Integrated Energy Generating Damper

Abstract

To provide an energy-generating device that captures energy associated with relative motion, whilst providing damping to movement in a compact, self-contained apparatus, offering the ability to be a direct replacement for non-energy harvesting dampers.SOLUTION: When a piston moves, hydraulic fluid is pressurized and drives a hydraulic motor. The hydraulic motor drives an electric generator that produces electricity. Both the motor and generator are arranged in a central portion of a device housing. Exemplary configurations are disclosed such as mono-tube, twin-tube, tri-tube and rotary based structures. By varying electrical characteristics on an internal generator, kinematic characteristics of an energy harvesting apparatus can be dynamically altered. In another mode, the apparatus can be used as an actuator to perform linear movement. Applications include vehicle suspension systems, railcar bogie dampers, and other industrial applications.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] Each aspect involves a damper system and linear and rotational energy capture systems that capture energy associated with relative motion. [Background technology]

[0002] A typical damper dissipates energy associated with motion. A linear damper typically includes a housing with a piston disposed therein that is movable through both a compression stroke and an expansion stroke. An orifice is disposed within the piston. As the piston moves to dampen the motion, the movement of the piston forces a viscous fluid through the orifice.

[0003] Early damper technology has been in use for decades and can be divided into two main groups: monotube dampers and twin-tube dampers (some tri-tube dampers have been produced but are used for specialized adaptive damping and are not widely manufactured). Monotube dampers feature a hydraulic ram with an orifice in the piston head and a gas-filled reservoir inside the main fluid chamber. Twin-tube dampers feature two concentric tubes where the inner tube is filled with hydraulic fluid and the outer tube contains a fluid and gas or some other compressible medium. Summary of the Invention [Problem to be solved by the invention]

[0004] Conventional dampers dissipate a significant amount of energy as heat when performing braking. The inventors have recognized that conventional damper technology can be improved to recover energy and provide dynamic damping control capabilities (while sharing a significant number of parts with conventional low-cost damper technology). [Means for solving the problem]

[0005] Each aspect relates to an energy generating device that captures the energy associated with relative motion while damping the motion in a compact, self-contained device and can directly replace non-energy collecting dampers.

[0006] According to one aspect, the energy generating damper includes a piston head having a self-contained hydraulic motor (which in some embodiments is a positive displacement motor), the self-contained hydraulic motor including a first port and a second port. The first port is in fluid communication with the compression volume and the second port is in fluid communication with the expansion volume. The piston head further includes a generator directly coupled to the hydraulic motor. Fluid flow rotates the hydraulic motor, which in turn rotates a generator that generates electricity. According to another aspect, the energy generating damper includes a housing including a compression volume and an expansion volume. A piston head is disposed within the housing, the piston head including a self-contained hydraulic motor having a first port and a second port. The first port is in fluid communication with the compression volume and the second port is in fluid communication with the expansion volume. The piston head further includes a generator directly coupled to the hydraulic motor, where rotation of the hydraulic motor rotates a generator that generates electricity as it rotates. In a first mode, the piston travels at least a portion of a jounce (compression) stroke, causing fluid to flow from the compression volume to the first port, rotating the hydraulic motor and generator, and generating electricity. In a second mode, the piston travels at least a portion of a reverse (extension) stroke, causing fluid to flow from the expansion volume to the second port, causing the hydraulic motor and generator to reverse rotation, and generating electricity. A fluid reservoir is in fluid communication with either the compression volume or the expansion volume. According to another aspect, the energy generating damper includes an inner housing including a compression volume and an expansion volume. A piston is disposed within the inner housing. In a first mode, the piston travels at least a portion of a jounce stroke, causing hydraulic fluid to move from the compression volume. In a second mode, the piston travels at least a portion of a reverse stroke, causing hydraulic fluid to move from the expansion volume. An outer tube is concentric with the inner tube, which includes the compression volume and the expansion volume. The outer tube includes a low pressure volume. The low pressure volume contains a compressible medium. A piston head disposed within the inner housing includes a self-contained hydraulic motor including a first port and a second port. The first port is in fluid communication with the compression volume and the second port is in fluid communication with the expansion volume.The piston rod is hollow and includes a shaft connecting a hydraulic motor on the piston head to a generator on the other end of the piston rod. Rotation of the hydraulic motor rotates the generator. Braking is provided by a generator connected to the hydraulic motor via a shaft inside the piston rod to restrict fluid flow between the compression and expansion volumes. One or more valves restrict flow to and from the low pressure volume such that during jounce, fluid flows from the compression volume to the low pressure volume and then into the expansion volume, and the compressible medium in the low pressure volume contracts to accommodate the volume of the rod. During reverse, fluid flows from the low pressure volume to the compression volume and the compressible medium expands to fill the volume of the piston rod.

[0007] According to another aspect, the energy generating damper includes a base valve at an end of the damper opposite the fixed rod end. The base valve includes a hydraulic motor including a first port and a second port. The hydraulic motor is coupled to an electric motor. Rotation of the hydraulic motor rotates an electric generator. The energy generating damper further includes two concentric tubes having an inner housing, the inner housing including a compression volume and an expansion volume. A piston is disposed within the inner housing. In a first mode, the piston travels at least a portion of a jounce stroke to displace hydraulic fluid from the compression volume. In a second mode, the piston travels at least a portion of a reverse stroke to displace hydraulic fluid from the expansion volume. An outer tube is concentric with the inner tube including the compression volume and the expansion volume. The outer tube includes a low pressure volume. The low pressure volume includes a compressible medium. A first port of the hydraulic motor is in fluid communication, either directly or through a valve, with the expansion volume, and a second port of the hydraulic motor is in fluid communication, either directly or through a valve, with a low pressure volume containing a compressible medium.

[0008] According to another aspect, the energy generating damper includes an inner housing including a compression volume and an expansion volume. A piston is disposed within the inner housing. In a first mode, the piston travels at least a portion of a jounce stroke to displace hydraulic fluid from the compression volume. In a second mode, the piston travels at least a portion of a reverse stroke to displace hydraulic fluid from the expansion volume. A second tube is concentric with the inner tube including the compression volume and the expansion volume and is exterior to the inner tube. A high pressure volume is located in a space between the second tube and the inner tube. A third tube is concentric with the second tube and is exterior to the second tube. A low pressure volume is located in a space between the third tube and the second tube. The high pressure volume and the low pressure volume may also be configured as being between the third tube and the second tube and between the second tube and the inner tube, respectively. The low pressure volume contains a compressible medium. A hydraulic motor is connected including a first port and a second port. The first port is in fluid communication with the high pressure volume and the second port is in fluid communication with the low pressure volume. One or more valves restrict and / or direct flow such that during jounce, the compression volume is connected to the high pressure volume and the expansion volume is connected to the low pressure volume, and during reverse, the compression volume is connected to the low pressure volume and the expansion volume is connected to the high pressure volume. Thus, in this embodiment, flow through the hydraulic motor is unidirectional and reverses during both jounce and reverse stroke modes. The hydraulic motor is coupled to an electric motor. Rotation of the hydraulic motor rotates an electrical generator.

[0009] According to another aspect, the energy generating damper includes an inner housing including a compression volume and an expansion volume. A piston is disposed within the inner housing. In a first mode, the piston travels at least partially through a jounce (compression) stroke to displace hydraulic fluid from the compression volume. In a second mode, the piston travels at least partially through a reverse (expansion) stroke to displace hydraulic fluid from the expansion volume. The hydraulic motor is coupled to a shaft that is connected to a generator, which generates electricity when the shaft rotates. The hydraulic motor has a first port that connects to the compression volume and a second port that is in fluid communication with the expansion volume. In this regard, in one embodiment, the second port is directly connected to the expansion volume, e.g., as in an embodiment in which an integral piston head or a hydraulic motor piston head with a piston rod faces the generator. In another embodiment, the second port is connected via an outer tube, e.g., as in a base valve configuration. The hydraulic motor and the generator are coupled such that rotation of one rotates the other. The outer tube is concentric with the inner tube, which contains a compression volume and an expansion volume. The outer tube includes an outer volume in fluid communication with the expansion volume. Both the expansion volume (through the outer volume) and the compression volume are in fluid communication with a valve block, which operates such that an accumulator, also attached to the valve block, is in fluid communication with either the low pressure volume, or the compression volume or the expansion volume.

[0010] According to another aspect, the energy generating damper includes a housing including a compression volume and an expansion volume. A piston is disposed within the housing. In a first mode, the piston travels at least partially through a jounce (compression) stroke to displace hydraulic fluid from the compression volume. In a second mode, the piston travels at least partially through a reverse (extension) stroke to displace hydraulic fluid from the expansion volume. The piston head includes a self-contained hydraulic motor including a first port and a second port. The first port is in fluid communication with the compression volume and the second port is in fluid communication with the expansion volume. The piston head further includes a generator that generates electricity when the shaft rotates. The hydraulic motor and generator attached to the piston head are coupled such that rotation of one rotates the other. The piston rod is double-ended with rod portions on opposite sides of the piston head, each rod portion passing through the compression volume and the expansion volume, respectively, and exiting the housing from both sides.

[0011] According to another aspect, the energy generating damper includes an integrated motor and generator connected to the rotary damper. The integrated motor-generator includes a hydraulic motor including a first port and a second port. The hydraulic motor is coupled with an electric motor. Rotation of the hydraulic motor rotates the generator. The energy generating rotary damper further includes an input lever connected to the first volume(s) and the second volume(s). In a first mode, the input lever rotates through at least a portion of a stroke to displace fluid from the first volume. In a second mode, the input lever rotates through at least a portion of a stroke to displace fluid from the second volume. The first port of the hydraulic motor is in fluid communication with the first volume and the second port of the hydraulic motor is in fluid communication with the second volume.

[0012] According to another aspect, the energy generating actuator includes a base valve at an opposite end of the piston rod. The base valve includes a hydraulic motor including a first port and a second port. The hydraulic motor is coupled to an electric motor. Rotation of the hydraulic motor rotates an electric generator. The energy generating actuator further includes two concentric tubes having an inner housing including a compression volume and an expansion volume. A piston is disposed within the inner housing. In a first mode, the piston travels at least partially through a compression stroke to pressurize hydraulic fluid in the compression volume. In a second mode, the piston travels at least partially through an expansion stroke to pressurize hydraulic fluid in the expansion volume. An outer tube is concentric with the inner tube including the compression volume and the expansion volume. The outer tube includes a low pressure volume and is in fluid communication with the expansion volume. The low pressure volume contains a compressible medium. A first port of the hydraulic motor is in fluid communication, either directly or through a valve, with a compression volume, and a second port of the hydraulic motor is in fluid communication, either directly or through a valve, with a low pressure volume containing a compressible medium.

