is operatively coupled to the processor.

[0036] Aspect 28 generally concerns the system of any previous aspect in which the controller includes a power supply.

[0037] Aspect 29 generally concerns the system, of any previous aspect in which the power supply7includes an energy storage system (ESS),

[0038] Aspect 30 generally concerns the system of any previous aspect in which the ESS includes a buttery.

[0039] Aspect 31 generally concerns the system of any previous aspect in which the power supply is configured to supply power to the processor.

[0040] Aspect 32 generally concerns the system, of any previous aspect including an occupancy7sensor (OCS).

[0041] Aspect 33 generally concern s th e system of any pre vious aspect in which th e occupancy sensor is located in the seat bottom.

[0042] Aspect 34 generally concerns the system of any previous aspect in which the occupancy sensor is a pressure sensor.

[0043] Aspect 35 generally concerns the system, of any previous aspect in which the occupancy sensor is a weight sensor.

[0044] Aspect 36 generally concerns the system of any previous aspect in which the occupancy sensor is configured to sense if someone is sitting.

[0045] Aspect 37 generally concerns the system of any previous aspect in which the occupancy sensor is operatively coupled to the controller. Aspect 38 generally concerns the system of any previous aspect in which the seat monitoring system includes a buckle sensor.

[0046] Aspect 39 generally concerns the system of any previous aspect in w hich the buckle sensor is configured to monitor status of the buckle.

[0047] Aspect 40 generally concerns the system, of any previous aspect in which the tongue of at least one of the latch plates is configured to contact the buckle sensor when latched to the buckle.

[0048] Aspect 41 generally concerns the system of any previous aspect in which the buckle sensor includes a reed switch.

[0049] Aspect 42 generally concerns th e system of any pre vious aspect in which th e buckle sensor includes a micro switch.

[0050] Aspect 43 generally concerns the system of any previous aspect in which the micro switch includes a hinged spring.

[0051] Aspect 44 generally concerns the system of any previous aspect in which the hinged spring is configured to close the micro switch when the tongue presses against the hinged spring when latched.

[0052] Aspect 45 generally concerns the system of any previous aspect in which the buckle sensor is positioned inside the buckle.

[0053] Aspect 46 generally concerns the system of any previous aspect in which the buckle sensor is operatively coupled to the controller.

[0054] Aspect 47 generally concerns the system of any previous aspect in which the buckle sensor is operatively coupled to the processor.

[0055] Aspect 48 generally concerns the system of any previous aspect in which the buckle includes a. buckle wire, Aspect 49 generally concerns the system, of any previous aspect in which the buckle wire operatively coupling the buckle sensor to the controller.

[0056] Aspect 50 generally concerns the system of any previous aspect in which the buckle has a buckle belt.

[0057] Aspect 51 generally concerns the system of any previous aspect in which the buckle belt secures the buckle to the child safety seat.

[0058] Aspect 52 generally concerns the system of any previous aspect in which the buckle wire is embedded in the buckle belt.

[0059] Aspect 53 generally concerns the system of any previous aspect in which the controller is mounted on a back side of the child safety seat.

[0060] Aspect 54 generally concerns the system of any previous aspect in which the buckle wire extends from the buckle to the back side of the child safety seat via the buckle belt,

[0061] Aspect 55 generally concerns the system of any previous aspect in which the seat monitoring system includes a tension sensor.

[0062] Aspect 56 generally concerns the system of any previous aspect in which the tension sensor is configured to monitor tension of the harness.

[0063] Aspect 57 generally concerns the system of any previous aspect in which the tension sensor is housed in the controller,

[0064] Aspect 58 generally concerns the system of any previous aspect in which the tension sensor is configured to monitor tension to the harness applied by the harness adjuster.

[0065] Aspect 59 generally concerns the system of any previous aspect in which the tension sensor is housed in the buckle. Aspect 60 generally concerns the system of any previous aspect in which the tension sensor includes a strain gauge.

[0066] Aspect 61 generally concerns the system of any previous aspect in w hich the harness adjuster strap extends along the tension sensor.

[0067] Aspect 62 generally concerns the system of any previous aspect in which the tension sensor has a housing.

[0068] Aspect 63 generally concerns the system of any previous aspect in which the harness adjuster strap is configured to slide along the housing.

[0069] Aspect 64 generally concerns the system of any previous aspect in w hich the tension sensor includes a tension arm.

[0070] Aspect 65 generally concerns the system, of any previous aspect in which the tension sensor includes a shaft upon which the tension ami is pivotally mounted.

[0071] Aspect 66 generally concerns th e system of any pre vious aspect in which th e tensi on arm has a surface where the harness adjuster strap contacts the tension ami.

[0072] Aspect 67 generally concerns the system of any previous aspect in w hich the harness adjuster strap is configured to pivot the tension ami when tension is applied.

[0073] Aspect 68 generally concerns the system of any previous aspect in which the tension sensor is configured to sense the tension in the harness adjuster strap when the tension arm pivots.

[0074] Aspect 69 generally concerns the system of any previous aspect in which the tension sensor includes a magnetic sensor.

[0075] Aspect 70 generally concerns the system of any previous aspect in w hich the magnetic sensor is a Hall effect sensor. Aspect 71 generally concerns the system of any previous aspect in which the tension sensor includes a magnet.

[0076] Aspect 72 generally concerns the system of any previous aspect including a magnet mounted to the tension arm.

[0077] Aspect 73 generally concerns the system, of any previous aspect in which the magnetic sensor is configured to measure the magnetic field from the magnet to determine the tension in the harness.

[0078] Aspect 74 generally concerns the system of any previous aspect in which the controller includes a circuit board.

[0079] Aspect 75 generally concern s th e system of any pre vious aspect in which th e processor and the memory are mounted on the circuit board.

[0080] Aspect 76 generally concerns the system of any previous aspect in which the magnetic sensor is mounted on the circuit board.

[0081] Aspect 77 generally concerns the system of any previous aspect in which the circuit board has a terminal to which the buckle wire is connected.

[0082] Aspect 78 generally concerns the system of any previous aspect in which the tension arm is biased against the harness adjuster strap.

[0083] Aspect 79 generally concerns the system of any previous aspect in which the tension sensor includes a spring configured to bias the tension arm against the harness adjuster strap.

[0084] Aspect 80 generally concerns the system of any previous aspect in which the spring includes a torsion spring.

[0085] Aspect 81 generally concern s th e system of any pre vious aspect in which th e torsion spring is wrapped around the shaft. Aspect 82 generally concerns the system of any previous aspect in which the tensor sensor includes one or more strap guides.

[0086] Aspect 83 generally concerns the system of any previous aspect in w hich the strap guides are configured to guide the harness adjuster strap across the tension arm.

[0087] Aspect 84 generally concerns the system, of any previous aspect in which the strap guides are positioned on opposite sides of the tension arm.

[0088] Aspect 85 generally concerns the system of any previous aspect in which the strap guides have guide amis that define a guide slot where the harness adjuster strap is received.

[0089] Aspect 86 generally concerns the system of any previous aspect in w hich the guide arms define a gap.

[0090] Aspect 87 generally concerns the system, of any previous aspect in which the tension ami has one or more guide flanges.

[0091] Aspect 88 generally concerns th e system of any pre vious aspect in which th e gui de flanges define a guide channel where the harness adjuster strap is received.

[0092] Aspect 89 generally concerns the system of any previous aspect in w hich the guide flanges are configured to minimize lateral movement of the harness adjuster strap.

[0093] Aspect 90 generally concerns the system, of any previous aspect in which the seat monitoring system includes an output device.

[0094] Aspect 91 generally concerns the system of any previous aspect in which the output device is located on the buckle.

[0095] Aspect 92 generally concerns the system of any previous aspect in which the output device is located proximal to the release button of the buckle to enhance visibi lity. Aspect 93 generally concerns the system of any previous aspect in which the output device is configured to provide the status of the buckle.

[0096] Aspect 94 generally concerns the system of any previous aspect in which the output device is configured to provide an indication of the tension of the harness.

[0097] Aspect 95 generally concerns the system of any previous aspect in which the output device is integrated into the controller.

[0098] Aspect 96 generally concerns the system of any previous aspect in which the output device includes a display.

[0099] Aspect 97 generally concerns the system of any previous aspect in which the output device includes a speaker.

[0100] Aspect 98 generally concerns the system, of any previous aspect in which the output device includes one or more indicator lights.

[0101] Aspect 99 generally concern s th e system of any pre vious aspect in which th e i ndi cator lights include passive light emitters.

[0102] Aspect 100 generally concerns the system of any previous aspect in which the indicator lights include a buckle indicator light.

[0103] Aspect 101 generally concerns the system of any previous aspect in which the buckle indicator light is configured to indicate status of the buckle.

[0104] Aspect 102 generally concerns the system of any previous aspect in which the buckle indicator light is configured to indicate if the latch plates are secured to the buckle.

[0105] Aspect 103 generally concerns the system of any previous aspect in which the indicator lights include a tension indicator light. Aspect 104 generally concerns the system of any previous aspect in which the tension indicator light indicates if the harness is properly tensioned.

[0106] Aspect 105 generally concerns the system of any previous aspect in which the tension indicator light indicates the level of tension in the harness.

[0107] Aspect 106 generally concerns the system of any previous aspect in which the indicator lights include an occupancy indicator light.

[0108] Aspect 107 generally concerns the system of any previous aspect in which the occupancy indicator light indicates if someone is sitting in the seat.

[0109] Aspect 108 generally concerns the system of any previous aspect in which the occupancy indicator light indicates weight.

[0110] Aspect 109 generally concerns the system of any previous aspect in which the indicator lights are configured to change color to indicate status.

[0111] Aspect 1 1.0 generally concerns the system of any previous aspect in which the indicator lights are configured to change brightness to indicate status.

[0112] Aspect 11 I generally concerns the system of any previous aspect including an interface communicatively coupled to the processor.

[0113] Aspect 112 generally concerns the system of any previous aspect including a buckle sensor line communicatively connecting the controller to the buckle sensor.

[0114] Aspect 113 generally concerns the system of any previous aspect in which the buckle sensor Line includes an electrically conductive wire.

[0115] Aspect 114 generally concerns the system of any previous aspect in which the buckle sensor line is operatively connected to the interface. Aspect 115 generally concerns the system of any previous aspect including an output line extending from the controller to the buckle to provide light from the controller to the indicator lights.

[0116] Aspect 1 16 generally concerns the system of any previous aspect in which the output line includes one or more light guides.

[0117] Aspect 117 generally concerns the system of any previous aspect in which the output line includes a fiber optic cable that has one or more optical libers.

[0118] Aspect 118 generally concerns the system of any previous aspect in which the fiber optic cable includes an end glow fiber optic cable.

[0119] Aspect 1 19 generally concerns the system of any previous aspect in which the indicator lights are exposed ends of the optical fibers in the end glow fiber optic cable.

[0120] Aspect 120 generally concerns the system of any previous aspect in which the end glow fiber optic cable extends from the controller to the buckle.

[0121] Aspect 121 generally concerns the system of any previous aspect in which the end glow fiber optic cable is configured to transmit light from the controller to the buckle.

[0122] Aspect 122 generally concerns the system of any previous aspect in which the indicator lights include emitters configured to change light properties.

[0123] Aspect 123 generally concerns the system of any previous aspect in which the fiber optic cable is coupled to the buckle belt.

[0124] Aspect 124 generally concerns the system of any previous aspect in which the end glow fiber optic cable is embedded in the buckle belt.

[0125] Aspect 125 generally concerns the system of any previous aspect in which the interface is configured to generate the light. Aspect 126 generally concerns the system of any previous aspect including a power, control module (PCM).

[0126] Aspect 127 generally concerns the system of any previous aspect in which the controller is incorporated into the PCM.

[0127] Aspect 128 generally concerns the system of any previous aspect in which the tension sensor is incorporated into the PCM.

