Air Spring Assembly with Microwave Distance Sensor
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Solution Overview
Problem
Existing air spring systems for vehicles, particularly trucks, face challenges in accurately and cost-effectively measuring the height and spring travel, as current methods are influenced by temperature, require significant installation space, and are sensitive to contamination and distance limitations.
Innovation Solution
An air spring arrangement utilizing a microwave-based distance sensor with an antenna and reflector, where the antenna emits and receives electromagnetic waves above 1 GHz, allowing for precise distance measurement independent of temperature and contamination, and providing higher sensitivity at larger distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasonic transit time measurement is used for distance sensing, then measurement capability is achieved, but temperature influences propagation speed and reduces measurement accuracy
Solution Approach 1:
The patent replaces ultrasonic measurement (acoustic wave-based) with electromagnetic wave-based measurement. Electromagnetic waves are not influenced by temperature in the same way acoustic waves are, eliminating the temperature compensation requirement and improving measurement accuracy under varying temperature conditions.
Solution Approach 2:
The patent changes the measurement parameter from acoustic wave propagation time to electromagnetic wave phase difference. This parameter change eliminates temperature dependency because electromagnetic wave propagation speed in air is not significantly affected by temperature variations, unlike ultrasonic waves.
2Measurement precision
If separate temperature sensors are added to compensate for temperature effects, then measurement accuracy is improved, but costs and space requirements increase
Solution Approach 1:
The patent eliminates the need for separate temperature sensors by replacing the entire measurement system with electromagnetic wave-based measurement. This substitution removes the requirement for temperature compensation hardware, reducing system complexity, cost, and space requirements while maintaining measurement accuracy.
3Measurement precision
If optical triangulation or time-of-flight sensors are used, then measurement capability is achieved, but dust settling on light-sensitive components affects functionality
Solution Approach 1:
The patent replaces optical measurement systems (triangulation or time-of-flight sensors with light-sensitive components) with electromagnetic wave-based measurement at microwave frequencies. This substitution eliminates the problem of dust settling on light-sensitive components because the measurement is performed using electromagnetic waves that penetrate or bypass dust particles rather than relying on light-sensitive surfaces.
4Measurement precision
If magnetic field-based distance sensors are used, then measurement is achieved, but field strength decreases with the cube of distance and sensitivity decreases
Solution Approach 1:
The patent replaces magnetic field-based measurement with electromagnetic wave-based measurement. Electromagnetic waves propagate differently than static or low-frequency magnetic fields, maintaining signal strength over distance without the inverse-cube relationship, thereby improving measurement sensitivity at larger distances.
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 enables more accurate, reliable, and cost-effective detection of forces acting on air springs, improving the measurement of spring height and travel, thus enhancing level control in vehicles with reduced space requirements and increased robustness against environmental factors.
Implementation Method 1
The transmitting/receiving unit (21) is designed to excite the antenna (14) by means of a predetermined power to emit at least one electromagnetic wave (A) with at least a first predetermined frequency above 1 GHz
Implementation Method 2
at least one first reflector (15), which is arranged in the area of the second connecting element (12)... The reflector is designed to reflect electromagnetic waves
Implementation Method 3
An air spring arrangement utilizing a microwave-based distance sensor with an antenna and reflector, where the antenna emits and receives electromagnetic waves above 1 GHz, allowing for precise distance measurement
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Air spring assembly (1, 2) comprising an air spring (1) with a first connecting element (11) configured to be connected to a first body, with a second connecting element (12) configured to be connected to a second body, and with a bellows (13) arranged between the first connecting element (11) and the second connecting element (12). The air spring (1) has an antenna (14) arranged in the region of the first connecting element (11) and a first reflector (15) arranged in the region of the second connecting element (12), or vice versa.The air spring arrangement (1, 2) comprises a transmitting/receiving unit (21) configured to: • excite the antenna (14) by means of a predetermined power to emit an electromagnetic wave (A) with a first predetermined frequency above 1 GHz and • receive a reflected electromagnetic wave by means of the antenna (14), and an evaluation unit (22) configured to: • determine a power and a reflection frequency of the reflected electromagnetic wave, • determine the reflection coefficient from the power of the emitted electromagnetic wave (A) and from the power of the reflected electromagnetic wave, and • determine the distance between the antenna (14) and the first reflector (15) from the reflection coefficient and the reflection frequency.