111111
`
`1111111111111111111111111111111111111111111111111111111111111111111111111111
`US 20020101210Al
`
`(19) United States
`(12) Patent Application Publication
`Boisvert et al.
`
`(10) Pub. No.: US 2002/0101210 A1
`Aug. 1, 2002
`( 43) Pub. Date:
`
`(54) COLLISION MONITORING SYSTEM
`
`(75)
`
`Inventors: Mario Boisvert, Reed City, MI (US);
`Randall Perrin, Cadillac, MI (US)
`
`(60) Provisional application No. 60/169,061, filed on Dec.
`6, 1999.
`
`Publication Classification
`
`Correspondence Address:
`WATTS, HOFFMANN, FISHER & HEINKE
`CO., L.P.A.
`P.O. Box 99839
`Cleveland, OH 44199-0839 (US)
`
`(51)
`
`Int. Cl? .............................. H02P l/04; G05D 3/00;
`H02P 3/00; G05B 5!00; H02P 7/00;
`H02H 7/08
`(52) U.S. Cl. .............................................................. 318/469
`
`(73) Assignee: Nartron Corporation
`
`(21) Appl. No.:
`
`10/100,892
`
`(22)
`
`Filed:
`
`Mar. 18, 2002
`
`Related U.S. Application Data
`
`(63)
`
`Continuation-in-part of application No. 09!562,986,
`filed on May 1, 2000, now Pat. No. 6,404,158, which
`is a continuation-in-part of application No. 08/736,
`786, filed on Oct. 25, 1996, now Pat. No. 6,064,165,
`which is a continuation of application No. 08/275,
`107, filed on Jul. 14, 1994, now abandoned, which is
`a continuation-in-part of application No. 07/872,190,
`filed on Apr. 22, 1992, now Pat. No. 5,334,876.
`
`(57)
`
`ABSTRACT
`
`Disclosed is an improved system and method for sensing
`both hard and soft obstructions for a movable panel such as
`a sunroof. A dual detection scheme is employing that
`includes an optical sensing as the primary means and
`electronic sensing of motor current as a secondary means.
`The secondary means utilizes system empirical precharac(cid:173)
`terization, fast processing algorithms, motor parameter
`monitoring including both current sensing and sensorless
`electronic motor current commutation pulse sensing, and
`controller memory, to adaptively modify electronic obstacle
`detection thresholds in real time without the use of templates
`and cycle averaging techniques.
`
`VDC
`
`9
`
`DRIVE CURRENT
`COMMUNICATION
`SIGNAL
`
`DRIVE
`CURRENT
`SIGNAL
`
`8
`
`7a
`
`7b
`
`FORWARD
`MOTOR
`DRIVE
`
`2a
`
`REVERSE
`
`DRIVE
`
`~ MOTOR
`
`2
`
`OPTIONAL
`
`OPTIONAL
`
`3
`
`4
`
`5
`
`OPTIONAL
`VEHICLE
`COMMUNICATION
`BUS
`
`1/
`
`BNA/Brose Exhibit 1046
`IPR2014-00417
`
`

`
`Patent Application Publication Aug. 1, 2002 Sheet 1 of 9
`
`US 2002/0101210 A1
`
`POWER
`SUPPLY
`
`VDC
`
`COMMON
`
`VOLTAGE SENSE
`
`OPTIONAL
`3, TEMPERATURE
`..._,.. SENSOR
`t---.-j
`
`OPTIONAL
`4-t- RAIN
`SENSOR
`
`:--
`6
`
`LIMIT
`SWITCHES
`
`OPTIONAL
`VEHICLE
`COMMUNICATION ..........
`BUS
`
`DRIVE CURRENT
`1-- COMMUNICATION
`SIGNAL
`
`2b
`
`\
`
`A
`D
`c
`
`DRIVE ~~8
`.---___, CURRENT
`SIGNAL
`
`FORWARD 1 _-]a
`1-----t~ MOTOR ~
`DRIVE
`
`7b
`/
`
`REVERSE I
`t-----t~ MOTOR V
`DRIVE
`
`2a
`
`~
`
`/
`f
`2
`
`OPTIONAL
`
`FIFO
`MEMORY
`
`Fig.1
`
`Rc
`
`Rb
`
`R1
`
`RO
`
`Ra
`
`Fig.8
`
`

`
`'"""'
`>
`'"""' c
`'"""' N
`'"""' c
`~ c
`N c c
`
`'JJ.
`Cj
`
`'0
`0 .....,
`N
`~ .....
`'JJ. =(cid:173)~
`N 8 N
`'"""' ~
`~
`~
`.... 0 =
`0' -....
