experimental study of automated electrical car power
TRANSCRIPT
EXPERIMENTAL STUDY OF AUTOMATED
ELECTRICAL CAR POWER WINDOW ‘PRESET’
POSITION
BY
MUAZZIN MUPIT
A dissertation submitted in fulfilment of the
requirement of the degree of Master of Science in
Automotive Engineering
Kulliyyah of Engineering
International Islamic University
Malaysia
OCTOBER 2011
ii
ABSTRACT
This thesis is made to present the development and prototype, of an Experimental
Study of Automated Electrical Car Power Window with ‘Preset’ Position and anti-trap
system. The main reason of developing this system is, to produce the new invention
and diversification of the car power window technology. The idea is purposely to
fulfill the demand from automotive industry which drastically require up dated system
in their vehicles technology especially in power window development. Nowadays, a
lot of car manufacturers produced their own style or method of controlling power
window to make it more ergonomics, user friendly but still emphasized the safety
element in their system. For instance, KǕSTER Holding GmbH Germany produced its
safety system called, Anti Trap System with immediate reversal of the window in the
event of entrapment. Thus it gives full and reliable protection for children’s hand, neck
and any obstacles as well. In this research experiment, microcontroller PIC16F877A is
applied as a brain to achieve the goal. In general, it will control the degree opening
position of the window whenever the user or driver require, as well as anti-entrapment
feature on window lift control system. By doing that, drivers could give full
concentration on maneuvering their vehicles and let the power window be controlled
by this system.
iii
خلاصة البحث
مع الآلي على رافع النافذةدراسة تجريبية ل النموذج الأولي ،طريقة لتطوير هذه الأطروحة تقدم
والسبب الرئيسي لتطوير هذا النظام، هو لانتاج إختراع جديد . السيطرة على عدم انحباس النافذة
ادة الطلب على في عمل النافذة في السيارة ولتنويع تكنولوجيا صناعة السيارات وذلك لزي
في الوقت . الحصول على آخر ماتوصلت اليه التكنولوجيا وبخاصة فيما يتعلق بنافذة السيارة
الحاضر، الكثير من منتجي السيارات لهم أسلوبهم الخاص في الانتاج أو في طريقة السيطرة على
كيد على عنصر نافذة السيارة لجعلها أكثر ملائمة للبيئة وكذلك سهلة الاستعمال ولكن مع التا
على سبيل المثال، فان شركة كوستر الالمانية انتجت نظام سلامة تم . السلامة في هذا النظام
. ، والذي فيه قابلية الرجوع الفوري للنافذة في حالة الانحسار(نظام عدم الانحسار)تسميته
في . عائق امام النافذةوبالتالي، فانها تعطي وقاية تامة ومعتمد عليها لايدي الاطفال، الرقبة أو اي
كعقل للوصول الى ( أي 788أف 61بي آي سي )هذا البحث، تم تطبيق المسيطر المايكروي
بصورة عامة، سيتم السيطرة على مقدار فتحة النافذة بواسطة هذا . الهدف في هذه الدراسة
لة المسيطر في اي وقت يحتاجه السائق، وكذلك يعمل كمسيطر على عملية الانحسار في حا
بهذا العمل، فأن السائق سيعطي . حدوثها وذلك بالسيطرة على نظام الرفع الموجود في النظام
. كامل تركيزه على المناورة في سيارته ويترك السيطرة على النافذة بواسطة النظام المسيطر
iv
APPROVAL PAGE
I certify that I have supervised and read this study and that in my opinion; it confirms to
acceptable standards of scholarly of presentation and is fully adequate, in scope and
quality, as a dissertation for the degree of Master of Science in Automotive Engineering.
……………………………………..
Ahmad Faris Ismail
Supervisor
……………........................................
Amir Akramin Shafie
Co-Supervisor
I certify that I have read this study and that in my opinion, it confirms to acceptable
standards of scholarly of presentation and is fully adequate, in scope and quality, as a
dissertation for the degree of Master of Science in Automotive Engineering.
……………………………………..
Mohammed.Ataur Rahman
Internal Examiner
I certify that I have read this study and that in my opinion, it confirms to acceptable
standards of scholarly of presentation and is fully adequate, in scope and quality, as a
dissertation for the degree of Master of Science in Automotive Engineering.
……………………………………..
