AVR480: Anti-Pinch System for Electrical Window

Automotive motorized window or door apparatus which closes automatically involve

risks for trapping, squeezing or injury to people. They must reverse their movement in
case the force applied by the motor gets higher than one normalized limit. The feature Microcontrollers
implies the constant monitoring of the speed, current, position of the glass. For cost
and simplicity reasons, the system described in this application note uses universal
brush motor equipped with hall effect sensors. The detection algorithm is based on
speed derivate and torque and has been verified for robustness and fault tolerance. It Application Note
is applicable to all ATMEL AVR® with A to D converter and Interrupt-on-Change I/O.

7559B–AVR–12/06
Powered Today, electronic components and systems account for over 20% of the cost of a high end pas-
Equipments in senger car. The ability of dense electronics to better control sensors and actuators is utilized to
Modern Cars enhance comfort and safety in cars and it is very predictable that most of the middle and upper
class vehicles will be systematically equipped with motorized window or door systems.
The majority of these equipments come with full automation, means that they must be accompa-
nied by safety systems to prevent people injury or mechanical degradations.
The legislation offers set of rules to which powered systems must comply. This is particularly
true for window lifts or sliding doors. This application note describes how to implement an anti-
pinch algorithm which was initially developed for a powered window but which can be easily
adapted to any other moving part.

The Standards The automotive power-operated windows are governed by international standards, like
MVSS118 in USA or 74/60/EEC in Europe. For those relatives to the elimination of danger to
children, the requirements expressed in these documents can be summarized as follows (see
Figure 1):
• Detection area: 4 mm to 200 mm,
• Maximum pinch force = 100N,
• Reverse direction on a pinch.
• Tests with determined deflection ratio objects: 5N/mm to 20N/mm

Figure 1. Anti-Pinch window lift rules as per MVSS118

4mm

200mm

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 AVR480
Hardware Different detection strategies are possible to determine whether an obstacle is entering the criti-
Consideration cal pinching area:
• Without mechanical contact. It reacts before the pinch effort is exerted on the object. This is
the optimal protection since no force is applied to the obstacle. It is also independent to
vibration, aerodynamic variations, deformations. But, it requires integrated sensors (infrared,
ultrasonic, ...) with their electronic modules and wires leading to additional costs.
• With mechanical contact. The pressure measurement will tell the system an object is being
pinched. Also there, designers have two fundamental technologies available:
– Direct measurements: Force sensors or contactors are integrated on the door seal.
These solutions are inherently high cost and reduce the styling for window/door
designs
– Indirect measurements via physical monitoring. This is a globally cost optimized
solution.

Anti-Pinch The pinch detection algorithm shall, at first, respect the standards (FMVSS118 & 74/60/EEC)
Algorithm requirements:
Specification • Detection area from 4 to 200mm
• Maximum exerted force of 100N
• Reverse direction on Pinch detection
• Normalized tests for validation

It has to be adaptive since:

• The mechanical elements involved in the lift system will vary with time (ageing, local
deformation, wear, ...)
• The electrical characteristics could evolve significantly
• The environment will affect the friction forces (temperature, moisture, freeze, etc.)
The system should not react to disturbances neither detect inopportune pinches. It must be
robust against air friction, road vibration, power-cuts, etc...

Solution Using The force applied to the glass can be extrapolated from the current through the motor. The posi-
Motor’s Physical tion of the moving elements permanently provides information on speed. Both parameters can
Parameters then be used to determine whether an obstacle has been encountered and whether:
• It is in the detection area
• The force applied gets higher than the limit
This document describes one anti-pinch algorithm developed to work with motor current mea-
surements and hall-effect speed indications. With very little changes, it can adapat to other
systems like slidding doors or roof panels.

Modeling, To better design the pinch-detection algorithm, the physical parameters involved in the lift sys-
Simulation tem have been extracted. Starting from a generic description of an opening/closing aparatus,
one more precise model has been developed for the powered window. It is broken down into
several main components as illustrated in Figure 2.