`~
`.... 0 =
`~ 't:l -....
`~ = .....
`~ .....
`""C
`
`~ .....
`
`I")
`
`~ .....
`
`I")
`
`...,
`Q
`
`?0
`
`Fig.2B
`
`{)
`
`-
`
`-o \.226....,
`-Q
`~
`
`I
`216
`
`-o
`
`f=J-
`
`06
`~-1
`vee Lo-
`
`-o
`
`2
`
`I
`
`I
`
`0.
`o-r.
`
`- -
`
`-
`
`;>
`
`)C;> )'
`
`c
`
`()
`
`V SWITCH
`
`142_\
`
`I~'
`(~~fr:
`
`110
`
`vv
`
`I
`_L
`
`l
`+100nf 1 r
`
`?? T
`
`f
`0.01J,~.f+
`
`112
`
`'-'
`;:..
`'='
`;:;
`
`:"·
`
`;,:
`
`_A
`
`v
`
`()
`
`152
`\
`
`6o 6
`
`__...-194
`
`192--
`
`6-
`
`(
`
`183...-
`
`Fig.2Cj
`
`"::"
`
`"::"
`
`1 I o.o1J,~.f
`
`>~
`
`'t-99
`
`147nf
`
`'clos? f
`?
`
`I open
`
`=ig.2A
`
`-?
`~
`If T 47nf >
`' ? ':"
`
`q_ COMMON
`
`i 47of
`?
`"::"
`
`-.--
`
`1
`
`/
`
`/
`
`i47of
`
`i 47of
`
`limit? -:-
`not
`
`IT
`e
`
`li
`h
`5
`
`0
`v
`
`ve
`o.
`
`ve
`cl
`
`

`
`'"""'
`>
`'"""' c
`'"""' N
`'"""' c
`~ c
`N c c
`
`'JJ.
`Cj
`
`'0
`0 ......,
`~
`
`~ .....
`'JJ. =-~
`
`N
`
`N c c
`'"""' ~
`> = ~
`.... 0 =
`""C = 0' -....
`.... 0 =
`'t:l -....
`>
`~ = .....
`~ .....
`""C
`
`~ .....
`
`I")
`
`~ .....
`
`I")
`
`'t:l
`
`-:-
`
`136
`
`-:-
`
`122
`
`vee
`
`Fig.28
`
`Fig.2D I
`
`CONTROLLER
`V SWITCH TO
`
`214
`
`~
`
`226
`
`l
`
`I
`
`1\52
`
`I
`
`Q
`
`142
`
`-:-
`
`120
`
`GROU~~
`I -:-
`
`~
`
`~
`
`216
`
`Fig.2A
`
`130
`
`131
`
`

`
`Patent Application Publication Aug. 1, 2002 Sheet 4 of 9
`
`US 2002/0101210 A1
`
`HI•
`
`0.
`:::::;:
`<
`I
`0.
`0
`>
`
`0
`0'>
`
`~
`
`I•
`
`--
`
`0.
`~
`I
`~i----'\A/1., ....... -~-.....
`>
`
`t co
`
`co
`
`~
`
`() "' Ol u:
`
`0.
`:::.
`<
`I
`0.
`0
`>
`
`0 co
`
`l
`
`I•
`
`

`
`Patent Application Publication Aug. 1, 2002 Sheet 5 of 9
`
`US 2002/0101210 A1
`
`..--
`C\1
`
`\
`
`(D
`N
`Q)
`ti:
`
`0
`N
`C\1
`
`~ >
`
`C\1
`t0
`
`~
`a:: >
`
`0.
`0
`tO
`LO
`
`0
`l{)
`
`0
`C\1
`til ·-u..
`
`,.
`
`0
`N
`
`Ll)
`
`c:
`N q
`
`N
`tO
`
`""'"
`tO
`
`""'" 1'0
`..--
`
`tO
`l{)
`
`~I
`
`

`
`Patent Application Publication Aug. 1, 2002 Sheet 6 of 9
`
`US 2002/0101210 A1
`
`108
`
`108
`
`100
`
`\
`
`G
`I
`
`,102
`
`------... -----
`
`0
`
`100
`
`\
`
`104 t
`
`/102
`
`Fig.38
`
`

`
`Patent Application Publication Aug. 1, 2002 Sheet 7 of 9
`
`US 2002/0101210 A1
`
`r
`
`-
`
`107
`
`-
`-
`c
`Fig.3
`
`v-1oo
`,(
`I
`
`103
`
`102 "--
`
`I
`:r
`_p ------ --- -\--- -- - L
`
`105
`
`-----------------------------------------------------
`PINCH ZONE
`
`107
`
`~"""'-
`
`-
`
`r---
`
`'---
`
`1.....-f
`
`100
`
`~
`
`102
`
`----r----.......