[0013] According to another aspect, the energy generating actuator includes a base valve at an opposite end of the piston rod. The base valve includes a hydraulic motor including a first port and a second port. The hydraulic motor is coupled to the electric motor. The base valve is coupled to the actuator by a rectified hydraulic circuit such that a direction of rotation of the hydraulic unit remains constant regardless of a direction of stroke of the actuator.

[0014] According to another aspect, the energy generating damper described in the previous paragraph can include one or more directional and / or fluid restricting valves in fluid communication between the compression volume and the expansion volume to divert fluid around the hydraulic motor or to restrict fluid through the hydraulic motor.

[0015] According to another aspect, the energy generating damper described in the previous paragraph is used in conjunction with a controller that recovers the generated energy and controls the motion characteristics of the energy generating damper. The controller, in one aspect, is fully powered by the energy generating damper.

[0016] According to another aspect, the energy generating damper described in the previous paragraph is used with a spring assembly that urges the piston rod into an extended state. According to another aspect, the energy generating damper described in the previous paragraph is used with a spring assembly that urges the piston rod into a compressed state.

[0017] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component shown in various figures is represented by the same numeral. For clarity, only some components may be labeled in all figures. [Brief description of the drawings]

[0018] [Figure 1] 1 is an embodiment of an integrated piston head (IPH) including a hydraulic motor and generator. [Diagram 2] 1 illustrates another embodiment of an alternative integrated piston head including a hydraulic motor and generator. [Figure 2A] 1 illustrates another embodiment of an alternative integrated piston head including a hydraulic motor and generator. [Figure 2B] 1 illustrates another embodiment of an alternative integrated piston head including a hydraulic motor and generator. [Diagram 3] 1 illustrates another embodiment of an integrated piston head including an integrated hydraulic motor and generator. [Figure 3A] 1 illustrates another embodiment of an integrated piston head including an integrated hydraulic motor and generator. [Figure 3B] 1 illustrates another embodiment of an integrated piston head including an integrated hydraulic motor and generator. [Figure 3C]1 illustrates another embodiment of an integrated piston head including an integrated hydraulic motor and generator. [Figure 4] 1 illustrates an embodiment of a monotube damper including an IPH. [Figure 4A] 1 illustrates an embodiment of a monotube damper including an IPH. [Diagram 5] FIG. 13 is an embodiment of a twin-tube integrated energy recovery damper with a piston rod facing a hydraulic motor and generator. [Figure 6] 1 is an embodiment of a twin-tube integrated energy recovery damper with hydraulic motor electric motor / generator side valve. [Figure 7] 1 is an embodiment of a tri-tube integrated energy recovery damper with hydraulic motor electric motor / generator side valve base valve. [Figure 8] FIG. 1 is an embodiment of a twin-tube IPH, showing a schematic of an accumulator connected to a low pressure volume. [Figure 9] 1 is an embodiment of a monotube integrated piston head utilizing a through shaft configuration. [Figure 10] 1 is an embodiment of an integrated energy recovery rotating machine with an external integral hydraulic motor. [Figure 11] 1 illustrates an embodiment of an integrated energy recovery electro-hydraulic actuator. [Figure 11A] 1 illustrates an embodiment of an integrated energy recovery electro-hydraulic actuator. [Figure 12] An embodiment of an energy harvesting actuator that rotates a motor / generator in a fixed direction regardless of the direction of actuator stroke. [Figure 13] 1 illustrates an embodiment of an integrated hydraulic pump / motor and electric motor / generator. [Figure 13A] 1 illustrates an embodiment of an integrated hydraulic pump / motor and electric motor / generator. [Figure 14] 1 is an embodiment of a tri-tube integrated energy recovery damper with hydraulic motor electric motor / generator side valve and base valve. [Figure 14A] 1 is an embodiment of a tri-tube integrated energy recovery damper with hydraulic motor electric motor / generator side valve and base valve. [Figure 15] 1 shows an embodiment of a tri-tube integrated energy recovery damper with a hydraulic motor, electric motor / generator and controlled hydraulic valves. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Some aspects of the system relate to an integrated energy generating device that can utilize energy generated by high force but relatively slow motion without the need for external fluid circuits that typically reduce system efficiency, cause durability issues, and increase manufacturing costs. Some embodiments utilize traditional damper configurations and components, with improvements focused on incorporating energy collection elements and valves on the piston head and elsewhere in the housing. It is noted that while "damper" is used in the context of the system, the invention is not limited to vibration systems, nor is it merely an energy extraction device, as it may also drive the invention. The embodiments of the integrated energy generating device described may include a housing and a piston that travels at least partially through a compression stroke when compressed. The piston also travels at least partially through an extension stroke when extended (i.e., the piston may be double acting). As the piston travels, hydraulic fluid is pressurized and travels to drive a hydraulic motor. The hydraulic motor drives a generator that generates electricity.

[0020] According to one aspect, the coupled hydraulic motor and generator are incorporated into the piston head of a conventional damper. A conventional monotube configuration with a gas-charged accumulator at the base of the damper can be used. Alternatively, a twin tube configuration with a selectively valved accumulator configuration can be used with the integrated piston head. In other exemplary embodiments, the integrated piston head can be used with a dual through shaft damper configuration. However, the use of the integrated piston head is not limited to these exemplary embodiments.

[0021] According to another aspect, a hydraulic motor is incorporated into the piston head of the damper. The hydraulic motor has a shaft that extends through the piston rod to a generator on the opposite side of the piston rod. In this embodiment, the damper is otherwise configured similar to a conventional monotube. Alternatively, a twin tube configuration with compression bypass can be used with this hydraulic motor and electric motor / generator configuration. In another exemplary embodiment, the opposing motor / generator system can be used in a twin tube configuration with a selectively valved accumulator. However, the opposing hydraulic motor electric motor / generator system is not limited to these exemplary embodiments.

[0022] According to another aspect, the hydraulic motor and generator are integrated into the base valve of the damper. In one embodiment, a tri-tube rectification system is employed using a check valve, a low pressure volume, and a high pressure volume. In another embodiment, a twin tube design having an outer volume in communication with an expansion volume, in addition to a selectively valved accumulator, can be used with an integrated base valve. However, the use of the base valve system is not limited to these exemplary embodiments.

[0023] Further aspects relate to dynamically altering the motion characteristics of the energy generating damper. Controls can be implemented to control the magnitude of the force acting on the piston of the damper to a desired level. As an example, according to one embodiment, the response can be controlled to minimize the force / velocity response (i.e., damping) of a conventional automotive damper, or in another example, an embodiment can include a response that can be controlled to maximize the energy harvested from the ocean wave input. Some aspects relate to a controller that powers itself from the energy generated by the energy generating damper. This allows for wireless semi-active or fully active control.

[0024] Another aspect relates to an energy generating damper that is incorporated into a suspension system of a vehicle. The energy generating damper can be the primary source of damping for the suspension system, although the invention is not limited in this respect and other applications may be utilized. For example, another aspect relates to an energy generating damper that is incorporated into an industrial energy collection platform, such as an ocean swell energy collection system.

[0025] Turning now to the figures, and initially to FIG. 1, FIG. 1 illustrates an embodiment of an integrated piston head including a hydraulic motor and generator. Integrated piston head 1 is disposed within a hydraulic cylinder that contains fluid both above and below the piston head. When fluid is pressurized above the piston head (relative to the fluid below), the fluid flows into one or more inlet / outlet ports 2 above the piston head. In the embodiment of FIG. 1, a positive displacement gerotor 3 is used as the hydraulic motor, although the invention(s) is not limited in this respect. As fluid flows through inlet / outlet 2, the pressure differential causes gerotor mechanism 3 to rotate within its eccentric pocket. Gerotor motor 3 is drivingly coupled to generator shaft 8, which in turn is drivingly coupled to generator 5 that is immersed in the hydraulic fluid, such that rotation of the hydraulic motor rotates the generator and vice versa. Fluid passes from inlet / outlet 2 through hydraulic motor 3 and out outlet / inlet port(s) 4 below the piston head. This rotates shaft 8, which rotates generator 5, which generates electricity. Electricity is transmitted by wires routed through hollow rod 6 and out of the piston head and damper housing. Seals on the outer edge 7 of the piston head prevent fluid from traveling around the piston head and bypassing the inlet / outlet ports. As fluid is pressurized under the piston head, it travels to inlet / outlet port(s) 4 under the piston head, through the hydraulic motor, and out the inlet / outlet port(s) 2 above the piston head.

[0026] Generator shaft 8 is supported at both ends by bearings 9 and supports inner gerotor element 10 and rotor 11 of generator 5. Outer gerotor element 12 is supported by journal bearings 13. Cover plate 14 axially positions gerotor 3 within its pocket in the piston head. Shadow ports 15 may be present in both the piston head and cover plate to keep the gerotor assembly axially hydraulically balanced.

[0027] Figure 2 shows an alternative integrated piston head embodiment to that shown in Figure 1. In this embodiment, a positive displacement gerotor 16 is used as the hydraulic motor, and differs from the embodiment shown in Figure 1 in that outer element 17 of gerotor motor 16 is drivingly coupled to generator 18 via generator shaft 19, while inner element 36 of gerotor motor 16 is free to rotate about eccentric shaft 20. This configuration allows the larger diameter outer element of the gerotor to share a common low friction bearing (such as a deep groove ball bearing or the like) with the generator shaft, allowing the smaller inner diameter of the inner element to rotate directly against that shaft.

[0028] In a damper application, the speed of the piston, and therefore the speed of the gerotor motor, is continuously accelerated / decelerated in one direction, then stopped, then accelerated / decelerated in the opposite direction. Without wishing to be bound by theory, as the gerotor rotates slower, any fluid lift generated on the gerotor's sliding bearing is eliminated, and this bearing is subjected to higher friction. The larger the diameter of this bearing, the more torque is lost due to this increased friction, and if the gerotor is used as a motor in this application, this torque loss may equal or even exceed the torque generated by the motor itself, potentially causing the motor to stall. Even when there is sufficient speed at the sliding bearing interface to generate fluid lift, and therefore friction is significantly reduced, again without wishing to be bound by theory, it is believed that the energy loss at this interface is proportional to the fourth power of the diameter, and therefore it may be desirable to keep the sliding bearing diameter as small as possible to reduce energy loss. Utilizing the unique bearing configuration described above, the larger outer element is now supported by a low friction rolling element bearing that is also shared with the generator shaft, yet the plain bearing contact surface is located on the smaller diameter of the inner element, with the potential benefits of lower initial starting torque and lower power loss at high speeds. Although low friction bearings are more expensive than plain fluid bearings, some of the increased cost can be mitigated by the outer gerotor element sharing the same low friction bearing as the generator shaft.

