Active Aero Downforce Feedback via Actuator Pressure
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Solution Overview
Problem
Current motor vehicles lack effective closed-loop feedback systems to dynamically adjust and monitor aerodynamic forces on active aerodynamic devices, leading to suboptimal aerodynamic performance, increased drag, and potential damage detection challenges.
Innovation Solution
A closed-loop downforce feedback system using pressure sensors integrated with hydraulic or pneumatic actuators in active aerodynamic devices, such as deployable rear spoilers or repositionable front air dams, to continuously monitor and adjust fluid pressures, calculate actual downforce values, and compare them to calibrated data to achieve target downforce settings and detect device malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If active aerodynamic devices are deployed to improve aerodynamic performance, then vehicle stability and downforce are improved, but device complexity and control requirements increase
Solution Approach 1:
The patent implements a closed-loop feedback system where pressure sensors continuously monitor fluid pressure in the actuator, and this information is fed back to a controller that automatically adjusts the active aerodynamic device position. This feedback mechanism enables automatic adaptation to changing aerodynamic conditions without requiring complex manual intervention or overly sophisticated control systems.
Solution Approach 2:
The system uses the existing fluid pressure in the actuator system itself as the sensing mechanism. The pressure sensor monitors the pressure already present in the hydraulic or pneumatic actuator that moves the aerodynamic device, eliminating the need for separate downforce sensors or additional complex sensing systems. The actuator's own operating parameters provide the feedback information needed for control.
2Measurement precision
If dedicated downforce sensors are installed to accurately measure aerodynamic forces, then measurement precision is improved, but manufacturing costs and device complexity increase
Solution Approach 1:
The system repurposes the existing fluid pressure data from the actuator system to provide downforce measurement. Instead of installing dedicated downforce sensors, the patent uses the pressure already present in the hydraulic or pneumatic actuator that positions the aerodynamic device. This self-service approach leverages existing system parameters to obtain measurement information without additional hardware.
Solution Approach 2:
The fluid pressure in the actuator serves dual purposes: it both actuates the aerodynamic device and provides the measurement signal for downforce feedback. The same fluid system that moves the spoiler or air dam also provides the pressure information used to calculate aerodynamic forces, making the system multi-functional and eliminating the need for separate sensing systems.
3Manufacturing precision
If real-time pressure monitoring is implemented in actuator systems, then downforce control accuracy is improved, but device complexity increases
Solution Approach 1:
The patent implements a feedback loop where pressure sensors monitor fluid pressure in real-time and this information is continuously fed to a controller. The controller uses this pressure data to determine actual downforce values and automatically adjusts the active aerodynamic device position to achieve target downforce settings, enabling precise real-time control without requiring complex additional systems.
Solution Approach 2:
The pressure sensor acts as an intermediary that translates the physical state of the fluid system into electrical signals that the controller can process. By monitoring fluid pressure—an intermediate parameter that directly relates to aerodynamic forces—the system obtains accurate downforce information without requiring direct mechanical sensing of the aerodynamic loads themselves.
4Object-generated harmful factors
If active aerodynamic devices are used to reduce drag and noise, then aerodynamic performance is improved, but the system requires sophisticated control logic to function optimally
Solution Approach 1:
The closed-loop feedback system continuously monitors actual downforce through pressure sensing and automatically adjusts active aerodynamic device positioning to maintain optimal performance. This feedback mechanism enables the system to adapt to changing vehicle speeds, aerodynamic conditions, and operational requirements without requiring overly sophisticated control logic or manual intervention.
Solution Approach 2:
The patent replaces complex mechanical sensing systems with pressure sensing in the fluid actuator system. By using pressure sensors in the hydraulic or pneumatic actuator rather than mechanical downforce sensors, the system achieves accurate aerodynamic force measurement with simpler, more reliable sensing technology that integrates naturally with the existing actuation system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the control and accuracy of active aerodynamic devices, reduces wind-borne noise, minimizes drag, decreases manufacturing costs, and improves vehicle stability by providing real-time downforce monitoring and adjustment, while eliminating the need for dedicated sensors.
Implementation Method 1
Pressure sensors in a hydraulic or pneumatic actuator system of a deployable rear spoiler or repositionable front air dam systematically track supply-side fluid pressure changes
Implementation Method 2
one or more fluid-driven—pneumatically activated or hydraulically activated—actuators selectively operable to move the active aerodynamic device
Implementation Method 3
one or more fluid-driven—pneumatically activated or hydraulically activated—actuators selectively operable to move the active aerodynamic device
Data Source
AI summary
Disclosed are downforce feedback systems for active aerodynamic devices, methods for making/using such systems, and vehicles equipped with a closed-loop downforce feedback system to govern operation of the vehicle's active aero device(s). A feedback control system for operating an active aerodynamic device of a motor vehicle includes one or more pressure sensors for detecting fluid pressures in one or more pneumatic or hydraulic actuators for moving the active aero device. A vehicle controller receives fluid pressure signals from these sensor(s), and calculates an actual downforce value from these signal(s). The controller retrieves a calibrated downforce value from mapped vehicle downforce data stored in memory, and determines if the actual downforce value differs from the calibrated value. If so, the controller determines a target position for a target downforce value for a current vehicle operating condition, and commands the actuator(s) to move the active aero device to the target position.