Patent Publication Number: US-2022212595-A1

Title: Electromechanical control system for vehicle housing and door systems

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application relates to and claims priority to U.S. Provisional Application No. 62/851,943 filed on May 23, 2019, and U.S. Provisional Application No. 62/880,901 filed on Jul. 31, 2019, each of which is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     Embodiments of the present disclosure generally relate to electromechanical control systems, and more particularly, to systems having a controller for automotive fuel/recharge doors and housings. 
     BACKGROUND 
     Gas powered vehicles generally include a fuel door that is configured to pivot relative to a vehicle body to allow access to a fuel fill pipe. Electric vehicles similarly include a recharge door that is pivotably attached to a vehicle body to allow access to a recharge port for recharging the vehicle. 
     In both gas powered and electric vehicles, additional elements, such as, e.g., lights, a heater, a lock, etc., may be included to work with, around, or on the fuel or recharge door. However, in conventional vehicle systems, each additional element, such as, e.g., a light, a heater, a motor, etc., is a separate component. That is, each of these elements must be separately sourced and individually installed into the system. Therefore, conventional refuel or recharge systems require a wire harness, i.e., a plurality of wires, extending from the refuel or recharge system to a vehicle controller. As a result, existing refuel and recharge systems are complex systems that require considerable amounts of coordination, time, and money. Therefore, a need exists for a simplified refuel/recharge system. 
     SUMMARY 
     In one embodiment a control system for a refuel or recharge door of a vehicle is disclosed. The vehicle has a vehicle controller, a housing having a port, a door removably attached to the housing, a system controller communicably connected to the vehicle controller, and at least one module connected to the system controller. The system controller is configured to control the at least one module. 
     In another embodiment, a control system for a refuel or recharge door of an automobile is disclosed. The automobile has a vehicle controller, a housing having a port, a door removably attached to the housing, the door being configured to cover the port in a closed position and unobstruct the port in an open position, a system controller being communicably connected to the vehicle controller, and at least one module connected to the system controller so that the system controller controls the at least one module. The at least one module includes at least one of a latching module, a motor module, a light module, and a heating module. 
     In another embodiment, a control system for a refuel or recharge door of an automobile is provided. The automobile has a vehicle controller, a housing having a port, a door removably attached to the housing, the door being configured to cover the port in a closed position and unobstruct the port in an open position, a system controller communicably connected to the vehicle controller, and a plurality of modules connected to and controlled by the system controller. The plurality of modules includes at least a latching module, a motor module, a light module, and a heating module. Each of the plurality of modules is connected to a printed circuit board of the system controller with a wired connection. 
    
    
     
       BRIEF DESCRIPTION THE DRAWINGS 
         FIG. 1  is a rear, top, and right side isometric view of a control system for a refuel or recharge door, according to an embodiment of the disclosure; 
         FIG. 2  is a front, bottom, and left side perspective view of the control system of  FIG. 1  with the door in an open position; 
         FIG. 3  is a schematic of a control system according to an embodiment of the disclosure; 
         FIG. 4  is a rear, top, and right side isometric view of a system controller for use in the control system of  FIG. 1  with a top removed from a housing; 
         FIG. 5  is a front, bottom, and left side isometric view of the control system of  FIG. 1  with the door in a closed position; 
         FIG. 6  is a rear, bottom, and left side isometric view of the control system of  FIG. 1 ; and 
         FIG. 7  is a schematic of a circuit board for use in the controller of  FIG. 4 . 
     
    
    
     Before the embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The disclosure is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. 
