Slide-Out Actuator Synchronization With Dynamic End Stops
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Solution Overview
Problem
Existing slide-out assemblies in recreational vehicles face premature wear and failure due to inconsistent extension distances, leading to crooked or non-sealed slide-out rooms, and increased power consumption, which existing control systems fail to address effectively.
Innovation Solution
A control system that monitors the speed and position of each actuator using position sensors, synchronizes their movement, and dynamically updates the end stop positions based on actual travel distances to ensure synchronized actuator operation and reduced wear, employing pulse-width modulation to adjust speeds and reduce power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If full power is provided to actuators during extension and retraction operations, then the extension and retraction speed is improved, but increased wear occurs to the actuators and slide-out assemblies over time
Solution Approach 1:
The control system applies periodic action by varying the power delivery to actuators during operation. Full power is applied during mid-travel phases for rapid movement, while reduced power is applied near end positions to minimize wear. This periodic modulation of power delivery achieves both fast extension/retraction and reduced component wear over time.
Solution Approach 2:
The system dynamically changes the power parameter delivered to actuators based on their position in the travel range. By monitoring actuator position and adjusting power levels accordingly (high power during mid-travel, low power near ends), the system optimizes both speed and wear reduction. This parameter change resolves the contradiction between speed and reliability.
2Device complexity
If pre-programmed end stop positions are used for slide-out assemblies, then the control system operation is simplified, but manufacturing tolerances cause inconsistent extension distances and crooked slide-out rooms
Solution Approach 1:
The control system performs self-service by automatically learning and adapting the actual end stop positions of each actuator through multiple operation cycles. The system monitors actuator behavior and autonomously adjusts the programmed end stop positions to compensate for manufacturing tolerances, eliminating the need for manual calibration while achieving precise, consistent extension distances.
Solution Approach 2:
The system implements feedback by continuously monitoring actuator position and performance during operation. This feedback information is used to detect actual end stop positions and adjust the control parameters accordingly, ensuring that all slide-out assemblies extend to the same precise distance despite variations in manufacturing tolerances.
3Device complexity
If pre-programmed end stop positions are used for slide-out assemblies, then the control system operation is simplified, but the exterior wall may not be flush with the surrounding wall when retracted, leading to water ingress vulnerability
Solution Approach 1:
The control system autonomously learns the precise retracted position of each slide-out assembly by monitoring actuator behavior during retraction operations. This self-adjusting capability ensures that all assemblies retract to the exact same position, guaranteeing that exterior walls remain flush with surrounding walls and maintaining proper vehicle sealing to prevent water ingress.
Solution Approach 2:
Through continuous feedback monitoring of actuator position and retraction behavior, the system automatically adjusts end stop positions to ensure proper alignment when retracted. This feedback mechanism guarantees consistent sealing across all slide-out assemblies, preventing water ingress while maintaining simple automated operation.
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 extends the life of slide-out assemblies by minimizing wear and tear, ensuring flush retraction and extension, and reducing maintenance costs through precise actuator control and power optimization.
Implementation Method 1
employing pulse-width modulation to adjust speeds and reduce power consumption
Data Source
AI summary
A method for detecting and dynamically updating an end stop position of a slide-out assembly comprises the steps of: synchronizing a movement of each of at least two slide-out actuators during an extension operation; detecting a decreased speed of each slide-out actuator of the said at least two slide-out actuators; stopping each of the at least two slide-out actuators when the speed reaches an end-stop position threshold; comparing a travel distance of the at least two slide-out actuators to the said last saved travel distance; and updating the said last saved travel distance to a new saved travel distance, if the travel distance is greater than or less than the last saved travel distance. A control system for detecting and dynamically updating the end stop position is also provided.