Shahrul Naim Sidek
Internal Examiner
This dissertation was submitted to the Director, Advanced Engineering and Innovation
Centre and is accepted as a fulfilment of the requirements for degree of Master of Science
in Automotive Engineering.
……………………………………..
Agus Geter E. Sutjipto
Director, Advanced Engineering
and Innovation Centre
This dissertation was submitted to the Kulliyyah of Engineering and is accepted as a
fulfilment of the requirements for the degree of Master of Science in Automotive
Engineering.
……………………………………..
Amir Akramin Shafie
Dean, Kulliyyah of Engineering
v
DECLARATION
I hereby declare that this dissertation is the result of my own investigations, except
where otherwise stated. I also declare that it has not been previously or concurrently
submitted as a whole for any other degrees at IIUM or other institutions.
MUAZZIN MUPIT
Signature:………………………………….. Date: …………………………..
vi
INTERNATIONAL ISLAMIC UNIVERSTY MALAYSIA
DECLARATION OF COPYRIGTHT AND AFFIRMATION
OF USE OF UNPUBLISHED RESEARCH
Copyright © 2010 by International Islamic University Malaysia.
All rights are reserved.
EXPERIMENTAL STUDY OF AUTOMATED ELECTRICAL CAR
POWER WINDOW WITH ‘PRESET’ POSITION
I hereby affirm that the International Islamic University Malaysia (IIUM)
hold all rights in the copyright of this work and henceforth any
reproduction or use in any form or by means whatsoever is prohibited
without the written consent of IIUM. No part of this unpublished research
may be reproduced, stored in a retrieval system, or transmitted, in any
form or by means, electronic, mechanical, photocopying, recording or
otherwise without prior written permission of the copyright holder.
Affirmed by: MUAZZIN BIN MUPIT
…………………………….. ………………………………
Signature Date
vii
Dedication to my beloved parents and my wife
viii
ACKNOWLEDGEMENTS
In the name of Allah, The Most Compassionate and The Most Merciful.
I would like to take this opportunity to express my sincere gratitude and highest
appreciation to my supervisors Prof. Dr. Engr. Ahmad Faris Ismail and Assoc. Prof.
Dr. Amir Akramin Shafie for all the guidance, advice, technical support and
constructive comment towards the completion of this project.
I would also like to extend my appreciation to Advanced Engineering and Innovation
Centre (AEIC) especially for Sister Rohamah for her endless support and motivation.
Special thanks to my colleagues in UniKL, especially Br. Ismail Adam from UniKL-
BMI for his support and guidance in microcontroller program and hardware
development.
My hearties thanks to my wife, Wahida Mahmor and family for giving me full moral
support, patience, deepest encouragement in completing this project.
ix
TABLE OF CONTENTS
Abstract .......................................................................................................................... ii
Abstract in Arabic ......................................................................................................... iii
Approval Page ............................................................................................................... iv
Declaration Page ............................................................................................................. v
Copyright Page ............................................................................................................. vi
Dedication .................................................................................................................... vii
Acknowledgements ...................................................................................................... vii
List of Tables ............................................................................................................... vii
List of Figures .............................................................................................................. vii
List of Abbreviations ................................................................................................... vii
CHAPTER 1: INTRODUCTION ................................................................................ 1
1.1 Overview ....................................................................................................... 4
1.2 Problem Statement and its Significance ...................................................... 18
1.3 Research Objectives .................................................................................... 18
1.4 Research Methodology ............................................................................... 18
1.5 Research Scope ........................................................................................... 18
1.6 Dissertation Organization ...............................................................................
CHAPTER 2: LITERATURE REVIEW .................................................................. 18
2.1 Introduction ................................................................................................. 18
2.2 Power Windows System ............................................................................. 18
2.3 Sensing Element System ............................................................................. 18
2.4 Summary ..................................................................................................... 18
CHAPTER 3: MATERIALS AND METHODOLOGY .......................................... 18
3.1 Introduction ................................................................................................. 18
3.2 Method of Control ....................................................................................... 18
3.3 Hardware Development .............................................................................. 18
3.3.1 Introduction ........................................................................................ 18
3.3.2 Motor Selection .................................................................................. 18
3.3.3 Power Window Motor Selection ........................................................ 18
3.3.3.1 Mechanical System for Power Window Regulator ................ 18
3.3.3.2 Load / Window Glass ............................................................. 18
3.3.3.3 Load Force & Torque ............................................................. 18
3.3.4 Conventional Power Window Circuit ................................................ 38
3.4 Motor Driver Selection .............................................................................. 18
3.4.1 Motor Driver Specification ................................................................ 18
3.4.2 Installation of Motor Driver ............................................................... 18
3.4.2.1 Battery & Motor Connection ................................................ 18
3.4.2.2 Microcontroller Connection ................................................... 18
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3.5 Distance Measurement Sensor ........................................................................
