Infinite Vehicle Door Check via Electric Brake Torque
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Solution Overview
Problem
Conventional door checks for vehicle passenger doors provide limited, inconvenient open positions and inconsistent door release forces, especially on inclines, and fail to prevent door collisions with obstacles in tight parking situations.
Innovation Solution
An automotive door system with a hinge, door check module, linkage assembly, brake assembly, and controller that allows for infinite door position adjustment, consistent release force, and obstacle detection, using a gearbox to multiply torque and a coil to adjust magnetic flux for enhanced door arresting capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional door check with detents is used, then the door can be held in discrete open positions, but the door cannot be held at arbitrary angles and the release force is inconsistent on inclines
Solution Approach 1:
The patent replaces the conventional mechanical detent-based door check system with an electric brake assembly controlled by a motor. The motor can apply precise braking torque to hold the door at any angular position, eliminating the need for discrete mechanical detents. This substitution enables continuous position adjustment and consistent holding force regardless of vehicle attitude, as the electric motor can compensate for gravitational effects on inclines.
Solution Approach 2:
The patent changes the control parameter from discrete mechanical detent positions to continuous electric torque control. The motor controller can adjust the braking torque parameter dynamically to maintain the door at any desired angle, providing infinite position flexibility. The system monitors door position and adjusts torque in real-time to maintain holding force consistent across different vehicle attitudes.
2Device complexity
If a conventional door check is used, then the structure is simple, but the door cannot be prevented from hitting obstacles in tight parking situations
Solution Approach 1:
The patent incorporates sensors that provide feedback on door position and obstacle detection. When an obstacle is detected or the door approaches a predefined safety position, the feedback signal triggers the motor controller to apply braking torque, preventing the door from hitting the obstacle. This closed-loop control system actively monitors and responds to potential collision scenarios.
Solution Approach 2:
The system performs preliminary action by detecting potential obstacles before the door actually contacts them. The sensor system identifies obstacles in the door's path and pre-applies braking torque to stop the door before collision occurs, preventing harmful effects rather than reacting after impact.
3Adaptability or versatility
If passive infinite door check solutions are used, then continuous door positioning is achieved, but the door release feel is inconsistent depending on vehicle attitude
Solution Approach 1:
The patent uses the electric motor to counteract the gravitational force acting on the door. When the vehicle is on an incline, the motor applies additional torque to compensate for the weight component parallel to the door swing arc. This active counterweight mechanism ensures that the door can be held securely and released consistently regardless of vehicle attitude, eliminating the inconsistent release feel of passive systems.
Solution Approach 2:
The system transitions from a static passive holding mechanism to a dynamic active control system. The motor continuously adjusts the holding torque based on real-time conditions including vehicle attitude and door position. This dynamic adjustment ensures consistent door behavior and release characteristics across varying operating conditions, as the system actively adapts rather than passively responding.
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
Enables the door to be held in any desired position, providing consistent door operation and preventing collisions with obstacles, regardless of vehicle attitude, with adjustable torque to ensure safe and convenient ingress and egress.
Implementation Method 1
The brake assembly includes a permanent magnet grounding the shaft member to the housing in the normally closed position
Implementation Method 2
A coil is configured to overcome a magnetic flux of the permanent magnet to provide an open position that permits the shaft member to freely rotate relative to the housing
Implementation Method 3
The controller is configured to reverse a polarity of current to the coil to supplement the magnetic flux in the normally closed position thereby increasing the door arresting torque
Data Source
Figure 1A~1B
Figure 2~3A
Figure 3B
AI summary
An automotive door system includes a hinge supporting a door. A door check module interconnects to one of the vehicle and the door by a linkage assembly. An output shaft is connected to the linkage assembly and rotates relative to a door check module housing. The output shaft provides an output torque to check the door in a desired door position. A sensor detects rotation of the shaft and produces a signal in response thereto. A brake assembly includes a shaft member operatively connected to the output shaft. The brake assembly has a normally closed position in which the shaft member is grounded to the housing in a door check mode. The brake assembly includes an open position that corresponds to one of a door closing mode and a door opening mode. The brake assembly moves from the normally closed position to the open position in response to the signal.