Smart Hinge Assembly with Position Sensor for Tailgate Alignment
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Solution Overview
Problem
Existing powered tailgate assemblies on motor vehicles face challenges in ensuring proper alignment and installation of the tailgate due to misalignment of the hinge pin socket, which can hinder trouble-free and efficient installation.
Innovation Solution
A smart hinge assembly incorporating a rotary drive cup with an absolute position sensor, such as a Hall effect sensor or a sensing element keyed to the drive shaft, monitors the angular orientation of the rotary drive cup and aligns the hinge pin socket with the fixed cup, ensuring proper alignment for installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a powered tailgate assembly is used, then the tailgate can be automatically opened and closed, but misalignment of the hinge pin socket occurs, hindering installation
Solution Approach 1:
The patent incorporates a position sensor that provides feedback on the angular orientation of the rotary drive cup to the controller. This feedback loop enables the system to detect misalignment and automatically adjust the drive cup position to achieve proper alignment of the hinge pin socket with the hinge pin passage, resolving the contradiction between automated operation and installation precision.
Solution Approach 2:
The patent performs preliminary alignment adjustment by automatically positioning the rotary drive cup in the correct angular orientation before tailgate installation. The controller uses position sensor data to pre-align the hinge pin socket with the hinge pin passage, ensuring proper alignment is established in advance of the actual installation process.
2Manufacturing precision
If manual alignment of the hinge pin socket is performed, then installation precision can be achieved, but installation time and complexity increase
Solution Approach 1:
The patent enables the hinge assembly to self-align by using the position sensor to automatically adjust the rotary drive cup orientation. The system performs the alignment function that would otherwise require manual intervention, reducing installation time while maintaining precision. The controller autonomously positions the drive cup based on sensor feedback, eliminating the need for time-consuming manual alignment procedures.
3Ease of operation
If the hinge pin socket is misaligned, then installation can be simplified, but the tailgate cannot be properly installed
Solution Approach 1:
The position sensor provides real-time feedback on the angular orientation of the rotary drive cup, enabling the system to automatically adjust and verify proper alignment. This feedback mechanism ensures that the hinge pin socket is correctly positioned relative to the hinge pin passage, guaranteeing reliable tailgate installation while maintaining ease of operation through automated adjustment rather than complex manual procedures.
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 smart hinge assembly automatically corrects any misalignment, facilitating seamless manual and automated installation and reinstallation of the tailgate by aligning the hinge pin socket with the hinge pin passage, enhancing the efficiency and ease of use of the powered tailgate system.
Implementation Method 1
the drive cup position sensor is a Hall effect sensor
Data Source
AI summary
A smart hinge assembly includes a fixed hinge pin, a rotary drive cup including a hinge pin socket to engage the fixed hinge pin and a drive cup position sensor. That drive cup position sensor is configured to monitor current rotary position of the rotary drive cup.