U.S. patent application number 15/081271 was filed with the patent office on 2017-09-28 for angle-detecting door handle assembly.
The applicant listed for this patent is Tesla Motors, Inc.. Invention is credited to Joris AERTS, Klaus HOFMOCKEL, Brian SVEC.
Application Number | 20170275930 15/081271 |
Document ID | / |
Family ID | 59896350 |
Filed Date | 2017-09-28 |
United States Patent
Application |
20170275930 |
Kind Code |
A1 |
AERTS; Joris ; et
al. |
September 28, 2017 |
ANGLE-DETECTING DOOR HANDLE ASSEMBLY
Abstract
An angle-detecting door handle assembly comprises: a handle
member; a four-bar link configured to move the handle member
between at least retracted and presented positions relative to a
door surface; a motor configured to actuate the four-bar link; a
rotary sensor configured to detect an angle of the four-bar link
throughout actuation and generate a signal corresponding to the
detected angle; and a controller configured to control the motor
based on the signal from the rotary sensor.
Inventors: |
AERTS; Joris; (San
Francisco, CA) ; HOFMOCKEL; Klaus; (El Granada,
CA) ; SVEC; Brian; (Castro Valley, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tesla Motors, Inc. |
Palo Alto |
CA |
US |
|
|
Family ID: |
59896350 |
Appl. No.: |
15/081271 |
Filed: |
March 25, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E05B 81/54 20130101;
B60Q 1/2669 20130101; E05B 81/76 20130101; E05B 81/64 20130101 |
International
Class: |
E05B 81/76 20060101
E05B081/76; E05B 79/06 20060101 E05B079/06; B60Q 1/26 20060101
B60Q001/26; E05B 85/10 20060101 E05B085/10 |
Claims
1. An angle-detecting door handle assembly comprising: a handle
member; a four-bar link configured to move the handle member
between at least retracted and presented positions relative to a
door surface; a motor configured to actuate the four-bar link; a
rotary sensor configured to detect an angle of the four-bar link
throughout actuation and generate a signal corresponding to the
detected angle; and a controller configured to control the motor
based on the signal from the rotary sensor.
2. The angle-detecting door handle assembly of claim 1, wherein the
four-bar link comprises a swing arm and a control arm, the swing
arm pivoting about a shaft relative to the door surface, wherein
the angle is detected by rotation of the shaft.
3. The angle-detecting door handle assembly of claim 1, further
comprising a magnet, wherein the rotary sensor detects orientation
of poles of the magnet.
4. The angle-detecting door handle assembly of claim 3, wherein one
of the magnet and the rotary sensor is mounted relative to a
carrier of the door handle assembly, and another of the magnet and
the rotary sensor is mounted on a separate member attached to the
carrier, wherein the separate member is adjustable relative to the
carrier to change a gap between the magnet and the rotary
sensor.
5. The angle-detecting door handle assembly of claim 4, wherein the
separate member is adjustable in a single dimension relative to the
carrier.
6. The angle-detecting door handle assembly of claim 5, wherein one
of the separate member and the carrier has at least one elongate
slot and wherein another of the separate member and the carrier has
at least one datum feature corresponding to the elongate slot.
7. The angle-detecting door handle assembly of claim 4, further
comprising one or more oversized fastener openings on one of the
separate member and the carrier to allow attachment that
accommodates adjustment between them.
8. The angle-detecting door handle assembly of claim 3, wherein the
rotary sensor comprises a Hall sensor or a magnetoresistive
sensor.
9. The angle-detecting door handle assembly of claim 1, wherein the
controller is configured to stop the motor from actuating the
four-bar link upon detecting that the motor actuates the four-bar
link to a specific angle.
10. The angle-detecting door handle assembly of claim 1, wherein
the controller is configured to start or stop the motor upon
detecting user actuation of the four-bar link by touching the
handle member.
11. The angle-detecting door handle assembly of claim 1, further
comprising a biasing member acting on the four-bar link to bring
the handle member to the retracted position, wherein the motor
actuates the four-bar link against bias of the biasing member to
bring the handle member to the presented position.
12. The angle-detecting door handle assembly of claim 1, further
comprising a mounting member on which the rotary sensor is mounted,
and further comprising a light in the handle member, wherein the
mounting member serves as a breakout for signals to the motor and
to the light.
13. The angle-detecting door handle assembly of claim 12, wherein
the mounting member comprises a printed circuit board, the door
handle assembly further comprising a multi-connector harness that
is a sole connector for the door handle assembly.
