Open Roof Pinch Force Testing With a Generic Control Unit
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Solution Overview
Problem
Testing an open roof assembly for maximum pinch force without a dedicated control unit is challenging, as it requires developing a test device for each vehicle type, which is time-consuming and costly, and may not be feasible due to legal limitations.
Innovation Solution
A method and device using a generic control unit, force sensitive sensor, drive circuitry, and sensors to determine a torque-related constant representative of the maximum pinch force, allowing for direct motor control and data collection without pre-defined parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dedicated control unit is used during manufacturing, then testing for maximum pinch force can be performed, but device complexity and manufacturing costs increase
Solution Approach 1:
A force-sensitive sensor is introduced as an intermediary element positioned in the roof opening. This sensor mediates between the closure member and the testing system, enabling pinch force measurement without requiring a dedicated control unit. The sensor outputs force data that can be processed by generic control units already present in the vehicle.
Solution Approach 2:
Instead of using a specialized dedicated control unit, the invention uses generic control units that are already supplied in vehicles. The force-sensitive sensor creates a simplified measurement system that copies the essential testing function without requiring the full complexity of a dedicated control unit.
2Measurement precision
If a test device is developed for each vehicle type, then accurate pinch force testing is achieved, but development time and costs increase significantly
Solution Approach 1:
The force-sensitive sensor and testing method are designed to be universal across different vehicle types. The same sensor can be positioned in the roof opening of various vehicle models, and the generic control unit can process the force data without requiring vehicle-specific programming or calibration procedures.
Solution Approach 2:
The invention changes the approach from developing vehicle-specific test devices to using a parameter-based measurement system. The force-sensitive sensor directly measures physical parameters (force, position, speed) that are universally applicable across different vehicle types, eliminating the need for extensive development and calibration for each model.
3Ease of manufacture
If indirect measurement using motor current is used, then pinch force can be determined, but measurement precision is affected by motor characteristics
Solution Approach 1:
The invention replaces the electrical measurement approach (monitoring motor current) with a direct mechanical measurement approach. The force-sensitive sensor physically contacts the closure member and directly measures the mechanical force, providing accurate readings independent of motor characteristics or electrical parameters.
Solution Approach 2:
The force-sensitive sensor performs self-service by directly measuring the pinch force without requiring complex calculations or corrections based on motor characteristics. The sensor outputs direct force data that can be used immediately for compliance verification.
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 efficient and cost-effective testing of open roof assemblies for maximum pinch force, predicting the pinch force without the need for a dedicated control unit, thus addressing the challenges of varying vehicle types and legal compliance.
Implementation Method 1
a force sensitive sensor operatively coupled to the generic control unit and configured to output force data representing a force exerted on the force sensitive sensor
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3C
AI summary
A method for testing an open roof assembly comprises steps of providing a test device, the test device comprising a generic control unit, a force sensitive sensor and a drive circuitry; operatively coupling the motor drive assembly to the drive circuitry; positioning the force sensitive sensor in the roof opening; and operating the generic control unit to move the closure member from the open position to the closed position such that the closure member collides with the force sensitive sensor, to receive force data from the force sensitive sensor and to determine from the force data a system property constant. The system property constant is representative for a maximum pinch force of the open roof assembly.