Sensor module, vibration damper, damping system and vehicle

Abstract

Sensor module (1) for a vibration damper with at least one damper unit (10), at least one sensor unit (20) and at least one energy generation unit (30) which is at least partially integrated in the damper unit (10), wherein the energy generation unit (30) is configured to convert mechanical force into electrical energy, such that at least the sensor unit (20) can be operated autonomously with energy from the energy generation unit (30), wherein the energy generation unit (30) is configured as a free-vibrating, electromagnetic energy generation unit (30), wherein the damper unit (10) has a housing (12) and at least one first spring element (14), wherein the energy generation unit (30) is configured with a plurality of permanent magnets (32) in the housing (12) of the damper unit (10), wherein the permanent magnets (32) are arranged for resilient mounting on the first spring element (14) of the damper unit (10).and with at least one stationary electromagnetic coil (36) on or in the housing (12) for generating electrical energy from an oscillating motion of the permanent magnets (32), characterized in that the damper unit (10) has a second spring element (16) and the permanent magnets (32) are arranged between and received by the first and the second spring element (14, 16).

Description

[0001] The invention relates to a sensor module for a vibration damper comprising at least one damper unit, at least one sensor unit, and at least one energy generation unit. The invention further relates to a vibration damper, a damper system, and a vehicle.

[0002] In everyday use, defective shock absorbers or vibration dampers pose a significant safety risk to motor vehicles. Studies show that approximately 22% of all passenger cars in operation have defective shock absorbers. Even at low speeds, the braking distance can increase dramatically, and directional stability and cornering performance can be significantly reduced. It is estimated that defective shock absorbers or vibration dampers contribute to 50% of accidents involving passenger cars with a mileage of more than ten years or 150,000 km.

[0003] From DE 10 2010 042 459 A1, a motor vehicle system is known that generates electrical energy through the movement of a motor vehicle suspension device by means of an energy absorption device. Additionally, a sensor is attached to the motor vehicle suspension device and coupled to the energy absorption device for the purpose of absorbing electrical energy.

[0004] From DE 10 2010 008 315 A1 a device for energy generation with a vehicle shock absorber is known, wherein a piezoelectric device is coupled with a spring stop.

[0005] US patent 2015 / 0333598A1 discloses a system for energy recovery in which vibration energy is converted into electrical energy and used for fault monitoring in bridge construction.

[0006] US patent 2010 / 0225527A1 describes a system for measuring the distance between two vehicle components, such as shock absorbers, using a wireless ultra-wideband (UWB) transreceiver.

[0007] EP 3 461 662 A1 discloses a damping device for vehicles, wherein a sensor for determining kinetic quantities and a radio device connected to the sensor are provided in order to achieve continuous monitoring of the damping device with regard to possible damage or wear.

[0008] US patent 2017 / 0241362A1 discloses a motor monitoring system that includes an energy generation unit with an energy converter. Control signals are also generated from measurement signals to protect the motor from damage.

[0009] Detecting a defect in a shock absorber is extremely difficult for a layperson or end user of motor vehicles. Regular visual inspections for oil leaks or dirt stains on the shock absorber, as well as the observation of uneven (stubbly) tire wear, are only possible for a very experienced and attentive driver. There is a risk that vehicles may have an undetected defect and thus pose a safety hazard on the road.

[0010] The invention is based on the objective of providing a sensor module that enables simple, independent determination of the wear condition and / or a defect of the vibration damper or the damping function of a chassis, has a compact, space-saving design, and allows for long-term, low-maintenance operation. Furthermore, the invention aims to provide a vibration damper, a damping system, and a vehicle equipped with such a sensor module.

[0011] According to the invention, this problem is solved with respect to the sensor module by the subject matter of claim 1, with respect to the vibration damper by the subject matter of claim 6, with respect to the damping system by the subject matter of claim 7, and with respect to the vehicle by the subject matter of claim 8. Preferred embodiments are specified in the dependent claims.