     DETAILED DESCRIPTION 
     Conventional gas vehicles, such as automobiles, typically include a refuel system that includes a fuel fill pipe that extends from an opening, i.e., a fuel port, in a vehicle body. A fuel door is positioned to cover the fuel fill pipe, the door being configured to pivot relative to the vehicle body to allow access to the fuel fill pipe. Similarly, electric vehicles include a recharge system including a recharge door that is pivotably attached to a vehicle body to allow access to a recharge port for recharging the vehicle. In both cases, additional elements, such as, e.g., lights, a heater, a lock, etc., may be included to work with, around, or in the fuel or recharge system. For example, some vehicles have lights that illuminate during a refueling or recharging process. Further, some vehicles include a motor for opening and/or closing a fuel door. However, in conventional vehicle systems, each additional element, such as, e.g., a light, a heater, a motor, etc., is a separate component. That is, each of these elements must be separately sourced and individually installed into the system. Therefore, conventional refuel or recharge systems require a wire harness, i.e., a plurality of wires, extending from the refuel or recharge system to a vehicle controller. As a result, existing refuel and recharge systems are complex systems that require considerable amounts of coordination, time, and money. Therefore, a need exists for a simplified refuel/recharge system. 
     The present disclosure may alleviate some or all of the above-referenced deficiencies of conventional systems. Generally, the present disclosure provides a refuel/recharge system that includes a central hub for controlling a plurality of functional modules, such as, e.g., lights, a heater, a motor, etc. Therefore, systems according to embodiments of the present disclosure may be sourced as a complete system comprising a controller that is configured to control a plurality of functional modules. This controller may be communicably connected to a vehicle controller. As a result, rather than sourcing separate functional modules for a refuel or recharge system, vehicle manufacturers need only install a system according to embodiments of the present disclosure. The controller may additionally be configured to accept and control OEM and/or aftermarket modules. Furthermore, systems disclosed herein may be customizable according to a vehicle manufacturer&#39;s preferences. That is, functional modules may be selected and configured to accommodate particular requirements, further simplifying the sourcing and coordination process for vehicle manufacturers. 
     Embodiments of the present disclosure are discussed herein in connection with gas and electric automobiles; however, embodiments of the present disclosure may be installed in a variety of appropriate applications. Further, it should be understood that embodiments discussed herein in connection with refuel systems, i.e., gas vehicles, may also be used with recharge systems, i.e., electric vehicles, and vice versa. That is, throughout descriptions of embodiments herein, the terms “refuel system” and “refuel door” for gas vehicle installations may be replaced with or interchangeable with “recharge system” and “recharge door,” respectively, for electric vehicle installations. Similarly, the term “refuel port” may be interchangeable with “recharge port”. 
       FIG. 1  illustrates a control system  100  for use on a refuel or recharge door of a vehicle, such as an automobile, according to an embodiment of the present disclosure. The system  100  is configured to allow access to a fuel pipe (not shown). More specifically, the system  100 , which may also be referred to as a refuel system or recharge system, may include a housing  104  having an internal wall  108  defining a fuel port  112 . Generally, the fuel port  112  is configured to align with a fuel pipe that feeds into a fuel tank. Further, the system  100  includes a door  116  that is removably attached to the internal wall  108 . The door  116  is configured to be outwardly disposed from the internal wall  108  when installed in the vehicle so that the door  116  substantially obstructs the fuel port  112  and the fuel pipe when the door  116  is in a closed position. Further, the door  116  is configured to be movable from the closed position to an open position in which the fuel port  112  is substantially unobstructed by the door  116 . For example, turning to  FIG. 2 , in the illustrated embodiment, the door  116  is attached to the housing  104  with hinge  120  that is configured to pivot relative to the door  116  and the housing  104 , thereby moving the door  116  away from the housing  104  and the fuel port  112 . Although the illustrated embodiment illustrates the door  116  connected to the housing  104  with the pivotable hinge  120 , embodiments of the present disclosure may include various configurations. Embodiments of the present disclosure, for example, may include one or more doors that are slidable, laterally or longitudinally translatable, or completely removable from the housing. 
