Embedded Wireless Sensors in Air Spring Elastomeric Walls
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional air springs lack real-time monitoring capabilities to effectively sense and report parameters such as forces, stresses, strains, temperatures, and vibrations, which are crucial for maintaining optimal performance and preventing overheating due to excessive shear forces, leading to potential breakdowns.
Innovation Solution
Integration of wireless sensors within the elastomeric spring wall of air springs, capable of sensing various parameters and transmitting data wirelessly to a data collection device for real-time monitoring and processing, allowing for active management of vehicle suspension systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wireless sensors are integrated into the elastomeric spring wall, then real-time monitoring capability is improved, but device complexity increases
Solution Approach 1:
The patent embeds wireless sensors directly within the elastomeric spring wall structure, nesting the monitoring functionality inside the existing component rather than adding external monitoring systems. This integration approach enables real-time monitoring while minimizing additional complexity by utilizing the existing structural framework of the air spring.
Solution Approach 2:
The patent combines the spring wall structural function with the sensor housing function, merging two separate components into one integrated element. The elastomeric material itself serves as both the structural spring component and the protective housing for the embedded wireless sensors, reducing overall system complexity.
2Measurement precision
If sensors are embedded in the spring wall, then measurement precision is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes the elastomeric material's inherent properties of flexibility and moldability during the manufacturing process. The sensors are embedded while the elastomeric material is in a pliable state, allowing for easier integration without requiring extremely tight tolerances. After curing or setting, the material maintains the sensor positions with sufficient precision for accurate measurements.
Solution Approach 2:
The sensors are positioned and embedded within the elastomeric spring wall during the initial manufacturing process, before the final operational configuration is established. This preliminary embedding ensures proper sensor placement and orientation without requiring subsequent complex adjustment procedures.
3Reliability
If real-time data collection is implemented, then reliability is improved through preventive maintenance, but energy consumption increases
Solution Approach 1:
The wireless sensors are configured to transmit data periodically or at predetermined intervals rather than continuously. This periodic transmission approach enables effective monitoring of air spring conditions and early detection of potential failures while significantly reducing the energy consumption compared to continuous data transmission.
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 real-time data collection and analysis of air spring conditions, preventing overheating and improving performance by allowing for timely adjustments and maintenance, thereby extending the operational life of air springs.
Implementation Method 1
sensing parameters including forces, stresses, strains, temperatures, vibrations
Implementation Method 2
sensing parameters including forces, stresses, strains, temperatures, vibrations
Implementation Method 3
The spring wall of a conventional gas load bearing device is adapted to flex during dynamic operation and use of the air spring device and is therefore normally made from a flexible, elastomeric material. When an elastomeric article experiences conditions beyond this operational window, the performance of the article can be shortened. These internal forces generate heat that will raise the internal temperature of the air spring.
Data Source
Figure 1~1A
Figure 2
Figure 3~4
AI summary
A sensor system for obtaining data from an air spring having an elastomeric body with a plurality of wireless sensors embedded therein. The sensor length-scales range from nano- to micro-scale devices that are small enough to avoid becoming occlusions within the elastomeric body. The air spring may include a spring wall having an internally reinforced elastomeric body portion with the sensors embedded within. The air spring may include a spring wall having an unreinforced elastomeric body portion with the sensors embedded within. The sensors may be configured to provide data related to one or more of temperature, pressure, sidewall flex, stress, strain, and other parameters. The sensors may be LCD sensors, and/or conductive polymer sensors, and/or bio-polymer sensors, and/or polymer diodes suitable for sensing data during the operation of the air spring.