`
`Fig.3D
`
`Fig.3E
`
`------ --
`
`~----------G----------~
`
`L...,l-~
`
`303
`
`303
`
`304
`
`305
`
`

`
`Patent Application Publication Aug. 1, 2002 Sheet 8 of 9
`
`US 2002/0101210 A1
`
`TYPICAL
`STARTUP
`ENERGIZATION
`
`200
`
`(/)
`I-
`z
`::>
`(.') 150
`z
`
`0:: w w z
`
`(.')
`13100
`I-z w
`
`0:::
`0:::
`::>
`u
`0:::
`0
`I-
`0
`~
`
`50
`
`0
`
`0
`
`25
`
`50
`TIME (ms)
`
`75
`
`100
`
`Fig.4
`
`50
`
`75
`
`(/)
`I-
`z
`100 ::>
`0 z
`125 0:: w
`w z
`150 0 z
`w
`175 8
`w
`a..
`200 (f)
`0::: w
`225 a..
`
`250
`
`~
`z
`::>
`0 z
`0::: w w
`z
`(.') z
`w
`z
`0
`~
`0::: w
`a..
`0
`0:::
`
`~
`
`~
`
`PATENTED THRESHOLD - OBSTACLE DETECTION
`INVENTIVE THRESHOLD - OBSTACLE DETECTION FUNCTION
`-------------------------------------------------------------------------------------.-
`NOMINAL UPPER RANGE
`
`NOMINAL MOTOR OPERATION FUNCTION
`
`-------------------------------------------------------------------------------------~
`
`NOMINAL LOWER RANGE
`
`0
`
`Fig.S
`
`I
`I
`2000
`1000
`TIME(ms) or POSITION
`
`I
`3000
`
`

`
`Patent Application Publication Aug. 1, 2002 Sheet 9 of 9
`
`US 2002/0101210 A1
`
`UJ
`
`!:: z
`
`:J
`(.!) z
`a:::
`w
`w z
`(3
`z w
`z
`0
`~
`0:: w
`0..
`0
`a:::
`~
`0
`:::2:
`
`PATENTED THRESHOLD-OBSTACLE DETECTION
`
`ADAPTIVE THRESHOLD-OBSTACLE DETECTION FUNCTION
`
`------------·~------------~
`
`-------------------------------~
`MOTOR OPERATION-FUNCTION
`------------------------------------____________ _,_ __ ---- --------------------------------
`
`0
`
`Fig.6
`
`1000
`
`2000
`TIME (ms) or POSITION
`
`3000
`
`~
`z
`:::J
`
`(.!)
`z
`a::: w
`w
`z
`(.!)
`z
`w
`z
`0
`~
`0:: w
`D..
`0
`0::
`
`~ :::2:
`
`PATENTED THRESHOLD-OBSTACLE DETECTION
`
`ADAPTIVE THRESHOLD-OBSTACLE DETECTION FUNCTION
`
`MOTOR OPERATION-FUNCTION
`--------------------------------------------------------------------------------------------~
`
`0
`
`1000
`
`Fig.7
`
`2000
`TIME (ms) or POSITION
`
`3000
`
`

`
`US 2002/0101210 A1
`
`Aug. 1, 2002
`
`1
`
`COLLISION MONITORING SYSTEM
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`[0001] The present application is a continuation-in-part of
`application Ser. No. 09!562,986 filed May 1, 2000 which is
`a continuation-in-part of application Ser. No. 08/736,786 to
`Boisvert et al. which was filed on Oct. 25, 1996, now U.S.
`Pat. No. 6,064,165 which was a continuation of U.S. appli(cid:173)
`cation Ser. No. 08/275,107 to Boisvert et al. which was filed
`on Jul. 14, 1994 which is a continuation in part of applica(cid:173)
`tion Ser. No. 07/872,190 filed Apr. 22, 1992 to Washeleski
`et al., now U.S. Pat. No. 5,334,876. These related applica(cid:173)
`tions are incorporated herein by reference. Applicants also
`incorporate by reference U.S. Pat. No. 5,952,801 to Boisvert
`et al, which issued Sep. 14, 1999. This application also
`claims priority from U.S. Provisional application serial No.
`60/169,061 filed Dec. 6, 1999 which is also incorporated
`herein by reference.