[0029] By locating the low-friction bearing on or near the axial centerline of the outer gerotor element, all or nearly all of the radial loads generated by the outer gerotor element are transferred to the low-friction bearing, which allows the use of a lower-cost plain bearing at the opposite end of the generator shaft. As shown in FIG 2, the diameter of plain bearing 34 can be reduced to a size significantly smaller than the diameter of the outer gerotor element to reduce its friction losses.

[0030] In the embodiment shown in FIG. 2, integral piston head 21 is disposed within a hydraulic cylinder that contains fluid both above and below the piston head. When fluid is pressurized above the piston head (relative to the fluid below), the fluid flows along flow path 23 into one or more inlet / outlet ports 22 in piston head 21. As fluid flows through inlet / outlet 22, the pressure differential causes gerotor 16 to rotate about eccentric journal 24 of gerotor shaft 20. Gerotor motor outer element 17 is drivingly coupled to generator shaft 19, which in turn is drivingly coupled to generator 18 (submerged in hydraulic fluid), such that rotation of the hydraulic motor rotates the generator, and vice versa. Fluid flows from inlet / outlet 22, through hydraulic motor 16, through inlet / outlet port(s) 25 in the gerotor shaft, through flow path 26 in generator vessel 27, and below the piston head, as shown by flow path arrows 28. This fluid flow rotates the gerotor, which in turn rotates generator shaft 19, which rotates generator 18, which generates electricity. In this embodiment, electricity is transmitted by electrical wires 29 that pass through hollow piston rod 30 connected to generator can 27, through high pressure hydraulic seal 31, and out of the piston head and damper housing. Seals 32 on the outer edge of the piston head prevent fluid from traveling around the piston head and bypassing the inlet / outlet ports. As fluid is pressurized under the piston head, it travels through flow passage 26 to generator can 27, through inlet / outlet port 25 in gerotor shaft 20, through the hydraulic motor, and out through inlet / outlet port(s) 22 in the piston head.

[0031] Generator shaft 19 is supported at both ends by bearings 33, 34, and shaft 19 supports outer gerotor element 17 and rotor 35 of generator 18. Inner gerotor element 36 is supported on gerotor shaft 20 via journal bearing 24. The gerotor shaft also functions as a cover plate that axially positions gerotor 16 between the gerotor shaft and piston head 21. Shadow ports 37, 38 may be provided in both the piston head and gerotor shaft to keep the gerotor assembly axially hydraulically balanced.

[0032] As shown in FIG. 2A , port 25 in the gerotor shaft is open to the pressure in generator vessel 27 and has no external sealing land around it. Because there is a pressure differential between port 25 and the fluid in generator vessel 27, no external sealing land is needed and the gerotor's land contact surface can be reduced to reduce frictional resistance between the gerotor and the gerotor shaft sealing surface. The opposite shadow port 37 in the piston head is also open to the pressure in generator vessel 27 and has no external sealing land around it. Not only does this help keep the gerotor in axial hydraulic balance, but it also means that as fluid moves from the gerotor vessel to port 25, it also flows through shadow port 37. As fluid moves in and out of shadow port 37 it must pass through the rolling elements of low-friction bearing 33, which keeps the bearing rotating with a continuous replenishment of fluid and minimizes localized heating of the fluid due to frictional losses.

[0033] As shown in FIGURE 2B, outer gerotor element 17 is drivingly connected to the generator shaft by drive pins 39 secured to the outer element. The pins are connected to the generator shaft by slots 40 disposed about the outer diameter of the generator shaft. In one embodiment, the pins are of the split spring type and not only transmit the drive torque from the gerotor to the generator shaft, but also function as miniature shock absorbers to absorb shock loads generated in the gerotor by high frequency motion of the damper.

[0034] The generator shaft has a passage 41 that allows flow from the port in the gerotor shaft through the generator shaft and into the generator vessel 27 and from there into the volume below the piston head.

[0035] Referring again to FIG. 2, the generator shaft includes a check valve 42 that allows free flow from the piston head, through the gerotor, through the shadow port in the generator shaft, through the passage in the gerotor shaft, into the generator can, and from there into the volume below the piston head, to bypass the gerotor, thereby reducing damping (and reducing energy recovery) during the compression stroke. The check valve is actuated by a spring 43, the preload on which can be adjusted to vary compression damping from a minimum to a maximum value, thereby achieving maximum compression damping suitable for different applications. The check valve prevents flow from bypassing the gerotor during the expansion stroke, thereby achieving maximum expansion damping (and energy recovery).

[0036] A blow-off valve 44, shown in FIG. 2, can be used to limit the maximum pressure in the generator can and therefore the bottom side of the integrated piston head (IPH). The pressure in the generator can act on a sealing washer 45 via a passage 46. The sealing washer is held against the sealing surface of the piston head by a spring 47, blocking flow from the passage 46. Pressure acting across the area of ​​the passage 46 generates a force that disengages the sealing washer, and when the force of the pressure in the generator can acting on the sealing washer overcomes the spring force of spring 47, the sealing washer disengages, allowing flow from the generator can, and therefore from the underside of the IPH to the top side of the IPH, to bypass the gerotor through a slot 48 in the piston head (shown in FIG. 2A). The spring force acting on the sealing washer and the number of passages can be varied to suit different applications, varying the pressure at which the blow-off valve opens.

[0037] The blowoff valve is used to limit the pressure difference between the top and bottom of the gerotor under high expansion strokes, so as to limit not only the maximum expansion damping force but also the maximum RPM of the gerotor. This keeps the gerotor bearing and generator RPM within reasonable limits under high expansion forces, thereby enhancing the durability of the IPH.

[0038] Figures 3, 3A, 3B, and 3C show an embodiment of an integrated motor / generator unit (IMGU) that incorporates features of the embodiment shown in Figure 2, but with a reduced part count in a more compact unit. This embodiment can be used either in an IPH device as shown in Figure 4A, or as a separate "valve" that can be incorporated into a damper or actuator as described below in connection with Figure 6. As with the previous embodiment, the IMGU can be used as a generator or as a hydraulic power source for an electro-hydraulic actuator.

[0039] In this embodiment, and similar to the embodiment shown in FIG. 2, the outer element of the gerotor motor is drivingly coupled to generator 50 in a manner similar to that shown in the embodiment shown in FIG. 2, while the inner element of the gerotor motor 51 is free to rotate about eccentric shaft 52. This configuration allows the outer element of the gerotor to share a common low-friction bearing 53 with generator shaft 54, allowing the smaller inner diameter of the inner gerotor element to rotate directly against eccentric shaft 52, providing the efficiency and cost benefits outlined in the embodiment shown in FIG. 2. In the embodiment shown in FIG. 3, generator 50 is now concentric and coplanar with gerotor motor 55, rather than concentric and adjacent as shown in FIG. 2. This configuration not only reduces the overall length and weight of the unit, but also reduces the number of parts, thereby reducing costs while increasing durability. The generator magnets 56 can be drivingly connected (by adhesive or other suitable means) directly to the generator shaft 54 ​​(as shown in FIG. 3B) or directly connected to the outer gerotor element 49, thereby eliminating a separate rotor element. Two low-friction bearings 53 support the generator shaft and evenly share the radial load from the outer gerotor element. In this case, the two bearings share this load evenly, greatly increasing bearing life and enhancing the durability of the IMGU. In the embodiment shown, the bearing outer race 57 of the low-friction bearing is formed directly on the generator shaft, eliminating the need for an additional outer race component while simultaneously reducing the mass of the IMGU and the rotational inertia of the generator rotating assembly.

[0040] Gerotor caps 58 are located on either side of the gerotor element and contain first and second flow ports 59 and 60, which may be full flow or shadow ports as needed for the application, to hydraulically balance the gerotor assembly in the axial direction. The port configuration may be symmetric about both the vertical and horizontal centerlines. The gerotor cap is coupled to and secured to an IMGU end cap 61. The IMGU end cap contains flow channels 62, 63 that connect to the first and second flow ports in the gerotor cap so that fluid flows from one port to the other causing the gerotor to rotate.

[0041] Introducing a symmetrical arrangement of ports allows the inlet and outlet flow paths of the hydraulic unit to be on the same or opposite sides of the IMGU, thereby improving versatility of use for various applications. This symmetrical part configuration also allows valves and connectors such as bypass valves, pressure relief valves, accumulators, etc. to be added on opposite sides of the first and second flow ports, allowing flow to occur through and even around the gerotor (i.e., into and out of the first and second ports) to provide parallel flow paths for the hydraulic unit. This again provides a preferred mounting configuration.

[0042] By locating gerotor motor 55 flush with the generator, rather than around or adjacent to the generator as shown in the embodiment of Figures 1 and 2, flow into and out of the hydraulic unit through the first and second ports is now generated through the center of the generator, which shortens and simplifies the flow path, reducing viscous losses and thereby increasing the efficiency of the unit.

[0043] Additional valves such as pressure relief valves, bypass valves, load holding valves, etc. may be incorporated into the gerotor cap and / or the IMGU end cap (or even outside the IMGU end cap) to provide additional functionality both as a generator and as an actuator.

[0044] The low friction bearing inner race 64 is formed directly into the gerotor cap (or IMGU end cap) and is axially retained between the gerotor cap and the IMGU end cap. This further reduces part count by eliminating the need for a separate bearing inner race. In the embodiment shown, the low friction bearing is of the cylindrical roller type, although it will be appreciated that the bearing configuration shown can be readily modified to incorporate other types of low friction bearings, or even plain bearings, as the application permits, and a particular application is not limited in this respect.