[0012] Specifically, the problem is solved by a sensor module for a vibration damper comprising at least one damper unit, at least one sensor unit, and at least one energy generation unit, which is at least partially integrated into the damper unit. The energy generation unit is designed to convert mechanical force into electrical energy, such that at least the sensor unit can be operated autonomously using energy from the energy generation unit.

[0013] The invention is based on the fundamental concept of designing a sensor module with an integrated energy generation unit in such a way that the individual components of the sensor module can be supplied with energy permanently and autonomously. It is intended that the energy from mechanical shocks or forces acting on a chassis, and thus on the vibration dampers of a vehicle, can be utilized by means of the sensor module. The energy for operating the sensor module can be generated by the energy generation unit during the intended operation of the sensor module within a vehicle or at a vibration damper of the vehicle. This should make it possible to provide a completely independent and self-contained sensor module.

[0014] Furthermore, the invention is based on the fact that the sensor module should have a compact design, so that the sensor module according to the invention can preferably also be used in commercially available motor vehicles or expediently attached to commercially available vibration dampers. In this sense, the sensor module according to the invention can be considered as a retrofittable option for existing motor vehicles.

[0015] According to the present invention, the energy generation unit is at least partially integrated into the damper unit. Thus, at least part of the energy generation unit can be arranged in and / or on the damper unit.

[0016] In particular, a movable or dynamic part of the energy generation unit can be arranged in the damper unit, while a stationary or static part of the energy generation unit can be provided on the damper unit or outside the damper unit.

[0017] A compact, space-saving design of the energy generation unit in conjunction with the damper unit is available.

[0018] Furthermore, dynamic movements of the damper unit are preferably used for energy generation, particularly in the sense of so-called "energy harvesting". In this context, thermal energy in the form of waste heat, especially from the vibration damper or a drive unit of the vehicle, can alternatively or additionally be used to provide electrical energy. Thus, energy-efficient operation of the sensor module according to the invention is possible.

[0019] Furthermore, it is provided that the energy generation unit can convert mechanical force and / or thermal energy into electrical energy, so that at least the sensor unit of the sensor module can be operated autonomously in a suitable manner.

[0020] In particular, the entire sensor module can be operated solely using the electrical energy from the power generation unit. Besides the sensor unit, other components of the sensor module can also be adequately supplied with electrical energy from the power generation unit. By conveniently positioning the sensor module, especially the sensor unit, on or within the vibration damper, the wear or a potential defect of the vibration damper can be detected using the sensor module.

[0021] According to the present invention, autonomous operation of the sensor module is possible, particularly independent of a vehicle's electrical circuit or vehicle battery. To implement such autonomous operation of the sensor module, existing forms of energy from the vehicle, such as mechanical kinetic energy or thermal energy, are utilized or made usable through "energy harvesting".

[0022] According to one embodiment, the sensor module has at least one energy storage device for intermediate storage of electrical energy from the energy generation unit and for supplying at least the sensor unit with electrical energy as needed.

[0023] The energy storage device is designed in such a way that at least the sensor unit can be operated even if the energy generation device can only produce an insufficient amount of electrical energy for a specific period during the operation of the sensor module. In this sense, the energy storage device is preferably designed as a short-term energy storage device. Furthermore, other components of the sensor module can also be supplied with sufficient electrical energy temporarily by means of the energy storage device.

[0024] The integrated energy storage system provides a lightweight and practical solution for the continuous operation of the sensor module. Continuous energy generation by the energy generation unit is not strictly necessary. Instead, insufficient energy input from the energy generation unit can be compensated for by the energy storage system.

[0025] According to a further embodiment, the sensor unit comprises at least one acceleration sensor and / or at least one temperature sensor for detecting the wear condition and / or an existing or developing defect of a vibration damper or shock absorber. In particular, the sensor unit can detect temperatures, vibrations, damping oscillations, displacements during a damping oscillation, or the like at the respective vibration damper.

