Electro-Magnetic Damper Actuator for Adaptive Ride Control
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Solution Overview
Problem
Conventional passive shock absorbers provide uniform damping regardless of input frequency, leading to harshness and decreased ride quality during high-frequency motions and handling events, while active shock absorbers are expensive due to the need for re-design and high-cost electro-magnetic materials.
Innovation Solution
A modular damper system incorporating a magnetic rotor and stator assembly with electro-magnetic actuator that can be retro-fitted to existing passive shock absorbers, combining hydraulic and electro-magnetic damping for adaptive control, reducing costs and improving ride comfort and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional passive shock absorbers are used, then the structure is simple and cost-effective, but the damping force remains constant regardless of input frequency leading to harshness and decreased ride quality
Solution Approach 1:
The patent replaces the traditional mechanical valve assembly with an electro-magnetic actuator system. The actuator uses electromagnetic fields to control the piston rod position and damping force, eliminating complex mechanical linkages and valves. This substitution maintains manufacturing simplicity while enabling adaptive damping control that improves ride comfort across different frequency inputs.
Solution Approach 2:
The patent transforms the static damping characteristic of passive shock absorbers into a dynamic system. The electro-magnetic actuator continuously adjusts the damping force based on real-time detection of piston rod velocity and input frequency, allowing the system to adapt to varying road conditions and maintain optimal ride comfort without increasing manufacturing complexity.
2Ease of operation
If electro-magnetic actuators with permanent magnets and coils are used, then adaptive damping control is achieved, but the cost increases significantly due to expensive electro-magnetic materials
Solution Approach 1:
The patent segments the electro-magnetic actuator into distinct functional modules: a stator assembly with coils, a rotor assembly with permanent magnets, and a piston rod assembly. This segmentation allows for optimized material usage in each module, reducing the total amount of expensive electro-magnetic materials required while maintaining adaptive damping control functionality.
Solution Approach 2:
The patent designs the electro-magnetic actuator to serve multiple functions: generating electromagnetic force for damping control, detecting piston rod velocity through back-EMF, and providing position feedback. This multi-functionality reduces the need for separate sensors and actuators, thereby reducing the overall cost of electro-magnetic materials while maintaining adaptive damping control.
3Ease of operation
If shock absorbers are re-designed to accommodate electro-magnetic actuators, then active damping is achieved, but the device complexity and re-design requirements increase
Solution Approach 1:
The patent merges the electro-magnetic actuator components directly into the existing shock absorber structure. The stator assembly is integrated with the piston rod, the rotor assembly is combined with the outer tube, and the valve assembly is merged with the electromagnetic force generation system. This integration eliminates the need for separate mounting structures and reduces overall device complexity while maintaining active damping performance.
Solution Approach 2:
The patent employs a nested configuration where the rotor assembly with permanent magnets is positioned inside the outer tube, the stator assembly with coils is nested around the piston rod, and the valve assembly is integrated within the electromagnetic components. This nested arrangement maximizes space utilization and eliminates the need for additional external mounting structures, reducing structural complexity while enabling active damping.
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 system achieves active damping and energy harvesting at reduced costs, enhancing ride comfort and body motion control across various frequencies without the trade-offs of traditional systems, while providing a fail-safe hydraulic damping in case of electro-magnetic actuator failure.
Implementation Method 1
When electricity is supplied to the plurality of coils, the plurality of coils create an electro-magnetic field that interacts with the magnetic field of the permanent magnets and applies a magnetic force to the piston rod
Implementation Method 2
The one or more glide bearings are disposed radially between the plurality of coils and the magnetic rotor. The one or more glide bearings move longitudinally with the stator assembly and are arranged in a sliding fit with the magnetic rotor
Implementation Method 3
The outer tube contains a hydraulic fluid and the piston assembly separates the outer tube into a first working chamber and a second working chamber
Data Source
AI summary
A damper system for a vehicle is provided that includes an outer tube, a piston rod, and a piston assembly that is mounted to the piston rod and separates the outer tube into first and second working chambers. A valve assembly, mounted to the piston assembly, controls fluid flow between the first and second working chambers. A magnetic rotor is fixed to and extends annularly about the outer tube. A stator assembly is coupled to the piston rod by a spherical bearing assembly. The stator assembly includes a plurality of coils that apply an active damping force to the piston rod when energized. The coils can also generate electricity from axial movements of the piston rod relative to the outer tube. One or more glide bearings are disposed radially between the coils and the magnetic rotor in a sliding fit to stabilize the stator assembly.