[0045] 3, eccentric shaft 52 is held stationary in the gerotor cap, and the inner gerotor element rotates relative to the shaft supported by sliding journal bearings 65. The eccentric shaft is used to connect and locate the gerotor cap and the IMGU end cap, and the IMGU assembly is secured by threaded coupling 66 or other mechanisms such as staking and welding. Shoulder 67 on the eccentric shaft ensures precise spacing between the gerotor caps so that precise axial clearance is maintained between the gerotor and end caps for proper and efficient gerotor operation.

[0046] The generator stator 68 is drivingly coupled (by adhesive or other suitable process) to an outer sleeve 69, which is sandwiched between two IMGU end caps such that the stator is held concentric with the generator shaft and in the correct axial position. A timing mechanism between the two IMGU end caps and the outer sleeve determines the radial position of the IMGU end caps relative to each other to ensure precise timing of the flow ports and positioning of the eccentric shaft 52.

[0047] The compact nature of the integrated motor / generator unit shown in this embodiment allows the IMGU to be used as a cartridge type regenerative valve, with the unit placed in a machined hole or pocket in the device such that the flow ports are aligned and sealed against the first and second ports of the IMGU. In this case, the back EMF of the generator can be controlled to control the flow in the hydraulic circuit, or the IMGU can be powered to the generator to rotate the hydraulic unit so that it acts as a pump, with the IMGU acting as a hydraulic power source. Possible applications of this type of valve can include pressure regulators or relief valves for larger hydraulic circuits. Typically, hydraulic valves with controllable orifices are used to regulate pressure in hydraulic circuits, and thus energy is wasted by restricting flow across these orifices. In this case, the incorporation of the IMGU as a regenerative pressure control valve can capture this energy.

[0048] Other applications include variable hydraulic power sources, such as for engine or transmission lubrication pumps. Typically, these pumps are fixed displacement and driven at a specific shaft speed. These pumps are sized to meet the expected maximum flow demand at any given shaft speed, and therefore, these pumps provide more flow than is normally required, and energy is wasted through the use of flow control valves. The compact size and cylindrical shape of the IMGU allows it to be used to replace these pumps, either as a simple cartridge unit inserted into a machined cavity in the engine, or as an externally mounted unit. The variable speed control, and therefore flow control capabilities, of the IMGU allows the pump's output to always be precisely matched to demand, thereby reducing energy consumption in these applications.

[0049] Although FIGS. 4 and 4A show an embodiment of a monotube damper 10 utilizing the integrated piston head 1 of FIGS. 2 and 3, respectively, the IPH can also be configured as shown in FIG. 1. In this case, the integrated piston head 71 is disposed within a housing that includes a compression volume 73 and an expansion volume 74. Additionally, a floating piston 75 seals a gas-charged accumulator 76 and maintains pressure on the fluid within the housing. When the piston rod 30 is jounced, fluid flows from the compression volume 73 through the integrated piston head 71 into the expansion volume. During the jounce stroke, the floating piston 75 moves to compress the gas to compensate for the piston rod volume introduced into the expansion volume 74. During reverse, fluid flows from the expansion volume 74 through the integrated piston head 71 into the compression volume 73. At the same time, the floating piston 75 moves to expand the accumulator gas volume 76 to compensate for the piston rod volume that has left the housing during reverse.

[0050] As fluid flows through the integrated piston head 71, the hydraulic motor rotates and turns a generator, which generates electricity from the movement of fluid forced through the piston head 71 by the movement of the piston 30. Energy from the generator is delivered by wires 29 that exit the IPH through the hollow piston rod 30, through rod end 77, and out the end of the piston rod and out the damper housing. A high pressure pass-through 31 can be used to seal the portion of the wires immersed in the hydraulic fluid with the generator from the portion of the wires that exit the piston rod towards the outside environment.

[0051] By changing the electrical characteristics of the generator, the motion characteristics of the damper can be changed. If a lower impedance is added to the terminals, increasing the load on the generator, the force / velocity characteristic of the generator will be higher (more force per angular velocity). As the hydraulic motor and generator are coupled, this is transferred to the hydraulic motor and therefore to the fluid path through the integrated piston head. A linear relationship dictates that adding a lower impedance to the generator will result in a higher force / velocity characteristic acting on the damper piston and adding a higher impedance to the generator will result in a lower force / velocity characteristic acting on the damper piston.

[0052] Additionally, a generator can be driven as a motor and a hydraulic motor can be utilized as a hydraulic pump. This allows for the driving of a damper, resulting in an active linear actuator. An example of such a use, using the embodiment of FIG. 4 as an example, is to drive an electric motor / generator 18 by applying a voltage. By way of example, a brushed DC motor can be used as the generator and a gerotor pump can be used as the hydraulic motor, although the invention(s) are not limited in this respect. When a voltage is applied to the generator 18, the hydraulic motor mechanism rotates and forces fluid either from the compression volume 73 to the expansion volume 74 or vice versa, depending on the direction of rotation (determined by the voltage polarity on the DC motor / generator). The movement of fluid from one volume to the other moves the piston head and drives the piston rod. In some applications, this may be useful as an active suspension system in a vehicle, allowing for controllable positioning of the wheels to improve ride comfort and terrain crossing characteristics. In some industrial applications, this may be useful as a standalone sealed hydraulic actuator with high power density characteristics.

[0053] In one embodiment, the gas in accumulator 76 should be pressurized to ensure that the maximum compression (jounce) damping does not exceed the force exerted by accumulator 76 on compression volume 73. In one embodiment, the pressure is typically in the range of 200-800 psi, but a suitable value can be calculated as follows: accumulator pressure > maximum jounce damping force / surface area of ​​floating piston.

[0054] The embodiment of Figure 4A shows a monotube damper of the configuration shown in Figure 4, with IPH 71 being of the embodiment shown in Figure 3. In this case, IPH 72 is connected to a piston head 150 which is connected to piston rod 30. Seal 151 is housed in a piston adapter, allowing IPH 72 to be common to other damper configurations, for example as shown in Figure 6. It is of course possible for the seal to be housed directly in IPH 71 and for the IPH to be directly connected to piston rod 30.

[0055] Some embodiments of the described monotube damper incorporating the integrated piston head 1 have additional features. In applications such as vehicle dampers, it is often necessary to minimize damping during jounce. A check valve "bypass" 42 can be incorporated into the integrated piston head (or other location) so that during jounce, fluid can flow from the compression volume to the expansion volume through the bypass valve, but not the other way around, to reduce damping compared to if the fluid path was through a hydraulic motor. Additionally, other valves such as non-directional, bypass, and blow-off valves 44 can be used to further tune the ride characteristics.

[0056] In some cases, it may be desirable to eliminate the gas-charged accumulator and operate the system at low pressure to minimize the possibility of fluid leakage from the shaft seal. Additionally, it may be desirable to locate the generator off the piston head (e.g., to allow for a larger motor to be installed without compromising the piston stroke to housing length ratio). Figure 5 shows an embodiment of an integrated energy generating damper that operates at low pressure, has a generator off the piston head, and features a compression bypass.

[0057] The twin tube damper embodiment of FIG. 5 has a piston head 81 disposed within an inner housing that includes a compression volume 79 and an expansion volume 80. In a first mode, the piston 81 travels at least partially through a jounce stroke to pressurize hydraulic fluid in the compression volume 79. In a second mode, the piston travels at least partially through a reverse stroke to pressurize hydraulic fluid in the expansion volume 80. An outer tube concentric with the inner tube includes a low pressure volume 82. The low pressure volume 82 includes both fluid and a compressible medium (gas, foam, bladder, etc.). The piston head 81 disposed within the inner housing includes a self-contained hydraulic motor 83 that includes a first port 84 and a second port 85. The first port 84 is in fluid communication with the compression volume 79 and the second port 85 is in fluid communication with the expansion volume 80. The piston rod 86 is hollow and includes a shaft 87 that connects a hydraulic motor 83 on the piston head 81 with an electric motor / generator 89 on the other end of the piston rod 86. Rotation of the hydraulic motor 83 causes the electric motor / generator 89 to rotate.

[0058] In the embodiment of Figure 5, reverse damping is provided by an electric motor / generator 89, transmitted via a shaft 87 inside the piston rod 86. The resistive force acting on the shaft 87 is transmitted to the hydraulic motor 83 to restrict fluid flow between the compression volume 79 and the expansion volume 80. As mentioned above, the motion characteristics of the damper can be changed by changing the electrical characteristics of the terminals of the electric motor / generator. Additionally, the system can be actively driven by supplying power to the electric motor / generator.

[0059] Valves 90, 91 restrict flow to and from low pressure volume 82 such that during jounce, fluid flows freely from compression volume 79 through the unrestricted release valve 90, through low pressure volume 82, and through check valve 91 into expansion volume 80. During reverse, check valve 91 closes, allowing fluid from expansion volume 80 to pass through piston head 81 while a small amount of fluid flows from low pressure volume 82 through release valve 90 into compression volume 79 to replenish the lost piston rod volume.

[0060] In the twin-tube embodiment of Figure 5, during a jounce, pressurized fluid in compression volume 79 flows through release valve 90 into low pressure volume 82 and out check valve 91 into expansion volume 80. In this embodiment, the volume of fluid entering release valve 90 is greater than the volume of fluid exiting check valve 91, and this volume difference is stored in the low pressure volume by compressing the compressible medium in the low pressure volume. In addition to this fluid path, some fluid also travels from compression volume 79 through piston head 81 to expansion volume 80, while generating electricity in generator 89.

[0061] During reverse travel, the embodiment of FIG. 5 pressurizes the fluid in the expansion volume 80, causing the check valve 91 to close. Fluid is forced to flow from the expansion volume 80 through the piston head 81 into the compression volume 79. At the same time, the accumulated fluid in the low pressure volume 82 flows through the release valve 90 into the compression volume 79 to replenish the piston rod volume as the compressible medium in the low pressure volume 82 expands. Fluid flows from the compression volume 80 through port 85 into the hydraulic motor 83 and out port 84 into the expansion volume 79, causing the hydraulic motor 83 to rotate. This causes the shaft 87 that extends inside the piston rod 86 and the motor / generator 89 to rotate, causing a back electromotive force (EMF) in the motor / generator to provide braking.

