Tailgate Interlocking Occupant Step Pinch Prevention
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Solution Overview
Problem
Vehicles with motor-driven occupant steps and tailgates are independently controlled, leading to potential pinching hazards when the steps extend or the tailgates open, as there is no integrated system to detect and prevent collisions with users.
Innovation Solution
A controller with processing circuitry and a kick sensor that interlocks the operation of the powered occupant step and tailgate, deploying both simultaneously upon a kick gesture and stopping their operation if a pinch force is detected, using actuators and sensors to manage the interlocked operation and prevent pinching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the occupant step and tailgate are independently controlled by separate ECUs, then each component can operate autonomously, but pinching hazards occur because there is no coordinated control to detect and prevent collisions with users
Solution Approach 1:
The patent combines the control of the occupant step and tailgate into a single integrated controller that coordinates their operations. The controller receives signals from sensors (kick sensor, pinch sensors) and simultaneously controls both the occupant step motor and tailgate motor, enabling unified decision-making to prevent pinching hazards while maintaining autonomous operation capability.
Solution Approach 2:
The system implements feedback mechanisms through sensors that detect user presence and pinch conditions. The kick sensor detects when a user approaches or kicks the bumper, triggering coordinated deployment. Pinch sensors monitor during operation and provide feedback to the controller, which then stops motor operation when pinching is detected, creating a closed-loop safety system.
2Ease of operation
If the occupant step extends first before the tailgate opens, then the step is ready for user entry, but the tailgate may pinch the user's hand or body during opening
Solution Approach 1:
The system performs preliminary detection through the kick sensor before initiating any movement. When the kick sensor detects a user's approach or kick gesture, the controller pre-coordinates the sequence of operations, ensuring the tailgate and occupant step move in a synchronized manner that prevents pinching, rather than simply extending the step first.
Solution Approach 2:
The control system dynamically adjusts the operation sequence based on real-time sensor feedback. Rather than a fixed sequence, the controller monitors pinch sensors throughout the operation and can dynamically stop or reverse movement if pinching is detected, allowing flexible adaptation to user presence and movement during the opening process.
3Adaptability or versatility
If the tailgate opens without coordinated control with the occupant step, then the tailgate can open independently, but the occupant step may extend into the user or the tailgate may close on the user
Solution Approach 1:
The patent merges the control functions into a single controller that manages both the occupant step motor and tailgate motor. This unified control enables coordinated operation where the controller can simultaneously manage both components, ensuring they work together harmoniously to prevent pinching while maintaining the versatility of independent operation capability when needed.
Solution Approach 2:
The system uses multiple sensors including kick sensors and pinch sensors that provide continuous feedback to the controller. The pinch sensors specifically monitor for contact between the occupant step or tailgate and the user during operation, allowing the controller to detect and respond to potential pinching conditions in real-time by stopping motor operation.
4Device complexity
If separate ECUs control the occupant step and tailgate, then system complexity is reduced with simpler individual controls, but safety coordination between components is lost
Solution Approach 1:
The patent consolidates the control architecture by merging the separate ECUs into a single integrated controller that manages both the occupant step and tailgate. This reduces the number of independent control units while adding coordination capabilities, effectively trading a small increase in controller complexity for a significant decrease in overall system complexity and improved safety.
Solution Approach 2:
The integrated controller performs multiple functions: it controls the occupant step motor, controls the tailgate motor, processes signals from the kick sensor, processes signals from pinch sensors, and makes coordinated decisions to prevent pinching. This multi-functional controller replaces multiple single-function ECUs, achieving safety coordination without proportionally increasing system complexity.
Data Source
AI summary
A tailgate interlocking occupant step apparatus and method for a vehicle, includes a powered tailgate, a powered occupant step, a kick sensor mounted to the occupant step, and a controller having processing circuitry. The processing circuitry detects a signal from the kick sensor, operates the powered occupant step to move the occupant step to an extended position, operates the powered tailgate to lower the tailgate to an opened position, and when a pinch force is detected either in the occupant step or the tailgate, stops the operation of both the occupant step and the tailgate.