14. The angle-detecting door handle assembly of claim 13, further
comprising a housing that accommodates the rotary sensor and the
printed circuit board, the housing having a first cavity for the
multi-connector harness at one end, and respective cavities for the
motor and the light at an opposite end.
15. The angle-detecting door handle assembly of claim 12, wherein
the mounting member comprises a lead frame.
16. A method performed with regard to an angle-detecting door
handle assembly, the method comprising: causing actuation of a
four-bar link by a motor, the four-bar link connected to a handle
member of the door handle assembly, the handle member initially in
a retracted position relative to a door surface; detecting an angle
of the four-bar link throughout the actuation; and when the
detected angle corresponds to a presented position of the handle
member, stopping the actuation of the four-bar link.
17. The method of claim 16, further comprising, in the retracted
position, detecting a change in the angle indicating user actuation
of the four-bar link by pushing of the handle member, and causing
the actuation of the four-bar link in response to the detected
change.
18. The method of claim 16, further comprising, in the presented
position, detecting a change in the angle indicating user actuation
of the four-bar link by pulling of the handle member, and, in
response to the detected change, actuating the four-bar link to
advance the handle member to a clamped position.
19. The method of claim 16, further comprising reprogramming the
angle-detecting door handle assembly so that a different angle
corresponds to the presented position of the handle member.
20. The method of claim 19, further comprising also reprogramming
the angle-detecting door handle assembly to change an angle
corresponding to the retracted position of the handle member, or to
change an angle corresponding to a clamped position of the handle
member.
Description
BACKGROUND
[0001] Some approaches have been used for providing moveable
handles on vehicle closures such as doors. One approach is to
provide one or more force sensors as part of the mechanics of the
handle. For example, this approach is described in co-assigned U.S.
Pat. Nos. 9,080,352; 9,103,143 and 9,151,089. However, force
sensing may not provide the flexibility in operation that may be
desired, and the system can be expensive and relatively difficult
to assemble.
[0002] Another approach is to provide switches as a part of the
mechanism in the handle assembly. For example, switches can sense
the position of a movable component in the handle mechanism, such
as when it travels to the extreme ends of its path of motion.
However, when the handle is traveling (or stationary) in between
the switch positions the system does not have information on the
handle's position. It may therefore be necessary to apply broader
parameters to the travel in order to account for significant
friction or other unexpected factors that could affect the movement
of the handle.
SUMMARY
[0003] In a first aspect, an angle-detecting door handle assembly
comprises: a handle member; a four-bar link configured to move the
handle member between at least retracted and presented positions
relative to a door surface; a motor configured to actuate the
four-bar link; a rotary sensor configured to detect an angle of the
four-bar link throughout actuation and generate a signal
corresponding to the detected angle; and a controller configured to
control the motor based on the signal from the rotary sensor.
[0004] Implementations can include any or all of the following
features. The four-bar link comprises a swing arm and a control
arm, the swing arm pivoting about a shaft relative to the door
surface, wherein the angle is detected by rotation of the shaft.
The angle-detecting door handle assembly further comprises a
magnet, wherein the rotary sensor detects orientation of poles of
the magnet. One of the magnet and the rotary sensor is mounted
relative to a carrier of the door handle assembly, and another of
the magnet and the rotary sensor is mounted on a separate member
attached to the carrier, wherein the separate member is adjustable
relative to the carrier to change a gap between the magnet and the
rotary sensor. The separate member is adjustable in a single
dimension relative to the carrier. One of the separate member and
the carrier has at least one elongate slot and wherein another of
the separate member and the carrier has at least one datum feature
corresponding to the elongate slot. The angle-detecting door handle
assembly further comprises one or more oversized fastener openings
on one of the separate member and the carrier to allow attachment
that accommodates adjustment between them. The rotary sensor
comprises a Hall sensor or a magnetoresistive sensor. The
controller is configured to stop the motor from actuating the
four-bar link upon detecting that the motor actuates the four-bar
link to a specific angle. The controller is configured to start or
stop the motor upon detecting user actuation of the four-bar link
by touching the handle member The angle-detecting door handle
assembly further comprises a biasing member acting on the four-bar
link to bring the handle member to the retracted position, wherein
the motor actuates the four-bar link against bias of the biasing
member to bring the handle member to the presented position. The
angle-detecting door handle assembly further comprises a mounting
member on which the rotary sensor is mounted, and further
comprising a light in the handle member, wherein the mounting
member serves as a breakout for signals to the motor and to the
light. The mounting member comprises a printed circuit board, the
door handle assembly further comprising a multi-connector harness
that is a sole connector for the door handle assembly. The
angle-detecting door handle assembly further comprises a housing
that accommodates the rotary sensor and the printed circuit board,
the housing having a first cavity for the multi-connector harness
at one end, and respective cavities for the motor and the light at
an opposite end. The mounting member comprises a lead frame.