[0128] Aspect 129 generally concerns the system of any previous aspect in which the controller is configured to initiate a calibration mode based on a sequence of input signals from at least one existing input.

[0129] Aspect 130 generally concerns the system of any previous aspect in which the control ler is configured to calibrate the tension sensor during the calibration mode.

[0130] Aspect 131 generally concerns the system of any previous aspect in which the sequence is nonstandard for normal operation.

[0131] Aspect 132 generally concerns the system of any previous aspect in which the sequence is unlikely to occur during normal operation of the restraint system.

[0132] Aspect 133 generally concerns the system of any previous aspect in which the sequence includes buckling and unbuckling the latch plates with the buckle more than once within a designated time interval.

[0133] Aspect 134 generally concerns the system of any previous aspect in which the sequence includes buckling and unbuckling die latch plates with the buckle 4 times within a 5-second interval.

[0134] Aspect 135 generally concerns the system of any previous aspect in which the sequence includes buckling and unbuckling the latch plates with the buckle 5 times within a 15-second interval. Aspect 136 generally concerns the system of any previous aspect in which the calibration mode includes calibrating the tension sensor.

[0135] Aspect 137 generally concerns the system of any previous aspect in which the controller is configured to illuminate the indicator lights during the calibration mode.

[0136] Aspect 138 generally concerns the system of any previous aspect in which the controller is configured to blink the indicator lights during the calibration mode.

[0137] Aspect 139 generally concerns the system of any previous aspect in which the controller is configured to change color of the indicator lights during the calibration mode.

[0138] Aspect 140 generally concerns the system of any previous aspect in which the controller is configured to extinguish the indicator lights when the calibration mode ends.

[0139] Aspect 141 generally concerns the system of any previous aspect in which the controller is configured to provide a calibration in progress indicator during the calibration mode.

[0140] Aspect 142 generally concerns the system of any previous aspect in which the control ler is configured to remain in the calibration mode for a limited time.

[0141] Aspect 143 generally concerns the system of any previous aspect in which the controller is configured to initiate a timer to track duration of the cal ibration mode.

[0142] Aspect 144 generally concerns the system of any previous aspect in which the controller is configured to collect multiple tension sample readings from the tension sensor during the calibration mode.

[0143] Aspect 145 generally concerns the system of any previous aspect in which the controller is configured to collect more than one sample during the calibration mode.

[0144] Aspect 146 generally concerns the system of any previous aspect in which the control ler is configured to determine a calibration value based on sample readings during the calibration mode. Aspect 147 generally concerns the system of any previous aspect in which the controller is configured to determine a calibration value based at least on averaging the sample readings during the calibration mode.

[0145] Aspect 148 generally concerns a method.

[0146] Aspect 149 generally concerns the method of any previous aspect including receiving a sequence of input signals at a processor for a restraint system,

[0147] Aspect 150 generally concerns the method of any previous aspect including determining with the processor that the sequence indicates to start a calibration mode for the restraint system.

[0148] Aspect 151 generally concerns the method of any previous aspect including starting the calibration mode in response to the determining.

[0149] Aspect 152 generally concerns the method of any previous aspect in which the restraint system includes a buckle and a harness with one or more latch plates.

[0150] Aspect 153 generally concerns the method of any previous aspect including initiating a calibration duration timer with the processor in response to the starling the calibration mode.

[0151] Aspect 154 generally concerns the method of any previous aspect including exi ting the calibration mode upon expiration of the calibration duration timer.

[0152] Aspect 155 generally concerns the method of any previous aspect in which the calibration duration timer has a time-out interval of 30 seconds,

[0153] Aspect 156 generally concerns the method of any previous aspect in which the calibration duration timer has a time-out interval of 30 seconds to perform 1 calibration attempt.

[0154] Aspect 157 generally concerns the method of any previous aspect in which the calibration duration timer has a time-out interval of 3 minutes. Aspect 158 generally concerns the method of any previous aspect in which the calibration duration timer has a. time-out interval of 3 minutes to perform 3 to 5 calibration attempts.

[0155] Aspect 159 generally concerns the method of any previous aspect in which the indicating the calibration mode is in progress in response to the starting the calibration mode.

[0156] Aspect 160 generally concerns the method of any previous aspect in which the indicating the calibration mode is in progress includes illuminating one or more indicator lights of the restraint system.

[0157] Aspect 161 generally concerns the method of any previous aspect in which the indicator lights are located in the buckle.

[0158] Aspect 162 generally concerns the method of any previous aspect in which the indicator lights are preexisting components of the restraint system.

[0159] Aspect 163 generally concerns the method of any previous aspect in which the indicator lights are configured to indicate safety status of the restraint system during normal operation.

[0160] Aspect 164 generally concerns the method of any previous aspect in which the illuminating includes blinking one of the indicator lights at a predetermined rate.

[0161] Aspect 165 generally concerns the method of any previous aspect in which the illuminati ng includes blinking two or more of the indicator lights simultaneously at a predetermined rate.

[0162] Aspect 166 generally concerns the method of any previous aspect in which the illuminating includes blinking two or more of the indicator ligh ts alternately at a predetermined rate.

[0163] Aspect 167 generally concerns the method of any previous aspect in which the predetermined rate is 1Hz.

[0164] Aspect 168 generally concerns the method of any previous aspect in which the blinking includes illuminating and darkening the indicator lights showing a single color. Aspect 169 generally concerns the method of any previous aspect in which the blinking includes alternating the indicator lights between two or more colors.

[0165] Aspect 170 generally concerns the method of any previous aspect in which the indicating the calibration mode is in progress includes producing an audible sound.

[0166] Aspect 171 generally concerns the method of any previous aspect in which the restraint system has a tension sensor operatively coupled to the processor.

[0167] Aspect 172 generally concerns the method of any previous aspect including performing calibration tests across multiple sessions.

[0168] Aspect 173 generally concerns the method of any previous aspect including performing multiple calibration tests in a single session.

[0169] Aspect 174 generally concerns the method of any previous aspect including measuring with the tension sensor one or more tension measurement samples at a measurement rate as tension is applied to the harness adjuster strap.

[0170] Aspect 175 generally concerns the method of any previous aspect in which the measurement rate is 3Hz.

[0171] Aspect 176 generally concerns the method of any previous aspect including tensioning the harness adjuster strap until a target tension is achieved.

[0172] Aspect 177 generally concerns the method of any previous aspect including detecting the target tension with an inline calibration sensor disposed along the harness adjuster strap.

[0173] Aspect 178 generally concerns the method of any previous aspect including holding the harness adjuster strap at the target tension for a hold duration.

[0174] Aspect 179 generally concerns the method of any previous aspect including releasing the harness adjuster strap from tension after the hold duration. Aspect 180 generally concerns the method of any previous aspect in which the hold duration is at least 3 seconds.

[0175] Aspect 181 generally concerns the method of any previous aspect including calculating a calibration value with the processor at least based on the tension measurement samples.

[0176] Aspect 182 generally concerns the method of any previous aspect including determining a calibration test value by averaging with the processor a sample size limit number of tire tension measurement samples measured prior to the releasing of the harness adjuster strap.

[0177] Aspect 183 generally concerns the method of any previous aspect in which the sample size limit number is at least 9 tension measurement samples.

[0178] Aspect 184 generally concerns the method of any previous aspect including storing the calibration test value in memory.

[0179] Aspect 185 generally concerns the method of any previous aspect in which the calculating the calibration value includes averaging the calibration test value stored in memory with one or more prior calibration test values stored in memory from prior calibration tests.

[0180] Aspect 186 gen erall y concerns the method of any pre vious aspect in which the calibration value is calculated based on at least 3 calibration tests.

[0181] Aspect 187 generally concerns the method of any previous aspect in which the measuring, the tensioning, the detecting, the holding, and the releasing are performed multiple times to perform multiple calibration tests in a single session.

[0182] Aspect 188 generally concerns the method of any previous aspect in which the calculating the calibration value includes averaging the calibration test values from at least the multiple calibration tests in the single session.

[0183] Aspect 189 generally concerns the method of any previous aspect including outputting a hold alert in response to the detecting the target tension. Aspect 190 generally concerns the method of any previous aspect in which the hold alert includes flashing one or more indicator lights.

[0184] Aspect 191 generally concerns the method of any previous aspect in which the hold alert includes a sound.

[0185] Aspect 192 generally concerns the method of any previous aspect including producing a calibration end alert when the calibration mode is canceled.

[0186] Aspect 193 generally concerns the method of any previous aspect in which the calibration end alert includes extinguishing illumination of the light indicators.

[0187] Aspect 194 generally concerns the method of any previous aspect in which the calibration end alert includes an audible sound.

[0188] Further forms, objects, features, aspects, benefits, advantages, and embodiments of the present invention will become apparent from a detailed description and drawings provided herewith.

[0189] BRIEF DESCRIPTION OF THE DRAWINGS

[0190] FIG. 1 is a block diagram of a seat monitoring system according to one example.

[0191] FIG. 2 is a front view of a child safety seat that includes the FIG. 1 seat monitoring system.

[0192] FIG. 3 is a rear view of the FIG. 2 child safety seat.

[0193] FIG. 4 is a bottom view of the FIG. 2 child safety seat.

[0194] FIG. 5 is a bottom perspective view of the FIG. 2 child safety seat.

[0195] FIG. 6 is an enlarged perspective view of a buckle used in the FIG. 1 seat monitoring system.

[0196] FIG. 7 is a bottom perspective view of the FIG. 6 buckle.

[0197] FIG. 8 is an enlarged view of latch plates and a buckle sensor used in the FIG. 1 seat monitoring system,

[0198] FIG. 9 is a top perspective view of a power / control module ("PCM”) used in the FIG. I seat monitoring system.

[0199] FIG. 10 is a perspective view of the FIG. 9 PCM with a harness adjuster strap in a loose state. FIG. 11 is a perspective view of the FIG. 9 PCM with the harness adjuster strap in a tensioned state.

[0200] FIG. 12 is a cross-sectional view of the FIG. 9 PCM.

[0201] FIG, 13 is a. cross-sectional perspective view of the FIG. 9 PCM.

[0202] FIG. 14 is a cross-sectional view of the FIG. 9 PC-M and the harness adjuster strap during tensioning.

[0203] FIG. 15 is a block diagram of a calibration configuration for calibrating the FIG. I seat monitoring system.

[0204] FIG. 16 is a flowchart illustrating a calibration technique for the FIG. 1 seat monitoring system.

[0205] DETAILED DESCRIPTION OF SELECTED EMBODIMENTS

[0206] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention i s thereby intended. Any alterations and further modifications in the described embodiments and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates. One embodiment of the invention is shown in great detail, although it will be apparent to those skilled in the relevant art that some features that are not relevant to the present invention may not be shown for the sake of clarity.

[0207] The reference numerals in the following description have been organized to aid the reader in quickly identifying the drawings where various components are first shown. In particular, the drawing in which an element first appears is typically indicated by the left-most digit(s) in the corresponding reference number. For example, an element identified by a " 100" series reference numeral vvil I likely first appear in FIG. 1 , an element identified by a ”200" series reference numeral will likely first appear in FIG, 2, and so on.

[0208] FIG. 1 depicts a block diagram of a seat monitoring system 100 according to one example. As shown, the seat monitoring system 100 includes a restraint system 105 and a power / control module (PCM) 1 10 configured to monitor the restraint system 105. The PCM 1 10 is configured to sense whether a seat occupant is properly secured in the restraint system 105 as well as provide other information.

