Power Vehicle Door Module With Brake-Hold Torque Control
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Solution Overview
Problem
Conventional passenger doors in vehicles require manual operation and lack efficient power drive modules, which are often complex and require clutches, limiting automated opening and closing capabilities.
Innovation Solution
A power door system with a hinge, motor, gearbox, brake assembly, and position sensor that allows automatic door operation via a controller, eliminating the need for manual pushing or pulling, and providing a holding torque for desired door positions without discrete detents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a power drive module is applied to a passenger door, then automated opening and closing capability is improved, but device complexity increases due to the need for motors, clutches, and gears
Solution Approach 1:
The patent extracts and eliminates the clutch component from conventional power drive modules. The brake assembly is designed to directly couple and decouple the motor from the gearbox without requiring a separate clutch mechanism, thereby reducing device complexity while maintaining automated operation capability
Solution Approach 2:
The brake assembly serves multiple functions: it acts as a holding brake to maintain door position, serves as a coupling mechanism between motor and gearbox, and provides controlled engagement and disengagement. This multi-functionality eliminates the need for separate clutch and brake components, reducing overall system complexity
2Extent of automation
If a clutch mechanism is used to couple and decouple the motor, then automated operation is enabled, but device complexity and potential failure points increase
Solution Approach 1:
The patent removes the clutch mechanism entirely from the power drive module. The brake assembly directly performs the coupling and decoupling function by engaging and disengaging the motor from the gearbox, eliminating an entire subsystem and reducing complexity
Solution Approach 2:
The brake assembly automatically engages and disengages the motor based on control signals, performing the coupling function without requiring a separate clutch actuation mechanism. The system self-regulates motor engagement through the brake's inherent design
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 automated and manual operation of vehicle passenger doors with enhanced torque control, reducing complexity and improving user experience by providing smooth opening and closing without the need for manual effort or complex clutch systems.
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
Data Source
Figure 1A~1B
Figure 2~3A
Figure 3B
AI summary
An automotive door system includes a hinge that supports a door. A switch provides a first input in response to a user request to automatically open or close the door. An output shaft of a power drive module is connected to the door and a gearbox to provide an output torque that corresponds to a desired motion of the door about the hinge. A brake assembly is connected to a shaft member and has a normally closed position in which the shaft member is grounded to the housing and an open position that corresponds to one of a door closing mode and a door opening mode. A position sensor detects rotation of the output shaft and provides a second input in response thereto, which corresponds to a manually initiated movement of the door that exceeds a slip torque of the brake assembly in the normally closed position.