[0062] In the embodiment shown in FIG. 5, an offset loop 93 is used to attach the piston rod 86 to the vehicle, but any suitable attachment method, such as a loop coupling, or a threaded piston rod attachment, can be employed. In the system of FIG. 5, the generator sits on top of the piston rod attachment point. Several embodiments allow this. In one embodiment, the shaft 87 passes through a shaft seal that separates the fluid-containing side of the shaft from the ambient air side of the shaft. In one example, this allows the keyed shaft 87 to be inserted into a generator can 92 that can thread onto the piston rod and acts as the primary attachment for the piston rod end of the damper. In another embodiment, offset loop adapters are used on the top and bottom to allow a bolted attachment without side loading the damper. In this case, the entire length of the shaft 87 and the generator 92 can be sealed in fluid during manufacture, eliminating the need for pressure shaft seals for field installation. In another embodiment, an adapter can be attached to the piston rod to allow either an eyelet attachment point that does not require threading the generator can during installation, or a piston rod nut attachment method. Again, this allows for the elimination of a friction-inducing shaft seal on the motor shaft 87. Although several methods of mounting the piston rod end of the damper have been presented, the invention is not limited in this respect.

[0063] Figure 6 shows an embodiment of an integrated energy generating damper similar to that shown in Figure 5, operating at low pressure, with the generator located off the piston head, and featuring a compression bypass, but differing in that the motor / generator is located perpendicular to the cylinder body rather than at the end of the piston rod opposite the piston head. This configuration has the benefit of shortening the overall shock length and also eliminating the need for a long, thin concentric shaft. This configuration may be better suited for vehicle damper applications where shock length and packaging requirements are constrained.

[0064] The twin tube damper embodiment of FIG. 6 includes a piston 94 disposed within an inner housing that includes a compression volume 95 and an expansion volume 96. In a first mode, the piston 94 travels at least partially through a jounce stroke to pressurize hydraulic fluid in the compression volume 95. In a second mode, the piston travels at least partially through a reverse stroke to pressurize hydraulic fluid in the expansion volume 96. An outer tube, concentric with the inner tube, includes a low pressure volume 97. The low pressure volume 97 includes both fluid and a compressible medium 98 (such as gas, foam, or bladder). An integrated motor / generator unit (IMGU) 72 is disposed at the rod end of the damper. The IMGU shown in FIG. 6 is similar to that shown in FIG. 3, but may be similar to that shown in FIG. 1 or FIG. 2, and includes a first port 100 and a second port 101. A first port 100 is in fluid communication with the low compression volume 97 and a second port 101 is in fluid communication with the expansion volume 96 .

[0065] The valve 102 restricts flow to and from the low pressure volume 97 such that during a jounce, fluid flows from the compression volume 95 through the valve 102 into the low pressure volume 97. The valve 102 provides the required flow resistance in this direction to impart the appropriate jounce damping characteristics for the application. During reverse, the valve 102 allows free flow from the low pressure volume 97 to the compression volume 95.

[0066] In the twin tube embodiment of FIG. 6, during a jounce, the pressurized fluid in the compression volume 95 flows through valve 102 into the low pressure volume 97, enters the IMGU 72 through port 100, exits the IMGU at port 101, and enters the expansion volume 96. In this embodiment, the volume of fluid exiting the compression volume 95 is greater than the volume of fluid entering the expansion seat 96, and this volume difference is stored in the low pressure volume 97 by compressing the compressible medium 98 in the low pressure volume 97. During reverse, the embodiment of FIG. 6 pressurizes the fluid in the expansion volume 96 such that flow passes from the expansion volume 96 through the IMGU 72 via ports 101, 102 into the low pressure volume 97, and through the release valve 102 into the compression volume 95. At the same time, the accumulated fluid in the low pressure volume 97 also flows through the release valve 102 into the compression volume 95 due to the expansion of the compressible medium 98 in the low pressure volume 97, replenishing the piston rod volume. As fluid flows from the expansion volume 96 through port 101 into the IMGU 72 and exits the IMGU at port 100 back to the compression volume 96, the hydraulic motor 55 and generator 50 rotate. As explained in FIG. 2, this generates a back electromotive force (EMF) in the motor / generator to provide braking and also generate electricity. As previously mentioned, the motion characteristics of the damper can be changed by changing the electrical characteristics at the terminals of the electric motor / generator. Additionally, the system can be actively driven by supplying power to the electric motor / generator.

[0067] In the embodiment shown in FIG. 6, during a jounce, fluid flows from the compression volume 95 through valve 102 into the low pressure volume 97, then flows through port 100 into the IMGU 72, exits the IMGU through port 101, and then enters the expansion volume 96. Fluid flowing through the IMGFU during a jounce stroke rotates the motor 55 and generator 50, and even if no back EMF is generated, the required jounce damping force is small, so parasitic losses from the fluid flow and rotating parts may generate jounce damping forces that are too high for certain applications. In these applications, it is possible to incorporate a bypass check valve 105 that connects the low pressure volume 97 to the compression volume 96. The check valve allows fluid to flow freely from the low pressure volume 97 directly to the compression volume 96, thereby reducing the jounce damping force, but prevents flow from bypassing the IMGU during reverse braking.

[0068] In the embodiment shown in FIG. 6, during the last portion of both the jounce and reverse strokes, there is a quantity of oil trapped between the pocket 103 of the piston 94 and the journal 104 of the end cap. When the piston 94 strokes such that the journal 104 enters the pocket 103 (either on the jounce or reverse stroke), the hydraulic fluid trapped within the pocket 103 is forced to exit through an annular gap formed between the outer diameter of the journal and the inner diameter of the pocket. The annular gap is sized such that at the end of both the jounce and reverse strokes, a pressure spike is created that acts across the pocket area, generating an additional force that acts as a hydraulic damper. The clearance between the pocket 103 and the journal 104 can be selected to provide the exact amount of damping effect appropriate for the application.

[0069] In some application scenarios, it is desirable to have an energy generating damper that is not gas pressure limited on compression braking, features energy capture on both compression and reversal, and maximizes stroke length per body length. Several embodiments incorporating the above features are described below.

[0070] According to the embodiment shown in FIG. 7, a tri-tube damper structure incorporating an energy collecting IMGU is disclosed. In this embodiment, a piston rod 105 and a hydraulic ram type (solid) piston 106 are disposed in an internal fluid filled cylinder 107. The inner housing (combining compression volume 108 and expansion volume 109) is surrounded by a second tube 110 that is concentric with the inner tube 107. The space between the inner tube and the second tube is the high pressure volume 111. The second tube 110 is surrounded by a third tube 112 that is concentric with the second tube. The space between the second tube and the third tube is the low pressure volume 112. In some embodiments, the high pressure and low pressure tubes can be reversed.

[0071] In the embodiment of Figure 7, an integrated motor / generator unit (IMGU) 72 is located at the rod end of the damper. The IMGU shown in Figure 7 is similar to that shown in Figure 3, or may alternatively be similar to that shown in Figures 1 or 2, and includes a first port 113 and a second port 114. The first port 113 is in fluid communication with the high pressure volume 111, and the second port 114 is in fluid communication with the low pressure volume 112.

[0072] During a jounce, the piston rod 105 pushes the piston 106 into the compression volume 108, which causes fluid to pass from the compression volume to the high pressure volume through the directional check valve 115. The high pressure volume 111 is in fluid communication with a first port 113 of the IMGU 72. Fluid passes from the high pressure volume 111 through the first port 113, through the IMGU 72, out the second port 114 into the low pressure volume 112, and through the directional check valve 116 into the expansion volume 109. At the same time, a compressible medium 117, such as a cellular foam or air bladder, in the low pressure volume 112 contracts to replace the volume of the introduced piston rod.

[0073] Upon reversing, the piston rod 105 draws the piston 106 into the expansion volume 109, which forces fluid to pass from the expansion volume through the directional check valve 118 to the high pressure volume 111. The high pressure volume 111 is in fluid communication with a first port 113 of the IMGU 72. Fluid passes from the high pressure volume 111 through the first port 113, through the IMGU 72, out the second port 114 into the low pressure volume 112, through the directional check valve 119 and into the compression volume 108. At the same time, the compressible medium 117 in the low pressure volume 112 is decompressed to fill the volume of the withdrawn piston rod.

[0074] As fluid flows from the high pressure volume 111 through port 113 into the IMGU 72 and exits the IMGU at port 114 back to the low pressure volume 112, the hydraulic motor 55 and generator 50 rotate. As described in the embodiment of FIG. 2, this generates a back electromotive force (EMF) in the motor / generator to provide braking and also generate electricity. As previously described, the motion characteristics of the damper can be altered by changing the electrical characteristics at the terminals of the electric motor / generator. Additionally, the system can be actively driven by supplying power to the electric motor / generator.

[0075] According to another embodiment, FIG. 8 shows a twin tube structure that is not gas pressure limited, features bidirectional energy capture, and has a large stroke to body length ratio. This system utilizes an integrated piston head as shown in FIG. 2 in a twin tube body structure with a valve mechanism that operates to ensure that whichever port is at low pressure is always connected to an accumulator (although the piston head may be an IPH as shown in FIG. 1 or FIG. 3). A check valve or a pilot operated valve such as a three-port pilot operated spool valve can perform this operation. A shuttle valve can also ensure that the gas accumulator 124 on the common port is always in fluid communication with the low pressure side of the piston head.

[0076] In the embodiment shown in Figure 8, the integral piston head 71 is disposed within an inner cylinder which contains hydraulic fluid. An expansion volume 120 of the inner cylinder is in fluid communication with an outer fluid volume 121 contained between the inner cylinder and a concentric outer cylinder. Both the compression volume 122 and the outer fluid volume 121 are in fluid communication with a pilot operated valve block 123. A gas charged accumulator or reservoir 124 is also in fluid communication with the pilot operated valve block 123.

[0077] During a jounce, the piston rod 30 is forced into the cylinder, forcing fluid from the compression volume 122 through the hydraulic motor 16 and into the expansion volume 120, which turns the electric motor / generator 18. Electricity from the generator runs down a wire through the center of the piston rod 30. A high voltage wire pass-through seals the fluid portion of the internal shock body from the outside. Since the jounce stroke introduces the piston rod volume into the expansion volume, fluid must move from the expansion volume to the accumulator 124, which is done through the valve block 123. When the compression volume is pressurized, a pilot operated check valve 125 is opened by a pilot line 127 in the valve block 123. This allows free flow between the accumulator 124 and the expansion volume 120, thereby allowing the introduced rod volume to flow from the expansion volume into the accumulator 124.