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 Figure 2. Powered Window Mechanical Components

Motor

Endless screw

« Flexible »
coupling
Non-linearity

Roller for cable

cable + sheath slides Pulley Cable window fixation

The identification of the mechanical components leads to consider:

• Motor Effects
– Mechanical Parameters
– Electrical Parameters
• Window-Lift:
– Frictions (limited to slides)
– Machanical non-linearity (coupling mostly)
– Inertia (glass weight)

Motor Model The DC universal motor used can be modeled using a very classical scheme as illustrated in
Figure 3.

Figure 3. DC Motor Equivalent Model

i(t)

U J
f

i(t) e(t)
L
U
R

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 AVR480
Differential (t) and Laplace domain (p) equations are extracted for Electrical and Mechanical
elements:

di
U(t ) = e (t ) + Ri (t ) + L U ( p) = E ( p) + RI ( p) + LpI ( p)
dt
e (t ) = k Ω(t ) E ( p ) = k Ω( p )
m (t ) = k i (t ) , motor torque M ( p) = k I ( p)
dΩ
J = m (t ) − fΩ(t ) JpΩ( p) = M ( p) − fΩ( p)
dt

The model chosen is a second order process. This allows the simulation of the motor, with its
power supply (Voltage), including speed and current measurements. It also authorizes to inject
disturbances or connect load (Co). It is detailed in Figure 4.

Figure 4. Second Order Motor Model

U 1 I Cem M 1 Ω
+
-- R + Lp K +
-- f + Jp

E Co

K K*U(p) + Co(R+Lp)
Ω (p)=
(f + Jp)(R + Lp) + K²

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7559B–AVR–12/06
Window-lift Model In addition to the DC motor model, the components from the window-lift system must be
inserted. They are introduced to estimate the torque provided by the motor, and to access to
position, speed and acceleration. The mechanical elements are described in Figure 5.

Figure 5. Window-lift Model

T1 n
M r
T2 Z

F1
r
T1 ≈ (M&z&2 + Fv z&2 + Fs + Mg ) Z1
n Z2
F2
n : Gear ratio F Weight
r : Radius
T1, T2 : Torque
Mg
Fv : Viscous Friction
Fs : Static Friction
This model is executed to obtain system behavior and to verify the pinch-detection algorithm.
Described parameters and others (static and viscous frictions, weight,...) are tuned and intro-
duced in the model to verify their influence.

Figure 6. Full Window-lift and Pinch-detection Algorithm Model

Mechanical
components

motor

Pinch &
Disturbances
sensors Anti-pinch
Algorithm

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 AVR480
Pinch Detection Usual pinch-detection algorithm operation is using indirect measurements out of the window-lift
Algorithm system:
• Current (torque)
• Position (speed)
The algorithm detailed in this document agregates two techniques based on
• Calibrated torque stored in non-volatile memory: Preliminary learning sequence is executed
and torque values are stored in memory. This is quite memory consuming and requires
regular calibration sequences
• Speed derivate calculation: Interesting method since it requires less memory but needs
more computing power
and takes benefit from the two methodologies.

Pinching Condition A pinch is detected by comparing the current measurement with a reference (see Figure 7).
M(t) ) kϕ x i(t) = K x i(t)

The threshold can be determined out of the Motor Torque constant (K) combined with the
response time of the system (Motor and the load).

Figure 7. Condition for Pinch

i measured Pinch
iref Threshold

Current Reference One solution to elimnate need for calibration is to calculate expected current all along the mov-
Synthesis ment. One pinch condition makes the speed decreasing and the current growing upassociated
with increasing torque. Those two conditions are used to determinate the occurence of a pinch.
In this document, speed derivate is preferred for its higher robustness to noise or fast
disturbances.
An example is given in Figure 8. The Current Reference (Iref) is permanently calculated until the
speed increases or remains unchanged. As soon as the speed decreases rapidly (Derivate
becomes negative), Iref is frozen. Current through the motor (Imot) continues to be measured
and compared with Current Reference + Margin. In case Imot gets higher than the limit, then a
Pinch is declared and several actions are taken by the application (First is to stop the motor and
reverse its rotation to release the obstacle).

