Active Suspension Damper for Caster Windup Control
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Solution Overview
Problem
Current vehicle suspension systems face challenges with caster windup, which can negatively impact vehicle performance by causing wheel contact with the body or suspension components to bottom out, and require additional weight, cost, and complexity due to the use of rigid integral links to limit caster angle changes.
Innovation Solution
A vehicle suspension assembly with an adjustable damper that resists changes in caster angle by using a control module to adjust damping force based on detected or predicted changes in caster angle, incorporating sensors to monitor vehicle characteristics such as acceleration and ride height, and strategically mounting the damper and spring to manage caster dynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid integral link is used to limit caster windup, then caster angle stability is improved, but device complexity and weight increase
Solution Approach 1:
The patent replaces the static rigid integral link with a dynamic active damping system that adjusts its characteristics in real-time. The adjustable damper (146) with variable damping force, controlled by control module (50) based on sensor inputs, dynamically adapts to different driving conditions to limit caster windup only when necessary, thereby maintaining stability while reducing overall system complexity and weight.
Solution Approach 2:
The patent substitutes the purely mechanical rigid integral link with a hybrid system combining mechanical damper components and electronic control. The control module (50) processes sensor data and adjusts damper force electronically, replacing the need for complex mechanical linkages with a more compact and lighter electromechanical system.
2Stability of the object's composition
If a rigid integral link is used to limit caster windup, then caster angle stability is improved, but weight increases
Solution Approach 1:
The active damping system dynamically adjusts damper force based on real-time sensor feedback, providing rigid support only when caster windup occurs. During normal operation, the damper remains compliant, reducing the need for heavy-duty components and allowing for a lighter overall suspension assembly compared to a constantly rigid integral link.
Solution Approach 2:
The patent changes the damping parameter of the damper (146) from fixed to variable, allowing the system to optimize weight by using lighter damper components that can achieve high damping forces only when needed. The control module adjusts damping parameters based on sensor inputs, enabling weight reduction while maintaining caster angle stability when required.
3Adaptability or versatility
If an adjustable damper with active control is used, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent segments the control function into modular components: sensors (54, 58, 62) for detection, control module (50) for processing, and adjustable damper (146) for actuation. This segmentation allows each component to be independently optimized and simplified, reducing overall system complexity while maintaining high adaptability for caster control.
4Ease of manufacture
If caster windup is limited by a rigid integral link, then manufacturing is simplified, but adaptability decreases
Solution Approach 1:
The patent introduces dynamic adjustability to the damper system, allowing caster angle control characteristics to be modified during vehicle operation. The control module (50) adjusts damper force based on sensor inputs, enabling the system to adapt to different driving conditions and caster angle requirements, thereby providing versatility that a fixed rigid link cannot achieve.
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
The solution effectively limits caster windup, improving vehicle handling and ride comfort by actively controlling caster angle changes, reducing the need for rigid integral links and associated weight and complexity, while allowing for dynamic adjustment of permitted caster windup during vehicle operation.
Implementation Method 1
The damper has an adjustable damping force and includes a first end mounted to the frame and a second end mounted such that a change in caster angle of the knuckle extends or contracts the damper
Data Source
AI summary
A suspension assembly for a vehicle having a frame includes a control arm, knuckle, spring, damper, and control module. The control arm is pivotably coupled to the frame. The knuckle is coupled to the control arm and supports a wheel hub for rotation relative to the knuckle. The spring is mounted between the frame and the control arm or the knuckle. The damper has an adjustable damping force and includes a first end mounted to the frame and a second end mounted such that a change in caster angle of the knuckle extends or contracts the damper. The control module is in communication with the damper and configured to adjust a damping force of the damper based on an actual or predicted change in caster angle of the knuckle. The control module is configured to increase the damping force in a direction that resists a change in the caster angle.