[0026] Preferably, the sensor module or sensor unit of the sensor module is designed and arranged on or in the vibration damper in such a way that the wear condition or any existing or developing defect of the vibration damper can be determined. Preferably, one sensor module is provided for each vibration damper of a vehicle. This allows everyday users or end users to easily and reliably determine the proper operational readiness of a vehicle.

[0027] In one embodiment of the present invention, the energy generation unit is designed as a free-oscillating, electromagnetic energy generation unit, in the form of at least one piezoelectric crystal and / or in the form of at least one Peltier element.

[0028] The energy generation unit can be designed in such a way that a vibrational movement, which is dampened or absorbed by means of the damping unit, can be used as a mechanical force acting on the energy generation unit.

[0029] Alternatively, another method of generating electrical energy from mechanical force and / or thermal energy may be provided, such as the use of piezoelectric crystals or Peltier elements. The at least one piezoelectric crystal and / or the at least one Peltier element may be suitably attached to or within the vibration damper.

[0030] In accordance with the present invention, a mechanical force applied to the vibration damper, and thus to the damping unit of the sensor module, can be used to generate electrical energy by means of the energy generation unit. In the sense of "energy harvesting," it is possible to utilize an existing force or thermal energy in or on the sensor module for energy generation or conversion.

[0031] According to a further embodiment, the damper unit comprises a housing and at least one first spring element. The damper unit is specifically designed to convert shocks or vibrations absorbed by the vibration damper during operation into an oscillating motion. In addition to the first spring element, the damper unit has a second spring element, with the permanent magnets arranged between and held by the first and second spring elements.

[0032] The energy generation unit is designed with a plurality of permanent magnets in the housing of the damper unit, wherein the permanent magnet is arranged for spring-mounted support on the first spring element of the damper unit. Furthermore, the energy generation unit is designed with at least one stationary coil on or in the housing for generating electrical energy from the oscillating motion of the permanent magnets.

[0033] Generally, the energy generation unit is integrated into the damper unit or is integrally designed within the damper unit. This allows for a compact, space-saving, energy-efficient, and reliable energy generation system to operate the sensor module.

[0034] The energy generation unit can be configured, according to the present invention, to generate electrical energy by electromagnetic induction. In particular, the permanent magnet of the energy generation unit can be arranged or mounted on the at least one first spring element in such a way that, when damping an oscillating movement, the permanent magnet itself is set into an oscillating movement along a longitudinal axis of the first spring element.

[0035] The coil of the energy generation unit is statically arranged on the damper unit. Preferably, the coil is integrated into the housing material or arranged on an outer surface of the damper unit housing. In this sense, the coil can be cast or embedded in the housing material. Alternatively, the coil can also be advantageously arranged inside the housing, particularly within the area of ​​an inner diameter of the housing. Furthermore, the coil comprises an electrical conductor or an electrically conductive material.

[0036] The combination of a permanent magnet and a coil enables passive energy generation according to the invention, which does not require an additional, external energy source. The energy generation device allows the sensor module according to the invention to be operated autonomously, and thus, in particular, independently of any further, external energy source.

[0037] As the permanent magnet oscillates along the longitudinal axis of the first spring element or damper unit, it travels a certain distance relative to the at least one stationary coil. This relative motion of the permanent magnet causes an electrical charge separation in the coil, resulting in an electrical voltage. According to the principle of electromagnetic induction, electrical energy, or voltage, is generated in the statically arranged coil. The permanent magnet represents the dynamic component, and the coil the static component, of the energy generation unit.

[0038] Furthermore, it is conceivable, within the scope of the present invention, that the energy generation unit is designed to generate electrical energy from the waste heat of the vibration damper, a brake unit, or the drive unit of a vehicle. Electrical energy can be generated passively from thermal energy. In this case, energy generation can also occur independently of a mechanical force, solely through the conversion of thermal energy into electrical energy.