[0005] In a second aspect, a method performed with regard to an
angle-detecting door handle assembly comprises: causing actuation
of a four-bar link by a motor, the four-bar link connected to a
handle member of the door handle assembly, the handle member
initially in a retracted position relative to a door surface;
detecting an angle of the four-bar link throughout the actuation;
and when the detected angle corresponds to a presented position of
the handle member, stopping the actuation of the four-bar link.
[0006] Implementations can include any or all of the following
features. The method further comprises, in the retracted position,
detecting a change in the angle indicating user actuation of the
four-bar link by pushing of the handle member, and causing the
actuation of the four-bar link in response to the detected change.
The method further comprises, in the presented position, detecting
a change in the angle indicating user actuation of the four-bar
link by pulling of the handle member, and, in response to the
detected change, actuating the four-bar link to advance the handle
member to a clamped position. The method further comprises
reprogramming the angle-detecting door handle assembly so that a
different angle corresponds to the presented position of the handle
member. The method further comprises also reprogramming the
angle-detecting door handle assembly to change an angle
corresponding to the retracted position of the handle member, or to
change an angle corresponding to a clamped position of the handle
member.
BRIEF DESCRIPTION OF DRAWINGS
[0007] FIG. 1 shows an example of an angle-detecting door handle
assembly.
[0008] FIG. 1A shows an example of a rotary sensor of the door
handle assembly in FIG. 1.
[0009] FIGS. 2A-E schematically show examples of operations of an
angle-detecting door handle assembly.
[0010] FIG. 3 shows a graph of measured angles that can be used to
control an angle-detecting door handle assembly.
[0011] FIG. 4 shows components of an angle-detecting door handle
assembly.
[0012] FIG. 5 shows another example of an angle-detecting door
handle assembly.
[0013] FIG. 6 shows an example of the lead frame of FIG. 5.
[0014] FIG. 7 shows an example of a housing that can be used for a
rotary sensor.
[0015] FIG. 8 shows a cross section of the housing in FIG. 7.
[0016] FIG. 9 shows an example of a rotary sensor and a magnet.
[0017] FIGS. 10-13 show examples of adjusting a housing relative to
a carrier of an angle-detecting door handle assembly.
DETAILED DESCRIPTION
[0018] This document describes examples of systems and techniques
for detecting the angle of a movable handle so as to control its
operation based on that angle. In some implementations, a moveable
handle is installed in a vehicle closure, such as a door, and the
handle is configured to be retracted into the body of the closure
when not being used and to be extended outside the surface of the
door when the handle is ready to use. The angle can be detected
using a rotary sensor, such as a Hall sensor or a magnetoresistive
sensor, to effectively allow the system to operate the handle in
its current state. For example, the angle detection can serve as an
input that determines when to stop the motor that drives the
handle. As another example, the angle detection can serve to convey
a user interaction to the handle controller, such as when the user
presses or pulls on the handle, and the controller can then operate
the handle motor based on that input.
[0019] Some examples herein relate to a closure on a vehicle.
However, some implementations can involve closures in other
contexts than a vehicle. Also, while a door is sometimes mentioned,
this is for illustrative purposes only. Some implementations can
involve other closures on a vehicle, including, but not limited to,
a lift gate or other trunk closure. Examples of earlier types of
vehicle door handles are described in co-owned U.S. Pat. Nos.
9,080,352, 9,103,143 and 9,151,089, the contents of which are
incorporated herein by reference.
[0020] FIG. 1 shows an example of an angle-detecting door handle
assembly 100. In some implementations, each door on a vehicle can
have a corresponding one of the assembly 100. For example, an
assembly on the left side of the vehicle can in some or all
respects be a mirror image counterpart of an assembly on the right
side. Operations described herein can then be performed on only one
of the handles, or they can be performed on all handles
collectively, or combinations thereof. The assembly is here being
shown from inside the door looking outward. As such, the part of
the door handle that can protrude beyond the outer door panel is
not directly visible here.
