Vehicle Level Control Unit for Integrated Axle Load Sensing
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Solution Overview
Problem
Existing systems for determining axle load in vehicles require separate installations for level control and axle load determination, are costly, and are not integrated into existing level control apparatuses, with inaccuracies in low load ranges, especially for mechanically suspended axles.
Innovation Solution
An electronic control unit with an electrical interface and non-volatile memory that can receive and process signals from various sensors, including travel and load sensors, to determine axle load on mechanically and pneumatically/hydraulically suspended axles, using sensor-specific characteristic curves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate installation systems are used for level control and axle load determination, then axle load can be determined, but the system becomes costly and complex
Solution Approach 1:
The patent combines the axle load determination function with the existing level control apparatus by integrating a travel sensor into the suspension system. The control unit processes both level control signals and axle load measurement signals through a unified system architecture, eliminating the need for separate installation systems while maintaining measurement capability.
Solution Approach 2:
The control unit is designed to perform multiple functions: it controls the suspension level by regulating spring element position and simultaneously determines axle load by evaluating travel sensor signals. This multi-functional approach allows one system to serve dual purposes, reducing overall system complexity and cost.
2Adaptability or versatility
If travel sensors are used for axle load determination on mechanically suspended axles, then the system integrates with level control, but accuracy decreases in low load ranges
Solution Approach 1:
The system dynamically adapts its measurement and control strategy based on operating conditions. The control unit evaluates travel sensor signals in conjunction with pressure sensor data from air spring elements, switching between or combining measurement methods depending on the load range and suspension type to maintain accuracy across all operating conditions.
Solution Approach 2:
The system changes measurement parameters based on the operating state. For mechanically suspended axles in low load ranges, the control unit adjusts how travel sensor signals are processed and combined with other sensor data, modifying the evaluation parameters to compensate for reduced sensitivity in the travel sensor under light loads.
3Measurement precision
If pressure sensors are used for axle load determination on air-suspended axles, then measurement is possible, but the system cannot determine load on mechanically suspended axles
Solution Approach 1:
The control unit is designed with universal functionality to handle both pneumatic and mechanical suspension systems. It processes pressure sensor signals from air spring elements for pneumatic axles and travel sensor signals from the suspension travel for mechanical axles, using a unified control algorithm that adapts to the suspension type to determine axle load in both cases.
Data Source
AI summary
A control unit for a level control device of a mechanically and/or pneumatically/hydraulically suspended vehicle includes a control device configured to control the level and a sensor device installed in the vehicle and/or are functionally expanded such that in addition to the level control or in lieu of the level control, functions can be added for ascertaining the load on mechanically suspended axles and on pneumatically/hydraulically suspended axles. An interface is configured to receive signals from sensors suitable at least for ascertaining the load on mechanically suspended axles. The control unit has a first storage for sensor-specific characteristic curves and a second storage for an algorithm for processing or reprocessing the signals forwarded or processed using the interface. For each stored sensor type, the current load on the mechanically suspended axle in question can be ascertained by correlating the signal with the characteristic curve for the sensor type.