Axle Load Calculation via Pneumatic Suspension Sensors
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Solution Overview
Problem
Existing systems cannot accurately determine the load weighing on axles with mechanical suspensions, as they lack load measurement devices, making it impossible to calculate the overall load of a vehicle without using weighing machines, which are often unavailable and time-consuming.
Innovation Solution
A method that calculates the load on axles with mechanical suspensions by using a balance of forces and empirical data from two different load conditions, leveraging sensors and control units already present in vehicles with pneumatic suspensions to determine the load distribution proportionally among axles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If weighing machines are used to determine overall vehicle load, then measurement precision is improved, but loss of time increases and productivity decreases
Solution Approach 1:
The patent replaces the mechanical weighing machine system with an electronic sensor-based load detection system. Sensors installed on the vehicle axles directly measure load forces and transmit data to a control unit, eliminating the need for external weighing machines and enabling continuous real-time monitoring during vehicle operation.
Solution Approach 2:
The vehicle itself performs the measurement function through integrated sensors and control units that automatically detect and calculate axle loads and overall vehicle weight. The system serves its own measurement needs without requiring external weighing infrastructure, enabling the vehicle to self-monitor its load conditions continuously.
2Measurement precision
If load detection systems are installed on all axles, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it processes data from sensors, calculates individual axle loads, determines overall vehicle weight, monitors load distribution, and provides feedback to the driver. This multi-functional approach consolidates what would otherwise require separate systems into a single integrated unit, reducing overall system complexity.
Solution Approach 2:
The patent combines the sensor system, data processing unit, calculation algorithms, and driver interface into an integrated load detection system. The control unit merges data from multiple sensors and performs all necessary calculations, while the display system consolidates multiple pieces of information (individual axle loads, total weight, load distribution) into a single interface for the driver.
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
Enables accurate calculation of load on each axle and overall vehicle load without the need for weighing machines, reducing time and costs associated with weighing operations and providing real-time load data to drivers and operators.
Implementation Method 1
one or more sensors, installed near the air springs of the pneumatic suspension, detect the existent pressure, which is proportional to the load
Data Source
Figure 1~2
AI summary
The present invention relates to a method for defining the load weighing on an axle with mechanical suspension of a vehicle provided with at least an axle with pneumatic suspension and a system for detecting the load on this axle, wherein the additional payload is proportionally distributed among the axles. The proposed method allows to calculate in a simple way, without using additional devices and exploiting the electronic system already present on vehicles which detect the load on at least one axle with pneumatic suspension, the value of the load weighing on each vehicle axle, also on the axle with mechanical suspension without load sensor, and the overall load, making this data immediately available to the driver. Moreover, a further advantage of the method proposed here is that it may be carried out by the manufacturer only once in order to obtain the needed parameters for the calibration of an electronic control unit. This calibration may be used for each vehicle of the same range.