`
`FIELD OF THE INVENTION
`
`[0002] The present invention concerns motor driven
`actuator control systems and methods whereby empirically
`characterized actuation operation parameters are subse(cid:173)
`quently monitored.
`
`BACKGROUND
`
`[0003] National Highway Traffic Safety Administration
`(NHTSA) Standard 118 contains regulations to assure safe
`operation of power-operated windows and roof panels. It
`establishes requirements for power window control systems
`located on the vehicle exterior and for remote control
`devices. The purpose of the standard is to reduce the risk of
`personal injury that could result if a limb catches between a
`closing power operated window and its window frame.
`Standard 118 states that maximum allowable obstacle inter(cid:173)
`ference force during an automatic closure is less than 100
`Newton onto a solid cylinder having a diameter from 4
`millimeters to 200 millimeters.
`
`[0004] Certain technical difficulties exist with operation of
`prior art automatic power window controls. One difficulty is
`undesirable shutdown of the power window control for
`causes other than true obstacle detection. Detection of
`obstacles during startup energization, soft obstacle detec(cid:173)
`tion, and hard obstacle detection each present technical
`challenges requiring multiple simultaneous obstacle detec(cid:173)
`tion techniques. Additionally, the gasket area of the window
`that seals to avoid water seepage into the vehicle presents a
`difficulty to the design of a power window control, since the
`window panel encounters significantly different resistance to
`movement in this region. Operation under varying power
`supply voltage results in actuator speed variations that result
`in increased obstacle detection thresholds.
`
`SUMMARY OF THE INVENTION
`
`[0005] This invention concerns an improved actuator sys(cid:173)
`tem that provides faster operation, more sensitive obstacle
`detection, faster actuator stopping with reduced pinch force,
`and reduced false obstacle detection all with less costly
`hardware. This invention has utilization potential for diverse
`automatic powered actuator applications including position(cid:173)
`ing of doors, windows, sliding panels, seats, control pedals,
`
`steering wheels, aerodynamic controls, hydrodynamic con(cid:173)
`trols, and much more. One exemplary embodiment of pri(cid:173)
`mary emphasis for this disclosure concerns an automatic
`powered actuator as a motor vehicle sunroof panel.
`
`[0006] An exemplary system built in accordance with one
`embodiment of the invention implements position and speed
`sensing is via electronic motor current commutation pulse
`sensing of the drive motor. Motor current commutation
`pulse counting detection means and counting correction
`routines provide improved position and speed accuracy.
`
`In one exemplary embodiment, stored empirical
`[0007]
`parameter characterizations and algorithms adaptively
`modify obstacle detection thresholds during an ongoing
`actuation for improved obstacle detection sensitivity and
`thresholds resulting in quicker obstacle detection with lower
`initial force, lower final pinch force and reduced occurrences
`of false obstacle detection.
`
`[0008] An exemplary embodiment of the collision sensing
`system uses a memory for actuation speed measurement,
`motor current measurement, and calculations of an ongoing
`actuation with real time adaptive algorithms enables real
`time running adaptive compensation of obstacle detection
`thresholds.
`
`BRIEF DESCRIPTIONS OF THE DRAWINGS
`
`[0009] FIG. 1 is a block diagram schematic of the com(cid:173)
`ponents of an exemplary embodiment of the present inven(cid:173)
`tion;
`
`[0010] FIGS. 2A-2D are schematics of circuitry for con(cid:173)
`trolling movement and sensing obstructions of a motor
`driven panel such as a motor vehicle sunroof;
`
`[0011] FIG. 3A is a plan view depicting an optical sensing
`system for monitoring an obstruction in the pinch zone of a
`moving panel such as a motor vehicle sunroof;
`
`[0012] FIG. 3B is a front elevation view of the FIG. 3A
`optical sensing system;
`
`[0013] FIG. 3C is a plan view depicting an optical system
`with moving optics for monitoring an obstruction at the
`leading edge of a moving panel such as a motor vehicle
`sunroof;
`
`[0014] FIG. 3D is a front elevation view of the FIG. 3C
`optical sensing system;
`
`[0015] FIG. 3E is a plan view depicting an optical sensing
`system with moving optics, flexible optic fiber, remote IR
`emission, and remote IR detection for monitoring an
`obstruction at the leading edge of a moving panel such as a
`motor vehicle sunroof;
`
`[0016] FIG. 4 represents typical startup energization char(cid:173)
`acteristics of motor current and per speed versus time;
`
`[0017] FIG. 5 represents a simplified example of charac(cid:173)
`teristic steady state nominal motor operation function versus
`time or position;
`
`[0018] FIG. 6 represents a simplified example character(cid:173)
`istic dynamic transient motor operation function versus time
`and/or position showing motor operation function with
`transients;
`
`

`
`US 2002/0101210 Al
`
`Aug. 1, 2002
`
`2
`
`[0019] FIG. 7 represents a simplified example character(cid:173)
`istic dynamic periodic cyclic motor operation function ver(cid:173)
`sus time and/or position showing motor operation function
`with cyclic disturbances; and
`
`[0020] FIG. 8 is a sequence of measurements taken by a
`controller during successive time intervals and operation of
`a monitored panel drive motor.