[0039] An effective way to generate the electrical energy necessary for operating the sensor module, especially the sensor unit, is available.

[0040] According to another embodiment, the sensor module includes a radio unit for wireless transmission of measurement data from the sensor unit. This radio unit enables any type of wireless data transmission, in particular energy-saving or energy-efficient methods.

[0041] In this way, sensor data or measurement data from the sensor unit can be transmitted from the sensor module to any control unit or similar device. In particular, the sensor module can be designed as an independent component on or within the vibration damper of a wheel or wheel axle using the radio unit.

[0042] No cable connection is necessary for energy or data transmission. Rather, the sensor module according to the invention preferably represents a self-contained, independent and autonomously functioning component of a vehicle.

[0043] In a preferred embodiment, the energy storage device is designed as at least one capacitor. In this way, the energy storage device can be configured, in particular, as a short-term energy storage device.

[0044] The energy storage system makes it possible to bridge short-term and / or, in particular, short-term shortages of electrical energy from the power generation unit. The functionality of the sensor module, especially the sensor unit and the radio unit, can be ensured. The period that the energy storage system is intended to bridge for energy supply can be dimensioned as needed based on its capacity.

[0045] Furthermore, it may be provided that the operation of the sensor unit can be ensured with electrical energy from the energy storage device, whereby, for example, the transmission of measurement data via the radio unit or the like only takes place temporarily, especially when sufficient energy is available for data transmission or for the operation of the radio unit.

[0046] In a secondary aspect of the invention, a vibration damper with a sensor module according to the invention is provided.

[0047] The sensor module is designed for convenient mounting or attachment to or within the vibration damper of a wheel or axle, so that the wear or a possible defect of the vibration damper can be detected by means of the at least one sensor unit of the sensor module. Preferably, one sensor module according to the invention can be arranged on each vibration damper of a vehicle. Furthermore, the sensor module can also be designed for convenient, integral arrangement within a vibration damper.

[0048] In a further subordinate aspect of the invention, a damping system is provided with at least one sensor module or at least one vibration damper according to the invention and with a control unit which is configured to receive signals from the at least one sensor module.

[0049] The damper system according to the invention enables the operation of the sensor module to provide information about the wear state or a defect of an associated vibration damper, as well as the processing of the sensor and measurement data. The control unit is designed to receive data corresponding to the radio unit of the sensor module. Thus, the control unit and the sensor module, or the radio unit of the sensor module, can exchange data via a wireless data connection.

[0050] Furthermore, the control unit can be designed such that a multiple sensor modules can be operated in conjunction with a single control unit. In this sense, the damping system can have one control unit and at least one sensor module per wheel and / or wheel axle.

[0051] The damping system can advantageously provide information about a potential defect in a shock absorber or vibration damper to an end user or everyday user of a vehicle.

[0052] In a further subordinate aspect of the invention, a vehicle is provided with at least one sensor module according to the invention, a vibration damper according to the invention or a damping system according to the invention.

[0053] Thus, an advantageous sensor module or an advantageous vibration damper or an advantageous damping system in the sense of the present invention is available to every everyday user of a motor vehicle, wherein the degree of wear or a defect state of the shock absorbers or vibration dampers can be easily monitored in the long term and without maintenance effort.

[0054] The invention is explained in more detail below with reference to the attached schematic drawings and various exemplary embodiments.

[0055] These show: Fig. 1 a schematic representation of a sensor module with a damper unit in conjunction with the energy generation unit; and Fig. 2 a schematic overview of a damping system and vehicle according to the invention.

[0056] Fig. Figure 1 shows a schematic representation of a sensor module 1 with a damper unit 10 in conjunction with an energy generation unit 30.

