Development of an Anti-Pinch System for Passenger Vehicles
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Development of an Anti-Pinch System for Passenger Vehicles A Product Development Project at Volvo Cars Master’s thesis in Product Development MARCUS BOHLIN GUNJAN NAGPAL Department of Industrial and Materials Science CHALMERS UNIVERSITY OF TECHNOLOGY Gothenburg, Sweden 2020 www.chalmers.se MASTER’S THESIS 2020 Development of an Anti-Pinch System for Passenger Vehicles An Anti-Pinch System that can replace multiple such systems used today, while also meeting legal safety regulations. In collaboration with Volvo Car Corporation. Marcus Bohlin Gunjan Nagpal Department of Industrial and Materials Science Division of Product Development CHALMERS UNIVERSITY OF TECHNOLOGY Gothenburg, Sweden 2020 iii Development of an Anti-Pinch System for Passenger Vehicles An Anti-Pinch System that can replace multiple such systems used today, while also meeting legal safety regulations. In collaboration with Volvo Car Corporation. MARCUS BOHLIN GUNJAN NAGPAL © MARCUS BOHLIN, GUNJAN NAGPAL, 2020. Supervisor: Egoi Sanchez Basualdo, Volvo Car Corporation, Interior Lights and Functional Parts Examiner: Dr. Erik Hulthén, Chalmers University of Technology, Department of Industrial and Materials Science Master’s Thesis 2020 Department of Industrial and Materials Science Division of Product Development Chalmers University of Technology SE-412 96 Gothenburg Telephone +46 31 772 1000 Cover: A lineup of Volvo Cars. © Volvo Car Corporation Printed by Chalmers Reproservice Gothenburg, Sweden 2020 v Development of an Anti-Pinch System for Passenger Vehicles An Anti-Pinch System that can replace multiple such systems used today, while also meeting legal safety regulations. In collaboration with Volvo Car Corporation. A Product Development Project at Volvo Cars MARCUS BOHLIN GUNJAN NAGPAL Department of Industrial and Materials Science Chalmers University of Technology Abstract Products are becoming increasingly complex and so is every vehicle on the road. Passenger car manufacturers are adding more customer-oriented comfort features at every price segment in order to differentiate themselves from the competition. A lot of these features make use of automating the movement of various parts such as sunroof panels, seats and tailgates. Automation through motorized components needs to be accompanied by systems that can act as safeguards to prevent human injury due to this automation process. This thesis aims to lay the groundwork thereby equipping Volvo Cars with the knowledge to develop a consolidated anti-pinch system that could potentially be used in several different automotive components. Different approaches for detecting pinch situations across industries and environments were evaluated. Two principally different approaches were chosen for further development, the first using hall sensors and the second leveraging ripple counting. A fundamental requirement for the developed concepts was conforming with legal regulations, namely the US regulation FMVSS No. 118 and the UN regulation ECE-R21-01. Taking an approach of early prototyping and testing, the concepts were continuously being tested along with their development. After going through prototyping and testing, three different recommendations were made for Volvo Cars based on different timescales. A concept that meets legal testing requirements was suggested for implementation in 1-2 years, whereas other concepts that would require more developmental effort were suggested for timescales of 3-4 years and 7+ years. With an in- house system at their disposal, Volvo will have greater control over the functionality and safety of their anti-pinch systems, while also enabling cost savings. Keywords: Automotive, Mechatronics, Passenger Safety, Anti-Pinch System, Hall Sensors, Sensorless Motor Control, Product Development vii Acknowledgements We would like to express our gratitude to our supervisor and examiner from Chalmers, Dr. Erik Hulthén, Associate Professor at Chalmers University of Technology, for his guidance throughout the project. We would also like to thank our supervisor from Volvo, Egoi Sanchez Basualdo, System Architect Interior Lights at Volvo Cars, for his support and constant motivation. We are also grateful for the irreplaceable help and guidance received from David Johansson, Analysis Engineer at Volvo Cars, in the Strength and Endurance laboratory, and from Patrick Bobink, Hardware Designer DCU in Steering Wheel and Seat Electronics. We would also like to thank our colleagues at Chalmers Technical University and Volvo Cars, especially interior light team and the HIL Laboratory. Finally, we would like to thank all the people who were involved in the progress made during this thesis work for their contributions. Marcus Bohlin and Gunjan Nagpal, Gothenburg, June 2020 ix Contents 1 Introduction ........................................................................................................................ 1 1.1 Background ................................................................................................................. 1 1.2 Problem Description .................................................................................................... 2 1.3 Aim .............................................................................................................................. 3 1.4 Limitations .................................................................................................................. 3 1.5 Scope ........................................................................................................................... 3 2 Methodology ....................................................................................................................... 5 2.1 Planning ....................................................................................................................... 5 2.2 Research and Technology Study ................................................................................. 5 2.3 Customer Needs Study ................................................................................................ 6 2.4 Concept Development ................................................................................................. 6 2.5 Prototyping .................................................................................................................. 6 2.6 Prototype Testing ........................................................................................................ 6 2.7 Concept Evaluation ..................................................................................................... 7 3 Risk Management ............................................................................................................... 9 4 Customer Needs Analysis ................................................................................................. 13 4.1 Interview Structure .................................................................................................... 13 4.2 Interview Summary ................................................................................................... 13 4.3 Observation Structure ................................................................................................ 17 4.4 Observation Summary ............................................................................................... 17 4.5 Legal Requirements................................................................................................... 17 4.6 Customer Needs List ................................................................................................. 19 4.7 Metrics for User Requirements ................................................................................. 20 5 Technology Study ............................................................................................................. 23 5.1 Driving Systems ........................................................................................................ 23 5.2 Electrical Drive ......................................................................................................... 24 5.3 Sensors for Detecting Pinch Situations ..................................................................... 25 5.4 Signal Filtering .......................................................................................................... 30 5.5 Communication Protocols ......................................................................................... 33 6 Concept Generation .......................................................................................................... 35 6.1 Identification of sub-functions .................................................................................. 35 6.2 Morphological matrix ................................................................................................ 35 6.3 Generated Concepts................................................................................................... 38 6.4 Concept Elimination .................................................................................................. 39 6.5 Concepts Proceeding from the Elimination Matrix................................................... 40 7 Prototyping ....................................................................................................................... 45 7.1 Early Prototyping Quick & Dirty .............................................................................. 45 7.2 Prototyping Concept 1 ..............................................................................................