`
`BEST MODE FOR PRACTICING THE
`INVENTION
`
`[0021] FIG. 1 shows a functional block diagram of an
`actuator safety feedback control system 1 for monitoring and
`controlling movement of a motor driven panel such as a
`motor vehicle sunroof. A panel movement controller 2
`includes a commercially available multipurpose microcon(cid:173)
`troller IC (integrated circuit) with internal and/or external
`FIFO memory and/or RAM (Random Access Memory) 2a
`and ADC (analog-to-digital-converter) 2b.
`
`[0022] Eight-bit word bytes, eight-bit counters, and eight(cid:173)
`bit analog-to-digital conversions are used with the exem(cid:173)
`plary controller 2. It should be fully realized, however, that
`alternative word lengths may be more appropriate for sys(cid:173)
`tems requiring different parameter resolution. Larger word
`bytes with equivalent ADC resolution enables greater reso(cid:173)
`lution for motor current sensing. Likewise, larger word bytes
`with higher microcontroller clock speeds enable greater
`resolution for motor per speed sensing plus quicker digital
`signal processing and algorithm processing for quicker
`response time.
`
`[0023] A temperature sensor 3 (which according to the
`preferred embodiment of the invention is an option) when
`installed, is driven by and sensed by the controller 2.
`Temperature sensing allows the panel controller 2 to auto(cid:173)
`matically sense vehicle cabin temperature and open or close
`the sunroof to help maintain a desired range of temperatures.
`Temperature compensation of actuator obstacle detection
`thresholds is typically unnecessary.
`
`[0024] An optional rain sensor 4 can be both driven by and
`sensed by the microcontroller 2. Automatic closing of the
`sunroof panel occurs when the sensor is wet. Subsequently,
`the sunroof panel can be opened when either falling rain has
`stopped for some time duration or when the rain has evapo(cid:173)
`rated to some extent.
`
`[0025] Manual switch inputs 5 are the means by which
`operator control of the system occurs.
`
`[0026] Limit switch inputs 6 indicate to the control system
`such physical inputs as HOME position, VENT/NOT OPEN
`Quadrant Switch, and end of panel movement. Limit switch
`signals
`indicate where microcontroller encoder pulse
`counter registers are set or reset representative of specific
`panel position(s).
`
`[0027] Motor drive outputs 7a and 7b control whether the
`motor drives the panel in the forward or the reverse direc(cid:173)
`tion. When neither the forward nor the reverse direction are
`driven, the motor drive terminals are electrically shorted
`together, possibly via a circuit node such as COMMON,
`resulting in an electrical loading and thus a dynamic braking
`effect.
`
`optional method of more quickly stopping the motor, but has
`been unnecessary for use with the preferred embodiment of
`the sunroof panel controller due to satisfactory performance
`taught by this disclosure. Very large motor plugging currents
`are often undesirable because they can easily exceed typical
`maximum stalled rotor currents producing undesired motor
`heating in large applications. Such high motor plugging
`currents can be detrimental to the life and reliability of
`electromechanical relay contacts and solid state switches
`used to switch motor operating currents. High motor plug(cid:173)
`ging currents can also cause undesirable transients, trip
`breakers, and blow fuses in a power supply system.
`
`[0029] Application of brakes and/or clutches is also
`unnecessary with the automotive sunroof system due to the
`improved real time obstacle detection performance taught by
`this disclosure.
`
`[0030] Optical Obstacle Detection
`
`[0031] Obstacle detection by actual physical contact and/
`or pinch force with human subjects is somewhat unnerving
`to some individuals. For improved system safety and user
`comfort, the preferred system utilizes non-contact detection
`of obstacles in the path of the moving panel. Of various
`technologies by which it is possible to sense an obstacle
`without physical contact, IR (infrared) emission with trans(cid:173)
`mission interruption mode detection is preferred. IR emit(cid:173)
`ting diodes and/or IR laser diodes are the two preferred IR
`emission sources. IR photodiodes and/or IR phototransistors
`are the two preferred IR detection means. Optical obstacle
`detection senses and enables stopping of the actuator move(cid:173)
`ment prior to significant applied pinch force and possibly
`prior to actual physical contact with a subject. In unusual
`light conditions, explained below, optical sensing means
`becomes temporarily ineffective, thus obstacle detection via
`motor current sensing or current sensing and speed sensing
`means becomes the remaining reliable backup method of
`detecting an obstacle.
