Modular ECAS Control with Auxiliary Units for Main Unit Failure

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Solution Overview

Problem

Current air suspension systems for vehicles are complex and require high computing capacity, leading to system shutdowns in case of control device failure, and are not easily adaptable to different vehicle types.

Innovation Solution

A modular air suspension control system with a main control unit and multiple auxiliary control units, where the auxiliary units can independently actuate actuators based on stored functions and sensor data, reducing the main control unit's computing load and enabling adaptable functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a single control device is used to manage all air suspension functions, then centralized control is achieved, but system complexity and computing capacity requirements increase significantly

Engineering Contradiction:

Improvecentralized controlVSAvoidcontrol device complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The control system is divided into a main control unit and multiple auxiliary control units. Each auxiliary control unit is responsible for specific air springs or actuators, processing sensor data and generating control signals independently. This segmentation reduces the computing burden on any single control device while maintaining centralized coordination through the main control unit.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If a single control device processes all sensor data and generates all control signals, then unified control logic is maintained, but quick reaction time is compromised due to high computing load

Engineering Contradiction:

Improvecontrol logic unityVSAvoidreaction time

Core Design Contradiction:

Stability of the object's compositionVSSpeed

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Control algorithms and response strategies are pre-programmed in the auxiliary control units. When sensor data is received, the auxiliary units can immediately execute pre-prepared control logic without waiting for complex calculations from the main control unit, significantly reducing reaction time while maintaining unified control behavior.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If the control device is highly integrated, then system coordination is improved, but the entire system shuts down upon control device failure

Engineering Contradiction:

Improvesystem coordinationVSAvoidsystem reliability

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The control system is divided into a main control unit and multiple auxiliary control units. Each auxiliary control unit can operate independently to control specific air springs or actuators. If the main control unit fails, the auxiliary units continue to function using their embedded control logic, preventing complete system shutdown and maintaining basic suspension functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each auxiliary control unit contains self-contained control logic and can autonomously process sensor data and generate control signals without requiring continuous intervention from the main control unit. This self-service capability ensures that localized control functions remain operational even if central coordination is lost.

Inventive Principle:

Principle #25Self-service

4Adaptability or versatility

If a single control device is designed to accommodate all vehicle types, then universal applicability is achieved, but adaptability to specific vehicle configurations is reduced

Engineering Contradiction:

Improvevehicle type adaptabilityVSAvoidcontrol device configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The control system is divided into a main control unit and multiple auxiliary control units. Each auxiliary control unit can be independently configured for specific vehicle types or suspension configurations. This modular approach allows the system to be adapted to different vehicles by reconfiguring auxiliary units rather than redesigning the entire control device.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The auxiliary control units are designed with universal interfaces and configurable parameters that allow them to work with different vehicle types and suspension configurations. The same auxiliary control unit hardware can be programmed to control different numbers and types of air springs, enabling a single control system design to serve multiple vehicle applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11975582B2Air spring system and control

Publication Date: 2024.05.07 ZF CV SYST EURO BV

AI summary

An air suspension control system (ECAS, electronic controlled air suspension) (10) for a utility vehicle, such as a truck or the like, or for a passenger car, includes a main control unit (12) for operating the air suspension control system (10) and at least two auxiliary control units (14) connected to the main control unit (12) via a data link (16). The auxiliary control units (14) each have at least one output (18) for actuating at least one actuator (20) which can be connected to the output (18), in particular an adjustment drive (28) for a valve (30). Furthermore, at least one function for generating control signals at the output (18) can be stored in the auxiliary control units (14), and the main control unit (12) is adapted to call up and/or to parameterize at least the stored functions by transmitting commands via the data link (16).