Internal IFP Stroke Sensing for Real-Time Shock Position Control
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Solution Overview
Problem
Existing vehicle suspension systems lack the ability to dynamically adjust shock stroke measurements in real-time, particularly for internal floating piston (IFP) shock assemblies, which can lead to suboptimal ride comfort and performance across varying terrains without requiring extensive aftermarket modifications or sensor installations.
Innovation Solution
An internal stroke sensor assembly is integrated within the shock assembly, utilizing a modular design with an IFP location sensor and processor to determine and transmit the stroke position, enabling active or semi-active control systems to adjust settings such as bottom-out control, compression, and rebound stiffness, while being resistant to damage and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external sensors and extensive wiring are installed to measure shock stroke, then measurement capability is achieved, but device complexity and susceptibility to damage increase
Solution Approach 1:
The patent combines the stroke measurement function with the existing IFP seal assembly by integrating a sensor into the seal cartridge. This merging eliminates the need for separate external sensors and extensive wiring, as the measurement capability is embedded within the existing structural component.
Solution Approach 2:
The sensor is nested within the seal cartridge assembly, which itself is integrated into the shock valve mechanism. This nested arrangement allows the measurement system to be housed within existing structural boundaries, reducing overall device complexity while maintaining measurement precision.
2Measurement precision
If external sensors are installed on the shock assembly, then stroke measurement is enabled, but reliability decreases due to susceptibility to damage and contamination
Solution Approach 1:
By nesting the sensor within the sealed seal cartridge assembly, the sensor is protected from external contaminants and physical damage. The existing seal structure serves as a protective enclosure, maintaining sensor reliability in harsh automotive environments.
Solution Approach 2:
The seal cartridge assembly acts as an intermediary structure that houses the sensor, isolating it from direct exposure to external damaging factors while still allowing the sensor to functionally measure stroke position through the integrated mechanism.
3Adaptability or versatility
If traditional shock assemblies are used without internal sensors, then device complexity is low, but adaptability to varying terrains is limited
Solution Approach 1:
The patent merges the adaptability function with the existing valve control system by integrating stroke measurement capability into the valve mechanism. This allows the system to adapt to varying terrains through controlled valve operation based on sensor feedback, without adding separate complex control systems.
Solution Approach 2:
The seal cartridge assembly serves multiple functions: it maintains system sealing, controls valve operation, and houses the stroke measurement sensor. This multi-functionality enables terrain adaptability while minimizing the addition of separate components that would increase overall device complexity.
Data Source
AI summary
An internal stroke sensor for an IFP shock assembly is disclosed herein. The shock assembly includes a damper chamber and a damping piston coupled to a piston shaft. The damping piston disposed in the damper chamber and axially movable relative to the damper chamber, the damping piston separating a compression portion from a rebound portion within the damper chamber. The shock assembly also includes an internal floating piston (IFP) and an IFP location sensor. The IFP location sensor to determine a position information for the IFP. A processor is configured to receive the position information for the IFP from the IFP location sensor and utilize the position information for the IFP to determine a shock stroke position of the shock assembly.