[0209] In the illustrated example, the PCM 110 includes a controller 1 15 and a tension sensor 120 operatively coupled to the controller 115. The controller 1 15 includes a processor 125, memory 130 operatively coupled to the processor 125, an energy Storage System (ESS) 135 configured to provide electrical power to the PCM 1 10 as well as the other components in the seat monitoring system 100, and an interface 140 operatively coupled to the processor 125 for facilitating communications between the controller 115 and other components of the seat monitoring system 100 such as the tension sensor 120. The tension sensor 120 is configured to sense the tension of the restraint system 105 to determine if the seat occupant is properly secured. In the illustrated example, the tension sensor 120 is communicatively coupled to the interface 140 of the controller 1 15 via. a tension sensor line 142 such as in the form of a wire. The processor 125 is able to monitor tension of the restraint system 105 by receiving signals from the tension sensor 120 via the tension sensor line 142 and the interlace 140. In one form, the signals from the tension sensor 120 are in the form of one or more analog si gnals, but in other examples, the signals from the tension sensor 120 can be digital signals or some combination of analog and digital signals. Among other things, the processor 125 processes the status information from the tension sensor 120, and based on this information, the processor 125 provides the status of the restraint system 105 to a user.

[0210] As shown in FIG. 1 , the restraint system 105 includes a buckle 145 and one or more latch plates 150 that can be buckled to and unbuckled from the buckle 145. The restraint system 105 further includes a harness 155 that is configured to secure the seat occupant in the seat. The harness 155 is detachably secured to the buckle 145 via the latch plates 150. In the depicted example, the restraint system 105 further includes a splitter plate 160 that couples the harness 155 to a harness adjuster strap 165 that is used to tighten the harness 155. The restraint system 105 further has a harness adjuster 170 configured to releasably secure the harness adjuster strap 165 once the desired tension in the harness 155 is achieved. In one form, the harness adjuster 170 includes a cam buckle, but the harness adjuster 170 can include other types of devices for securing the harness adjuster strap 165. As will be explained in greater detail below, the harness adjuster strap 165 runs across or through the tension sensor 120 so that the tension sensor 120 is able to measure the tension in the harness

[0211] 155 via the harness adjuster strap 165.

[0212] The buckle 145 includes a release button 175 that is configured to release the latch plates 150 from the buckle 145. In the depicted example, the release button 175 is in the form of a button, but the release button 175 can take other forms in other examples. To sense whether the latch plates 150 are properly secured in the buckle 145, the buckle 145 has a buckle sensor 180. The buckle 145 further has an output device 185 that provides information from the controller 115 of the PCM 1 10. The buckle sensor 180 of the buckle 145 is communicatively coupled to the interface 140 of the controller 115 via a buckle sensor line 190, and the output device 185 of the buckle 145 is operatively coupled to the interface 140 of the controller 115 via an output line 195. Ln one form, the buckle sensor line 190 is in the form of an electrically conducti ve wire, and the output li ne 195 is a light guide such as in the form of one or more fiber optic cables. The output device 185 in the buckle 145 in this example are in the form of passive light emitters. The processor 125 in the controller 115 generates light or optical signals via the interface 140. These optical signals from the interface 140 are conducted by the fiber optic cables forming the output line 195 to the emitters of the output device 185. The emitters at the output de vice 185 of the buckle 145 then shine the light from the interface 140 of the PCM 1 10 to indicate various states and other information. With the output line 195 being in the form of light conductors, the buckle 145 does not need a circuit board within the buckle 145 which is commonly required for light emitting diodes (LEDs). The space inside the buckle 145 is quite cramped, and the buckle 145 is impacted and otherwise abused quite often during routine use. Eliminating the circuit board inside the buckle 145 via. the fiber optic cables of the output line 195 frees up spaced inside the buckle 145 and further enhances the reliability of the output device 185 of the buckle 145.

[0213] Hie processor 125 of the PCM 110 can indicate whether the buck! e 145 is buckled properly via the output device 185. The PGM 110 can indicate whether the restraint system 105 is properly tensioned via the output device 185 as well as whether the seat is occupied via the output device 185 of the buckle 145. Among other things, the memory 130 is used to store safety operational limits or ranges used by the processor 125. For instance, the memory 130 can store proper tension ranges for the restraint system so that the PCM 1 10 is able to indicate via the output device 185 whether the seal occupant is properly secured. The ESS 135 is operatively coupled to the processor 125 so as to provide power to the controller 115, the tension sensor 120, and the buckle 145. In one form, the ESS 135 is a portable type power supply, such as in the form of a battery and / or super capacitor, and in other forms, the ESS 135 i s a hardwired power source directly connected to the electrical po wer supply of the vehicle.

[0214] The buckle 145 is operatively connected to the controller 1 15 via the buckle sensor line 190 and the output line 195. It should be recognized that the components of the seat monitoring system 100 can be operatively coupled together in other manners or ways. For instance, the components of the seat monitoring system 100 can be operatively coupled together via liber optic cables and / or wirelessly. In another variation, the buckle 145 and PCM 1 10 are integrated together to form a single unit, and in other variations, the tension sensor 120 is incorporated into the buckle 145. The seat monitoring system 100 in sti.il yet other variations includes fewer or more sensors as well as other components than is illustrated in FIG. 1 . FIG. 2 shows one example of a child safety seat 200 that can incorporate the seat monitoring system 100 of FIG. 1. As shown, the child safety scat 200 includes a seat assembly 205 where a seat occupant, such as a baby or child, can sit. The seat assembly 205 includes a seat back 210 and a seat bottom 215 extending from one end of the seat back 210.

[0215] The child safety seat 200 further includes the restraint system 105 that is configured to safely restrain the seat occupant such as during a collision or other accident. In one form, the restraint system 105 includes the harness 155 with one or more belts 220 that secure the seat occupant. The belts 220 have the latch plates 150 that are configured to latch with the buckle 145. The buckle 145 is secured to the seat bottom 215 of the child safety seat 200 via a buckle belt 225. In the depicted example, the harness 155 is in the form of a five-point type harness, but other types of harnesses can be used.

[0216] To provide easy visibility, the buckle 145 has the output device 185 facing outward to the user. The output device 185 is located along one side to enhance visibility and minimize interference with other internal components of the buckle 145. The buckle sensor line 190 and the output line 195, which operatively connect the buckle 145 to the controller 1 15, are woven into or otherwise incorporated into the buckle belt 225 in the illustrated embodiment. This allows the buckle sensor line 190 and the output line 195 to readily run through the child safety seat 200 to the backside of the child safety seat 200 where the PCM 110 is mounted. As can be seen, the buckle 145 has the release button 175 that i s used to unbuckle or unlatch the latch plates 150 from the buckle 145 so that the seat occupant can be removed from the child safety seat 200.

[0217] To loosen or tighten the belts 220 in the harness 155, the restraint system 105 further includes the harness adjuster 170. The harness adjuster 170 receives the harness adjuster strap 165 that is configured to tighten the belts 220 of the harness 155 when pulled and to loosen the belts 220 when slackened. In the depicted example, the harness adjuster 170 includes a releasable cam buckle 230 that is configured to secure the harness adjuster strap 165 to maintain the tension in the belts 220 of the harness 155. The cam buckle 230 is actuated to release the harness adjuster strap 565 so as to slacken the harness adjuster strap 165 which in turn releases tension in the belts 220 of the harness 155. It should be recognized that other types of harness adjusters 170 can be used in other examples. FIG. 3 shows the back of the child safety seat 200, and FIGS. 4 and 5 show' various bottom views of the seat assembly 205, As can be seen, the PCM 1 10 is mounted on the backside of the seat assembly 205. The belts 220 and the harness adjuster strap 165 are connected together via the splitter plate 160. The harness adjuster strap 165 extends along the PCM 1 10 so that the tension sensor 120 is able to measure the tension of the harness adjuster strap 165 which is indicative of the tension in the belts 220 of the harness 155.

[0218] Turning to FIGS. 6 and 7, the buckle 145 has the output device 185 in the form of one or more indicator lights 605. The indicator lights 605 along with the buckle sensor 180 are operatively connected to the controller 115 via tlie output line 195 and the buckle sensor line 190, respectively. The controller 115 is then able to control the indicator lights 605 based on the current status of the chi ld safety seat 200. In the depicted example, the indicator lights 605 are in the form of passi ve, multi-color emitters 610 that are fed light from the interface 140 in the controller 115 via the output line 195 which in one case is in the form of one or more optical fibers. The optic fibers of tlie output line 195 in one form are end glow fiber optic cables with ends that form the indicator lights 605 or emitters 610. The end glow fiber optic cables are a type of optical fiber designed to emit light from one end. In this case, the light emitting ends of the end glow liber optic cables form the indicator lights 605. In some variations, the end of the fiber optic cable can include a cap or other structure, like a reflector or diffuser, to change the property of the light emitted from the emitters 610.

[0219] In the illustrated example, each of the indicator lights 605 are indicative of the status of a particular sensor. The indicator lights 605 include a buckle indicator 615 that indicates whether the latch plates 150 are properly buckled via the buckle sensor 180. For instance, the buckle indicator 615 can be lit red to indicate that the latch plates 150 are not properly buckled and lit green to indicate that the latch plates 150 are properly buckled to the buckle 145. For this example, the buckle indicator 615 provides a binary output, but in other examples, the buckle indicator 615 can provide an analog or gradient type indication as to the extent to which the latch plates 150 are buckled with the buckle 145.

[0220] In some versions, the indicator lights 605 further include an occupancy indicator 620 which indicates whether and / or to what extent an occupant sensor detects an occupant in the child safety seat 200. For example, the occupancy indicator 620 can display different colors depending on the weight or pressure applied to the occupant sensor. In one particular example, the controller 115 lights the occupancy indicator 620 to red when no pressure is detected by the occupant sensor. The occupancy indicator 620 is lit to have yellow color when some weight or pressure is detected, but the weight is below a particular threshold level stored in the memory 130 of the controller 115. The occupancy indicator 620 is lit green when the weight of the occupant i s at or above the threshold. In another example, the occupancy indicator 620 is lit in a binary fashion. For instance, the occupancy indicator 620 is only lit when a seat occupant is detected.

[0221] The indicator lights 605 also include a tension indicator 625 that indicates the tension state of the belts 220 of the harness 155 sensed by the tension sensor 120. The tension indicator 625 can operate in a binary fashion where the tension indicator 625 is lit green when the harness 155 is properly tensioned and lit red when the harness 155 is not at the proper tension. In another variation, the tension indicator 625 is turned on only when the harness 155 is properly tensioned, and the tension indicator 625 is turned off when the harness 155 is not at the correct tension. In other variations, the intensity and / or color of the light varies in a general analog or gradient fashion depending on the tension of the 455.

[0222] As shown in FIG. 7, the buckle sensor line 190 and the output line 195 are incorporated into the buckle belt 225. The buckle belt 225 in one version has a cable guide 705 that houses the buckle sensor line 190 and the output line 195. The indicator lights 605 are positioned proximal to where the latch plates 150 engage the buckle 145 as well as where the release button 175 is used to unbuckle the latch plates 150. Having the indicator lights 605 positioned at such a location makes the output device 185 readily visible to the user so that the user can quickly discern whether the seat occupant is secured properly. To minimize interference with the internal components of the buckle 145, the indicator lights 605 are aligned in a line along one side of the buckle 145.