[0057] According to Fig. The damper unit 10 is designed with a housing 12, a first spring element 14 and a second spring element 16. The first and second spring elements 14 and 16 are arranged as ring springs in the housing 12 and are designed to convert shocks or mechanical forces in the longitudinal direction of the damper unit 10 into an oscillating motion.

[0058] The energy generation unit 30 is designed with at least one coil 36 having several windings and with several permanent magnets 32. The coil 36 is configured according to Fig. 1 is arranged on the housing 12 of the damper unit 10, in particular on an outer side or outer diameter of the housing 12. The windings of the coil 36 continue in the longitudinal direction of the housing 12.

[0059] The coil 36 of the power generation unit 30 can be arranged according to Fig. The coil 36 may be integrated into the housing 12 or into a wall of the housing 12. In particular, the coil 36 may be cast into the housing 12 or the like. By means of the permanent magnets 32 and the coil 36, the energy generation unit 30 is fully integrated into the damper unit 10.

[0060] The permanent magnets 32 of the energy generation unit 30 are arranged within the housing 12. In particular, the permanent magnets 32 are arranged between and received by the first and second spring elements 14; 16. The permanent magnets 32 are spring-mounted.

[0061] Furthermore, according to Fig. 1 A total of seven permanent magnets 32 are provided, wherein the permanent magnets 32 are spaced apart from each other by separating elements 34. In particular, the permanent magnets 32 are arranged such that like poles of adjacent permanent magnets face each other across the respective separating element 34.

[0062] When a shock or mechanical force is damped, an oscillating movement of the first and / or second spring element 14; 16 leads to a relative movement of the permanent magnets 32 with respect to the coil 36. Consequently, a charge separation occurs in the coil 36, which has an electrical conductor, and an electrical voltage is induced. The energy generation unit 30 according to Fig. 1 is based on the principle of electromagnetic induction.

[0063] By using the mechanical force from the damper unit 10 to generate a relative motion between permanent magnets 32 and coil 36, the energy generation by the energy generation unit 30 can be considered a passive energy generation.

[0064] Furthermore, according to Fig. 1 At one longitudinal end of the damper unit 10, further components of the sensor module 1 are arranged. In particular, an energy storage device 40 in electrical connection with the energy generation unit 30, a sensor unit 20 and a radio unit 50 are provided.

[0065] Furthermore, the energy generation unit 30 can be provided in conjunction with a voltage supply 38 for the appropriate conversion of the generated electrical energy.

[0066] Preferably, the radio unit 50, the sensor unit 20 and the energy storage unit 40, in combination with the power supply 38, are arranged according to Fig. 1 each provided on separate circuit boards, which are arranged one above the other in the longitudinal direction of the sensor module 1.

[0067] The energy generation unit 30 can supply both the energy storage unit 40 and the other components, such as the sensor unit 20 and the radio unit 50, with electrical energy. In this way, a completely self-sufficient functionality of the sensor module 1 according to the invention can be provided.

[0068] Fig. Figure 2 shows a schematic overview of a damping system and a vehicle 100.

[0069] The vehicle 100 has a total of four sensor modules 1. In particular, one sensor module 1 is provided for each shock absorber or vibration damper of a wheel. Thus, preferably, each vibration damper of a commercially available vehicle can be supplemented or equipped with a sensor module 1, and the respective vibration damper can be monitored and controlled with regard to its wear condition and any possible defects.

[0070] Furthermore, the damping system or vehicle 100 has a control unit 60, each of which has a wireless radio connection with the individual sensor modules 1 for data transmission. Thus, measurement data from the individual sensor units 20 of the sensor modules 1 can be transmitted to the central control unit 60 and processed by it.

[0071] Furthermore, according to Fig. 2. It is provided that the control unit 60 can provide a radio connection for data transmission to an end device 70, such as a smartphone or the like. Thus, the collected data and the resulting findings regarding wear and / or a defect can be communicated to an end user or everyday user of the vehicle 100.

