Air Spring PCR Height Sensor Without Mechanical Linkages
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Solution Overview
Problem
Existing air spring systems require extensive effort and resources to repair due to the need for multiple parts, additional holes, and mechanical components that wear out over time, leading to inaccurate and durable issues.
Innovation Solution
Integration of a Pulsed Coherent Radar (PCR) system within the air spring with both emitter and receiver protected from the elements, using a non-contact pneumatic sensor fitting for accurate height measurement, eliminating the need for mechanical linkages and reducing part wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical height sensors with linkages are used, then installation is simpler, but measurement accuracy deteriorates over time due to slack and wear
Solution Approach 1:
The patent replaces mechanical height sensing linkages with a pulsed coherent radar (PCR) electromagnetic sensing system. The PCR sensor emits electromagnetic waves that reflect off the air spring piston, and the time-of-flight measurement provides contactless height detection, eliminating mechanical wear and slack issues while maintaining installation feasibility through integration into the air spring cap.
Solution Approach 2:
The patent introduces electromagnetic waves as an intermediary medium between the sensor and the air spring piston. Instead of direct mechanical contact, the electromagnetic waves serve as the mediator to transmit measurement information, enabling accurate height detection without physical linkages that would wear or develop slack.
2Ease of manufacture
If the sensor is exposed to the external environment, then installation is easier, but durability deteriorates due to environmental damage
Solution Approach 1:
The patent nests the PCR sensor and its protective housing within the air spring cap structure. The sensor is housed inside the cap, which provides protection from environmental elements such as rain, mud, ice, and debris. This nested arrangement allows the sensor to be installed as part of the air spring assembly while being shielded from the harsh external environment.
Solution Approach 2:
The patent employs the air spring cap and housing structures as protective shells that enclose and protect the PCR sensor. These shell structures provide a barrier against environmental damage while allowing the sensor to function internally, ensuring durability without compromising the protective enclosure.
3Adaptability or versatility
If multiple parts and holes are required, then sensor functionality is achieved, but repair complexity increases
Solution Approach 1:
The patent merges the PCR sensor, its housing, and the air spring cap into an integrated assembly. The sensor is built into the air spring cap structure, eliminating the need for separate mounting components and multiple holes. This integration simplifies the overall structure, reducing the number of parts that could wear or fail, and makes repair easier by allowing the sensor to be serviced as part of the existing air spring assembly.
4Device complexity
If mechanical components are used, then structure is simpler, but reliability deteriorates due to component wear
Solution Approach 1:
The patent substitutes mechanical height measurement components with a pulsed coherent radar electromagnetic sensing system. The PCR sensor uses electromagnetic wave time-of-flight measurement instead of mechanical linkages, pistons, or contact-based sensors. This eliminates wear-prone mechanical parts while maintaining relatively simple integration into the air spring structure, significantly improving reliability and expected lifetime.
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 provides superior accuracy, reduced installation time, improved durability, and protection from environmental damage, enabling air springs to maintain accuracy and functionality for the life of the vehicle.
Implementation Method 1
A PCR sensor built into the pneumatic sensor fitting and installed in the air spring upper cap emits continuous pulses of PCR electromagnetic waves. These reflect off the lower piston and return to the PCR sensor.
Implementation Method 2
The PCR sensor determines the time elapse between emission and detection of pulses of reflected electromagnetic waves. This time measurement is then filtered and processed through known algorithms to calculate a representative distance between the sensor and the lower piston.
Implementation Method 3
Both the transmitting portion and the receiving portion of the PCR are housed in same unit to protect these sensitive components in a secure housing and obviate issues arising from housing the components in separate housings, such as the number of holes needed in the air spring body for electrical connections.
Data Source
AI summary
An air spring height sensor has a PCR (Pulsed-Coherent-Radar) sensor encased in a housing attached to an air spring. The housing also provides an integral channel for adding air to an air spring or releasing air. The PCR sensor is aligned with a connector to orient the sensor with respect to the air spring to accurately determine the height of the air spring.