[0021] The assembly here includes a handle assembly tray 102 that
holds essentially all components of the assembly. In some
implementations, an inner door panel has an opening where the tray
102 is mounted. For example, the tray can be made of a plastic
material, such as by a molding process.
[0022] While not all of the movable handle portion that is to be
grasped by a user is visible in this illustration, a handle base
member 104 is shown. For example, the member 104 can have posts 106
extending in an essentially transverse direction at either end
thereof. The handle base member 104 is pivotally connected to a
swing arm 108 in the handle assembly by way of one or more shafts
at the handle member. The swing arm is pivotally connected to the
tray 102 by a shaft 110. The handle base member 104 is also
pivotally connected to a control arm 112 in the handle assembly by
way of one or more shafts at the handle member. The control arm is
pivotally connected to the tray 102 by a shaft 114. The handle base
member is pivotally connected to the swing arm 108 and the control
arm 112, respectively, each of which has its respective pivotal
connection to the tray by the shafts 110 and 114. Accordingly, this
can form a four-bar link for the handle assembly. In some
implementations, the four-bar link can allow the handle base member
to remain essentially level while traveling into and out of the
door. For example, this can allow the rotational movement of the
four-bar link to provide the visual appearance of purely horizontal
travel of the movable handle.
[0023] The four-bar link can be biased in at least one direction by
the handle assembly using one or more biasing elements. Here,
springs 116 are shown acting on the swing arm. For example, the
biasing element(s) can urge the four-bar link in an inward
direction in the door.
[0024] The handle assembly includes a motor 118 that is configured
for actuating the four-bar link, and thereby the handle member, in
one or more directions. In some implementations, the motor is a DC
motor that can be caused to rotate in either direction. For
example, an H-bridge can be used for driving the motor. The motor
can actuate the four-bar link using one or more gears. For example,
a paddle gear can be used. The foregoing is an example showing that
the spring(s) 116 can act on the four-bar link to bring the handle
member to a retracted position, and that the motor 118 can actuate
the four-bar link against bias of the biasing member to bring the
handle member to a presented position.
[0025] The handle assembly includes a sensor assembly 120. This
assembly includes an encoder or other rotary sensor that detects
the rotational position of one or more aspects of the four-bar
link. The sensor output can be provided in form of a signal to one
or more controllers for purpose of using such signal to control the
operation of one or more components, including the motor. As such,
the sensor assembly can also play a role in facilitating such
communications to and from various components of the assembly.
Here, the sensor assembly includes a door harness cavity 122 that
is configured for having a single harness of connectors lead to and
from the door handle. For example, this can eliminate the need to
have multiple harnesses for the respective functions, such as power
supply and control signaling. The sensor assembly includes a motor
cavity 124 that by way of a connector 126 extends to the motor 118.
The sensor assembly includes an illumination cavity 128 that by way
of a connector 130 leads to at least one light 132 in the door
handle assembly. In some implementations, the light is incorporated
in the handle base member or in the post(s) to that member. For
example, one or more LEDs can be used.
[0026] The sensor assembly, in addition to providing angle
detection, can facilitate passthrough of signals between respective
ones of the sensor, the motor, the LED and a remote controller. In
some implementations, the harness that connects to the cavity 122
contains respective cables for power supply (e.g., 12V), ground and
signaling, to name some examples, and the sensor assembly ensures
that the signaling conductor is connected to the sensor, while the
motor and LED conductors are coupled to those respective
components. One advantage is that the cavity 122 can serve as the
single point of connection for the rest of the door and the vehicle
to the door handle assembly. As such, the sensor assembly or a part
thereof can serve as a breakout for signals to the motor 118 and to
the light 132.
[0027] FIG. 1A shows an example of a rotary sensor 134 of the door
handle assembly in FIG. 1. The door handle assembly is here shown
only in part, and is presented from an opposite direction than in
the previous figure. As such, the sensor 134 extends from the
sensor assembly 120 (FIG. 1) through an opening in the handle
assembly tray 102. In this position, the sensor can detect the
movement or position or relative position of a magnet assembly 136.
The magnet assembly can include a magnet mounted on the shaft 110
so as to rotate therewith. As such, the magnet can represent the
position of the shaft while or after the four-bar link is subjected
to rotation. The rotary sensor, which can detect the relative
positions of respective poles on the magnet, can therefore detect
the angle of the shaft at all times. The rotary sensor can be a
non-contact sensor. In some implementations, the sensor is a Hall
sensor or a magnetoresistive sensor configured to detect the rotary
position of the magnet attached to the rotatable shaft. For
example, a gap 138 can be formed between the sensor and the
magnet.
