Vehicle Occupant Step Kick Sensor Pinch Prevention

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Solution Overview

Problem

In vehicles with motor-driven occupant steps and tailgates, there is a risk of pinching or harm to individuals due to independent control, where the occupant step may extend or retract without proper detection of obstacles, leading to high pinch loads that can be harmful.

Innovation Solution

A powered occupant step system equipped with a kick sensor and a controller that uses processing circuitry to detect kick gestures, halt the occupant step operation, and interlock the operation of the occupant step and tailgate, preventing pinching by stopping the motor operation when a pinch is detected and reversing the step if necessary.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If the occupant step and tailgate are independently controlled by separate ECUs, then each component can operate autonomously, but the risk of pinching increases because one component may extend or retract without detecting obstacles

Engineering Contradiction:

Improveautonomous operation of occupant step and tailgateVSAvoidpinching risk

Core Design Contradiction:

Extent of automationVSObject-affected harmful factors

Solution Approach 1:

The patent combines the control of the occupant step and tailgate into a single integrated control system that coordinates their operations. The controller monitors both components and implements interlocking logic where the tailgate operation is dependent on the occupant step position and vice versa, eliminating the independence that caused pinching risks while maintaining automated operation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system implements feedback mechanisms where the controller continuously monitors the position and operation status of both the occupant step and tailgate. When an obstacle or pinch condition is detected through sensors or motor current analysis, the controller receives feedback and automatically halts or reverses the offending component, preventing harm while maintaining autonomous operation.

Inventive Principle:

Principle #23Feedback

2Device complexity

If the occupant step operates without a coordinated control system, then the device complexity is reduced, but safety is compromised due to inability to detect obstacles during operation

Engineering Contradiction:

Improvecontrol system structureVSAvoidpinch load

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent merges the control functions into a single controller that manages both the occupant step and tailgate operations. This integration adds some complexity but eliminates the need for multiple independent control systems, providing coordinated safety monitoring while maintaining reasonable system simplicity through unified control logic.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated controller acts as an intermediary between the occupant step and tailgate systems, coordinating their operations and mediating conflicts. The controller receives inputs from both systems, processes their operational states, and outputs coordinated control signals that prevent pinching while maintaining efficient operation of both components.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If the occupant step extends rapidly to improve access speed, then productivity increases, but the risk of pinching increases due to higher speed and force

Engineering Contradiction:

Improvespeed of occupant step deploymentVSAvoidpinch load

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent implements dynamic speed control where the occupant step motor operates at high speed during normal extension but automatically reduces speed and increases torque monitoring when approaching extended position or when obstacles are detected. The system dynamically adjusts operational parameters based on real-time conditions, maintaining high productivity during normal operation while preventing pinching through adaptive speed and force control.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system uses feedback from motor current sensors and position sensors to monitor the extension process. When rapid extension is detected or obstacles are sensed, the feedback loop triggers immediate speed reduction and force limitation, preventing pinching while allowing high-speed operation during safe, unobstructed deployment.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS11225195B2Occupant step with kick sensor

Publication Date: 2022.01.18 AISIN WORLD CORP OF AMERICA

AI summary

An occupant step apparatus and method for a vehicle, includes a powered occupant step, a kick sensor mounted to the occupant step, and a controller having processing circuitry. The processing circuitry detects a kick gesture signal from the kick sensor, controls operation of the powered occupant step to move the occupant step, and upon detection of a step gesture signal from the kick sensor while the occupant step is being operated, halts operation of the occupant step.