Seat Range Setting Using Contactless Sensor and Hall Feedback
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Solution Overview
Problem
Conventional seat operation systems face challenges in setting a virtual limit effectively, especially in new power frame structures where the seat may separate from the rail during vehicle collisions, due to reduced overlap between rails, and Hall sensors may malfunction, leading to inaccurate seat positioning.
Innovation Solution
A seat operation range setting system utilizing a contactless sensor connected to an upper rail that senses a bracket on a lower rail, in conjunction with a Hall sensor to detect motor rotation, allowing the controller to set and update virtual limits based on sensor signals and pulse counts, ensuring accurate seat movement range even when Hall sensors malfunction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a Hall sensor is used to detect motor rotation for seat position control, then the seat position can be accurately controlled, but the Hall sensor may malfunction leading to inaccurate seat positioning
Solution Approach 1:
The patent changes the detection parameter from motor rotation (Hall sensor) to direct seat position (contactless sensor). The contactless sensor detects the position of the lower rail bracket directly, bypassing the motor rotation detection that is prone to malfunction, thereby maintaining measurement precision while improving reliability.
Solution Approach 2:
The patent replaces the contact-based Hall sensor detection system with a contactless sensor system. The contactless sensor uses electromagnetic fields to detect the position of the lower rail bracket without physical contact, eliminating the mechanical linkage issues that cause Hall sensor malfunction.
2Length of moving object
If the overlap between upper rail and lower rail is reduced in new power frame structure, then the seat can move to the frontmost position, but the seat may separate from the rail during vehicle collision
Solution Approach 1:
The patent sets a virtual limit position in advance before collision occurs. The contactless sensor detects when the lower rail bracket reaches the predetermined virtual limit position, and the controller stops the seat movement before the rail overlap is completely reduced, preventing seat separation during subsequent collisions.
Solution Approach 2:
The patent introduces a virtual limit position as an intermediary control point between the seat and the physical rail end. The contactless sensor and controller work together to establish this virtual boundary, which mediates the interaction between seat movement and rail structure, allowing full movement range while preventing dangerous separation.
3Reliability
If a virtual limit is set to prevent seat pinching and separation, then seat safety is improved, but the seat operation range may be unnecessarily restricted
Solution Approach 1:
The patent makes the virtual limit position dynamic and adjustable rather than fixed. The controller can adjust the virtual limit position based on different operating conditions, allowing the seat operation range to be maximized when safe and restricted only when necessary for safety, thus resolving the contradiction between safety and range.
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 system accurately sets and maintains virtual limits, preventing seat separation from the rail during vehicle impacts and sensor malfunctions, ensuring reliable seat operation by using a combination of contactless and Hall sensors to determine physical ends and adjust virtual limits accordingly.
Implementation Method 1
a contactless sensor connected to the upper rail, the contactless sensor being configured to sense a bracket disposed at one side of the lower rail
Implementation Method 2
a Hall sensor configured to output a pulse based on the rotation amount of the motor
Data Source
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AI summary
The present disclosure relates to a seat operation range setting system. The seat operation range setting system includes a lower rail disposed on a frame mounted to a floor panel of a chassis, an upper rail installed so as to be slidable along the lower rail, a contactless sensor connected to the upper rail, the contactless sensor being configured to sense a bracket disposed at one side of the lower rail, and a controller configured to receive an ON/OFF signal of the contactless sensor and to set a virtual limit of a seat.