3.5.1 Measurement Data & Plotted Graph .....................................................
3.6 Microcontroller Selection ...............................................................................
3.7 Sequence of Operation ....................................................................................
3.8 Anti-Trap Position ...........................................................................................
3.9 Compilation of Design Mechanism ................................................................
3.10 Software Development ..................................................................................
3.10.1 Introduction ..........................................................................................
3.10.2 Choice of Programming Language ......................................................
3.10.3 Microcontroller Interface .....................................................................
3.10.3.1 Switch/Contact with a Digital Input ........................................
3.10.3.2 Position Measurement by Potentiometer/Sensor .....................
3.10.3.3 Anti-Trap Interface to Microcontroller ....................................
3.11 Schematics Diagram Development ..............................................................
3.12 Programming Flowchart ...............................................................................
3.13 Summary .......................................................................................................
CHAPTER 4: ANALYSIS OF RESULTS ................................................................ 18
4.1 Introduction ................................................................................................. 18
4.2 Result Analysis ........................................................................................... 50
4.3 Summary .........................................................................................................
CHAPTER 5: CONCLUSION AND RECOMMENDATION ............................... 50
5.1 Conclusion .................................................................................................. 50
5.2 Recommendation......................................................................................... 50
BIBLIOGRAPHY ....................................................................................................... 50
APPENDIX A: Source Code ........................................................................................ 52
APPENDIX B: Software Simulation ............................................................................ 57
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LIST OF TABLES
Table No. Page No.
3.1
3.2
4.1
4.2
Normal operating condition truth table
Measurement data
Data Climatetepm.info
Bearing and Winding Characteristic Life - B and W
35
40
70
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4.3 DC motor life cycle determination 72
4.4 Type of motor determination 73
xii
LIST OF FIGURES
Figure No. Page No.
1.1
1.2
1.3
1.4
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
Electric window motor and regulator
Experimental project overview
Power window regulators
A flowchart
Electronic power window circuit
Power window mechanism
Transmission mechanism
Ball-type cog
Sensing edge front view
Cross-section of sensing edge
Obstruction simulation
Sensing element
Trunk lid sensing element
Sensing element detectors
Cross section of the window frame
Infrared sensors for smart window system
Histogram detection of the sensor
Flowchart of research methodology
Pre-determined positions
Positioning for the window opening and closing
DC motor & power window regulator
Worm gear
Spur gear
DC motor gear ratio 73:1
Pulley Diameter 4.8 cm
End to end distance window glass movement
Window Regulator and DC Motor
DC Motor Internal Structure
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3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
3.22
3.23
3.24
3.25
3.26
3.27
3.28
3.29
3.30
3.31
3.32
3.33
3.34
3.35
3.36
3.37
3.38
3.39
3.40
3.41
3.42
3.43
3.44
DC Motor Gears
Weight of the window glass
Upward window force relation
Downward window force relation
Toyota’s electrical power window wiring diagram
Motor driver
Standard circuit connections
Independent motor controls by switches
Clockwise switch closed
Counters clockwise switch closed
Interfaces between motor driver and microcontroller
GP2D12 sensor
GP2D12 internal block diagram
GP212 output response –Provided by SHARP
GP2D12 tested on the PIC board
Experiment result
PIC 16F877A
PIC 16F877A architecture
PIC 16F877A mapping configuration
Sequence of operation
Weather-strips
Simulink illustration
Cross-section of weather-strip
Overall design mechanisms
Actual project testing
Project block diagram
Door structure
Assembly of the equipment
Distance measurement sensor
Contacts with a digital input
Alternative circuits
Oscilloscope output on the bouncing signal
Micro C and potentiometer interface
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3.45
3.46
3.47
3.48
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
Micro C and GP2D12 interface
Anti-trap system
Connection of anti-trap to Micro C
PIC 16F877 Board Circuit diagrams
Sensor location
Sensor Alignment
Reflector’s illustration due to manually fabricated the reflector’s
track in a farthest distance
Gap between window and door structure
Power windows fully open
Reflector illustration in closer distance
Cable pulley failures
Overview of Kaptoris DAQ system and power window regulator
Kaptoris DAQ systems
Measurement Sensor & button down (auto mode)
Measurement Sensor & button up (auto mode)
Preset position & button down (preset mode)
Preset position & button up (preset mode)
Measurement sensor & button down (manual mode)
Measurement sensor & button up (manual mode)
Manual – preset –Auto modes and down button
Manual – preset –Auto modes and up button
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LIST OF ABBREVIATIONS
PIC Programmable Interface Controller
μC Microcontroller
DC Direct Current
DAQ Data Acquisition
1
CHAPTER 1
INTRODUCTION
1.1 OVERVIEW
In early edition of the automobile window design, the car manufacturer used hand-
turned cranks handle to raise and lower the windows. But nowadays instead of hand-
turned crank handle, electric or power window is used to control the window by
pressing a button or switch as shown in Figure 1.1
Figure 1.1: Electric window motor and regulator Courtesy of DaimlerChrysler
Corporation
With safety and technology advancements, most car manufacturers upgrade
their power window mechanism from time to time to be more efficient and user
friendly.
