Fiber Composite Spring with Integrated Metal Thread
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Solution Overview
Problem
Existing load-bearing springs in motor vehicles lack the ability to accurately determine actual force conditions, which is crucial for controlling driver assist and regulating systems like ESP and ABS, and maximizing tire adhesion.
Innovation Solution
A fiber composite spring with a metal thread that changes electrical resistance in response to deformation, allowing for precise measurement of force conditions through a control device, and optionally featuring multiple threads for redundancy and temperature-compensated characteristic diagrams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional spring is used, then the structure is simple and manufacturing is easy, but the ability to determine actual force conditions is lacking
Solution Approach 1:
The patent combines the spring structure with a metal thread that has electrical resistance properties into a single integrated component. The metal thread is embedded within the spring's fiber composite structure, merging the mechanical load-bearing function with the electrical sensing function. This allows the spring to simultaneously support loads and provide force condition information through resistance changes, eliminating the need for separate sensors and reducing overall system complexity.
Solution Approach 2:
The spring is designed to perform multiple functions: it serves as both a load-bearing mechanical component and a force sensing element. The metal thread integrated into the spring structure enables the spring to detect and report force conditions through changes in electrical resistance, making it a multi-functional component that eliminates the need for separate measurement systems.
2Measurement precision
If a metal thread is integrated into the spring, then force measurement capability is enabled, but manufacturing complexity increases
Solution Approach 1:
The spring is constructed as a fiber composite structure with the metal thread embedded within it. This composite construction allows the metal thread to be integrated during the spring manufacturing process itself, rather than requiring post-manufacturing assembly. The fiber composite material provides both structural support and a matrix for embedding the sensing element, streamlining the manufacturing process.
3Measurement precision
If temperature-compensated characteristic diagrams are provided, then measurement accuracy under temperature fluctuations is improved, but data storage and processing requirements increase
Solution Approach 1:
The patent accounts for temperature effects by providing characteristic diagrams that show the relationship between resistance, force, and temperature. The control device uses these pre-stored diagrams to compensate for temperature variations by selecting the appropriate diagram based on measured temperature and using it to interpret the resistance signal. This allows accurate force determination across a wide temperature range without requiring complex real-time compensation algorithms.
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 precise determination of spring force and wheel contact force, enhancing the control of motor vehicle systems and maximizing tire adhesion by correlating resistance changes with force conditions, even under extreme temperature fluctuations.
Implementation Method 1
having an electrical resistance which changes in dependence on a deformation of the spring
Data Source
AI summary
A spring made of a fiber composite includes a metal thread which is connected to the spring and has an electrical resistance which changes in dependence on a deformation of the spring. The metal thread can be integrated inside the spring or may also be arranged on an outer side of the spring.