[0072] Furthermore, data transmission from the control unit 60 can also be sent to a vehicle's own internal entertainment or software system 100 to inform the end user accordingly. In this sense, the damping system according to the invention can be retrofitted into any vehicle without the need for additional cable connections or the like to a vehicle's own control unit. Rather, the control unit 60 of the damping system can transmit the necessary data according to the present invention via any wireless connection, such as Bluetooth. Fig. 2, provide.

[0073] In summary, the sensor module 1 according to the invention provides an advantageous solution for detecting wear or potential defects in a shock absorber or vibration damper. Furthermore, a commercially available vibration damper of a vehicle can be easily supplemented and retrofitted with a sensor module 1 or damper system.

[0074] Energy-efficient and autonomous operation of the sensor module 1 according to the invention is enabled at the respective vibration damper, whereby an internal power supply 38 or energy generation unit 30 can provide the necessary electrical energy. During operation of a sensor module 1, the functionality of the individual components of the sensor module 1, in particular the sensor unit 20 and the radio unit 50, can thus be ensured. Furthermore, the radio unit 50 enables convenient data transmission to, for example, a control unit 60 of the damper system.

[0075] Furthermore, a compact and integrated design of the sensor module 1 is provided. By preferably integrating the energy generation unit 30 into the damper unit 10, installation space can be saved. In addition, for example, an existing mechanical (vibrational) force from the vibration damper or from the chassis can be used to generate electrical energy.

[0076] The present invention allows the wear or defect condition of the shock absorber or vibration damper to be monitored in a simple and advantageous manner over the long term, and ensures proper functionality. Reference symbol list 1 sensor module 10 damper unit 12 cases 14 first spring element 16 second spring element 20 sensor units 30 energy generation units 32 permanent magnet 34 Separating element 36 coil 38 Power supply 40 energy storage units 50 radio units 60 Control unit 70 terminal devices 100 vehicles

Claims

Sensor module (1) for a vibration damper with at least one damper unit (10), at least one sensor unit (20) and at least one energy generation unit (30) which is at least partially integrated in the damper unit (10), wherein the energy generation unit (30) is configured to convert mechanical force into electrical energy, such that at least the sensor unit (20) can be operated autonomously with energy from the energy generation unit (30), wherein the energy generation unit (30) is configured as a free-vibrating, electromagnetic energy generation unit (30), wherein the damper unit (10) has a housing (12) and at least one first spring element (14), wherein the energy generation unit (30) is configured with a plurality of permanent magnets (32) in the housing (12) of the damper unit (10), wherein the permanent magnets (32) are arranged for resilient mounting on the first spring element (14) of the damper unit (10).and with at least one stationary electromagnetic coil (36) on or in the housing (12) for generating electrical energy from an oscillating motion of the permanent magnets (32), characterized in that the damper unit (10) has a second spring element (16) and the permanent magnets (32) are arranged between and received by the first and the second spring element (14, 16). Sensor module (1) according to claim 1, characterized in that the sensor module (1) has at least one energy storage device (40) for intermediate storage of electrical energy from the energy generation unit (30) and for supplying at least the sensor unit (20) with electrical energy as required. Sensor module (1) of claim 1 or 2, characterized in that the sensor unit (20) has at least one acceleration sensor and / or at least one temperature sensor for detecting the wear condition and / or a defect of the vibration damper. Sensor module (1) according to one of the preceding claims, characterized in that the sensor module (1) has a radio unit (50) for wireless transmission of measurement data from the sensor unit (20). Sensor module (1) according to one of the preceding claims, characterized in that the energy storage device (40) is designed as at least one capacitor. Vibration damper with a sensor module (1) according to one of the preceding claims. Damper system comprising at least one sensor module (1) or a vibration damper according to one of the preceding claims and a control unit (60) configured to receive signals from the at least one sensor module (1). Vehicle (100) comprising at least one sensor module (1), a vibration damper or a damping system according to any of the preceding claims.

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