`
`[0032] Of two preferred configurations utilized for imple(cid:173)
`menting IR transmission interruption mode of obstacle
`detection, the first is use of at least one emitter and at least
`one detector sensing at least across the pinch zone in close
`proximity to an end of travel region of a sunroof. As shown
`in FIGS. 3A and 3B, at least one IR emitter 100 and at least
`one IR detector 102 are separated from each other by a
`sunroof pinch zone 104. In an exemplary embodiment of the
`invention, opto sensing of obstructions is across and in
`relatively close proximity to a pinch zone near the end of
`travel region of a sunroof. The depictions in FIGS. 3A and
`3B do not show the entire region between emitter and
`detector but it is appreciated that a gap G between emitter
`and detector is on the order of the width of the moving
`sunroof. In this preferred embodiment, cabling 108 passes to
`the region of the detector 102 around the end of the sunroof
`liner in the region of the end of the sunroof travel. The
`detector and emitter are fixed to the sunroof liner and do not
`move. Implementation of this fixed configuration is simpli(cid:173)
`fied by lack of moving components, although the sunroof
`may have to push the obstacle into a sensing field between
`the emitter 100 and the detector 102. Thus, although the
`sensing means is non-contact, the sunroof can still contact
`the obstacle.
`
`[0028] Motor plugging drive, which is the application of
`reverse drive polarity while a motor is still rotating, is an
`
`[0033] Of two preferred configurations utilized for imple(cid:173)
`menting IR transmission interruption obstacle detection, the
`
`

`
`US 2002/0101210 Al
`
`Aug. 1, 2002
`
`3
`
`second is use of at least one emitter and at least one detector
`sensing at least immediately ahead of the front moving edge
`of the moving portion of a sunroof. As shown in FIGS. 3C
`and 3D, at least one IR emitter 100 and at least one IR
`detector 102 are separated proximal a front moving edge of
`a sunroof 103. In an exemplary embodiment of the inven(cid:173)
`tion, opto-sensing of obstructions is across and in relatively
`close proximity to a front edge 105 of the sunroof 103. The
`depictions in FIGS. 3C and 3D show the entire region
`between emitter and detector for which a gap G, between
`emitter and detector, is on the order of the width of the
`moving sunroof. In this preferred embodiment, flexible fiat
`circuitry 107 passes to the emitter 100 and the detector 102
`of the moving panel or window to the region of the front
`moving edge. Alternate means to supply electrical signal
`and/or power to the moving opto-electronic components
`includes means such as electrical contact brushes cooperat(cid:173)
`ing with conductive traces on the moving panel. Power and
`signal are optionally both transmitted over the same con(cid:173)
`ductors. FIG. 3E shows an alternative means to supply IR
`emission to receive IR detection from the front edge of the
`moving panel via flexible moving optic fiber 303 means
`connected with components 300, 302 that respectively emit
`IR and detect IR signals. IR optical fibers are terminated at
`each end to optical components 304, 305 that perform
`collimating, reflecting, and focusing requirements. The
`structure depicted in FIGS. 3A-3E make it possible to sense
`obstructions with no physical obstacle contact regardless of
`the position of the moving sunroof.
`
`[0034] Alternate, non-preferred means of obstacle detec(cid:173)
`tion include sensing back reflection from a reflective surface
`of radiation emitted from an emitter, electric field sensing of
`proximal material dielectric properties, and magnetic field
`sensing of proximal material inductive properties.
`
`[0035] Various techniques improve the operation and reli(cid:173)
`ability of non-contact optical detection sensing. In accor(cid:173)
`dance with an exemplary embodiment of the present inven(cid:173)
`tion, the IR emitter 100 is driven with a duty cycle and
`frequency. One typical automobile sunroof application uses
`20% duty cycle at 500 Hz IR emitter drive synchronized
`with IR detector sensing. Pulsed drive allows the IR emitter
`100 to be driven harder during its on time at a low average
`power. This harder drive yields improved signal-to-noise for
`IR sensing by the IR detector. The IR detector circuit
`synchronously compares the IR signal detected during IR
`emitter on times with IR emitter off times to determine
`ambient IR levels for drive and signal compensation pur(cid:173)
`poses. This allows the IR emitter to IR detector optical
`coupling to be determined with a level of accuracy and
`reliability using closed loop feedback techniques.