[0078] During reverse travel, the piston rod 30 is withdrawn from the cylinder, forcing fluid from the expansion volume 120 through the hydraulic motor 16 and into the compression volume 122, which turns the electric motor / generator 18. Because the reverse stroke removes the piston rod volume from the compression volume, fluid must be moved from the accumulator 124, which is done via the valve block 123. When the rod volume needs to be replenished from the accumulator to the compression volume, the pressure in the compression volume is lower than the accumulator pressure, which allows fluid to flow from the accumulator 124 through the check valve 126 and into the compression volume 122.

[0079] In the embodiment shown, the valve block 123 includes a check valve 126 and a pilot operated check valve 125 to ensure that whichever port is at low pressure of the IPH is always connected to the accumulator, although this can be done using other valve configurations such as a spool valve mechanism that can switch the connection of the accumulator 124 between the compression volume 122 and the expansion volume 120 so that the accumulator is always in fluid communication with the lower pressure volume. In this embodiment, during a jounce, the pressure in the compression volume 122 is higher than the pressure in the expansion volume 120 and the internal pilot port in the valve block 123 connected to the compression volume 122 pushes the shuttle mechanism to allow fluid communication between the accumulator 124 and the expansion volume 120. During reverse flow, the pressure in expansion volume 120 is higher than the pressure in compression volume 122, and an internal pilot port in valve block 123, connected to expansion volume 120, pushes the shuttle mechanism to allow fluid communication between accumulator 124 and compression volume 122. Shuttle valve mechanisms, other pilot operated mechanisms, and valves (including mechanically and electrically actuated valves) that selectively connect different fluid volumes based on pressure differentials are known in the art and are not limited in the present invention(s).

[0080] Although the hydraulic motor 16 and electric motor / generator 18 are shown in an integrated piston head 71 configuration, the embodiment of FIG. 8 can also be constructed in the piston head, piston rod, and electric motor / generator configuration of FIG. 5, where the piston head includes the hydraulic motor, the piston rod includes the internal rotating shaft, and the electric motor / generator is on the opposite side of the piston rod. In another embodiment, the system of FIG. 8 can be constructed with a solid piston head and a hydraulic motor and generator pair located at the base and outside of the damper, such as the system disclosed in FIG. 6. In this case, a first port of the hydraulic motor is in fluid communication with the compression volume 122 and a second port is in fluid communication with the expansion volume 120 (via the outer fluid volume 121). The remainder of the system, including the valve block 123, can remain as shown in FIG. 8.

[0081] Certain industrial applications of sealed hydraulic linear energy generating devices allow for other form factors than typical automotive dampers. In the embodiment shown in FIG. 9, an integrated piston head system with a shaft running through it is shown. In this embodiment, an integrated piston head 128 is placed in a cylinder containing hydraulic fluid and is connected to a first piston rod 129 and a second piston rod 130. The piston head shown in FIG. 9 is similar to that shown in FIG. 3, but may also be similar to that shown in FIG. 1 or FIG. 2. In some embodiments, the second piston rod 130 exiting the device can be connected to a spring mechanism to return the other piston rod to a standard compressed state.

[0082] As the piston rod travels in a first direction, fluid from a first volume 131 is forced to flow through a hydraulic motor 132 and into a second volume 134, which rotates an electric motor / generator 133. Electricity from the generator travels down a wire that runs through the center of one of the piston rods, and a high voltage wire pass-through seals the fluid portion of the internal shock body from the outside.

[0083] As the piston rod moves in the second direction, fluid from the second volume 134 is forced to flow through the hydraulic motor 132 and into the first volume 131, which in turn rotates the electric motor / generator 133.

[0084] To compensate for volumetric changes of the fluid due to temperature variations, there is a device internal to the system to displace the fluid. In the embodiment shown in FIG. 9, this is shown to be a compressible cell foam inserted in a gap 135 in one of the piston rods 134. However, the placement of the fluid compensation mechanism may be at another location internal to the unit or external. Additionally, accumulators, among other devices, may be used as an alternative or in addition to foam to displace the fluid. In some embodiments, it may be desirable to limit the pressure experienced by the fluid compensation mechanism. In these embodiments, a shuttle valve may be employed, as described in FIG. 8.

[0085] In certain applications, such as heavy military vehicles, it is desirable to have an energy harvesting rotary damper. The embodiment of FIG. 10 shows the damper as a system with an integrated motor / generator unit (IMGU) coupled to a rotary damper unit 136. In the embodiment shown, the IMGU 72 is similar to that shown in FIG. 3, but may be similar to that shown in FIG. 1 or FIG. 2. During stroke of the damper lever in a first direction, fluid from the first volume(s) is forced to enter the first port 59, pass through the hydraulic motor 55, and exit the second port 60 into the second volume(s) 139. As fluid flows through the motor 55, the motor and generator rotate and generate electricity, as described in FIG. 7. During stroke of the damper lever in the second direction, fluid from the second volume(s) 139 is forced to flow into the second port 60, pass through the hydraulic motor 55, and out the first port 59 into the first volume(s) 138. As fluid flows through the motor 55, the motor and generator rotates and produces electricity, as described in FIG. 7. To compensate for fluid volume changes due to temperature fluctuations, a fluid replacement device can be incorporated either internally or externally, such as a compressible cellular foam or an accumulator, among other devices.

[0086] In the embodiment shown, the IMGU is shown as an external device to the rotary damper, however, the IMGU could easily be incorporated into the rotary damper mechanism, thereby reducing the overall size of the mechanical unit and eliminating external hydraulic connections.

[0087] Other rotary damper configurations may be employed and energy collecting IPH or IMGUs may be incorporated into these devices, although the invention is not limited in this respect.

[0088] Certain industrial applications of electro-hydraulic linear actuators provide the ability to capture energy in a direction opposite to the actuator's actuation, such as in a lifting device where a mass is lifted and then lowered. In the embodiment shown in Figures 11 and 11A, a twin-tube energy harvesting electro-hydraulic linear actuator is presented that captures energy on the compression stroke and can be electrically actuated on the expansion stroke.

[0089] In the embodiment shown in Figure 11, the IPH valve is located at the base of the actuator, concentric with the actuator, although it is also possible to place the IPH valve at the base of the actuator body but perpendicular to the axis of the actuator, as seen in the embodiment shown in Figure 11A (the IPH valve could also be at the base of the actuator body but parallel to the actuator axis), which can provide packaging benefits in certain applications where the length of the actuator is important.

[0090] The twin-tube embodiment of Figures 11 and 11A has a piston 140 disposed within an inner housing 141 that includes a compression volume 142 and an expansion volume 143. In a first mode, the compression volume 142 is pressurized to overcome a force that moves the piston 140 through at least a portion of the expansion stroke. In a second mode, the piston moves at least partially through a compression stroke, causing the force to pressurize hydraulic fluid in the compression volume 142. An outer tube 144 concentric with the inner tube 141 includes a low pressure volume 145 that is in fluid communication with the expansion volume via a flow passage 146. The low pressure volume 145 includes both fluid and a compressible medium 147 (gas, foam, bladder, etc.). An integrated piston head (IPH) assembly 71 (72 in Figure 11A) is disposed at the base of the actuator. The IPH assembly can be similar to that shown in Figures 1, 2, or 3 and includes a first port 148 and a second port 149. A first port 148 is in fluid communication with the compression volume 142 and a second port 149 is in fluid communication with the low pressure volume 145. In the twin tube embodiment of Figures 11 and 11A, during extension, power is provided to the electric motor / generator 18 to rotate the electric motor / generator 18 and the hydraulic motor 16, which causes fluid to flow from the hydraulic motor through port 148 and into the compression volume 142. This creates pressure in the compression volume, creating a force acting on the piston rod 140 that overcomes the force currently on the piston rod, causing the piston to extend. As the piston extends, fluid moves from the extension volume 143, through the low pressure chamber 145, and through the second port 149 into the low pressure side of the hydraulic motor 16. In this embodiment, the volume of fluid entering the compression volume 142 is less than the volume of fluid leaving the expansion volume 143, and this volume difference is drawn from the volume stored in the low pressure volume 145 by expanding the compressible medium 147 in the low pressure volume 145.

[0091] A load holding valve (such as a check valve) can be disposed between the first port 148 and the compression volume 142 to eliminate leakage through the hydraulic motor when the actuator is under load holding operation. This prevents piston retraction during load holding, which creates a safety hazard. The load holding valve can be pilot operated, electrically driven or mechanically driven; these valves are known in the art and this patent is not limited in this respect.

[0092] In this embodiment, the piston can retract in two ways: in a first mode, when there is an external load acting on the piston rod (when the actuator is used, for example, to lower a payload), the piston will attempt to retract under this force. If a load-holding valve is used, the piston will not retract until the valve is actuated to allow fluid flow from the compression volume 142 to the first port 148. When the valve is actuated (by electronic means, mechanical means, etc.), due to the load on the piston rod, fluid will flow from the compression volume 142 to the first port 148, rotating the motor 16. This will rotate the generator 18, which will generate a back electromotive force (EMF) in the motor / generator to oppose this flow, producing electricity, as described in FIG. 2. The controller can apply different impedances to the generator, thereby controlling the rate at which fluid flows from the compression volume to the first port, providing a controllable and safe method for lowering the payload.

[0093] In a second mode, where there is no payload acting on the actuator, the piston is retracted by powering the electric motor / generator 18 to rotate the electric motor / generator 18 and the hydraulic motor 16. The rotation of the hydraulic motor 16 causes fluid to flow from the compression volume 142 to the first port 148 to pressurize the low pressure volume 145 and the expansion volume 143, thereby retracting the piston 140. Although this requires the low pressure volume to be pressurized, the load to retract the piston in this application is very small since it only needs to overcome the friction of the actuator and any associated mechanisms, and therefore the pressure reached by the low pressure volume is within the limits of the compressible medium contained within the low pressure volume. If a load-holding valve is utilized as described above, this valve must be actuated first before the piston is retracted.

[0094] During piston retraction, fluid flows from the compression volume 142 into the first port 148, through the motor 16, through the second port 149 into the low pressure volume 145, and into the expansion volume 143. In the embodiment shown, the volume displaced from the compression volume is greater than the volume entering the expansion volume, and this volume difference is stored in the low pressure volume 145 by compressing the compressible medium 147 in the low pressure volume 145.

[0095] In certain applications of the energy harvesting electro-hydraulic linear actuator shown in the embodiment of Figures 11 and 11A, it may be necessary to add other valves such as pressure relief valves, thermal expansion relief valves, etc., and the incorporation of these valves is known in the art for this type of actuator, and this patent is not limited in this respect.

