Compliant Suspension Height Sensor Linkage With Flexible Joints
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Solution Overview
Problem
Existing mechanical linkages for monitoring the relative position of a vehicle suspension with respect to its frame are complex, time-consuming to manufacture, and prone to long-term reliability issues due to numerous rigid components.
Innovation Solution
A compliant mechanism comprising flexible joints interposed between rigid links, which can be made from different materials or over-molded with the links, reducing the number of components and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical linkages with multiple rigid components are used to monitor suspension position, then the monitoring function is achieved, but the device complexity and manufacturing time increase significantly
Solution Approach 1:
The patent combines multiple rigid mechanical linkage components into a single integrated compliant mechanism body. The compliant mechanism integrates the functions of multiple separate linkages, pivots, and mounting structures into one monolithic component with built-in flexibility, thereby reducing component count while maintaining the suspension position monitoring function
Solution Approach 2:
The patent employs a compliant mechanism with flexible regions that allow controlled deformation to accommodate suspension movement. These flexible regions replace traditional rigid joints and pivots, enabling the mechanism to adapt to relative motion between the frame and suspension without requiring multiple separate moving parts
2Reliability
If traditional mechanical linkages with numerous components are used, then the suspension position can be monitored, but manufacturing time and cost increase
Solution Approach 1:
The patent merges multiple manufacturing steps and assembly operations into a single monolithic component production process. By integrating functions that previously required separate components into one compliant mechanism body, the number of assembly operations is dramatically reduced, directly improving manufacturing productivity
Solution Approach 2:
The compliant mechanism is designed with distinct functional regions (rigid regions and flexible regions) that can be optimized independently during manufacturing while being produced as a single integrated component, allowing for efficient manufacturing process planning and execution
3Device complexity
If flexible joints and multiple links are used in the compliant mechanism, then the number of components is reduced, but the manufacturing complexity of the flexible joint increases
Solution Approach 1:
The patent combines the flexible joint functionality directly into the mechanism body through integrated flexible regions, eliminating the need for separate flexible joint components. This integration reduces the total number of parts while the flexible regions are designed with standardized geometries that simplify the manufacturing process
Solution Approach 2:
The flexible regions are designed with specific geometric parameters (thickness, curvature, material properties) that are optimized for manufacturing. By carefully selecting these parameters, the compliant mechanism achieves the desired flexibility while maintaining compatibility with standard manufacturing 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
The compliant mechanism significantly reduces manufacturing time and cost while improving reliability by minimizing the number of components and allowing for efficient monitoring of suspension position.
Implementation Method 1
a flexible joint coupled to both the engagement structure of the first link and the engagement structure of the second link so as to allow relative movement between the first and second links
Data Source
AI summary
A compliant mechanism is provided for monitoring the position of a suspension of a vehicle. The compliant mechanism can include a body for coupling to both an angle sensor and the suspension of the vehicle. The body can have at least two first portions and at least one second portion. The second portion is coupled to both of the two first portions and is more flexible than the two first portions.