[0028] Referring again to FIG. 1, the door handle assembly is
connected, by the harness, to a door handle controller 140 which in
turn is coupled to a body controller 142 for the vehicle. The body
controller can be responsible for a variety of functions in the
vehicle, including, but not limited to, latching and unlatching the
door using a door latch 144. Any suitable processor that executes
instructions can be used for the controller(s), such as an
integrated circuit provided with firmware instructions.
[0029] In this example, the magnet is mounted on the rotatable
member (the shaft) and the sensor is stationary (mounted on the
tray). In other implementations, the positions can be the opposite,
for example such that the magnet is mounted to the tray and the
sensor rotates with the four-bar link, thereby detecting the angle
of rotation between these components.
[0030] FIGS. 2A-E schematically show examples of operations of an
angle-detecting door handle assembly 200. FIG. 3 shows a graph 300
of measured angles that can be used to control an angle-detecting
door handle assembly. Here, the assembly 200 is arranged in a door
of which an outer panel 202 is partially shown. For example, this
panel is the skin of the door that faces outward after
installation. An opening 204 is formed in the outer panel. For
example, this opening allows a door handle 206 of the assembly to
be extended outside the door, and to be at least partially
retracted inside the door.
[0031] The door handle is mounted on a swing arm 208 that can
rotate about a pivot point, such as a shaft 210. The handle 206 is
pivotally mounted to the swing arm itself as part of a four-bar
link that allows essentially horizontal travel of the door handle.
For example, the rotational angle of the shaft 210 can be
continuously monitored by a controller so as to give the controller
information about the position of the door handle. For example, the
monitoring can detect the rotational angle many times every second
so as to produce an essentially continuous detection of the angle.
A spring 212 or other biasing element can be applied to the
four-bar link. The biasing element can urge the handle away from
the outer panel 202 so as to tend to retract the handle into the
door.
[0032] A motor shaft 214 is driven by a motor (not shown). For
example, the motor 118 (FIG. 1) can be used. The motor shaft 214
here has a paddle gear 216 attached to it so as to rotate with the
shaft 214. For example, the paddle gear 216 can actuate the swing
arm 208 toward the outer panel 202. FIG. 2A shows the handle
assembly in a retracted position.
[0033] Referring also to the graph 300, the retracted position can
be determined using an angle threshold 302. For example, the
threshold angle is specified against a vertical axis in the graph,
which axis can have an arbitrary scale. When a detected angle 304
goes below the threshold 302, the handle can be considered in the
retracted position. As a result, other operations can be ceased
(e.g., motor operation and light illumination) and/or initiated
(e.g., door latching).
[0034] Operation of the door handle assembly can be triggered in
one or more ways. For example, because the angle of the shaft is
continuously monitored, it can be registered that a user pushes the
handle 206 inward. In FIG. 2B, an arrow 218 schematically
represents this user interaction. The user's pressing of the door
handle generates a small movement of the handle inward, which can
in turn be detected as a change in the angle of the shaft 210 of
the four-bar link. For example, this movement can be facilitated by
a spring that allows the handle to be pressed somewhat further
inward than its retracted position, or the movement can be
performed against the compliance of the door handle mechanism.
[0035] In the graph 300, the detection of the inward pressing can
be determined using an angle threshold 306. For example, when a
detected angle 308 goes below the threshold 306, it can be deemed
that the handle has been pressed inward. The detection of the
change in shaft angle resulting from an inward push of the door
handle can trigger one or more operations. In some implementations,
this angle detection is interpreted as an input by a user that the
handle should be extended. As a result, one or more components in
the door handle assembly can be energized. For example, the motor
can be actuated to advance the four-bar link so as to extend the
handle through the opening in the outer panel. Other functions than
motor actuation can be triggered by the detection corresponding to
the inward push, including, but not limited to, illumination of one
or more lights on the door handle.
[0036] In FIG. 2C, the motor has been energized to drive the shaft
214 so that the paddle gear 216 advances the swing arm 208, thereby
moving the handle toward an extended position. This motion can be
done against the bias of the spring. The angle of the shaft 210 can
be monitored throughout this movement. As such, the motor can be
operated until the handle reaches a predetermined position (e.g.,
corresponding to the handle reaching 90% of its fully extended
position). Upon that target angle being detected, the motor can be
stopped. In the graph 300, an angle threshold 310 can be used for
determining when the handle has been presented. For example, an
angle 312 can be continuously monitored as the motor is advancing
the handle outward, and when the angle crosses the threshold 310,
the motor can be turned off. At this point, the handle is extended
outside the door to what can be considered a presented position and
can be grasped by a person.