[0223] It should be recognized that the buckle indicator 615, occupancy indicator 620, and tension indicator 625 can be positioned or arranged in a different order than illustrated. Moreover, other types of output de vices such as displays and / or speakers can be used for the output device 185. For instance, the output device 185 in other variations can include a speaker that issues an audible alert depending on the status of the various sensors. One example of the buckle sensor 180 during operation is depicted in FIG. 8. As can be seen, the buckle sensor 180 includes a micro-switch 805 with a hinged spring 810 extending at an end proximal to the latch plates 150. The latch plates 150 each have a tongue 815 that is configured to latch with the buckle 145, The tongues 815 are inserted into the buckle 145, When the tongues 815 of the latch plates 150 are properly inserted and latched, at least one of the tongues 815 actuates or depresses the hinged spring 810 so as to close the micro-switch 805. When the processor 125 of the controller 1 15 senses closure of the micro-switch 805, the interface 140 activates the buckle indicator 615 on the controller 115 to indicate that die buckle 145 is correctly buckled. For instance, the buckle indicator 615 can glow a green color to indicate that the latch plates 150 are latched in the buckle 145. When the user presses die release button 175 on the buckle 145 to release and eject the latch plates 150, the end of the tongue 815 disengages from the hinged spring 810 of the micro-switch 805 such that the micro-switch 805 is opened. Upon sensing opening of the micro-switch 805, the controller 1. 15 changes the color and or brightness of the buckle indicator 615 to indicate that the latch plates 150 are unbuckled from the buckle 145. For instance, the buckle indicator 615 can glow red or be turned off when the latch plates 150 are disengaged from the buckle 145,

[0224] FIG. 9 shows a top perspective view of the PCM 110. The PCM 110 is generally mounted at the seat bottom 215 of the seat assembly 205. The PCM 110 has a housing 905 upon which the harness adjuster strap 165 extends. The harness adjuster strap 165 slides along the housing 905 of the PCM 110 so as to engage the tension sensor 120. When tension is applied to the harness adjuster strap 165, the harness adjuster strap 165 presses against the tension sensor 120 which in turn senses the amount o f tension bei ng applied. It should be appreciated that such a configuration allows the tension sensor 120 to be implemented into existing harness adjuster designs with minimal changes. The harness adjuster strap 165 does not need to be severed or otherwise changed in order to include the tension sensor 120. The harness adjuster strap 165 just needs to be routed over the tension sensor 120,

[0225] Referring to FIGS. 10 and 11, the housing 905 of the PCM 1 10 has one or more bails or strap guides 1005 that guide the harness adjuster strap 165 over the tension sensor 120. The tension sensor 120 includes a lever or tension arm 1010 over which the harness adjuster strap 165 slides in a longitudinal direction. In the depicted example, the PCM 1 10 has two strap guides 1005 positioned on opposite sides of the tension arm 1010 of the tension sensor 120, The strap guides 1005 are designed to minimize the risk of the harness adjuster strap 165 disengaging from the tension arm 1010 of the tension sensor 120. The strap guides 1005 include one or more guide amis 1015 that define a. guide slot 1020 through which the harness adjuster strap 165 extends. In the i llustrated example, each strap guide 1005 has two guide amis 1015 that are spaced from one another to form a gap I 025 where the harness adjuster strap 165 can be inserted or removed during assembly, repair, and maintenance. The strap guides 1005 can have a different number of guide amis 1015 in other examples. Where the harness adjuster strap 165 rides over the tension arm 1010, the tension arm 1010 has one or more guide flanges 1030. In the depicted example, the guide flanges 1030 are located on opposite lateral sides of the harness adjuster strap 165. The guide flanges 1030 are configured to reduce the risk of the harness adjuster strap 165 sliding in a. lateral direction off from the tension ami 1010.

[0226] Looking at FIG. 12, the tension arm 1010 is pivotally mounted to a shaft 1205 that is secured to the housing 905 of the PCM 1 10. To bias the tension arm 1010 to engage the harness adjuster strap 165, the tension sensor 120 further includes a spring 1210, In the illustrated example, the spring 1210 includes a torsion spring 1215 that is wrapped around the shaft 1205. The torsion spring 1215 is engaged between the housing 905 of the PCM 110 and the tension arm 1010 so as to bias the tension ami 1010 in an outward direction to engage the harness adjuster strap 165. In other examples, di fferent types of springs or other devices can be used. The tension arm 1010 has a guide surface 1220 against which the harness adjuster strap 165 slides. The guide flanges 1030 and guide surface 1220 of the tension arm 1010 define a guide channel 1225 where the harness adjuster strap 165 is received. The guide channel 1225 helps to align and guide the harness adjuster strap 165 over the tension arm 1010.

[0227] As further shown in FIG. 12, the PCM 1 10 further includes a circuit board 1230 where the processor 125, memory' 130, and other components of the PCM 110 can be mounted in some versions. The electronic components on the circuit board 1230 as well as the other components of the seat monitoring system 100 are powered by the 1235.

[0228] The tension of the harness I 55 is determined based on the extent the tension ami 1010, which is biased by the spring 1210, is deflected by the harness adjuster strap 165 pressing against the guide surface 1220 of the tension ami 1010. As shown in FIG. 13, die tension sensor 120 includes a magnetic sensor 1310 that determines if and how far the tension arm 1010 is pivoted about the shaft 1205 by the harness adjuster strap 165. The sensor 1305 in the illustrated example includes a magnetic sensor 1310, such as a Hall effect sensor, that determines the relative position of the tension arm 1010 based on the magnetic field strength from a permanent magnet 1315 secured to the inside of the tension ami 1010. It should be recognized that other types of sensors, such as infrared (IR) and contact sensors, can be used to sense the relative position of the tension arm 1010. As can be seen, the magnetic sensor 1310 is mounted to the circuit board 1230. The circuit board 1230 further includes one or more terminals 1320 where the tension sensor line 142 of the tension sensor 120 is operatively connected to the PCM 110.

[0229] When tension is applied to the harness adjuster strap 165, the tension arm 1010 pivots about the shall 1205 against the force of the torsion spring 1215. As the magnet 1315 on the tension ami 1010 moves closer to the magnetic sensor 1310 on the circuit board 1230, the magnetic sensor 1.310 senses a stronger magnetic field. The tension sensor 120 in one version provides an analog signal indicative of this stronger magnetic field to the processor 125 of the PCM 1 10. The processor 125 of the PCM 1 10 correlates the stronger magnetic field to a stronger tension being applied to the harness 155, Conversely, when the tension in the harness adjuster strap 165 is released, such as when the cam buckle 230 is actuated to release the harness adjuster strap 165, the spring 1210 of the tension sensor 120 pivots the magnet 1315 on the tension arm 1010 away from the magnetic sensor 1310. This causes the magnetic sensor 1310 to sense a weaker magnetic field. The processor 125 of the PCM 1 10 interprets the weaker magnetic field to weaker tension being applied to the harness 155.

[0230] Turning to FIG. 14, when tension is applied to the harness adjuster strap 165, the tension arm 1010 pi vots about the shaft 1205 against the force of the torsion spring 1215 as is indicated by arrow 1405 in FIG. 14. As the magnet 1315 on the tension arm 1010 moves closer to the magnetic sensor 1310 on the circuit board 1230, the magnetic sensor 1310 senses a stronger magnetic field. The processor 125 of the PCM 1 10 correlates the stronger magnetic field to a stronger tension being applied to the harness 155. Once a specified tension (or magnetic field) strength limit i s reached in one version, the processor 125 of the PGM 110 illuminates the tension indicator 625 to indicate that the proper tension is being applied (e.g., shines a green l ight). In another variation, the color and / or brightness of the tension indicator 625 (FIG. 6) changes depending on the amount of tension being applied to the harness adjuster strap 165. Conversely, when the tension in the harness adjuster strap 165 is released, such as when the cam buckle 2.30 is actuated to release the harness adjuster strap 165, the spring .1210 of the tension sensor 120 pivots the magnet 1355 on the tension arm 1050 away from the magnetic sensor 1310 as is indicated by arrow 1410 in FIG. 14. This causes the magnetic sensor 1310 to sense a weaker magnetic field. The processor 125 of the PCM 110 interprets the weaker magnetic field to weaker tension being applied to the harness 155. Once the tension is below the limit, the processor 125 of the PCM 110 illuminates the tension indicator 625 to indicate that improper tension is being applied (e.g., shines a red light). Once more, the color and / or brightness of the tension indicator 625 in other variations changes depending on the amount of tension being applied to the harness adj uster strap 565. For instance, the tension indicator 625 can progress in a fashion similar to a traffic light where green signifies proper tension, yellow signifies there is too low of tension, and red signifies no tension in the harness 155. Of course, other indicator schemes can be used in other examples.

[0231] To ensure accuracy of the tension readings for the restraint system 105, the tension sensor 120 of the PCM 110 is typically calibrated at least during manufacturing and sometimes even alter the child safety seat 200 is sold. In a traditional approach, the tension sensor 120 is calibrated before installation on the seat assembly 205, and dedicated devices on the PCM 110, such as dedicated switches, buttons, and or ports, are used to initiate and perform the calibration process. When the PCM 110 is finally installed on the seat assembly 205, the calibration adj ustments may not be accurate due to variable properties of various components such as variations in the extent to which the harness 155 and the harness adjuster strap 165 are able to stretch. The extra components needed to initiate the calibration process as well as to communicate during calibration are mostly unnecessary throughout the rest of the life of the child safety seat 200. These extraneous calibration components add expense and create another source for product failure.

[0232] A unique technique and system has been developed to facilitate efficient end-of-line calibration of the tension sensor 120 of the chi ld safety seat 200 without the need of a special connection to the onboard electronics of the PCM 1 10. This design and technique eliminates the need to provide a special switch (e.g., button) or other input to initiate the end-of-line calibration procedure. This system and technique also eliminates the need to provide a special port (e.g., USB port) to communicate with the controller 115 during the end-of-line calibration procedure. If so desired, the seat monitoring system 100 can be calibrated by the child safety seat manufacturer after the PCM 110 has been attached to the seat assembly 205 such as in the manner depicted in FIGS. 3, 4, and 5.

[0233] FIG. 15 depicts a calibration configuration 1500 where the restraint system 105 and the PCM 110 are arranged to perform the calibration technique. As noted before, this arrangement allows the tension sensor 120 to be calibrated while the PCM 110 is secured to the seat assembly 205 in the manner as shown in FIGS, 3, 4, and 5, but in other variations, all or part of the calibration technique can be performed when the PCM 110 is not attached to the seat assembly 205. As can be seen, the restraint system 105 and the PCM 110 have the components of the type described before with respect to FIG. I . For the sake of brevity and clarity, the components in FIG. 15 that were described before will not be again described, but please refer to the previous description. In the calibration configuration 1500 of FIG. 15, the splitter plate 160 has been replaced with an inline force sensor or calibration sensor 1505 that is used to provide calibrated, standard load or tension readings. The splitter plate 160 is typically rigid such that the splitter plate 160 is generally not a significant variability source for readings. Moreover, the splitter plate 160 can be easily disconnected and reconnected to the harness 155 and the harness adjuster strap 165 during manufacturing. In the depicted example, the calibration sensor 1505 replaces the splitter plate 160 in the seat monitoring system 100 such that the calibration sensor 1505 connects the harness 155 to the harness adjuster strap 165. The calibration sensor 1505 is able to provide standard or calibrated readings. It should be recognized that the calibration sensor 1505 can be placed elsewhere along the restraint system 105. For instance, the calibration sensor 1505 can replace the harness adjuster 170 or be positioned along the harness adjuster strap 165 betw een the tension sensor 120 and the harness adjuster 170. In another example, the calibration sensor 1505 is attached to the end of the harness adjuster strap 165 located downstream from the harness adjuster 170. In this example, the user calibrates the tension by pulling the calibration sensor 1505.

[0234] The seat monitoring system 100 and the calibration technique utilize one or more existing system inputs, such as the buckle sensor 180, to initiate a special learning or calibration mode where the PCM 1 10 is taught a specific belt tension that is required to be present for the controller 1 15 to indicate that proper tensioning of the harness 155 has been achieved. The seat monitoring system 100 utilizes existing indicators, such as the indicator lights 605 in FIG. 6, to inform the individual performing tire calibration of the status of the procedure. In one version, the end-of-line calibration procedure is limited in time, after which the seat monitoring system 100 returns to normal operation, whether or not the calibration had been fully performed. In other variations, different limits or parameters can be used to limit the calibration mode.