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 Figure 8. Example of a Pinch detection

Example: blocking point Example: pinching

Rotation speed

Current Imot
t

Derivate speed
t

When derivate is negative,

reference is frozen
Reference Iref
t

Algorithm Robustness The permanent calculation of the Iref allows for highly adaptative algorithm. To even increase
Current Filtering the robustness of the alogrithm, the Current Reference is averaged over 8 consecutive mea-
surements (see Figure 9).

Figure 9. Global Current Reference Synthesis Principle

Derivative speed
Imeas
Measured Average (8 Low pass (2
current Imot samples) Exploited current samples)
Current
Reference Iref

Algorithm Robustness As Iref permanent calculation allows a highly adaptative algorithm, local great frictions variations
Blocking points called blocking points could involve bad pinch detection. Indeed, a local friction increase, even-
tually in addition to other disturbances (bumpy road, wind...) could result in a pinch condition, as
Iref would be frozen.
Those blocking points are detected the same way as pinches. The difference between current
and reference is monitored. When it is greater than a threshold, it is detected and blocking point
charateristics are stored into EEPROM.
A blocking point is described only by a position interval and an event counter (number of detec-
tions) to minimize memory requirements. It could be more precise by storing magnitude in the
interval or by using several threshold. But it would use more memory.
A table containing all hard point informations is stored in non volatile memory
When a blocking point is known (stored in table) and its event counter allows to consider it as a
blocking point, the threshold is added to pinch margin, in the correspondig interval, to increase
robustness.

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 AVR480
Figure 10. Blocking point example

Deformation:
Transition period

Position: upward (cm)

State Machine The main finite state machine (FSM) manages motor commands and pinch detection (Figure 11
presents states for upward movements. Downward operation is presented in Figure 12).

Figure 11. Finite State Machine for Moving Upward Operation

Stop motor
Upward Cmd Move up
Stop Start up
Timeout High position backlash
Or Timeout
stop motor
Go up
Stopping Cmd Timeout
Out of area Pinch condition

High position
Ou Timeout Obstruct

Pinch area

Stop motor
Pinch

Delay (no current)

Move
downward
Reverse
direction
Out of pinch area

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 Figure 12. Downwward Movement Finite State Machine

Stop motor Upward Cmd Move downward

Stop Move down

Timeout
Stop motor

Stop Cmd
request

Timeout

Bottom position Or Timeout

Calibrate / Init of the position

Adaptation function, FSM requires parameters (backlash, top and bottom ends, hall sensors resolution...) to work
portability properly. Those parameters could be constant parameters or measured at initialisation. Some of
them could change from one window lift to another. Thereby, optional adaptation function
acquire those parameters at first initialisation by operating the window lift. It also monitors bloc-
king points to initialize the memorization table.
This optionnal adaptation routine disables anti-pinch while running. It then operates window lift
downward and upward to detect bottom and top positions. Simultaneously, it monitors the block-
ing points. To acquire backlash, It operates downward and upward into the pinch detection area
(by comparing current reference to acquired current).

Other Interesting Not described here are secondary functions necessary for Window-lift operation:
Functions • Measuring current, filtering
• Hall-Effect interrupt generation, counting, speed calculation, direction
• Push-button management
• Memorization of critical parameters (position, last operation direction, ...) in case of power-
fail

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 AVR480
Simulation Results Numerous simulations have be ran to assess and tune the different parameters for the detection
threshold loop. Figure 13 visualizes how the speed and motor torque behave at the first and sec-
ond ‘go-upward’ commands. Also, a pinch condition is injected at t=10s with a compression
spring of 10N/mm.
Figure 14 shows the same curves but disturbances in motor torque are injected (frequency of
10Hz, 50N), after a second ‘go-upward’ command.

