Hybrid Leveling System Air Spring Height Control
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Solution Overview
Problem
Current vehicle leveling systems for large vehicles waste pressured air due to frequent height adjustments, leading to increased fuel consumption, and existing solutions are costly to implement effectively.
Innovation Solution
A vehicle leveling system that utilizes a mechanical-to-electrical sensor to generate an electrical signal indicating air spring height, connected to the vehicle's computer, which controls a blocking valve to minimize unnecessary air flow, leveraging existing sensors and computer systems to reduce air pressure usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a leveling valve with dampeners is used to control air flow into and out of the air spring, then the rate of air flow is minimized, but fuel consumption increases due to repeated pressurization cycles
Solution Approach 1:
The patent replaces the purely mechanical leveling system with an electronic control system that uses a height sensor to detect air spring position and a microprocessor to control the blocking valve. This electronic substitution allows for more precise control logic that can distinguish between temporary height changes (due to road conditions) and permanent height changes (due to load), thereby reducing unnecessary pressurization cycles and fuel consumption while maintaining proper air spring height stability
Solution Approach 2:
The patent implements a feedback control system where a height sensor continuously monitors the air spring position and sends signals to the microprocessor. The microprocessor uses this feedback information to intelligently control the blocking valve, opening it only when necessary to correct actual height deviations and keeping it closed during temporary fluctuations. This feedback mechanism enables the system to minimize fuel-consuming air flow while maintaining reliable air spring height
2Loss of energy
If a blocking valve is added to stop air flow during temporary height changes, then fuel waste is reduced, but system complexity and installation cost increase
Solution Approach 1:
The patent integrates the blocking valve functionality into the existing leveling valve assembly, allowing a single component to perform both the traditional leveling function and the new blocking function. The height sensor and microprocessor are part of the existing electronic control architecture in modern vehicles. This multi-functionality approach reduces overall system complexity compared to adding completely separate blocking valve and control systems
Solution Approach 2:
The patent combines the blocking valve with the leveling valve into an integrated assembly where both functions coexist. The electronic control system merges the traditional mechanical feedback mechanism with electronic sensing and control, creating a unified system that achieves fuel savings without requiring entirely separate control systems or multiple independent components
3Extent of automation
If a mechanical-to-electrical sensor is mounted on the leveling valve, then electrical signals for computer control are generated, but manufacturing and installation cost increases
Solution Approach 1:
The patent positions the height sensor on the leveling valve assembly itself, allowing it to utilize the existing mechanical motion and structure of the leveling mechanism. The sensor converts this mechanical motion directly into electrical signals without requiring separate mechanical-to-electrical conversion mechanisms. This self-service approach leverages the existing system's motion to generate the necessary control signals, reducing additional manufacturing complexity
Solution Approach 2:
The height sensor acts as an intermediary element that bridges the mechanical leveling mechanism and the electronic control system. By mounting it on the existing leveling valve, it converts mechanical position information into electrical signals that the microprocessor can process. This intermediary approach enables electronic control integration without requiring complete system redesign or expensive custom conversion mechanisms
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 moderate fuel savings by optimizing air flow into and out of air springs, installed at a low cost by utilizing existing vehicle components, thereby justifying the implementation through spread-out cost savings over multiple vehicles.
Implementation Method 1
mounts a mechanical-to-electrical sensor on the leveling valve to generate an electrical signal that indicates air spring height
Data Source
AI summary
A large vehicle with air bags and a leveling system that controls air flow into and out of an air spring (also known as an “air bag”) to maintain the air spring height close to the optimum level. The system is altered at minimum cost to further minimize the repeated flow of air into and out of the air spring, to thereby save fuel. A mechanical-to-electrical converter (50) is mounted on the air spring height sensor to generate an electrical signal indicating vehicle ride height, and the electrical output is connected to a computer (62) on the vehicle. The computer is programmed to control the flow of pressured air through a blocking valve (60) to a leveling valve (22) that flows air into and out of the air spring, according to the outputs of a plurality of sensors on the vehicle.