Axle Load Sensing Through Integrated Force Transmission Elements
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Solution Overview
Problem
Current methods for determining axle load in commercial vehicles are time-consuming and costly, requiring individual scaling under each axle, which is inefficient and labor-intensive.
Innovation Solution
An axle load detection system comprising a force transmission element with a sensor unit that detects forces between mounting areas, using sensors such as piezoceramic or strain gauges integrated into the force transmission elements, allowing for precise and redundant force measurement without separate components like scales.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If scales are positioned under each axle to determine axle load, then measurement precision is improved, but productivity deteriorates due to time-consuming and labor-intensive individual scaling
Solution Approach 1:
The patent combines multiple measurement functions into a single sensor unit that simultaneously measures forces from multiple air springs and control arms. Instead of using separate scales under each axle, the sensor unit integrates multiple sensors (strain gauges, piezoceramic sensors) that collectively measure the total axle load by detecting forces in the support direction transmitted through the force transmission element, thereby improving productivity while maintaining measurement precision.
Solution Approach 2:
The patent introduces a force transmission element as an intermediary component between the air springs/control arms and the measurement system. This force transmission element transmits the combined forces from multiple suspension components to the sensor unit, enabling indirect measurement of axle load without requiring direct contact scales under each axle, thus resolving the contradiction between measurement accuracy and measurement efficiency.
2Reliability
If multiple sensors are arranged on force transmission elements to detect forces, then reliability is improved through redundant measurement, but device complexity increases
Solution Approach 1:
The sensor unit is designed as a universal measurement device that can detect forces from multiple sources (air springs and control arms) simultaneously through a single integrated unit. The force transmission element serves multiple functions: it transmits forces from different suspension components, provides a common mounting structure for multiple sensors, and enables redundant measurement paths without requiring separate measurement systems for each force source, thereby improving reliability while controlling complexity.
3Ease of operation
If sensors are integrated into the force transmission element, then ease of operation is improved by enabling quick axle load determination, but manufacturing precision requirements increase
Solution Approach 1:
The sensors are pre-integrated into the force transmission element during the manufacturing process, rather than being installed separately during vehicle assembly. The force transmission element is designed with built-in mounting structures for the sensors, and the sensors are calibrated and positioned during force transmission element fabrication. This preliminary integration ensures precise sensor positioning and simplifies subsequent installation, improving ease of operation while managing manufacturing precision requirements through standardized production processes.
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 quick and accurate determination of axle loads, enhancing safety and reducing costs by integrating sensors directly into the force transmission elements, ensuring reliable measurement of forces acting on the axle system.
Implementation Method 1
using sensors such as piezoceramic or strain gauges integrated into the force transmission elements
Implementation Method 2
using sensors such as piezoceramic or strain gauges integrated into the force transmission elements
Data Source
Figure 1
Figure 2
AI summary
The invention relates to an axle load detection system (1), in particular for a utility vehicle, having a force transmission element (2) and a sensor unit (40), wherein the sensor unit (40) has at least one sensor (42), wherein the force transmission element (2) has a first mounting region (10) and a second mounting region (20), wherein the first mounting region (10) is or can be fixed indirectly and/or directly to a vehicle frame (52) of a vehicle, in particular a utility vehicle, wherein an air spring (120) and/or a link (110), in particular a longitudinal link, is and/or can be arranged indirectly and/or directly on the second mounting region (20), wherein the sensor unit (40) is designed to determine and/or to detect, between the first mounting region (10) and the second mounting region (20), in particular in a support direction (AR), a force transmitted via the force transmission element (2).