Dual Cable Seat Actuator Control Without Return Springs
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Solution Overview
Problem
Existing vehicle seat actuators face challenges in efficiently and reliably controlling both walk-in and folding functions, particularly in the absence of power, and often require springs for return mechanisms, which increase complexity and noise.
Innovation Solution
A dual release actuator with a motor, cable carrier, Hall sensor, and controller that uses a sensing magnet and arc-shaped guide slots to selectively operate two cables, and stores positions in a non-volatile memory for accurate return to initial positions without springs, reducing noise and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If springs are used for return mechanisms in existing actuators, then the return function is achieved, but the device complexity and noise increase
Solution Approach 1:
The patent removes the spring component from the actuator system entirely. The return mechanism is achieved through a rack-and-pinion system with a motor that can reverse direction, extracting the spring element and replacing it with an active motor-controlled mechanism. This eliminates the mechanical complexity and noise associated with springs while maintaining the return function.
Solution Approach 2:
The patent replaces the passive mechanical spring-based return system with an active motor-controlled rack-and-pinion system. The motor can drive the pinion in reverse to return the cable carrier to its initial position, substituting the mechanical spring energy storage and release mechanism with an electromechanical system that offers better control and reduced noise.
2Device complexity
If a single motor controls both walk-in and folding functions, then the device complexity is reduced, but the control precision and reliability may worsen
Solution Approach 1:
The patent implements a single motor that performs multiple functions by controlling a cable carrier with arc-shaped guide slots. The same motor drives the cable carrier to pull different cables (first cable for walk-in function, second cable for folding function) by rotating in different directions. This multi-functional design reduces the number of motors while maintaining reliable control through precise mechanical guidance.
Solution Approach 2:
The patent introduces a cable carrier with arc-shaped guide slots as an intermediary mechanism between the single motor and the two different cables. This intermediary component enables the motor to selectively pull either the first cable or the second cable by rotating in different directions, ensuring that only the intended cable is pulled while the other remains stationary. This mediator mechanism maintains control precision and reliability despite using a single motor.
3Ease of operation
If the cable carrier rotates to pull cables, then the walk-in and folding functions are achieved, but the initial position may drift after power failures
Solution Approach 1:
The patent implements a position learning function that automatically calibrates the initial position of the cable carrier after power restoration. The controller commands the motor to rotate the cable carrier in a predetermined direction until a stopper protrusion contacts a stopper groove, establishing a known reference position. This preliminary calibration action ensures position accuracy is restored after power failures without manual intervention.
Solution Approach 2:
The patent uses a Hall sensor to detect the position of the cable carrier and provide feedback to the controller. The Hall sensor generates pulses as the cable carrier rotates, allowing the controller to count pulses and determine the current position. This feedback mechanism enables the controller to monitor position drift after power failures and execute the position learning function to restore accurate positioning.
4Measurement precision
If arc-shaped guide slots are used to prevent unintended cable movement, then the control precision improves, but the manufacturing precision requirements increase
Solution Approach 1:
The patent divides the cable carrier into distinct regions with arc-shaped guide slots specifically designed for each cable. The first arc-shaped guide slot is positioned to guide the first cable when the cable carrier rotates in the first direction, while the second arc-shaped guide slot is positioned to guide the second cable when rotating in the second direction. This segmentation of the guide slot structure ensures that only the intended cable can be pulled during rotation in a specific direction, maintaining control precision while using standard manufacturing tolerances.
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 actuator ensures fast, quiet, and reliable operation of both walk-in and folding functions, even after power failures, with reduced mechanical load and fewer parts, enhancing durability and assembly efficiency.
Implementation Method 1
a Hall sensor configured to sense rotation of the motor... a sensing magnet mounted at a rotation shaft of the motor, wherein the Hall sensor is configured to sense a variation in a magnetic field caused by rotation of the sensing magnet
Data Source
AI summary
A dual release actuator for a vehicle seat includes a motor, a cable carrier configured to receive power of the motor, thereby rotating to selectively pull one of two different cables, a Hall sensor to sense rotation of the motor, and a controller configured to count a sensing pulse of the Hall sensor for controlling rotation of the motor.