Figure 13. Simulation of the Algorithm with two Consecutive ‘Go-Upward’ Commands

Motor speed (seen from window: dm/s)

1* 2* t

Pinch Force (N) Reverse direction

Pinching t

Current (A)* acquisition gain, after average and reference.

1* 2*

Current – Reference
> Threshold

1. The non-linearity of the transmission causes a speed overvalue at motor start. The torque
looks like un-coupled for a few moment.
2. There, the elasticity of the transmission system is no more involved and the torque and speed
images are different.

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 Figure 14. Algorithm Simulation Injecting 10Hz, 50N Disturbance

Motor speed (seen from window: dm/s)

Pinch Force (N)

Current (A)* acquisition gain, after average and reference.

AVR The algorithm detailed in the previous paragraphs has been implemented and tested using an
Implementation AVR ATMEGA88 based board.

Hardware The hardware used for the implementation of the algorithm is described in Figure 15. It imple-
Specification ments one standard ATmega88 as well as analog chain to measure motor current. It has two
hall effects sensors. The motor direction is controlled via one two-poles relay while the ON-OFF
of the motor is activated by a Mosfet.

Figure 15. ATmega88 Controlling the Window-lift with Anti-pinch Feature

Hall Sensor
x2

V Battery
M
INT

out

AVR

out

ADC
+
Shunt
-

The software involves several microcontroller resources as defined in Table 1.

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 AVR480

Table 1. Hardware / Software Partitioning

Feature A to D Timer0 Timer1 PCINT9 EEPROM IDLE
Converter (8-bit) (16-bit) (Soft)
Current Acquisition X X
Position, Speed, X x
direction
Determine Current X X
Reference
Timeout X
Save Parameters X X
Filter X
Anti-Pinching X
Operate Window-Lift X

Task Scheduling By considering, the algorithm described previously, as well as the allocation of hardware and
software resources, we obtain the following scheduling of the program

Normal Operations This schedule is valid when the algorithm is running in standard operating condition, i.e. when
the motor is operating (rotating) or is stopped. Indeed, position, speed and reference calcula-
tions are refreshed when events occurs from the position sensors (hall effect sensors) or don't
have to be done (when the motor is stopped in a stable and normal state).

Figure 16. Task Scheduling When Normal Operation

Computation of position, derivate speed,

Edge on position sensor current reference
PCINT9 interrupt

Reset of timer counter

Timer 1 overflow interrupt

Timer 0 overflow

ADC : Current acquisition

Idle

Filtering, Window-lift operations, Anti-pinching…

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7559B–AVR–12/06
Other Operations When the motor is brutally stopped, rotates abnormally slow or doesn't start for several reasons
(motor blocked, hall sensor disconnected…), timer1 is used to generate a timeout and to shut
down the power (or to reverse direction).

Figure 17. Task Sceduling When Timeout or Parameter Save Request has been Set

Interruption PCINT9

Interruption Timer 1 overflow

Timeout Save parameters into
Timer 0 overflow
EEPROM

ADC : current acquisition

Idle

Algorithm porting Such an algorithm should be portable from one opening aparatus to another. So, it uses like a
database stored into eeprom, which contains algorithm parameter set (extracted from model).
This allows algorithm to be portable. Refer to algorithm adaptation procedure (AVR191) for more
details.

Software All code is implemented in C language using IAR EWAVR 4.20. Implementation of basic func-
Description tions (position management, initializations, current measurements, window operations and anti-
pinch monitoring) requires 2Kb of flash memory. Adding extended functions like eeprom stor-
age, calibration, adaptation, blocking points detection increases code size up to 5.7Kb.

void init_window_peripherals (void)

Initialize pin change interrupt to be used with a Hall effect position sensor (sensitive to rising and
falling edges). It also initializes timers and the ADC used to measure speed and motor current.

void init_window_parameters (signed char *go_down)

This function load window lift parameters from EEPROM or from default values, to initialize the
window-lift. Those values are window dimensions, sensor values, pinch threshold, pinch area,
last known position… If a default is found on position, it is able to ask for a go down command to
initialize the window-lift at bottom-end limit.

void init_window_size_position()
Allows to automatically operate window down, then up to detect top and bottom positions, iden-
tify blocking points and backlash : It's an adaptation routine.

void save_window_parameters(void)
This function saves window lift parameters to EEPROM.