For instance in early power window system, its usually inoperable when the car
is not running as the electrical system is not 'live' once the ignition has been turned off.
Therefore, some manufacturers use a time delay for accessory power after the ignition
Window motor
2
switch is turned off. This feature permits the driver and passengers an opportunity to
close all windows or operate for certain period of time or until vehicle door is opened
after the ignition has been turned off.
Some vehicles are equipped with an express down window feature where this
feature fully opens the window by holding the window switch down for more than 0.3
seconds than releasing it. The window may be stopped at any time by pressing the UP
or DOWN switch. This express window option relies on an electronics module and a
relay. When signal detected, the module energize the relay, which completes the
motor’s circuit. When the window is fully down, the module opens the relay control
switch, which stops power to the motor. Therefore, the most attainable method on
improving the power window system is to add several innovative features to comply
the advancement of the automotive technology.
Conventional automobile power window system comprise a switch control in
which rising the window for closure requires a “manual” operation where the up
switch must be manually held in an activated state to power the window motor. When
this switch is released by an operator, window movement ceased. Typical power
window switch is placed on the arm rest or the side panel of the door. The problem
with such manual switch is that they require an intention of the operator’s physical and
mental during their operation as a safety is concern.
In this research project, the power window system are divided into two modes;
manual and auto mode. In ‘manual mode’, opening and closing of power window is
just like the usual passenger car. In ‘auto mode’ without pressing setting mode button,
the window only able to fully open or fully close. Whereas in auto mode with setting
mode button pressed once, the user able to set the degree of window opening at any
time the user required as shown in Figure 1.2.
3
Figure 1.2: Experimental project overview Courtesy Free Patent Online
In both modes, the upper and lower limit of power window was set in the range
of distance in order to prevent the overshoot current on the motor winding which can
ruin the motor itself and window regulator.
Manual indicator
Auto indicator
Set Button
Control Switch
4
1.2 PROBLEM STATEMENT AND ITS SIGNIFICANCE
Some motorists are still trying to close their window even though it is already closed.
The motorist is unaware of the maximum and minimum limit of the window. Due to
this consequence, it may damage the power window regulator.
Other than mentioned above, there are several other instances in the control of
power window; such as:
i. Monitoring the window position can distract the driving focus.
ii. There are some cases where children unintentionally get stuck at the
window.
For example, the article from CBC News February 21, 2007:
"She climbed up to pop her head out the window, to get some fresh air
or whatever," said MacLeod. "But by doing so she lifted her feet up on
to the arm rest, subsequently stepping on the button, which released the
window to go up."
Witnesses heard the girl yelling for her mother. When one witness got
closer to the vehicle, he realized the girl was trapped in the window,
police said.
iii. The power cable may pull off and get twisted due to prolonged usage
(Figure 1.3) which may deteriorate the DC motor and power window
regulator. This may occur due to the over current that entering to the
motor and ageing factor.