[0235] In one example, the calibration mode is initiated by buckling and / or unbuckling the latch plates 150 to and / or from the buckle 145 four (4) times in live (5) seconds. The calibration mode in other examples can require a different number of times and / or period lengths to initiate the calibration mode. For instance, tire calibration mode in another example is initiated by buckling and / or unbuckling the buckle 145 five (5) times in fifteen (15) seconds. The control ler 1 .15 via the buckle sensor 180 is able to detect this buckling / unbuckling action. The calibration mode in this example is Limited to thirty (30) seconds, but in other examples, the calibration mode can occur over longer or shorter periods of time. For i nstance, the calibration mode in another example is limited to five (5) minutes. In one case, the indicator lights 605 on the buckle 145 flash during the calibration mode. Alternatively or additional ly, the controller 1 15 can generate different types of alerts, such as an audible alert or tactile alert (e.g., vibrate), during the calibration learning mode. The alerts can change so as to provide a countdown timer. In some cases, the controller 115 provides no alerts during the calibration procedure.

[0236] During the calibration procedure, the user slowly tensions or pulls on the harness adjuster strap 165 so as to li ghten the harness 155 whi le the processor 125 of the con troller 115 via the tension sensor 120 measures the tension at a predetermined rate. The user tensioning the harness 155 utilizes the inline calibration sensor 1505 until a predetermined tension is achieved. In some cases, the calibration sensor 1505 provides a visual and / or audible alert when the predetermined tension is achieved. In other cases, the calibration sensor 1505 or other device provides a reading of the tensile force being applied, and the user determines whether or not the predetermined tension has been achieved. Once achieved, the desired tension is held constant for a predetermined amount of time, and then the user abruptly releases the tension from the harness adjuster strap 165. The controller 1 15 via the tension sensor 120 measurements the tension of the harness adjuster strap 165 for a predetermined number of samples prior to the release of tension, and thus, the drop in the measured tension. The processor 125 of the controller 1 / 15 stores the sample value in memory 130 as one of multiple calibration test values to be used in determining the overall calibration value. In the calibration mode, this pulling and releasing test can be performed multiple times. In one example, thi s pul l and release calibration procedure is performed three (3) times, but a different number can be used in other examples. The processor 125 in the controller 1 15 averages the values from the calibration tests along with a predetermined number of prior results to determine the final calibration value that is used during normal operation. In some cases, this calculated calibration value sets the required harness tension value or limit to be achieved during normal use, and when the calibration value is achieved, die controller 115 provides an alert via the output device 185 of the buckle 145 such as in the manner as described above with respect to FIGS. 6 and 7, In other cases, the calculated calibration value is not the desired harness tension value, but the calculated calibration value provides a offset value that adjusts the internal tension value measured by the tension sensor 120. It should be recognized that this calculated calibration value can be used to make adjustments in other ways. Once the desired calibration sample count is achieved or the calibration mode times out (e.g., exceeds the 30-second or 5-minute calibration time limit), the controller 115 of the PCM 110 returns to the normal operation mode.

[0237] FIG. 16 shows a flowchart 1600 that illustrates this unique calibration technique from the perspective of the controller 1 15 in the PCM 110. Most of these actions are performed by the processor 125 in the controller 115, but it should be recognized that at least some of these actions can be performed by other components of the PCM 1 10 or even de vices external to the PCM 1 10. Moreover, at least some of these actions can be performed in an order different than is illustrated. There are two general variations to this technique. In one variation, a single calibration test is performed in each calibration session. In this variation, multiple tension measurements from the calibration single test are averaged, and the average for this session or test is stored in memory' 130 as a calibration test value. The processor 125 averages this calibration test value with a selected number of calibration test values from previous tests to generate a calibration value that is used to calibrate the tension sensor 120. In the other variation, multiple calibration tests or samples occur within a single session. In this variation, the tension measurements for each sample are averaged like before and stored in memory 130 as sample calibration values. At the end of the session, the processor 125 averages the sample calibration values from the session together to generate the calibration value that is used to adjust or calibrate the tension sensor 120. Other approaches can be used as well. For instance, a combination of the two previously7discussed variations can be used in other examples. Moreover, different types of calculations besides averaging can be used to calculate the calibration value in other examples. For instance, the median or mode of the measurement data can be calculated. Since they share a number of common features, these different variations will be discussed together below.

[0238] Referring to FIGS. I , 2, 3, 15, and 16, the processor 125 of the PCM 110 in stage 1605 monitors the buckle sensor 180 or standard inputs for sequences or other actions that are indicative of entering the calibration procedure or mode for the seat monitoring system 100, The calibration procedure in one version is initiated by a sequence of events occurring on an existing input of the seat monitoring system 100 that usually do not occur during normal operation. For instance, the engagement / disengagement of an existing switch or other input in a specified number of times during a specified ti me interval initiates the calibration mode. Illis eliminates the need for calibration specific components or other devices. The calibration mode in one example is initiated by buckling and or unbuckling the latch plates 150 to and / or from the buckle 145 four (4) times in five (5) seconds. The calibration mode in other examples can require a different number of times and / or period lengths to initiate the calibration mode. The calibration mode in another example is initiated by buckling and / or unbuckling the buckle 145 five (5 ) times in fifteen (15) seconds. The processor 125 of the controller 1 15 via the buckle sensor 180 is able to detect this buckling / unbuckling action. The calibration mode in this example is limited to thirty (30) seconds, but in other examples, the calibration mode can occur over longer or shorter periods of time. For instance, the calibration mode in another example is limited to five (5) minutes, in stage 1610, the processor 125 in the PCM 1 1.0 determines whether or not to initiate the calibration mode or procedure, if not, the processor 125 continues to monitor for the unusual calibration initiation sequence in stage 1605.

[0239] When the calibration initiation sequence is detected in stage 1610, the processor 125 of the controller 1 15 initiates the calibration procedure or mode in stage 1615. The processor 125 in one version starts a timer in stage 1615 to keep track of how long the controller 115 has been in the calibration mode, and the processor 125 of the PCM 110 exits the calibration mode after a predetermined amount of time. In one example, this calibration mode time limit is thirty (30) seconds, and in another example, this calibration mode limit is five (5) minutes. It should be recognized that other time limits can be used depending on the number of calibration samples that need to be collected as well as based on other factors. Alternatively or additionally, the controller 1 15 in stage 1615 can signal to the user that the seat monitoring system 100 has entered the calibration mode. In one form, the calibration mode or calibration procedure in progress indication is conveyed to the user via illumination of the existing indicator lights 605 of the seat monitoring system 100 and / or producing an audible tone of a predetermined nat ure (e.g., a single tone, a particular sequence of tones, a musical tune, etc.). In other words, these indicators indicate the safety status of the child safety seat 200 (i.e., normal or calibration modes). For instance, looking at FIG. 6, the controller 1 15 starting in stage 1615 can flash or blink one, two, or three of the indicator lights 605 at a predetermined rate (e.g., I Hz). When multiple indicator lights 605 are used, the Hashing or blinking can occur simultaneously, alternately, or in other sequences. During the flashing or blinking, the indicator lights 605 can have the same single color or the indicator lights 605 can have different colors (e.g., red and green, white and blue, etc.). The indicator lights 605 can be illuminated (or not) in other ways. For instance, certain indicator lights 605 can emit a steady pattern of light or can change color's and / or brightness. Once the calibration mode ends, light from these indicator lights 605 ceases and / or other indications are provided to signify that the calibration mode has concluded.

[0240] In stage 1620, the processor 125 of the PCM 110 collects one or more samples of calibration data. During calibration, the user slowly tensions or pulls on the harness adjuster strap 165 so as to tighten the harness 155 whi le the processor 125 of the controller 1 15 via the tension sensor 120 measures the tension at a predetennined rate, in one version, the processor 125 samples the tension data at a rate of 3Hz, but the processor 125 in other examples can sample at different rates. The user tensioning the harness 155 utilizes the inline calibration sensor 1505 until a predetermined tension is achieved. In some cases, the calibration sensor 1505 provides a visual and / or audible alert when the predetermined tension is achieved. In other cases, the PCM 110 provides such alerts. For instance, the controller 1 15 in one version flashes the indicator lights 605 on the buckle 145 and / or beeps a tone during stage 1620. In still yet other cases, the calibration sensor 1505 or other device provides a reading of the tensile force being applied, and the user determines whether or not the predetermined tension has been achieved. Once achieved, the desired tension is held constant for a predetennined amount of time, such as three (3 ) seconds, and then the user abruptly releases the tension from the harness adjuster strap 165. The controller 115 via the tension sensor 120 measures the tension of the harness adjuster strap 165 for a predetermined number of samples prior to the release of tension, and thus, the drop in the measured tension. The processor 125 of the controller 115 stores the sample value in memory 130 as one of multiple calibration test values to be used in determining the overall calibration value. In the calibration mode, this pulling and releasing test can be performed multiple times, In one example, this pull and release calibration procedure is performed three (3 ) times, but a different sample size number, such as nine (9) samples, can be used in other examples.

[0241] In stage 1625, the controller 115 monitors one or more limits, like calibration time or sample count limits, and if these limits have not been exceeded, the processor 125 of the controller 115 continues to collect additional sample data in stage 1620. These limits for example can include time-out intervals for performing one or more calibration attempts or samples based on the calibration timer set in stage 1615. In one example, the time-out interval is thirty (30) seconds to perform one ( I ) calibration attempt or sample, and in another example, the timeout interval is three (3) minutes to perform three (3) to live (5) calibration attempts or samples. When the time and / or attempt limits arc exceeded in stage 1630, the calibration mode or procedure is stopped or canceled in stage 1635. In addition, the PCM 110 in stage 1635 can indicate or signal to the user when the calibration mode has ended. For instance, the processor 125 of the controller 115 can extinguish or otherwise darken the indicator lights 605 and / or cause the production of an audible tone of a predetermined nature (e.g., a single tone, a particular sequence of tones, a musical tune, etc.). Once the desired calibration sample count is achieved or the calibration mode times out (e.g., exceeds the 30-second or 5-minute calibration time limit), the controller 1 15 of the PCM 110 returns to the normal operation mode.

[0242] In stage 1640, the processor 125 of the controller 1 15 calculates the calibration value(s) based on the calibration data collected in stage 1620. The processor 125 in the controller 1 15 averages the values from the calibration tests along with a predetermined number of prior results to determine the final calibration value that is used during normal operation. In some cases, this calculated calibration value sets the required harness tension value or limit to be achieved during normal use, and when the calibration value is achieved, the controller 115 provides an alert via the output device 185 of the buckle 145. In other cases, the calculated calibration value is not the desired harness tension value, but the calculated calibration value provides an offset value that adjusts the internal tension value measured by die tension sensor 120, It should be recognized that this calculated calibration value can be used to make adjustments in other ways. Before, during, or after the calculations arc perfumed in stage 1640, the controller 115 returns to stage 1605 to monitor for one or more unique calibration initiation sequences.

[0243] Glossary of Terms

[0244] The language used in the claims and specification is to only have its plain and ordinary meaning, except as explicitly defined below. The words in these definitions are to only have their plain and ordinary meaning. Such plain and ordinary meaning is inclusive of all consistent dictionary definitions from the most recently published Webster’s dictionaries and Random House dictionaries. As used in the specification and claims, the following definitions apply to these terms and common variations thereof identified below.

[0245] ''Buckle” generally refers to device, such as in the form of a clasp, that releasably secures two or more loose ends together. Typically, but not always one end is secured to or otherwise attached to the clasp device, and the other end is releasably or adjustably held by the clasp device. The ends can be for a variety of objects such as straps, belts, cables, and webbing, to name just a few. One common type of buckle is a seat belt buckle found in a wide variety of vehicles. For instance, the buckle can be used in two-point, three-point, four-point, five-point, or six-point harness systems. In one example, the loose end of a seat belt is looped through a slot in a latch plate that includes a tongue, and to secure the loose end, the tongue is inserted into a seat belt buckle that is attached to a fixed seat belt or webbing.

