Vehicle Flap Control Module Using Current-Based Position Feedback
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Solution Overview
Problem
Existing in-vehicle networking protocols like LIN limit the number of actuators that can be coupled and addressed by a central vehicle control unit, leading to high costs due to the need for expensive actuators with built-in position sensors and multiple conductors, and requiring complex feedback systems.
Innovation Solution
A control unit with a communication module, power supply module, and current sensor module that shares control functionality across multiple driving units, using a single address for multiple actuators, reduces the need for position sensors and conductors, and senses current variations to derive flap positions, allowing for less expensive actuators and simplified feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If actuators are directly addressable with built-in position sensors and multiple conductors, then reliable position feedback is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The position sensing functionality is extracted from the actuator and relocated to the control unit. The control unit now performs the sensing and evaluation functions that were previously embedded in the actuator, simplifying the actuator structure while maintaining reliable position feedback through the existing current sensor module
Solution Approach 2:
The control unit is enhanced to perform multiple functions: it controls the driving units, senses current variations, derives position information, and provides feedback. This multi-functional approach eliminates the need for separate position sensors in each actuator, reducing overall system complexity while maintaining reliability
2Measurement precision
If actuators are equipped with position sensors and multiple conductors for direct addressing, then accurate position control is achieved, but manufacturing cost increases
Solution Approach 1:
The invention replaces expensive actuators with built-in position sensors and multiple conductors with simpler, cheaper actuators that use fewer conductors and no internal position sensors. The position measurement functionality is provided by the shared control unit, significantly reducing per-actuator manufacturing costs
Solution Approach 2:
The control functions for multiple actuators are merged into a single control unit that shares resources including the communication module, current sensor module, and processing logic. This consolidation eliminates redundant components across multiple actuators, reducing overall manufacturing cost while maintaining measurement precision through centralized intelligence
3Ease of operation
If each actuator has full control functionality built-in, then independent operation is achieved, but device complexity and cost increase
Solution Approach 1:
The control system is segmented into a centralized control unit that handles intelligence and multiple simplified actuators that execute commands. The control unit is divided into functional modules including communication module, driving module, and current sensor module, allowing independent operation through centralized coordination rather than embedded intelligence in each actuator
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
Reduces material costs and complexity by enabling cost-effective actuators with reduced wiring and eliminating the need for position sensors, while maintaining accurate flap position control through current variation monitoring.
Implementation Method 1
a current sensor module for sensing variations in the first supply current and the second supply current
Data Source
Figure 1~2
Figure 3
AI summary
A control unit is presented for controlling a driving unit arranged for adjustment of one or more first air guiding flaps of a motorised vehicle between a first outer position and a second outer position. The control unit comprises a communication module for communicating with a vehicle control network for receiving first adjustment instructions for adjusting the first flap, a power supply module comprising an input power terminal for receiving power from a vehicle power network and a first output power terminal for supplying a first current to the driving unit. The control unit further comprises a current sensor module for sensing variations in the first supply current and a control module arranged to control the first supply current in accordance with the adjustment instructions and the sensed variations. By separating the control module from the driving unit, functionality of the control module may be shared over multiple driving units.