`
`[0036] Automatic gain feedback control techniques main(cid:173)
`tain the level of the IR emitter drive and/or the gain of the
`IR detector circuit so that optical coupling is above mini(cid:173)
`mum desirable values. Such automatic gain compensates,
`within certain limitations, factors including decrease in IR
`emitter output over accumulated time at temperature, IR
`emitter output temperature coefficient, dirt and haze fouling
`optic components, and high ambient IR levels.
`
`[0037] Highly directional IR optical lenses and/or aligned
`polarized filters on both the IR emitter and IR detector
`maintain better optical coupling and reduce the effects of
`ambient IR and reflected IR from other directions. Location
`
`of the IR detector in a physical recess further reduces the
`possibility of extraneous IR "noise" from affecting the
`optical coupling.
`
`[0038] Despite various means to reduce the possibility of
`excess extraneous IR from being detected, certain conditions
`occur that may allow very high levels of direct and/or
`reflected sunlight to be "seen" by the detector. Sun IR power
`levels can saturate the detector output signal level so that
`obstacle blockage of the pulsed IR emitter signals is not
`reliably sensed. Under such unusual "white out" circum(cid:173)
`stances, the IR optical system is disabled by the panel
`controller 2 until the sunroof actuator is nearly closed, at
`which position ambient IR noise is shielded by the sunroof.
`Thus, the complete emitter-detector IR coupling is made
`more reliable for the last movement of pinch point closure.
`Complete body blockage of the IR coupling path between
`the emitter and detector is not a "white out" condition,
`although if the body is blocking both ambient IR and emitted
`IR signal at the detector, a "black out" condition is inter(cid:173)
`preted as an obstacle detection.
`
`[0039] Although the IR obstacle detection means may be
`temporarily found to be unreliable by high ambient levels of
`IR, the disclosed sensing of hard and/or soft obstacles by
`motor current monitoring is always active as a redundant
`obstacle detection means.
`
`[0040] Detailed Schematic
`
`[0041] The controller schematic shown in FIGS. 2A-2D
`implements collision sensing in one form by activating a
`light emitting diode 100a which emits at periodic intervals.
`In the event the infra red radiation is not sensed by a photo
`transistor detector 102a, the controller 2 assumes an obstruc(cid:173)
`tion and deactivates the sunroof motor M. There is also a
`redundant and more reliable obstacle detection means for
`detecting obstacles based upon sensed motor operation
`parameters.
`
`[0042] The preferred controller 2 is an Atmel 8 Bit micro(cid:173)
`processor having 8 Kilobytes of ROM and includes pro(cid:173)
`gramming inputs 106 which can be coupled to an external
`data source and used to reprogram the microprocessor
`controller 2. User controlled inputs Sa, 5b are coupled to
`user activated switches which are activated to control move(cid:173)
`ment of the sunroof. The inputs are similar to now issued
`U.S. Pat. No. 5,952,801 to Boisvert et al, which describes
`the functionality of those inputs. Limit switch outputs 5c, 5d,
`5e are also monitored by the controller 2 and used to control
`activation of the sunroof drive motor.
`
`[0043] The schematic depicts a clock oscillator 110 for
`providing a clock signal of 6 MHZ for driving the micro(cid:173)
`processor controller 2. To the upper left of the oscillator is
`a decoupling capacitor circuit 112 for decoupling a vee
`power signal to the microprocessor.
`
`[0044] The circuitry depicted in FIG. 2B provides power
`signals in response to input of a high signal at the ignition
`input 114. When the ignition input goes high, this signal
`passes through a diode 116 to the base input 118 of a
`transistor 120 which turns on. When the transistor 120 turns
`on, a regulated output of 5 volts (VCC) is provided by a
`voltage regulator 122 in the upper right hand corner of FIG.
`2B. A voltage input to the voltage regulator 122 is derived
`from two battery inputs 124, 126 coupled through a filtering
`and reverse polarity protection circuit 130. Immediately
`
`

`
`US 2002/0101210 Al
`
`Aug. 1, 2002
`
`4
`
`above the positive battery input 124 is a relay output 131
`which provides a signal one diode drop less than battery
`voltage VBAT which powers the relay coils 132, 134 (FIG.
`2D) for activating the motor.