[0246] "Cam Buckle" generally refers to a device or mechanism that includes a frame and a cam for jaw) pivotally coupled to the frame configured to lock a belt or webbing at a fixed position and or length. The cam commonly, but not always, includes a lever or handle to allow a user to rotate the cam. The cam can be pivotally mounted to the frame in a number of ways such as through one or more pins and or a shaft. In one use ease example, a. free end of the belt passes through a clearance or gap between the frame and the cam. When the cam is rotated relative to the frame, the size of the clearance gap between the cam and frame changes. For instance, rotating the cam in one direction reduces the clearance gap, and rotating the cam in the opposite direction increases the clearance gap. As an example, when the cam is rotated to a closed or locked position, the clearance gap between the cam and the frame is reduced such that the cam bites against the belt to clamp the belt between the cam and frame. In some designs, the cam has a knurled or serrated gripping surface configured to bite against the belt, and in oilier designs, the gripping surface can be generally smooth or have other types of textures. As tension is applied to the belt, the cam is configured to further rotate which in turn reduces the clearance so as to increasing the biting force applied by the cam against the belt. To release the belt, the cam is rotated in the opposite to an opened or unlocked (released) position, the clearance gap between the cam and the frame increases to such a point where the cam no longer grips or bite into the belt. When the cam is in the opened position, the belt is able to slide relative to the cam buckle such that the belt can even be removed from the cam buckle. In some design configurations, the cam buckle further includes a. spring or other biasing device that biases the cam to either the opened or closed position. In one design variation, the spring is coupled between the cam and frame so as to bias the cam to the closed position where the belt is locked in place. In such a case, the user presses against or otherwise actuates the lever of the cam to release the belt. The cam buckle can be made from a variety of materials such as metal and or plastic, and the cam buckle can come in a variety of shapes, sizes, and types. Cam buckles can be used in a large number of ways such as for securing equipment, child safety seals, or even bells for clothing. For example, one type of cam buckle for child restraint systems is sold under the brand A-LOK® by Indiana Mills and Manufacturing, Inc, (1MM1).

[0247] "Child Safety Seat", "Car Seat", or "Child Restraint System (CRS)" generally refer to a seat that is specifically designed to protect children from injury during a vehicle collision. Commonly, the child safety seat is an aftermarket product that is installed by an owner into a vehicle after purchase of the vehicle, but the child safety seat can be also integrated into a seal of the vehicle by a manufacturer of the vehicle. In contrast to most veh icle seats, which are designed to accommodate adults, the child safety seat is sized and configured to properly position a child or infant to reduce injury during an accident. The child safety seat further typically includes a passive restraint system, such as a harness, that generally holds an occupant of the seat in place during a. collision. The restraint system for example can include a five-point harness, but other types of harnesses and restraints can be used. When sold as a separate, aftermarket product, the child safety seat can include an anchoring mechanism, like an Isofix. connector, configured to secure the child safety seat to the vehicle (e.g., via an Isofix anchor in the vehicle). Some typical types of child safety seats include infant seats, convertible seats, combination seats, and booster seats, just to name a few. "Conductor" or "Conductive Material" generally refers to a material and / or object that allows the free flow of an electrical charge in one or more directions such that relatively significant electric currents wi ll flow through the material under the influence o f an electric field under normal operating conditions. By w ay of non-limiting examples, conductors include materials having low resistivity, such as most metals (e.g., copper, gold, aluminum, etc.), graphite, and conductive polymers.

[0248] "Controller" generally refers to a device, using mechanical, hydraulic, pneumatic electronic techniques, and / or a microprocessor or computer, which monitors and physical ly alters the operating conditions of a given dynamical system. In one non -limiting example, the controller can include an Allen Bradley brand Programmable Logic Controller (PLC). A controller may include a processor for performing calculations to process input or output, A controller may include a memory for storing values to be processed by the processor, or for storing the results of previous processing. A. controller may also be configured to accept input and output from a wide array of input and output devices for receiving or sending values. Such devices include other computers, keyboards, mice, visual displays, printers, industrial equipment, and systems or machinery of all types and sizes. For example, a controller can control a network or network interlace to perform various network communications upon request. The network interface may be part of the controller or characterized as separate and remote from the controller. A controller may be a single, physical, computing device such as a desktop computer, or a laptop computer, or may be composed of mul tiple devices of the same type such as a group of servers operating as one device in a networked cluster, or a heterogeneous combination of different computing devices operating as one controller and linked together by a communication network. The communication network connected to the controller may also be connected to a wader network such as the Internet. Thus, a controller may include one or more physical processors or other computing devices or circuitry and may also include any suitable type of memory. A controller may also be a. virtual computing platform having an unknown or fluctuating number of physical processors and memories or memory devices. A controller may thus be physically located in one geographical location or physically spread across several widely scattered locations with multiple processors linked together by a communication network to operate as a single controller. Multiple controllers or computing devices may be configured to communicate with one another or with other devices over wired or wireless communication links to form a network. Network communications may pass through various controllers operating as network appliances such as switches, routers, firewalls or other network devices or interfaces before passing over other larger computer networks such as the Internet. Communications can also be passed over the network as wireless data transmissions carried over electromagnetic waves through transmission lines or free space. Such communications include using Wi-Fi or other Wireless Local Area Network (WLAN) or a cellular transmitter receiver to transfer data.

[0249] "Current" generally refers to the rate of flow of electric charge past a point or region of an electric circuit. An electric current is said to exist when there is a net flow of electric charge through a region.

[0250] "End Glow Fiber Optic Cable" generally refers to a type of optical fiber or fiber optic cable designed to emit light from an exposed end. The end glow fiber optic cable includes one or more optical fibers located within a protective outer jacket. In one form, the end glow fiber optic cable includes multiple optical fibers bundled together within the protective outer jacket. When a light source is connected to one end of the cable, the light travels through the fibers and exits from the other end, creating a luminous effect.

[0251] "Energy Storage System’’ (ESS) or "Energy Storage Unit" generally refers to a device that captures energy produced at one time for use at a later time. The energy can be supplied to the ESS in one or more forms, for example including radiation, chemical, gravitational potential, electrical potential, electricity, elevated temperature, latent heat, and kinetic types of energy. The ESS converts the energy from forms that are difficult to store to more conveniently and / or economically storable forms. By way of non-limiting examples, techniques for accumulating the energy in the ESS can include: mechanical capturing techniques, such as compressed air storage, flywheels, gravitational potential energy devices, springs, and hydraulic accumulators; electrical and / or electromagnetic capturing techniques, such as using capacitors, super capacitors, and superconducting magnetic energy storage coils; biological techniques, such as using glycogen, biofuel, and starch storage mediums; electrochemical capturing techniques, such as using flow batteries, rechargeable batteries, and ultra batteries; thermal capture techniques, such as using eutectic systems, molten salt storage, phase-change materials, and steam accumulators; andfor chemical capture techniques, such as using hydrated salts, hydrogen, and hydrogen peroxide. Common ESS examples include lithium-ion batteries and super capacitors. "Gap" generally refers to a space between objects, surfaces, or points.

[0252] "Harness" generally refers to a set of straps and fittings for fasteni ng a human or other animal in a particular place and / or position. The straps can come on many forms, such as belts, webbing, or ropes, and the straps can be made of a variety of materials such as natural or synthetic materials. The fittings are designed in a variety of Conns for securing the straps around the individual as well as releasing the straps to free the individual. The harness can include webbing, buckles, latch plates, and / or length -adjustment mechanisms, such as a retractor, In one example, the fitting includes a set of latch plates that are secured in a buckle release mechanism. Harnesses can for instance be integrated into vehicle seats, child booster scats, and child safety seats. The straps and fitting can be configured in a number of manners such as to form three-point, five-point, and six-point harnesses, to name just a few examples.

[0253] "Harness Adjuster" generally refers to a device used to tighten and loosen a harness. The harness adjuster can be used to tighten a wide variety of harnesses, such as those used in vehicles. Commonly the harness adjusters are used in child safety seats, but the harness adjuster can have other use cases like for harnesses that secure adults. The harness adjuster can be located at a variety of locations. For instance, the harness adjuster can be located on the back of the seat, on the side of the seat, on the harness itself, and / or between the legs of a seat occupant.

[0254] "Hamess Adjuster Strap" or "Harness Adjuster Belt" generally refers to a single piece of belt or webbing used to tighten a harness. In one common design, the harness adjuster strap is coupled to a harness adjuster configured to loosen or tighten the harness adjuster strap. In this design, the other end of the harness adjuster strap is coupled to a splitter plate which in turn is coupled to one or more belts of the harness.

[0255] "Headrest" or "Head Restraint" generally refers to a structure attached or otherwise integrated into the top of a seat to limit the rearw ard movement of the head of the seat occupant, relati ve to the torso, in a collision. For instance, the headrest is designed to prevent or mitigate whiplash or other injury' to the cervical vertebrae. The headrest can include a fixed headrest or an adjustable headrest. The adjustable headrest is capable o f bei ng positioned to fit the morphology of the seated occupant. The adjustable headrest can be adjusted manually and / or automatically. Another type of headrest includes an active head restraint designed to automatically improve head restraint position and / or geometry for the seat occupant during a collision.

[0256] "Hole" generally refers to a hollow portion through a solid body, wall or a surface. A hole may be any shape. For example, a hole may be, but is not limited to, circular, triangular, or rectangular. A hole may also have varying depths and may extend entirely through the solid body or surface or may extend through only one side of the solid body.

[0257] "Housing" generally' refers to a component that covers, protects, or supports another thing.

[0258] For example, the easing of a desktop computer is its housing component and can be made of multiple materials to protect the internal component.

[0259] "Input Device" generally refers to any device coupled to a computer that is configured to receive input and deliver the input to a processor, memory', or other part of the computer. Such input devices can include keyboards, mice, trackballs, and touch sensitive pointing devices such as touchpads or touchscreens. Input devices also include any sensor or sensor array for detecting environmental conditions such as temperature, light, noise, vibration, humidity, and the like.

[0260] "Input. Output (I / O) Device" generally refers to any device or collection of devices coupled to a computing device that is configured to receive input and deliver the input to a processor, memory, or other part of the computing device and or is controlled by the computing device to produce an output. The I / O device can include physically separate input and output devices, or the input and output devices can be combined together to form a single physical unit. Such input devices of the I / O device can include keyboards, mice, trackballs, and touch sensitive pointing devices such as touchpads or touchscreens. Input devices also include any sensor or sensor array for detecting environmental conditions such as temperature, light, noise, vibration, humidity, and the like. Examples of output devices for the I / O device include, but are not limited to, screens or monitors displaying graphical output, a projecting device pro jecti ng a two-dimensional or three-dimensional i mage, or any kind of printer, plotter, or similar device producing either two-dimensional or three-dimensional representations of the output fixed in any tangible medium (e.g., a laser printer printing on paper, a lathe controlled to machine a piece of metal, or a three-dimensional printer producing an object), An output device may also produce intangible output such as, for example, data stored in a database, or electromagnetic energy transmitted through a medium or through free space such as audio produced by a speaker controlled by the computer, radio signal s transmitted through free space, or pulses of li ght passing through a fiber-optic cable.

[0261] "Insulator" or "Insulative Material" generally refers to a material and-'or object whose internal electric charges do not flow' freely such that very little electric current will flow through the material under the influence of an electric field under normal operating conditions. By way of non-limiting examples, insulator materials include materials having high resistivity, such as glass, paper, ceramics, rubber, and plastics.

[0262] "Integrally Formed” generally refers to a component and / or multiple components that are fused into a single piece. Integral ly formed components are incapable of being dismantled without destroying the integrity of the component.