5
Figure 1.3: Power window regulators
iv. The recent news related with power window faulty occurred on Honda
Jazz where the power window master switch is exposed to an excessive
amount of water (such as rainwater), especially when windows are left
open for prolonged period of time, electrolyte materials from rainwater
would seep into the power window switch unit. This would decrease
the insulation resistance between the electric circuits, which could lead
to current leaks. In severe cases, the switchboard would melt or burn.
The article from Honda South Africa website dated 28 January 2010 is
referred:
Honda SA has announced today a safety recall of the previous
generation Jazz to inspect and modify driver door power-window
switches that may, in some cases, short circuit as a result of water
intrusion into the housing.
Following the tragic fire in September 2009, Honda Motor Co. has
launched an extensive investigation to determine the cause of the
incident. Whilst the cause of the fire remains indeterminable, the
investigation has shown that water intrusion into the power window
switch housing may, in some instances cause a short circuit, which in
exceptional circumstances, may lead to potential damages.
As a precautionary measure, Honda has decided to implement a safety
recall of all 2002-2008 year model Jazz units in South Africa.
Overlapped
cable
6
Realizing these critical issues, the system proposed is able to overcome the
consequences as well as to make it more efficient for the motorists.
The embedded system design nowadays is the utmost important application not
only for electrical and electronics fields of engineering, but also applicable for
engineering discipline. Many control problems previously were used mechanical or
electrical switching systems are effectively and reliably handover by using electronics
devices which is microcontroller.
Therefore the significance of the thesis involve microcontroller interfacing
with the existing power window system with the maximum and minimum limitation
setting, contribute to the new innovation development especially in automotive
industry.
By having the microcontroller in this power window system, the controller
circuit design will be more compact, small and suitable for any power window
mechanism in real industry and able to lasting the power window regulator’s life
cycle.
7
1.3 RESEARCH OBJECTIVES
The objectives of this project are as follow:
i. To design and develop the automated “preset” position hardware for power
window system.
ii. To integrate the hardware and software to achieve the requirement needed.
iii. To analyze the positioning data of power window regulator.
1.4 RESEARCH METHODOLOGY
In order to achieve the objectives of this study, the following procedure are
considered:
a) The research begins with the understanding of existing power window
control mechanism.
b) The proper selection, design and fabrication of plant to be used as a case
study in the experimentation.
c) The hardware development.
d) The software development.
e) The hardware and software integrations.
f) The analysis of result.
Figure 1.4: A Flowchart
Literature Review
Development of
software and hardware
Overall system
integrations
Analysis of result
8
1.5 RESEARCH SCOPE
The scope of the research is about car power window system which emphasize on anti-
trap system with preset positioning where the minimum and maximum power window
glass limitation is only within the predetermine position.
1.6 DISSERTATION ORGANIZATION
The dissertation organization as follows:
In chapter 2, the literature review on technical papers which comprise the
mechanism of power window and safety elements from the car manufacturer has been
discussed.
Material and methodology for hardware development consisting of motor
driver selection and installation, and PIC interfacing was discussed in chapter 3.
Software development on how the communication between PIC and the outside world,
in order to give or receive signal from position sensor, an anti-trap sensor and
controller button as an input signal to drive the motor was also provided.
Chapter 4 presents analysis of the result on completed design and summarize
all the results obtained from the previous chapter.
Chapter 5 gives the conclusion and the improvement needed for further study.
9
CHAPTER 2
LITERATURE REVIEW
2.1 INTRODUCTION
The first electric power windows were introduced by Lincoln which operated under
the Ford Motor Company (SAE 100). These windows are driven by a small electric
motor inside the door and have come to be universal in the industry. Prior to that, in
the few vehicles offering this feature, the windows were driven by hydraulics or off
the engine vacuum. In the 1950s, electric power was applied to the tailgate window in
many station wagons. In a typical installation, there is an individual switch at each
window and a set of switches in the driver's door so the driver can operate all the
windows. However, some models have used switches located in the center console,
where they are accessible to all the occupants. In this case, the door-mounted switches
can be omitted.
Conventional power windows are usually inoperable when the ignition is
turned off. However, many modern cars have a time delay features and according to
Wikicar, first introduced by Cadillac which called retained accessory power. This
allows operation of the windows and some other accessories for ten minutes or so after
the engine is stopped. Another fairly recent innovation, pioneered by Nissan at about
the same time, is the express-down window, which allows the window to be fully
lowered with one tap on the switch, as opposed to holding the switch down until the
window retracts (Kiichi Konusuki, 2003).