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 AVR480
U8 window_ctrl (signed char *up_cmde, signed char *down_cmde ,U8
no_anti_pinch)
This contains the window-lift state machine. It controls window operations, with given events
parameters. It monitors the position, up and down end limits, and the anti-pinching condition. It
returns the state of the window-lift (same value as the get_window_state function).

__interrupt void hall_sensor_ISR (void)

This interrupt sub-routine is executed on hall sensor edges. It computes rotation direction, posi-
tion, derivative speed and motor current reference.
It's also able to detect a default on a hall effect sensor (which is not connected to an interrupt
pin) by counting successive direction changes. It is used to force the window to stop after a
defined step.

__interrupt void TIMER0_OVF_ISR (void)

This interrupt sub-routine is executed on timer 0 overflow to shedule ADC conversion starting.

signed char get_window_state (void)

It returns the state of the window-lift state machine (value used in the window_ctrl function).

signed char force_window_state (signed char temp)

Set-up window-lift state: useful to force operations (stop request…).

unsigned char mean (unsigned char)

Compute a mean on the 8 last samples. Used for filtering motor current.

void push_button (signed char *push)

This function monitors a push button and generates operation command events to be transmit-
ted to the window_ctrl function.

U8 blocking_point(signed char window_state)

This function monitors blocking points by comparing current value with reference. It shall be syn-
chronized with window control state machine. So, it requires window_ctrl to be called before and
its returned state shall be provided in parameter.

U8 update_point (void)
This function shall be called by blocking_point routine to sort, create or refresh blocking points
data table when a blocking point has just been completly detected. When this blocking point was
existing, it updates its event counter and its position interval. If it wasn’t existing, routine insert it
in the blocking points table.

void clean_point(void)
This routine shall be called by blocking_point routine and the end of each upward operation.
It’s in charge of decreasing blocking point event counter in the parsed area. It cleans blocking
points which event counter has decreased to zero (means they no more exists or it was a distur-
bance or a pinch and have no more been detected)

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 U8 get_block_point(U16 position)
This function returns the corresponding threshold value to add to pinch margin value if a block-
ing point has been confirmed at the provided position in parameter. Otherwise, when there are
no blocking point at this postion, it returns zero.

Main Control Loop Figure 18. Main Control Loop

Inits

ADC end
conversion

yes

clear conversion flag

current filtering

Read Push buttons

Window-lift control

monitor blocking points

save parameters

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 AVR480
Hall effect Position Figure 19. Hall effect Position Sensor Interrupt Sub-routine
Sensor Interrupt Sub-
routine Hall sensor ISR

save timer content

Direction ? downward

upward

decrement position increment position

Default ? yes
stop request

compute derivative speed (dv)

dv > 0 or
ref < current

yes

update current reference

end ISR

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Window Control State Figure 20. Window Control State Machine Implementation (part 1)
Machine
Implementation state

stop state

motor off

go up cmd? no

direction = up go down cmd?

motor on
direction = down no
reset timeout
reset timeout
state = start_up
state = go_down

start_up state

backlash end no

back up start position Timeout no

state = go up
current>0 no cmd?
no
state = pinch error : motor state = stopping
disconnected

go_up state

go up or down cmd no

state = stopping PINCH or Timeout no

position>4mm no end stop

state = obstruct motor off no

end stop state = stop

no

motor off
state = stop
null current &
Timeout pinch area

motor off
error : motor off after
update position a step
state = stop

obstruct state

go down cmd? no

state = stopping PINCH area no

state = pinch end stop no

state = stop Timeout no

motor off state = go up

update position
state = stop

18 AVR480
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