[0096] In certain energy harvesting applications, it may be beneficial to keep the motor / generator assembly rotating in the same direction regardless of stroke direction. For this application, the motor / generator assembly may be connected to an actuator (linear or rotary) via a rectifier valve circuit. In the embodiment shown in FIG. 12, an energy harvesting linear actuator is presented that is connected to an integrated motor / generator assembly via a rectifier valve circuit. In the embodiment shown, the rectifier valve circuit 150 is in the form of a four-check valve, although it should be appreciated that a pilot operated spool valve(s) or the like could be used to perform the same function, and this patent is not limited in this respect.

[0097] In the embodiment shown, the integrated motor / generator assembly is similar to that shown in FIG. 3, but may be similar to that shown in FIG. 1 or FIG. 2, and includes a first port 151 and a second port 152. The first port 151 is in fluid communication with the exhaust side of the rectification circuit, and the second port 152 is in fluid communication with the return side of the rectification circuit. In the embodiment shown, the linear actuator is in the form of a twin tube configuration having a first port 153 in fluid communication with the extension side of the actuator and a second port 154 in fluid communication with the compression side. A piston 155 is disposed within an inner housing that includes an extension volume 156 and a compression volume 157. In a first mode, the piston 155 pressurizes hydraulic fluid in the extension volume 156 through at least a portion of the extension stroke. In a second mode, the piston pressurizes hydraulic fluid in the compression volume 157 through at least a portion of the compression stroke. An outer tube, concentric with the inner tube, connects the compression volume 157 to the second port 154 .

[0098] The commutation circuit is configured such that fluid exhausted from the first port of the actuator on an expansion stroke, or the second port on a compression stroke, is always diverted to the exhaust side of the commutation circuit into the first port of the IMGU 72, and fluid exhausted from the second port 152 of the IMGU is always diverted to the first port 153 of the actuator on a compression stroke, or the second port 154 on an expansion stroke. This ensures that the direction of rotation of the motor / generator remains constant whether the actuator is extending or retracting under load.

[0099] An accumulator or reservoir 158 is connected to the second port 152 of the IMGU 72 to absorb the volume difference that occurs on the expansion and compression strokes. In the embodiment shown, the reservoir is connected to the symmetrical port opposite the second port 152, but the reservoir can be connected anywhere along the return line of the rectifier circuit.

[0100] One problem with using a rectifier circuit in an energy harvesting actuator is that the motor / generator cannot drive the actuator back; it can "wheel" under certain inertial conditions. However, this can be solved by replacing the check valve (or spool valve) with a pilot operated valve (either electrically or mechanically operated) and then sequencing the valves such that the discharge from the hydraulic motor through the first port 151 is in fluid communication with the first port 153 of the actuator when the second port 152 of the hydraulic motor is in fluid communication with the second port 154.

[0101] Certain applications, such as industrial, military, and aerospace, may require a hydraulic power supply with higher performance in terms of pressurizing capacity and efficiency in achieving the required power density. In the embodiment of Figures 13 and 13A, an integrated motor / generator unit is shown that includes an axial piston unit that is concentric and coplanar with the generator. This embodiment is similar to that shown in Figure 3, but in this case, the hydraulic unit is an axial piston unit (i.e., a swash plate unit) rather than a gerotor pump. Swash plate pumps can provide higher performance in terms of pressurizing capacity, speed, efficiency, and durability when compared to other types of hydraulic pumps.

[0102] In the embodiment shown, a cylinder block 160 of the axial piston unit 159 is drivingly coupled to a magnet 161 of a generator 162 and is supported by bearings 163 on end caps 164, 165. The end cap 163 includes a first port 166 and a second port 167 configured to function as a straightening plate to direct flow into and out of the cylinder block 160 via a passage 168. A swash plate 169 is disposed on the end cap 165 on the opposite side of the cylinder block passage 168. A number of pistons 170 are housed within bores in the cylinder block 160 and are held to the swash plate by piston feet 171. The manner in which pistons are held to the swash plate and forced against cams to move into and out of the cylinder bores is known in the art and it is not within the scope of this patent to disclose their operation, nor is the manner in which the cylinder block is supported (by springs or other means) on the straightening plate.

[0103] When electrical power is supplied to the generator, it acts as an electric motor and rotates the cylinder block 160, which in turn causes a pumping action by the pistons 170, resulting in flow through the first and second ports. The direction of flow depends on the direction of rotation of the cylinder block, which in turn depends on the direction of the current supplied to the electric motor. Conversely, if the first or second port is pressurized, the axial piston unit acts as a motor and rotates based on this pressure difference. This then generates electricity by the generator, as previously described.

[0104] By controlling the speed of the electric motor, the rotational speed of the axial piston unit, and therefore the flow rate, can be varied without having to change the displacement of the unit. Numerous variations of variable displacement axial piston pumps exist and although they have the advantage of being able to control the flow rate to meet demand, they all have the disadvantage that their volumetric efficiency drops off as their displacement approaches zero.

[0105] The advantage of locating the axial piston unit concentrically and flush with the motor / generator is that an axial piston pump, smaller in size than a variable displacement axial piston pump, can vary the flow rate while maintaining its maximum displacement and therefore its stroke volume.

[0106] In some usage scenarios, it is desirable to have an energy generating damper that is not gas pressure limited in compression braking and that features energy capture in both compression and reversal, and an embodiment incorporating the above features is described below, as shown in Figures 14 and 14A.

[0107] According to the embodiment shown in Figures 14 and 14A, a tri-tube damper structure incorporating an energy collecting IMGU is disclosed. In this embodiment, a piston rod 172 and a hydraulic ram type (solid) piston 173 are disposed within an internal fluid filled cylinder 174. The inner housing (combined compression volume 175 and expansion volume 176) is surrounded by a second tube 177 that is concentric with the inner tube 174. The space between the inner tube and the second tube is a high pressure volume 178. The second tube 177 is surrounded by a third tube 179 that is concentric with the second tube. The space between the second tube and the third tube is a low pressure volume 180. In some embodiments, the high pressure and low pressure tubes can be reversed.

[0108] In the embodiment of Figure 14, an integrated motor / generator unit (IMGU) 72 is laterally disposed at the base end of the damper, and in the embodiment of Figure 14A, an integrated motor / generator unit (IMGU) 72 is disposed at the base end of the damper. The IMGU shown in Figures 14 and 14A is similar to that shown in Figure 3, or alternatively may be similar to that shown in Figures 1 or 2, and includes a first port 181 and a second port 182. The first port 181 is in fluid communication with the high pressure volume 178, and the second port 182 is in fluid communication with the low pressure volume 180.

[0109] During a jounce, the piston rod 172 pushes the piston 173 into the compression volume 175, and the fluid in the compression volume 175 is prevented from entering the low pressure volume by the directional check valve 183 and is forced to flow from the compression volume 175 through the directional check valve 184 housed within the piston 173 and into the expansion volume 176. Because the volume displaced in the compression chamber is greater than the volume brought into the expansion chamber by the volume of the piston rod 172, the difference in volume flows through the high pressure volume 178 into the first port 181 of the IMGU and out the second port 182 into the low pressure volume 180. At the same time, the compressible medium 185, such as a cellular foam or air bladder, or gas mass in the low pressure volume 180 contracts to replace the piston rod volume being introduced.

[0110] During reverse travel, the piston rod 172 draws the piston 173 into the expansion volume 176, and the fluid in the expansion volume 176 is prevented from entering the low compression volume by the directional check valve 184 and is forced to proceed from the expansion volume to the high pressure volume 180. The high pressure volume 180 is in fluid communication with a first port 181 of the IMGU 72. Fluid passes from the high pressure volume 180 through the IMGU 72 through the first port 181, out the second port 182 into the low pressure volume 180, and through the directional check valve 183 into the compression volume 175. At the same time, the compressible medium 185 in the low pressure volume 180 is decompressed as the fluid passes from the low pressure volume 180 through the directional check valve 183 into the compression volume to fill the withdrawn piston rod volume.

[0111] The hydraulic motor 55 and generator 50 rotate as fluid enters the IMGU 72 from the high pressure volume 178 through port 181 and exits the IMGU at port 182 and returns to the low pressure volume 180. As described in the embodiment of FIG. 2, this generates a back electromotive force (EMF) in the motor / generator to provide braking and also generate electricity. As previously described, the motion characteristics of the damper can be changed by changing the electrical characteristics of the terminals of the electric motor / generator. Furthermore, by supplying electrical power to the electric motor / generator, the damping force of the system can be increased beyond the range of damping force provided by the back EMF in a power regeneration mode, or can be reduced below the damping force provided by the resistance due to the parasitic losses of the open circuit of the system. The motor / generator can be driven in either compression or reverse such that the fluid flow generated by the hydraulic motor opposes the fluid flow from the damper, thereby increasing the damping force, or the motor / generator can be driven in either compression or reverse such that the fluid flow generated by the hydraulic motor assists the fluid flow from the damper, thereby decreasing the damping force. The motor / generator can also be driven such that the hydraulic motor-generated fluid flow blocks fluid flow from the damper to the point where the damper is held stationary. However, in this embodiment, the damper cannot be actively driven to extend or retract by power being applied to the motor / generator. For example, when used in a monotube configuration, power can be applied to the motor / generator to extend or retract without additional valves, although the invention is not limited in this respect. In a triple tube configuration, when the motor / generator is driven to extend the damper, fluid flow from the second port 182 flows freely through the check valves 183, 184 back to the first port 181, and when the motor / generator is driven to retract the damper, fluid flow from the first port 181 pressurizes the expansion chamber 176, which in turn pressurizes the compression chamber 175, but the check valve 183 blocks any flow from the compression chamber, so the piston rod cannot retract.

[0112] In some use scenarios, it may be desirable to provide power to the motor / generator to actively expand or contract the damper, and in some embodiments, additional valves may be required. An embodiment incorporating additional valves is described below, as shown in FIG. 15. According to the embodiment shown in FIG. 15, a tri-tube damper structure is disclosed that incorporates an energy collecting IMGU 72 similar to that shown in FIG. 14 (alternatively, the energy collecting IMGU may be similar to that shown in FIG. 14A). In this embodiment, control valves 186, 187 are incorporated to provide power to the motor / generator to actively expand or contract the damper. The control valves 186, 187 may be electronically, hydraulically, or otherwise controlled.

