Powered Door Actuator Control Layout for EMI-Resistant Packaging
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Solution Overview
Problem
Existing power door systems face challenges with electromagnetic interference and packaging complications, including the power closure member actuation systems and power actuators which address and overcome limitations and drawbacks, as well as to provide increased convenience and enhanced operational capabilities.
Innovation Solution
The solution includes an actuator system with an electric motor and a rotary-to-linear conversion device, an actuator housing, an actuator controller, and an accelerometer to sense and control the movement of a closure member, such as a vehicle door, using a distributed control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-resolution position sensors (magnet wheel and Hall effect sensor) are used to accurately measure position, then measurement precision is improved, but the system becomes adversely affected by electromagnetic interference from the EM brake
Solution Approach 1:
A non-magnetic intermediary element (such as a non-magnetic spacer or housing component) is introduced between the EM brake and the position sensor. This intermediary blocks the electromagnetic field generated by the EM brake from reaching the sensor, thereby preventing interference while allowing the sensor to continue measuring position accurately.
Solution Approach 2:
The position sensor is repositioned or extracted from the immediate vicinity of the EM brake. By changing the spatial arrangement and moving the sensor away from the harmful electromagnetic field source, the system maintains measurement precision while eliminating the adverse electromagnetic interference effect.
2Device complexity
If power actuator packaging is integrated within the closure member cavity, then device complexity is reduced, but interference arises between the rotating power actuator and other structures and components
Solution Approach 1:
The power actuator system is segmented into separate functional modules (motor assembly, gear assembly, sensor assembly, controller assembly) that can be independently packaged and positioned. This segmentation allows each component to be optimized for its specific function while minimizing interference with other components, resolving the conflict between integrated packaging and operational interference.
Solution Approach 2:
The power actuator and its components are arranged in three-dimensional space with careful consideration of rotational movement paths. By utilizing vertical stacking and radial positioning, the design accommodates the rotating actuator without interference from door structures, effectively solving the spatial conflict through dimensional arrangement.
3Device complexity
If the actuator controller is disposed within the sensor housing, then device complexity is reduced, but the controller is exposed to electromagnetic interference and packaging constraints
Solution Approach 1:
A non-magnetic shielding barrier or intermediary structure is introduced between the EM brake and the actuator controller. This intermediary element protects the controller from electromagnetic interference while maintaining the compact integrated packaging arrangement, thus resolving the contradiction between simplified packaging and electromagnetic protection.
Solution Approach 2:
A thin non-magnetic shielding film or shell is applied around the actuator controller to protect it from electromagnetic fields. This flexible shielding approach provides electromagnetic protection without significantly increasing the overall packaging volume, thus maintaining design simplicity while addressing the interference issue.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides enhanced control over the movement of vehicle doors, reducing interference and packaging complications while improving operational convenience and efficiency.
Implementation Method 1
an accelerometer configured to sense movement of the closure member
Implementation Method 2
an electric motor disposed in the actuator housing and configured to rotate a driven shaft
Implementation Method 3
a rotary-to-linear conversion device having an externally-threaded leadscrew rotatively driven by the electric motor and an internally-threaded drive nut meshingly engaged with the leadscrew
Data Source
AI summary
An actuator assembly of an actuation system for a closure member of a vehicle is provided. The actuator assembly includes an actuator housing including a sensor housing. The actuator assembly also includes an electric motor disposed in the actuator housing and configured to rotate a driven shaft operably coupled to an extensible member that is coupled to one of a body or the closure member for opening or closing the closure member. The actuator assembly also includes an actuator controller disposed in the sensor housing of the actuator housing and coupled to electric motor and an accelerometer configured to sense movement of the closure member. The actuator controller is configured to detect the movement of the closure member using the accelerometer. The actuator controller then controls the opening or closing of the closure member based on the movement of the closure member using the electric motor.