     As discussed above, embodiments of the present disclosure may provide a simplified fueling or recharge system. That is, systems disclosed herein may include a plurality of functional modules that may constitute a single system. Examples of functional modules include, but are not limited to, light modules, heating modules, latching modules, and motor modules.  FIG. 3  provides an exemplary schematic of the control system  100 , which may include a plurality of functional modules  124 . The system  100  and its modules  124  may be installed in a vehicle  122 . Contrary to conventional refuel and recharge systems, in which each of these modules are individually sourced and installed, the system  100  may be preassembled with these modules so that vehicle manufacturers receive it in a simplified, installation-friendly package. Although the schematic illustrates the system  100  having three modules  124 , additional or fewer modules may be included. Further, it should be understood that systems according to embodiments of the disclosure may include a combination of different modules. For example, a system according to an embodiment may include at least one light module and/or at least one motor module. Moreover, a system may include only one module, such as, e.g., a heating module. An example of one particular combination of modules will be described below with respect to the system  100 . 
     Still referring to  FIG. 3 , the system  100  includes a local interconnect network (LIN) controller  126  that is configured to communicate with and control the plurality of modules  124 . The LIN controller  126 , which may also be referred to as a system controller, may be connected to a vehicle LIN controller  128 , for example, with wire  130 , so that the LIN controller  126  may communicate with the vehicle  122 . For example, the LIN controller  126  may be a slave LIN controller that is configured to communicate with a master LIN controller, i.e., the vehicle LIN controller  122 , housed within the vehicle  122 . Further, the LIN controller  126  and each of its modules  124  may be connected to and powered by a power supply  132 . 
     Returning to  FIG. 1 , according to the present embodiment, the control system  100  includes a heating module  140 , a first light module  142 , a second light module  144 , a motor module  146 , and push-button module  148 . The LIN controller  126  may comprise a controller housing  160  having a top  162  removably coupled thereto to enclose a printed circuit board (PCB)  164  that may be electrically integrated into a vehicle. That is, the PCB  164  may include internal processing capabilities for enabling it to share information with the vehicle. The PCB  164  may also be configured to control multiple functions, such as, e.g., locking, lighting, actuating, heating, etc., with a 3-wire connection to the vehicle, as shown by an exemplary PCB schematic in  FIG. 7 . As a result, the system  100  is flexible and simplified when compared with conventional refuel and recharge systems. Moreover, each of the modules discussed herein, i.e., the heating module  140 , the light modules  142 , 144 , the motor module  146 , and the push-button module  148 , may be modular. That is, as best seen in  FIG. 4 , each module may be connected to pins  168  on the PCB  164  with a wired connection using basic connectors, thereby providing enhanced customization and adjustment capabilities. In the illustrated embodiment, each of the heating module  140 , the light modules  142 , 144 , the motor module  146 , and the push-button module  148  is connected to one of the pins  168  of the PCB  164  with a connector  172  at an end of a wire  176 . However, some pins  168  may remain vacant to provide room for additional modules to be installed. 
     Returning to  FIG. 1 , the system  100  includes the motor module  146 . The motor module  146  may be configured to move the door  116  from the open position to the closed position, and vice versa. More specifically, referring to  FIGS. 2 and 5 , the motor module  146  may be configured to move the door  116  between the open position, e.g., shown in  FIG. 2 , and the closed position, e.g., shown in  FIG. 5 . The motor module  146  is configured to automatically open and/or close the door  116  when instructed to do so by the LIN controller  126 . In some installations, the LIN controller  126  may control the motor module  146  when a vehicle controller signals to do so. For example, a user may issue a command via a remote control or control on a dashboard of the vehicle, and that command may be sent to the LIN controller  126  to initiate the operation. 
     In some embodiments, the motor module  146  may comprise a motor and an actuator that may drive the door  116  open and/or closed automatically. Further, in some embodiments, e.g., a potentiometer may be used to control speed and degree of rotation of the motor. The potentiometer therefore controls voltage to the motor, thereby controlling the degree of rotation of the motor. Furthermore, in some embodiments, additional or alternative motor modules known in the art may be used for opening and/or closing a door. Additionally, in some embodiments the motor module may not be provided, i.e., the fuel door may be configured to be opened and/or closed manually. 