[0113] When the damper needs to extend, power is provided to the motor / generator to allow fluid flow from the first port 181 of the IMGU 72 into the high pressure chamber 178. The control valve 186 is held closed, the control valve 187 opens to allow fluid flow from the high pressure chamber 178 into the compression chamber 175, and the check valve 183 closes to block flow from the compression chamber 175 into the low pressure chamber 180. Since the high pressure chamber 178 is in fluid communication with the expansion volume 176, in this case pressure exists on both the extension and compression sides of the piston 173, causing the piston to extend due to the area difference between the two sides of the piston, which is equal to the area of ​​the piston rod. As the piston extends, fluid moves from the expansion volume 176 through the high pressure chamber 178 and the control valve 187 into the compression chamber 175, and at the same time fluid flows from the low pressure chamber into the second port 182 of the IMGU 72 to depressurize the compressible medium 185 in the low pressure chamber.

[0114] When the damper needs to retract, power is provided to the motor / generator to cause fluid flow from the first port 181 of the IMGU 72 into the high pressure chamber 178. Control valve 187 is held closed and control valve 186 is opened so that the compression chamber 175 is in fluid communication with the low pressure chamber 180, bypassing the check valve 183. In this case, since the compression volume 175 is in fluid communication with the low pressure chamber 180, a pressure differential exists between the two sides of the piston, causing the piston to retract. As the piston retracts, fluid flows from the compression chamber 175 into the low pressure chamber 180 and into the second port 182 of the IMGU 72. Because the volume of the compression chamber 175 is greater than the volume of the expansion chamber 176 by the volume of the rod, this volume differential flows from the compression chamber 175 into the low pressure chamber 180, compressing the compressible medium 185 in the low pressure chamber 180.

[0115] In some embodiments, the integrated system disclosed herein can be used with passive damping either in parallel with a bypass valve or in series with a hydraulic motor. Passive valve configurations are known in the art and often incorporate shim stacks, directional valves, and spring-loaded fluid restriction ports. The bypass path allows for either lighter damping than that provided by viscous losses through the hydraulic motor, or subtle adjustment of ride characteristics, although the invention(s) are not limited in this respect. The series valve configuration allows for stronger damping than the generator can provide at its full potential (at very high speeds), a requirement that is particularly important in heavy-duty application scenarios such as military dampers. The parallel or series damping can be integrated directly into the piston head, external bypass tubes, base valves, or other locations.

[0116] In some applications, the dynamic range required by the damper may exceed what can be reasonably provided from the hydraulic motor and generator. In such applications, the integrated system disclosed herein may be used with one or more active / control valves either in parallel or in series (or a combination of both) with the hydraulic motor. In one embodiment, the one or more active / control valves may be used independently or in combination with one or more passive valves. The active / control valves may be configured to operate at a predetermined pressure. The predetermined pressure may be varied depending on the operational needs of the damper, the hydraulic motor, or the generator. Additionally, the pressure may be selected to dynamically increase or decrease the damping range beyond what can be provided from the hydraulic motor and generator. One or more of the active / control valves may be controlled electrically or with some form of mechanical or hydro-mechanical action. Additionally, the one or more active / control valves may be configured to allow unidirectional flow of fluid. By placing a control valve in parallel with the hydraulic motor, the flow may be diverted by external controllable means to bypass the hydraulic motor, reducing the damping force by reducing viscous losses through the hydraulic motor. A control valve in-line allows external controllable means to restrict flow either to or from the hydraulic motor to increase braking power beyond what the generator can fully provide. These valves can be built directly into the piston head, externally into the base valve, or in other locations.

[0117] In some embodiments where the device is used as an actuator rather than or not only as an energy collecting damper, control valves such as load holding valves, pressure limiting valves, etc. can be added to provide different functions as required by the application.

[0118] According to some embodiments, the controller can apply different impedances to the generator to control the force response of the damper based on various parameters such as speed or position while simultaneously capturing energy associated with the motion within the damper. The force response can follow a formula or look-up table based on such parameters. This level of control is referred to as semi-active damping since the amount of damping is controlled but the system is not actuated. In other usage scenarios, the motor / generator within the damper can be operated to allow for full active control.

[0119] In some embodiments, the integrated system disclosed herein can be used autonomously, with the controller providing its own power from the energy harvesting damper. This allows for either a semi-active damper or, in some embodiments, an active damper that generates electricity and uses it to power its own control circuitry. Such a system allows vehicles to be easily retrofitted with improved semi-active or fully active suspensions without the need to run wires along the vehicle chassis. In one embodiment, a separate capacitor is connected to the output of the energy generating damper. As the damper generates electricity, the capacitor is charged. Meanwhile, the power input of the controller is connected in parallel to this capacitor. As soon as the separate capacitor reaches a certain voltage threshold, the controller kicks in and starts controlling the motion characteristics of the damper using the electricity it generates. A capacitor or a small battery can be used at the input of the controller to filter transient voltage inputs.

[0120] Of course, in many embodiments, the systems described herein can be used in conjunction with a spring mechanism to either compress or expand the piston.

[0121] Of course, for vehicle applications, the embodiment shown can be configured as a damper or as a strut type damper as the application requires.

Claims

1. A damper comprising: an inner tube slidably receiving a piston attached to a piston rod, said piston separating an internal volume of said inner tube into a compression volume and an expansion volume; an outer tube surrounding said inner tube and forming an annular volume between said inner tube and an outer tube; and an accumulator located in said annular volume; a hydraulic unit having a first port in fluid communication with the compression volume and a second port in fluid communication with the expansion volume, the hydraulic unit operating as a hydraulic pump at least in a first operating condition; a first control valve disposed along a first hydraulic flow path between the annular volume and the compression volume; a first check valve disposed along a second hydraulic flow path between the annular volume and the compression volume and configured to permit flow from the annular volume to the compression volume; an electric motor operably connected to the hydraulic unit; Equipped with configured to be actively extended or retracted by supplying power to the electric motor; Active suspension actuator.

2. Further comprising a third tube separating the annular volume into a first annular volume including the accumulator and a second annular volume including the second hydraulic flow path.

10. The active suspension actuator of claim 1.

3. The first annular volume is in fluid communication with the first port.

3. The active suspension actuator of claim 2.

4. The hydraulic unit operates as a hydraulic motor at least under a second operating condition.

10. The active suspension actuator of claim 1.

5. The accumulator is a gas-filled accumulator.

10. The active suspension actuator of claim 1.

6. The gas in the gas-filled accumulator is air.

6. The active suspension actuator of claim 5.

7. The accumulator further comprising a compressible medium.

10. The active suspension actuator of claim 1.

8. The active suspension actuator of claim 7, wherein the compressible medium is compressed to absorb the volume displaced by the piston rod.

9. Further comprising a third hydraulic flow path connecting the expansion volume and the second port.

10. The active suspension actuator of claim 1.

10. The piston includes at least a second check valve connecting the compression volume and the expansion volume.

10. The active suspension actuator of claim 1.

11. The hydraulic unit is a self-contained electric hydraulic unit including the electric motor.

10. The active suspension actuator of claim 1.

12. The self-contained electric hydraulic unit is fixedly attached to the outer tube.

12. The active suspension actuator of claim 11.

13. The self-contained electro-hydraulic unit is disposed at a base end of the active suspension actuator.

12. The active suspension actuator of claim 11.

14. The hydraulic system of claim 1, further comprising a second control valve disposed along the second hydraulic flow path between the compression volume and the second annular volume.

3. The active suspension actuator of claim 2.

15. The second control valve provides a unidirectional flow of fluid.

15. The active suspension actuator of claim 14.

16. The second control valve is electronically controlled.

15. The active suspension actuator of claim 14.

17. The first control valve is electronically controlled.

10. The active suspension actuator of claim 1.

18. The first control valve provides a unidirectional flow of fluid.

10. The active suspension actuator of claim 1.

19. Additionally comprising at least one load-retaining valve for fixing the piston.

10. The active suspension actuator of claim 1.

20. Further comprising at least two bypass valves disposed on the piston.

10. The active suspension actuator of claim 1.

21. A method of operating an active suspension actuator, comprising the steps of: operating the hydraulic unit as a pump at a first operating condition by supplying power to an electric motor operatively coupled to the hydraulic unit; flowing fluid through a first port of the hydraulic unit, the first port being in fluid communication with a compression volume of the active suspension actuator; flowing fluid through a first hydraulic flow path fluidly connecting the compression volume with an annular accumulator surrounding the active suspension actuator; controlling a flow of fluid in the first hydraulic flow path by controlling a first control valve disposed along the first hydraulic flow path; controlling, with a first check valve, a flow of fluid along a second hydraulic flow path fluidly connecting the compression volume and the annular accumulator; extending or contracting the active suspension actuator by displacing a piston attached to a piston rod within the active suspension actuator and separating the compression volume from the expansion volume; A method for operating an active suspension actuator comprising:

22. The method of claim 20, further comprising passing a fluid between the annular accumulator and the first port.

22. The method of claim 21.

23. Further comprising operating the hydraulic unit as a hydraulic motor under a second operating condition.

22. The method of claim 21.

24. The method of claim 23, further comprising compressing a compressible medium within the annular accumulator.

22. The method of claim 21.

25. The method of claim 20, further comprising compressing the compressible medium to absorb a volume of fluid displaced by movement of a piston rod within the active suspension actuator.

25. The method of claim 24.

26. The method of claim 20, further comprising: passing fluid through a third hydraulic flow path connecting the expansion volume with a second port of the hydraulic unit.

22. The method of claim 21.

27. The method of claim 20, further comprising bypassing fluid between the compression volume and the expansion volume, wherein the bypassed fluid does not pass through the hydraulic unit.

22. The method of claim 21.

28. The method of claim 27, further comprising bypassing fluid between the compression volume and the expansion volume by flowing the fluid through at least one valve disposed within the piston.

28. The method of claim 27.

29. The method of claim 20, further comprising regulating a flow of fluid through the first control valve by electronically controlling the first control valve.

22. The method of claim 21.

30. The method of claim 30, further comprising flowing fluid through a second control valve disposed along the second hydraulic flow path.

22. The method of claim 21.

31. Flowing a fluid through the second control valve includes flowing a fluid in one direction.

31. The method of claim 30.

32. The method of claim 31, further comprising regulating the flow of fluid through the second control valve by electronically controlling the second control valve.

31. The method of claim 30.

33. The method of claim 32, further comprising unidirectionally flowing fluid through the first control valve.

22. The method of claim 21.

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