[0037] Because the angle of the shaft 210 is being monitored in the
presented position, a further user interaction with the handle can
be registered and can be used to trigger additional functionality.
For example, FIG. 2D shows an arrow 220 representing that a user
pulls on the door handle 206. That is, when the shaft 210 of the
four-bar link rotates past the point of the presented position
(e.g., past the point where the handle is 90% presented) this can
be interpreted to be a pulling on the door handle by the user's
hand. In the graph 300, an angle threshold 314 can be used to
determine whether the handle is being pulled. For example, when a
monitored angle 316 exceeds the threshold 314, the system can
consider this to be a pulling of the door handle beyond its
presented position.
[0038] In response to this angle detection, one or more operations
can be performed. For example, the controller can open a door latch
so as to unlatch the door to allow it to be swung open. As another
example, the motor can again be energized to advance the door
handle further outward. FIG. 2E shows that the motor has actuated
the shaft 214 so as to apply the paddle gear 216 against the
four-bar link and thereby further extend the handle 206. For
example, this can be considered a clamped position (e.g., the
handle is now at 100% of its extended travel). This 100% extended
travel can help avoid handle movement due to its inertia as the
door is moving. In some implementations, the system immediately
drives the handle to 100%, and then drives it back to 90% based on
a latch status. For example, if the door is closed or ajar the
handle goes back to 90% so a new press can be detected. In the
graph 300, an angle 318 corresponds to the detected angle when the
handle has been moved to its most extended (e.g., clamped)
position.
[0039] A detected angle can also be used for one or more other
purposes. In some implementations, angle monitoring is used for
pinch detection or other accident avoidance. For example, when the
handle is retracting inward the monitored angle can indicate
whether the handle is being impeded by an obstacle. In such
situation, the retraction can be interrupted, for example by
instead using the motor to maintain the handle in place, or to
actuate the handle outward. As another example, when the handle is
being presented, the monitored angle can indicate whether the
handle is being impeded, and the motor can then be stopped to
prevent further extension of the handle.
[0040] FIG. 4 shows components of an angle-detecting door handle
assembly 400. The assembly has a magnet 402. For example, this can
be an elongate or circular magnet. The magnet will be attached to
or otherwise coupled with a shaft 404. For example, this shaft can
be part of a four-bar link that controls the movement of a door
handle. In some implementations, the magnet is attached to the
shaft by way of a carrier 406. For example, the carrier can be
fitted onto an end of the shaft and the magnet can be inserted into
a cavity on the carrier so as to be held in a particular
orientation relative to the shaft.
[0041] The assembly includes a rotary sensor 408 that can detect
the angle of the magnet, and thereby the angle of the shaft,
relative to the sensor. For example, the sensor can be a Hall
sensor or any other rotary encoder. The rotary sensor is here
connected to an integrated circuit (IC) 410. For example, the IC is
programmed according to the type of detection that the assembly is
intended to perform.
[0042] The IC 410 has legs 412 by which it receives power and sends
signals corresponding to the detected angle. The legs facilitate
mounting of the sensor onto some structure, here a printed circuit
board (PCB) 414. For example, the legs can be soldered onto
corresponding leads or other connectors of the PCB. The PCB can
also have first terminals 416 for connection to an external
multi-cable harness, and second terminals 418 that lead to one or
more other parts of the door handle assembly. For example,
terminals 418A can be dedicated for supplying a motor of the
movable door handle, and terminals 418B can be dedicated to one or
more other door handle components (e.g., a lighting unit). That is,
each of the terminals 418 can be connected with one or more of the
terminals 416 by way of pass-through interconnects on the PCB. As
such, the PCB can not only form the mounting structure for the
sensor circuitry, but can also serve as a breakout for the wiring
for the motor and another component (e.g., an LED unit). This can
provide the advantage of simplified installation and eliminating
the need for additional inline connectors for these components.
[0043] The assembly has an at least partially hollow housing 420
that is intended to accommodate the sensor components and the PCB.
In some implementations, the housing on one of its sides has a
cavity 420A to accommodate the terminals 416, and on an opposite
side has respective cavities 420B-C to accommodate the respective
terminals 418. The housing can also provide an arm 422 for housing
the sensor and the IC. For example, the housing can be made from a
plastic material, such as by way of injection molding.