     In addition to opening and/or closing the door  116 , the system  100  may include a latching module  178  for locking the door  116  in the closed position. In some embodiments, the latching module  178  may be an independent module that is connected to the PCB  164 . Further, in some installations, the latching module  178  may be controlled by a vehicle controller. That is, the latching module  178  is not connected to or controlled by the system controller, such as the system LIN controller  126 . In the illustrated embodiment, however, the latching module  178  is integrated into the motor module  146 . The latching module  178  is generally configured to automatically lock and/or unlock the door  116 . For example, in some embodiments, the latching module  178  may a use push-push mechanism for locking and unlocking the door. In this configuration, a motor module, such as the motor module  146  described above, may be configured to move the door from the closed position to an over-pressed position, thereby releasing the push-push mechanism. After releasing the push-push mechanism, the motor module may automatically move the door to the open position. To close the door, the motor module may move the door from the open position to the over-pressed position in order to reactivate the push-push mechanism, thereby reengaging the latching mechanism. Additionally or alternatively, a user may manually engage or release the push-push mechanism. 
     Furthermore, some embodiments may include a latching module  178  that uses an electronic lock that may, for example, comprise a solenoid. For example, a LIN controller, such as LIN controller  126 , may signal the latching module  178  to automatically engage and/or disengage the electronic lock. The electronic lock may be used with a motor module, such as the motor module  146  described above, to provide an entirely autonomous door. In any motor module and latching module installation, one or more sensors, such as, e.g., sensor  180  shown in  FIG. 2 , may be used with the modules to monitor a position of the door. The sensor  180  may be a position sensor, such as, e.g., an optical sensor, an inductive sensor, or a hall effect sensor. This information may be used to determine when a latching module  178  should be activated. Further, this information may be shared with the vehicle so that a user can be notified of the state of the door. 
     Still referring to  FIG. 1 , in the illustrated embodiment, the system  100  includes the heating module  140 . The heating module  140  may include a heater  184  that is configured to heat components of the system  100  during certain conditions. For example, the heater  184  may be an electric heater including a resistive wire that is configured to activate when cold ambient temperatures are detected. In some embodiments, therefore, one or more temperature sensors, such as thermocouples or thermistors, may be included in the system. That is, a temperature sensor, such as sensor  188  shown in  FIG. 2 , may be configured to communicate with the LIN controller  126  to indicate low temperature conditions. Accordingly, the LIN controller  126  may, in response, activate the heating module  140 . The LIN controller  126 , for example, may activate the heating module  140  when temperatures below freezing are detected. Additionally or alternatively, the LIN controller  126  may receive temperature conditions from the vehicle itself. That is, most conventional automobiles include temperature sensors, so the LIN controller  126 , which may be communicably connected to the vehicle, may monitor temperature conditions using temperature data from the vehicle. Generally, heating modules, such as the heating module  140 , may be used to mitigate or remedy ice and snow from impeding door operation in cold months. 
     With continued reference to  FIG. 1 , the system  100  includes the push-button module  148 . The push-button module  148  may be particularly useful for installations in an electric vehicle. More specifically, turning to  FIG. 2 , the push-button module  148  may include a push-button switch  192  that is configured to unlock a charge cable from the vehicle after charging is complete. When charging has ceased, a user may manually press the push-button switch  192  to allow removal of the charge cable. Additionally or alternatively, when (or as) a vehicle is actively charging, a user may manually press the push-button switch  192  to release the charge cable, thereby terminating charging prematurely, i.e., before reaching a full charge status. Therefore, the push-button switch  192  may be communicably connected to the LIN controller  126 , and the LIN controller  126  may be configured to engage and/or release a charge cable latch that is configured to lock a charge cable to a charge port. 