[0263] "Latch Plate" generally refers to a part of a vehicle belt assembly that releasably connects to a buckle and through which the belt or webbing is threaded or otherwise secured. Typically, but not always, the latch plate is at least in part made of metal and / or plastic. 1‘he latch plate includes one or more tongues that are inserted into the buckle. Each tongue can include a notch or other opening that is used to secure the latch plate to the buckle. By way of nonlimiting examples, the latch plates can include free-sliding latch plates, cinching latch plates, locking latch plates, and switchable latch plates, to name just a few examples.

[0264] "Lateral" generally refers to being situated on, directed toward, or coming from the side.

[0265] "Light Emitting Diode" or "LED" generally refers to a semiconductor diode, made from certain materials, in which light is emitted in response to application of an electrical current. A variety of materials in the LED can produce a. range of colors. The color of the light (corresponding to the energy of the photons) is determined by the energy required for electrons to cross the band gap of the semiconductor. Typically, but not always, white light is obtained by using multiple semiconductors or a layer of light-emitting phosphor on the semiconductor device. The LED can come in the form of a variety of colors, shapes, sizes and designs, including with or without heat sinking, lenses, or reflectors, built into the package. "Lever” generally refers to a simple machine including a beam, rod, or other structure pivoted at a fulcrum, such as a. hinge. In one form, the lever is a. rigid body capable of rotating on a. point on itself. Levers can be generally categorized into three types of classes based on the location of fulcrum, load, and'or effort, In a class 1 type of lever, the fulcrum is located in the middle such that the effort is applied on one side of the fulcrum and the resi stance or load on the other side. For class I type levers, the mechanical advantage may be greater than, less than , or equal to 1 . Some non-limiting examples of class 1 type levers inc lude seesaws, crowbars, and a pair of scissors, in a class 2 type of lever, which is sometimes referred to as a force multiplier lever, the resistance or load is located general ly near the middle of the lever such that the effort is applied on one side of the resistance and the fulcrum is located on the other side. For class 2 type levers, the load arm is smaller than the effort arm, and the mechanical advantage is typically greater than 1 . Some non-limiting examples of class 2 type levers include wheelbarrows, nutcrackers, bottle openers, and automobile brake pedals. In a class 3 type lever, which is sometimes referred to as a speed multiplier lever, the effort is generally located near the middle of the lever such that the resistance or load is on one side of the effort and the fulcrum is located on the other side. For class 3 type levers, the effort arm is smaller than the load arm, and the mechanical advantage is typically less than 1. Some nonlimiting examples of class 3 type levers include a pair of tweezers and the human mandible.

[0266] "Longitudinal” generally refers to the length or lengthwise dimension of an object, rather than across.

[0267] "Magnet" generally refers to a material or object that produces a magnetic field external to itself. Types of magnets include permanent magnets and electromagnets. By way of nonlimiting examples, magnets in certain circumstances are able to attract (or repel) objects such as those made of iron or steel.

[0268] "Memory" generally refers to any storage system or device configured to retain data or information. Each memory may include one or more types of solid-state electronic memory, magnetic memory', or optical memory, just to name a few. By way of non- limiti ng example, each memory may include solid-state electronic Random Access Memory (RAM), Sequentially Accessible Memory (SAM) (such as the First-In, First-Out (FIFO) variety or the Last-In-First-Out (LIFO) variety), Programmable Read Only Memory (PROM), Electronically Programmable Read Only Memory (EPROM), or Electrically Erasable Programmable Read Only Memory' (EEPROM); an optical disc memory (such as a DVD or CD ROM); a magnetically encoded hard disc, floppy disc, tape, or cartridge media; or a combination of any of these memory types. Also, each memory may be volatile, nonvolatile, or a hybrid combination of volatile and nonvolatile varieties.

[0269] "Operatively Coupled" means connected such that current can flow between two devices. In addition, two devices having an optional resistor connecting them are considered to be operatively coupled.

[0270] “Optical Fiber” generally refers to an electromagnetic waveguide having an elongate conduit that includes a substantially transparent medium through which electromagnetic energy travels as it traverses the long axis of the conduit. Electromagnetic radiation may be maintained within the conduit by total internal reflection of the electromagnetic radiation as it traverses the conduit. Total internal reflection is generally achieved using optical fibers that include a substantially transparent core surrounded by a second substantially transparent cladding material with a lower index of refraction than the core. Optical fibers are generally constructed of dielectric material that is not electrically conductive but is substantially transparent. Such material s may or may not include any combination of extruded glass such as silica, fluoride glass, phosphate glass, Chalcogenide glass, or polymeric material such as various types of plastic, or other suitable material and may be configured with any suitable cross-sectional shape, length, or dimension. Examples of electromagnetic energy that may be successfully passed through optical fibers include electromagnetic waves in the near-infrared, mid-infrared, and visible light portion of the electromagnetic spectrum, although electromagnetic energy of any suitable frequency may be used.

[0271] "Output Device" generally refers to any device or collection of devices that is controlled by computer to produce an output. This includes any system, apparatus, or equipment receiving signals from a computer to control the device to generate or create some type of output. Examples of output devices include, but are not limited to, screens or monitors displaying graphical output, any projecting device projecting a two-dimensional or three-dimensional image, any kind of printer, plotter, or similar device producing either two-dimensional or three-dimensional representations of the output fixed in any tangible medium (e.g., a laser printer printing on paper, a lathe controlled to machine a piece of metal, or a three- dimensional printer producing an object). An output device may also produce intangible output such as, for example, data stored in a. database, or electromagnetic energy transmitted through a. medium or through free space such as audio produced by a speaker controlled by the computer, radio signals transmitted through free space, or pul ses of light passing through a fiber-optic cable.

[0272] "Plastic" generally refers to a synthetic or semi-synthetic material made from a wide range of organic polymers, such as polyethylene, PVC, nylon, and the like. Typical ly, but not always, plastics are mostly thermoplastic or thermosetting polymers of high molecular weight and that can be made into objects, films, or fi laments. In some cases, plastics can be molded into shape while soft and then set into a rigid or slightly elastic form.

[0273] ‘'Processor" generally refers to one or more electronic components configured to operate as a single unit configured or programmed to process input to generate an output. Alternatively, when of a multi-component form, a processor may have one or more components located remotely relative to the others. One or more components of each processor may be of the electronic variety defining digital circuitry, analog circuitry, or both, In one example, each processor is of a conventional, integrated circuit microprocessor arrangement. The concept of a "processor" is not limited to a single physical logic circuit or package of circuits but includes one or more such circuits or circuit packages possibly contained within or across multiple computers in numerous physical locations. In a virtual computing environment, an unknown number of physical, processors may be actively processing data, and the unknown number may automatically change over time as well. The concept of a "processor" includes a device configured or programmed to make threshold comparisons, rules comparisons, calculations, or perform logical operations applying a rule to data yielding a logical result (e.g., "true" or "false"). Processing activities may occur in multiple single processors on separate servers, on multiple processors in a single server with separate processors, or on multiple processors physically remote from one another in separate computing devices.

[0274] "Seat assembly" generally refers to all the component parts that make up a seat within a vehicle. A seat assembly generally includes a seat back and a seat bottom.

[0275] "Seat Back" generally refers to the portion of a seat intended to support the back of a passenger. The seat back generally includes a housing, a panel, and a frame. In some instances, the seat back is outfitted, with safety features, such as buckle assemblies and / or child safety seats,

[0276] "Seat Belt", "Safety Belt", "Vehicle Belt", or "Belt" generally refers to an arrangement of webs, straps, and other devices designed to restrain or otherwise hold a person or other object steady such as in a boat, vehicle, aircraft, and / or spacecraft. For example, the seat belt is designed to secure an occupant of a. vehicle against harmful, movement that may result during a collision or a sudden stop. By way of non -limiting examples, the seat belt can include webbing, buckles, latch plates, and / or length-adjustment mechanisms, such as a retractor, installed in the vehicle that is used to restrain an occupant or a child restraint system. The seat belt for instance can include a lap belt only, a combination lap-shoulder belt, a separate lap belt, a separate shoulder belt, and / or a knee bolster.

[0277] "Seat Bottom" generally refers to the portion of a seat that a passenger sits on and the mounting structure, such as mounting pedestals, for securing the seat assembly to the vehicle.

[0278] "Sensor" generally refers to an object whose purpose is to detect events and / or changes in the environment of the sensor, and then provide a corresponding output. Sensors include transducers that provide various types of output, such as electrical and / or optical signals. By way of non Limiting examples, the sensors can include pressure sensors, ultrasonic sensors, humidity sensors, gas sensors, motion, sensors, acceleration sensors, displacement sensors, force sensors, optical sensors, and / or electromagnetic sensors, in some examples, the sensors include barcode readers, RFID readers, and / or vision systems.

[0279] "Shaft" generally refers to a part that rotates about a central axis. Shafts are a part of various mechanically rotating devices, such as motors, engines, transmissions, gearsets, and / or other devices. Shafts are usual ly, but not always, used to transfer mechanical, torque between various mechanical components. For example, the shaft of a motor may transfer energy to a transmission, an axle, a w heel, and / or another device. In some cases, the shaft of a device is integrated with other parts of that device. The shaft can be shaped in any number of manners. For instance, the shaft can have a cylindrical or rectangular shape, and the shaft can be hollow or solid. "Splitter Plate" generally refers to a component that connects one or more belts of a harness to a harness adjuster strap. Typically, the splitter plate is made of strong material, such as metal, but the splitter plate can be made from other materials. In one version, the splitter plate is a metal piece on the back of a car seat that attaches the ends of two shoulder belts of the harness to the harness adjuster strap. In another variation, a single belt that acts as one or more shoulder straps is looped through the splitter plate.

[0280] "Spring" generally refers to an elastic object that stores mechanical energy. The spring can include a resilient device that can be pressed, pulled, and / or twisted but returns to its former shape when released. The spring can be made from resilient or elastic material such as metal and or plastic. The spring can counter or resist loads in many Conns and apply force at constant or variable levels. For example, the spring can include a tension spring, compression spring, torsion spring, constant spring, and / or variable spring. The spring can take many forms such as by being a flat spring, a machined spring, and / or a serpentine spring. By way of nonlimiting examples, the springs can include various coil springs, pocket springs, Bonnell coils, offset coils, continuous coils, cantilever springs, volute springs, hairsprings, leaf springs, V -springs, gas springs, leaf springs, torsion springs, rubber bands, spring washers, and / or wave springs, to name just a. lew,

[0281] "Terminal" generally refers to a plug, socket or other connection (male, female, mixed, hermaphroditic, or otherwi se) for mechanically and electrically connecting two or more wires or other conductors.

[0282] "Voltage" generally refers to a difference in electric potential between two points. A given voltage value must reference another point such as a ground or neutral point as examples. Voltage can be the result of electric charge build-up, electromagnetic induction, electrochemical processes, piezoelectric effects, or thermoelectric effects as examples.

[0283] "Web" generally refers to a material made of a net work of thread, strings, cords, and or wires that form openings in-between. In one form, the cords are interlaced or woven together. The interlaced pattern can be uniform or random.

[0284] It should be noted that the singular forms "a," "an," "the," and the like as used in the description and / or the claims include the plural forms unless expressly discussed otherwise. For example, if the specification and / or claims refer to "a device" or "the device", it includes one or more of such devices.

[0285] It should be noted that directional terms, such as "up," "down," "top," "bottom," "lateral" "longitudinal," "radial" "circumferential" "horizontal," "vertical," etc., are used herein solely for the convenience of the reader in order to aid in the reader’s understanding of the illustrated embodiments, and it is not the intent that the use of these directional terms in any manner limit die described, illustrated, and / or claimed features to a. specific direction and / or orientation.

[0286] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes, equi valents, and modi fications that come w ithin the spirit of the inventions defined by the following claims are desired to be protected. Ail publications, patents, and patent applications cited in this specification are herein incorporated by reference as if each individual publication, patent, or patent application were specifically and individually indicated to be incorporated by reference and set forth in its entirety7herein.