[0044] In the assembly process, the sensor 408 and the IC 410 can
be attached to the PCB 414 by way of the legs 412. Next, the
PCB-sensor assembly can be installed inside the housing 420 such
that the sensor extends within the arm 422. Next, an overmold 424
can be created between the inside of the housing and the PCB-sensor
assembly. For example, this can fixate the circuitry inside the
housing and protect it from mechanical damage.
[0045] FIG. 5 shows another example of an angle-detecting door
handle assembly 500. The assembly includes a door handle tray 502,
a handle base member 504, handle posts 506, a swing arm 508, a
shaft 510, a control arm 512, a shaft 514, a spring 516, a motor
518, a sensor assembly 520, a harness cavity 522, a motor wire
cavity 524, a motor wire 526, an LED wire cavity 528, and an LED
wire 530. A mufti-connector harness 532 is currently attached to
the harness cavity 522. A lead frame 534 is here shown as part of
the sensor assembly 520. A part of the housing for the sensor
assembly has here been removed for clarity, but in normal use the
lead frame can be covered by the housing. The lead frame serves to
couple various connectors or terminals to each other.
[0046] In some implementations, the multi-connector harness 532
leads to a bus and from there to one or more other components in
the vehicle, including, but not limited to, a door handle
controller and a body controller. For example, the door handle
controller 140 and body controller 142 in FIG. 1 can be used.
[0047] In some implementations, the door handle controller can
monitor the angle that is continuously detected by the sensor
assembly, and can give the motor instructions to stop or start
based at least in part on that sensor signal. When it is determined
that a person pulls the handle in the presented position, the door
handle controller can send a signal to the body controller to open
the door. The body controller, in turn, can send a command to a
door latch to unlatch the door. The door handle controller,
moreover, can cause the motor to clamp the handle into the fully
extended (e.g., 100%) position so as to prevent rattling during
door opening. When the door is ajar or closed, the handle can move
back to presented position so it can be pulled again. For example,
when the door is closed the door controller can instruct the door
handle controller to bring the handle back to the presented
position. Upon the occurrence of another event, such as the vehicle
being placed into drive mode or the expiration of a countdown
timer, the door handle controller can actuate the motor to fully
retract the handle(s) into the door(s).
[0048] One advantage of a door handle system based on sensing of
rotational angle is that it can provide increased flexibility to
the installation. In some implementations, operational aspects such
as the position of the grip at various stages (e.g., retracted,
presented, clamped) can then be modified at a future point in time
by way of reprogramming the door handle controller. This can be
done by way of a firmware update, such as to change (or delete or
create) one or more of the threshold angles in the graph 300 of
FIG. 3. For example, a different angle can correspond to the
presented position of the handle member, a different angle can
correspond to the retracted position of the handle member, and/or a
different angle can correspond to a clamped position of the handle
member.
[0049] FIG. 6 shows an example of the lead frame 534 of FIG. 5. The
lead frame has terminals 600 at one end, and terminals 602 at the
other end. For example, the terminals 600 can lead to and from a
harness that is the sole connection from the handle assembly to the
rest of the vehicle. The terminals 602A can lead to the wiring for
an electric motor in the door handle, and the terminals 602B can
lead to a lighting element, such as an LED. The lead frame serves
as a breakout for the connection between, on the one hand, the
harness to the vehicle, and on the other, the motor/LED wiring. As
such, the lead frame can have pass through leads 604A for the
motor, and pass through leads 604B for the lighting or other
component. Terminals 606 allow connections to be made to the sensor
circuitry from the vehicle harness.
[0050] FIG. 7 shows an example of a housing 700 that can be used
for a rotary sensor. In some implementations, the housing can be
used with a lead frame that serves to both couple sensor circuitry
to a vehicle harness and to act as a breakout for signals to one or
more other components in the door handle assembly. The housing
includes a body 702 that is configured to hold the sensor circuitry
(e.g., a rotary sensor and its associated IC), as well as a lead
structure, such as a PCB or a lead frame. On the body are provided
a cavity 704 on one end, and parallel cavities 706 at another end.
For example, these can accommodate couplings for a vehicle harness
and internal components, respectively. The housing can be made from
an injection molded plastic material, to name just one example.
[0051] FIG. 8 shows a cross section of the housing 700 in FIG. 7.