     Returning to  FIG. 1 , systems according to embodiments of the present disclosure may include one or more light modules. In the illustrated embodiment, the system  100  includes the first light module  142  and the second light module  144 . The first light module  142  is included to illuminate during a recharge or refuel process, i.e., when the door  116  is in the open position. In some embodiments, one or more light modules may be configured to illuminate when the door is in the open position. In some embodiments, one or more light modules may be configured to illuminate when the vehicle is actively charging or refueling. Further, in some embodiments, one or more light modules may be configured to deactivate after charging or refueling has ceased. Additionally or alternatively, in some embodiments, one or more light modules may be configured to deactivate after a preset duration of time, such as, e.g., one, two, five, or ten minutes. 
     In the illustrated embodiment, as best seen in  FIG. 2 , the first light module  142  includes an LED light  194  that is positioned to illuminate an area surrounding the refuel port  112  of the system  100 . Therefore, in instances when a user is refueling in the dark, visibility may be enhanced. The second light module  144  may similarly include one or more LEDs  196 , e.g., RGB LEDs, that are arranged around the push-button switch  192  discussed above. The second light module  144  may be configured to provide a refuel or recharge status. For example, in electric vehicle installations, the second light module may include multi-color capabilities for clearly communicating a charge status of the vehicle be varying color, flashing, pulsing, etc. In some embodiments, more or fewer light modules may be used. For example, some embodiments may include a light module that provides a light integrated into a latching module. The light may be arranged so that it projects from, i.e., pipes from, the latching module itself. Some embodiments may include light modules having one or more lights, such as, e.g., one or more LEDs, that are directed onto a remote location. Additionally or alternatively, embodiments may include light modules comprising one or more LEDs that encircle a charge port or refuel port, such as, e.g., the fuel port  112 . 
     In any installation, light modules may be configured to activate when the door is open. Therefore, a LIN controller, such as the LIN controller  126 , may activate the light modules when the controller detects the door is open via position sensors, such as the sensor  180 . Alternatively, light modules may be configured to activate when the door is open during particular times-of-day. For example, the LIN controller may receive time-of-day information from the vehicle to determine when to activate one or more light modules. Additionally or alternatively, light modules may be configured to activate when ambient light is below a preset value. For example, optical sensors, such as, e.g., sensor  198 , may monitor ambient light, and the LIN controller may be configured to activate and/or deactivate the light modules in response to parameters detected by the sensors. Some embodiments may include a plurality of light modules, each including one or more lights. However, some embodiments may be configured so that only select light modules and/or select lights within light modules activate in response to particular conditions. Furthermore, in any installation, light modules may be controlled directly by a vehicle controller. That is, the one or more light modules may not be connected to the PCB of the system controller, such as PCB  164  shown in  FIG. 4 . 
     Again, the present disclosure may provide a refuel/recharge system that includes a controller for controlling a plurality of functional modules, such as, e.g., lights, a heater, a motor, etc. Therefore, contrary to conventional refuel and recharge systems, vehicle manufacturers need only source a system according to embodiments of the present disclosure, which may include a plurality of functional modules. Further, additional or alternative modules may be used with systems disclosed herein, and the systems may be customized according to vehicle requirements. That is, functional modules may be selected and configured to accommodate particular requirements, further simplifying the sourcing and coordination process for vehicle manufacturers. 
     While various spatial and directional terms, such as top, bottom, lower, mid, lateral, horizontal, vertical, front and the like may be used to describe embodiments of the present disclosure, it is understood that such terms are merely used with respect to the orientations shown in the drawings. The orientations may be inverted, rotated, or otherwise changed, such that an upper portion is a lower portion, and vice versa, horizontal becomes vertical, and the like. 
     Variations and modifications of the foregoing are within the scope of the present disclosure. It is understood that the embodiments disclosed and defined herein extend to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative embodiments of the present disclosure. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art. 
     Various features of the disclosure are set forth in the following claims.