[0287] Reference Numbers

[0288] 100 seat monitoring system

[0289] 105 restraint system

[0290] HO PCM

[0291] 1 15 controller

[0292] 120 tension sensor

[0293] 125 processor

[0294] 130 memory

[0295] 135 ESS

[0296] 140 interface

[0297] 142 tension sensor line

[0298] 145 buckle

[0299] 150 latch plates 155 harness

[0300] 160 splitter plate

[0301] 165 harness adjuster strap

[0302] 170 harness adjuster

[0303] 175 release button

[0304] 180 buckle sensor

[0305] 185 output device

[0306] 190 buckle sensor line

[0307] 195 output line

[0308] 200 child safety seat

[0309] 205 seat assembly

[0310] 210 seat back

[0311] 215 seat bottom

[0312] 220 belts

[0313] 225 buckle belt

[0314] 230 cam buckle

[0315] 605 indicator lights

[0316] 610 emitters

[0317] 615 buckle indicator

[0318] 620 occupancy indicator

[0319] 625 tension indicator

[0320] 705 cable guide

[0321] 805 micro-switch

[0322] 810 hinged spring

[0323] 815 tongues

[0324] 905 housing

[0325] 1005 strap guides

[0326] 1010 tension arm

[0327] 1015 guide amis

[0328] 1020 guide slot 1025 gap

[0329] 1030 guide flanges

[0330] 1205 shaft

[0331] 1210 spring

[0332] 1215 torsion spring

[0333] 1220 guide surface

[0334] 1225 guide channel

[0335] 1230 circuit board

[0336] 1305 sensor

[0337] 1310 magnetic sensor

[0338] 1315 magnet

[0339] 1320 terminal

[0340] 1405 arrow

[0341] 1410 arrow

[0342] 1500 calibration con figurati on

[0343] 1505 calibration sensor

[0344] 1600 flowchart

[0345] 1605 stage

[0346] 1610 stage

[0347] 1615 stage

[0348] 1620 stage

[0349] 1625 stage

[0350] 1630 stage

[0351] 1635 stage

[0352] 1640 stage

Claims

1. CLAIMSWhat is claimed is:

1. A system, comprising: a child safety seat; a. controller; a buckle having a buckle belt; wherein the buckle belt secures the buckle to the child safety seat; an output device being located on the buckle; wherein the output device includes one or more indicator lights; and an. output line extending from the controller to the buckle to provide light from the controller to the indicator lights.

2. The system of claim 1, wherein the output line includes a fiber optic cable that has one or more optical fibers.3, The system of claim 2, wherein: the fiber optic cable includes an end glow fiber optic cable; and the indicator lights are exposed ends of the optical fibers in the end glow fiber optic cable.

4. The system of claim 1, further comprisin g: a harness including one or more latch plates; wherein the latch plates are configured to be detachably secured to the buckle; a. harness adjuster being configured to adjust tension of the harness; wherein the harness adjuster includes a harness adjuster strap; a tension sensor being configured to monitor tension to the harness applied by the harness adjuster; w herein the harness adjuster strap extends along the tension sensor; and wherein the indicator lights include a tension indicator light.

5. The system of claim 4, wherein the controller i s configured to in itiate a calibration mode based on a sequence of input signals from at least one existing input.

6. The system of claim 5, wherein the sequence includes buckling and unbuckling the latch plates with the buckle more than once within a designated time interval7. The system of claim 5, wherein the calibration mode includes calibrating the tension sensor.

8. The system of claim 7, wherein: the controller is configured to collect multiple tension sample readings from the tension sensor during the calibration mode; and the controller is configured to determine a calibration value based at least on averaging the sample readings during the calibration mode.

9. The system of claim 5, wherein the controller is configured to illuminate the indicator lights during the calibration mode.

10. A system, comprising: a child safety seat; a buckle; a harness including one or more latch plates; wherein the latch plates are configured to be detachably secured to the buckle; a harness adjuster being configured to adjust tension of the harness; wherein the harness adjuster includes a harness adjuster strap; a tension sensor being configured to monitor tension to the harness applied by the harness adjuster; a. controller being configured to initiate a calibration mode based on a sequence of input signals from at least one existing input; and wherein the calibration mode includes calibrating the tension sensor.

11. The system of claim 10, wherein the controller is configured to provide a calibration in progress indicator during the calibration mode.

12. The system of claim 10, wherein the sequence includes buckling and unbuckling the latch plates with the buckle more than once within a designated time interval .

13. The system of claim 10, wherein: the control ler is configured to initiate a timer to track duration of the calibration mode; and the control ler is configured to remain in the calibration mode for a limited time.

14. The system of claim 10, wherein : the controller is configured to collect multiple tension sample readings from the tension sensor during the calibration mode; and the controller is configured to determine a calibration value based at least on averaging the sample readings during the calibration mode.

15. A method, comprising: receiving a sequence of input signals at a processor for a restraint system; wherein the sequence is unlikely to occur during normal operation of the restraint system; determining with the processor that the sequence indicates to start a calibration mode for the restraint system; and starting the calibration mode in response to the determining.

16. The method of claim 15, further comprising: initiating a calibration duration timer with the processor in response to the starting the calibration mode; and exiting the calibration mode upon expiration of the calibration duration timer.

17. The method of claim 15, further comprising: indicating the calibration mode is in progress in response to the starting the calibration mode.18, The method of claim 17, wherein: the indicating the calibration mode is in progress includes illuminating one or more indicator lights of the restraint system; and the indicator lights are configured to indicate safety status of the restraint system during normal operation.

19. The method of claim 15, wherein: the restraint system includes a buckle and a harness with one or more latch plates; and the sequence includes buckling and unbuckling the latch plates with the buckle more than once within a designated time interval.

20. The method of claim 19, wherein the sequence includes buckling and unbuckling the latch plates with the buckle 4 times within a 5-second interval.

21. The method of claim 19, wherein the sequence includes buckling and unbuckling the latch plates with the buckle 5 times within a 15-second interval.

22. The method of claim 19, wherein: the restraint system includes a harness adjuster; the harness adjuster includes a harness adjuster strap; the harness adjuster is configured to adjust tension of the harness; the restraint system has a. tension sensor operatively coupled to the processor; the harness adjuster strap extends along the tension sensor; and the calibration mode includes calibrating the tension sensor.

23. The method of claim 22, further comprising: measuring with the tension sensor one or more tension measurement samples at a measurement rate as tension is applied to the harness adjuster strap; tensioning the harness adjuster strap until a target tension is achieved; detecting the target tension with an inline calibration sensor disposed along the harness adjuster strap; holding the harness adjuster strap at the target tension for a hold duration; releasing the harness adjuster strap from tension alter the hold duration; and calculating a calibration value with the processor at least based on the tension measurement samples.

24. The method of clai m 23, further comprising: determining a calibration test value by averaging with the processor a sample size limit number of the tension measurement samples measured prior to the releasing of the harness adjuster strap;storing the calibration test value in memory; and wherein the calculating the calibration value includes averaging the calibration test value stored in memory with one or more prior calibration test values stored in memory from prior calibration tests.

25. The method of claim 24, wherein: the measuring, the tensioning, the detecting, the holding, and the releasing are performed multiple times to perform multiple calibration tests in a single session; and the calculating the calibration value includes averaging the calibration test values from at least the multiple calibration tests in the single session.26, The system or method of any of claims 1 to 25, wherein the output line includes a fiber optic cable that has one or more optical fibers.

27. The system or method of any of claims 1 to 26, wherein: the fiber optic cable includes an end glow fiber optic cable; and the indicator lights are exposed ends of the optical fibers in the end glow fiber optic cable.

28. The system or method of any of claims 1 to 27, further compri sing: a harness including one or more latch plates; wherein the latch plates are configured to be detachably secured to the buckle; a harness adjuster being configured to adjust tension of the harness; wherein the harness adjuster includes a harness adjuster strap; a tension sensor being configured to monitor tension to the harness applied by the harness adjuster; wherein tire harness adjuster strap extends along the tension sensor; and wherein the indicator lights include a tension indicator light.

29. The system or method of any of claims I to 28, wherein the controller is configured to initiate a calibration mode based on a sequence of input signals from at least one existing input.

30. The system or method of any of claims 1 to 29, wherein the sequence includes buckling and unbuckling the latch plates with the buckle more than once within a. designated time interval.

31. The system or method of any of claims 1 to 30, wherein the calibration mode includes calibrating the tension sensor.32, The system or method of any of claims 1 to 31, wherein: the controller is configured to collect multiple tension sample readings from the tension sensor during the calibration mode; and the controller is configured to determine a calibration value based at least on averaging the sample readings during the calibration mode.

33. The system or method of any of claims 1 to 32, wherein the controller i s configured to illuminate the indicator lights during the calibration mode.34, The system or method of any of claims 1 to 33, wherein the controller is configured to provide a calibration in progress indicator during the calibration mode.

35. The system or method of any of claims I to 34, wherein the sequence includes buckling and unbuckling the latch plates with the buckle more than once within a designated time interval.

36. The system or method of any of claims I to 35, wherein: the controller is configured to initiate a timer to track duration of the calibration mode; and the controller is configured to remain in the calibration mode for a limited time.

37. The system or method of any of claims 1 to 36, wherein: the controller is configured to collect multiple tension sample readings from the tension sensor during the calibration mode; and the controller is configured to determine a calibration value based at least on averaging the sample readings during the calibration mode.

38. The system or method of any of claims 1 to 37, further comprising: initiating a calibration duration timer with the processor in response to the starting the calibration mode; and exiting the calibration mode upon expiration of the calibration duration timer.

39. The system or method of any of claims 1 to 38, further comprising: indicating the calibration mode is in progress in response to the starting the calibration mode.

40. The system or method of any of claims 1 to 39, wherein : the indicating the calibration mode is in progress includes illuminating one or more indicatorLights of the restraint system; and the indicator lights are configured to indicate safety status of the restraint system during normal operation.

41. The system or method of any of claims 1 to 40, wherein: the restraint system includes a buckle and a harness with one or more latch plates; and the sequence includes buckling and unbuckling the latch plates with the buckle more than once within a designated time interval.

42. The system or method of any of claims I to 41, wherein the sequence includes buckling and unbuckling the latch plates with the buckle 4 times within a 5-second interval.

43. The system or method of any of claims 1 to 42, wherein the sequence includes buckling and unbuckling the latch plates with the buckle 5 times within a 15-second interval.44, The system or method of any of claims 1 to 43, wherein: the restraint system includes a harness adjuster; the harness adjuster includes a harness adjuster strap; the harness adjuster is configured to adjust tension of the harness; the restraint system has a tension sensor operatively coupled to the processor; the harness adjuster strap extends along the tension sensor; and the calibration mode includes calibrating the tension sensor.

45. The system or method of any of claims 1 to 44, further comprising: measuring with the tension sensor one or more tension measurement samples at a measurement rate as tension is applied to the harness adjuster strap; tensioning the harness adjuster strap until a target tension is achieved; detecting the target tension with an inline calibration sensor disposed along the harness adjuster strap; holding the harness adjuster strap at the target tension for a hold duration; releasing the harness adjuster strap from tension after the hold duration; and calculating a calibration value with the processor at least based on the tension measurement samples.46, The system or method of any of claims 1 to 45, further comprising: determining a calibration test value by averaging with the processor a sample size limit number of the tension measurement samples measured prior to the releasing of the harness adjuster strap; storing the calibration test value in memory; and wherein tire calculating the calibration value includes averaging the calibration test value stored in memory with one or more prior calibration test values stored in memory from prior calibration tests.47, The system or method of any of claims 1 to 46, wherein: the measuring, the tensioning, the detecting, the holding, and the releasing are performed multiple times to perform multiple calibration tests in a single session; and the calculating the calibration value includes averaging the calibration test values from at least the multiple calibration tests in the single session.