Here, the body 702 has an arm 800 that accommodates at least part
of the sensor circuitry. For example, the arm can allow the sensor
to be positioned on an opposite side of a door handle tray than the
rest of the sensor assembly. Terminals 802 can be used for making
connections with respective legs of the sensor IC. For example,
this can be similar to the terminals 606 in FIG. 6.
[0052] FIG. 9 shows an example of a rotary sensor and a magnet 900.
The rotary sensor is here enclosed in a housing 902. In some
implementations, this enclosure is part of a housing for the entire
sensor assembly, to facilitate that the rotary sensor is positioned
correctly relative to the magnet. For example, the housing can
extend through an opening in a door handle tray 904.
[0053] The magnet is mounted on a shaft 906. In some
implementations, the shaft is arranged so as to be rotatable
relative to the door handle tray when a door handle is being moved
by a motor. For example, the shaft can be part of a four-bar link.
The respective poles of the magnet can be detected by the sensor,
which thereby determines the angle of rotation of the shaft. For
example, the rotary sensor can be a Hall sensor or a
magnetoresistive sensor and can be configured for continuously
sensing the shaft angle, both for purposes of controlling handle
position and for detecting user inputs made by pushing or pulling
on the handle. The spacing between the sensor and the magnet can be
selected to obtain a sensor signal of sufficient quality.
[0054] FIGS. 10-13 show examples of adjusting a housing 1000
relative to a carrier 1002 of an angle-detecting door handle
assembly. The housing can be used with any or all sensor assemblies
described herein. In some implementations, the carrier is part of
respective ones of the door handle assemblies described herein. For
example, the carrier can be similar or identical to the door handle
tray 102 (FIG. 1).
[0055] It has been mentioned earlier that it can be useful to
ensure a particular spacing (or a spacing within a specified range)
between a rotary sensor and the object (e.g., a magnet) that it
detects. For example, a rotary sensor, such as a Hall sensor, works
best when there is a particular air gap between the sensor and the
magnet. However, the tolerances that are designed into the
dimensions of all relative components (e.g., the sensor, the sensor
housing, the magnet, the magnet mount, the shaft and the carrier)
can in some circumstances stack up so that the intended
sensor-magnet air gap becomes larger or smaller than intended.
Generally, the magnet field can be detected from a greater distance
if a stronger magnet is used, but this can have unwanted
consequences regarding cost, assembly size and possible
interference. The housing 1000, on the other hand, is an example of
how adjustability can be provided such that the magnet need not be
oversized in regards to the requirements of the system.
[0056] The housing has openings 1004A-B for attaching the housing
to the carrier. For example, a fastener such as a bolt can be used.
FIG. 11 shows the other side of the carrier 1002 such that the
housing 1000 is only partially visible through an opening 1006. The
sensor is positioned in an arm 1008 of the housing that extends
through the opening 1006.
[0057] A shaft 1010 is part of the door handle assembly. For
example, the shaft can be part of a four-bar link that is designed
to make the door handle movable between at least retracted and
presented positions. A magnet carrier 1012 with a magnet is mounted
on the shaft 1010 so that a gap 1014 is formed between the carrier
and the housing of the sensor.
[0058] FIG. 12 shows that the carrier 1002 can have one or more
datum features 1200. In some implementations, the datum features
are arranged in a particular orientation that corresponds to the
dimension in which the sensor assembly should be adjustable. For
example, the features can be aligned horizontally. FIG. 13,
moreover, shows that the housing 1000 can have one or more elongate
slots 1300. In some implementations, the slot(s) can be integrated
among ribs or other features that already make up the structure of
the housing. For example, the slots can be created in a process
where the housing is molded to a particular form. Here, the slots
are aligned with each other according to the locations of the datum
features.
[0059] The slot(s) 1300 can cooperate with the datum feature(s)
1200 to facilitate adjustment of the housing relative to the
carrier. For example, the housing can be manually slid in either
direction (i.e., as restricted by the one or more datum features
and corresponding elongate slot) until the air gap 1014 has a
specified size. The openings 1004A-B, moreover, can be oversized
relative to the respective locations 1302A-B on the carrier where
the fasteners should attach. As such, the oversized openings can
facilitate reliable securing of the housing to the carrier in
various positions, which enables a flexible control of the
dimensions of the air gap.
[0060] The above example involves two datum features and two
corresponding elongate slots. In other implementations, more or
fewer pairs can be used. Also, the respective positions can be the
opposite so that the datum feature(s) can be on the housing and the
elongate slot(s) can be on the carrier.
[0061] A number of implementations have been described as examples.
Nevertheless, other implementations are covered by the following
claims.
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