`
`[0045] The circuitry of FIGS. 2A-2D includes a number of
`operational amplifiers which require higher voltage than the
`five volt VCC logic circuitry power signal. At the extreme
`right hand side of the schematic of FIG. 2B are two
`transistors 136, 138 one of which includes a base 140
`coupled to an output 142 from the microprocessor controller
`2. The second transistor has its collector coupled to the
`battery and an output on the emitter designated V-SW. When
`the microprocessor turns on the transistor 138, the V-SW
`output goes to battery voltage. The V-SW output is con(cid:173)
`nected to a voltage regulator (not shown) which generates a
`DC signal that is supplied throughout the circuit for opera(cid:173)
`tion of the various operational amplifiers.
`
`[0046] The microprocessor controller 2 also has two motor
`control outputs 150, 152 which control two switching tran(cid:173)
`sistors 154, 156, which in turn energize two relay coils 132,
`134. The relay coils have contacts 162, 164 coupled across
`the motor M for energizing the motor windings with a
`battery voltage VBAT. One or the other of the transistors
`must be turned on in order to activate the motor. When one
`of the two transistors is on, the motor M rotates to provide
`output power at an output shaft for moving the sunroof or
`other panel along a path of travel in one direction. To change
`the direction of the motor rotation, the first transistor is
`turned off and the second activated. The motor used to drive
`the sunroof panel back and forth along its path of travel in
`the exemplary embodiment of the present invention is a DC
`motor.
`
`[0047] FIG. 2C depicts a circuit 180 for monitoring light
`emitting diode signals. A light emitting diode 100a has an
`anode connection 181 coupled to the V-switched signal and
`the cathode is coupled through a switching transistor 182 to
`a microprocessor output 183. The microprocessor outputs a
`500 hertz signal at this output 183 having a 20% duty cycle
`to the base input of the transistor. When the transistor turns
`on, the LED cathode is pulled low, causing the light emitting
`diode 100a to emit IR radiation. Under microprocessor
`control, the light emitting diode produces a 500 hertz output
`which is sensed by a photo detector 102a. As the light
`emitting diode pulses on and off at 500 hertz, the photo
`detector responds to this input. When current flows in the
`photo detector, a voltage drop is produced across a voltage
`divider 184 having an output coupled to an operational
`amplifier 186. When current flows in the photo detector in
`response to receipt of a light signal the voltage divider raises
`the voltage at the inverting input 188 to the amplifier 186.
`The non-inverting input to this amplifier is maintained at 2.5
`volts by a regulated voltage divider 188. The operational
`amplifier 186 and a second operational amplifier 190 define
`two inverting amplifiers which in combination produce an
`output signal of 500 hertz. With no signal appearing at the
`photo detector, an output 192 from the operational amplifier
`190 is 2.5 volts. This signal is coupled to the microprocessor
`controller 2. In response to receipt of the photo detector
`signal, this signal oscillates and this oscillating signal in turn
`is sensed by the microprocessor.
`
`[0048] The microprocessor controller 2 has two inputs
`192, 194 that provide input signals to a comparator imple-
`
`mented by the microprocessor controller. As the state of the
`comparator changes, internal microprocessor interrupts are
`generated which cause the microprocessor to execute certain
`functions. The first input 192 is derived from the output from
`the phototransistor 102a. The second input 194 to the
`comparator is a 3.3 volt signal generated by a voltage divider
`195.
`[0049] Motor Current Monitoring
`[0050] A motor current monitoring circuit is depicted in
`FIG. 2D and includes a number of operational amplifiers
`200-203 coupled to a current measuring resistor 210 in the
`lower right hand portion of the circuit diagram. This current
`measuring resistor is coupled to the operational amplifier
`200 configured as a differential amplifier through a second
`resistor 211. An output 212 from this differential amplifier is
`a signal proportional to the current through the motor
`windings which has been amplified by a factor of about four.
`The output from this amplifier passes to a second gain of 3
`amplifier 201 to an output 214 coupled to the microproces(cid:173)
`sor controller through a resistor 215. This signal is moni(cid:173)
`tored by the microprocessor and converted by an A to D
`conversion to a digital value directly related to motor
`current.
`[0051] An input 220 to the second pair of operational
`amplifiers 202, 203 is either an output from the first differ(cid:173)
`ential amplifier 200 or the second gain of 3 amplifier 201
`depending upon whether a resistor 222 is installed in the
`circuit. One but not both of the resistors 222, 223 are
`installed in the circuit.
`[0052] The changing signal output from the resistor 210 is
`coupled to an inverting input of an AC coupled amplifier and
`produces an output signal 226 to the microprocessor con(cid:173)
`troller 2 which changes with motor current and more par(cid:173)
`ticularly as the commutator brushes pass over th