Load-Limiting Suspension with Shear Tabs and Crush Tubes
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Solution Overview
Problem
Current vehicle active crash protection systems lack a universal solution for effectively controlling and limiting impact loads across various types of vehicles during impact events, as existing load-controlled suspension elements are application-specific and do not adequately address the diverse needs of different vehicle types and environments.
Innovation Solution
A vehicle load-limiting suspension apparatus featuring shear tabs and crush tubes, controlled by sensors and a servomotor system, which adjusts load settings based on impending impact data to absorb and dissipate impact energy, providing a scalable and adaptable solution for various vehicle structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If application-specific load-controlled suspension elements are used, then the system can be optimized for particular vehicle types, but the system lacks versatility for different vehicle types and environments
Solution Approach 1:
The patent applies universality by designing a suspension element with a universal control system that can be adapted to different vehicle types (aircraft, automobiles, motorcycles). The controller receives input from various sensors and adjusts damping coefficients through a standardized interface, allowing one system design to serve multiple vehicle applications rather than requiring separate optimized systems for each vehicle type.
Solution Approach 2:
The patent implements dynamics through actively adjustable damping coefficients that change in real-time based on vehicle conditions. The controller continuously monitors sensor data (acceleration, velocity, position) and dynamically adjusts the damping force of the suspension element, enabling the system to adapt to varying impact severity, vehicle weight, and operational environments rather than relying on fixed mechanical settings.
2Reliability
If heavier suspension elements are used to increase energy absorption capacity, then crash protection is improved, but vehicle weight increases reducing fuel efficiency
Solution Approach 1:
The patent replaces traditional passive mechanical energy absorption mechanisms (which require heavy springs and dampers designed for worst-case scenarios) with an active control system using sensors, processors, and electronically controlled damping elements. This substitution allows the system to provide equivalent or superior crash protection with reduced weight by using intelligent control rather than brute-force mechanical design.
Solution Approach 2:
The patent changes the damping coefficient parameter dynamically based on real-time vehicle conditions rather than using fixed heavy-duty components. The controller adjusts damping force from low values during normal operation to high values during impact events, allowing the suspension element to provide maximum protection only when needed, thereby reducing the overall weight requirement compared to systems designed for constant high-capacity absorption.
3Measurement precision
If complex sensor and control systems are implemented, then impact load control precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent segments the control system into distinct functional modules: sensor modules for detecting specific parameters (acceleration, velocity, position), a processing module for analyzing sensor data and determining impact characteristics, and actuator modules for executing control actions. This segmentation allows each module to be optimized independently and simplifies manufacturing and maintenance while maintaining high measurement precision through specialized sensors.
Solution Approach 2:
The control system implements self-service through automatic impact detection and response without requiring external intervention. The sensors continuously monitor vehicle conditions, the controller automatically processes the data to detect impact events, and the damping elements are adjusted in real-time based on algorithmic decision-making. This self-service capability reduces the need for complex manual control interfaces and external monitoring systems.
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 effectively controls and limits impact loads during vehicle impact events, enhancing crash survivability and reducing airframe damage while allowing for lighter aircraft design by optimizing load settings and energy absorption capabilities.
Implementation Method 1
at least one shear tab for controlling an amount of impact load applied to a vehicle structure when a vehicle impact event occurs
Implementation Method 2
at least one crush tube for limiting the amount of impact load applied to the vehicle structure after the at least one shear tab shears in response to occurrence of the vehicle impact event
Data Source
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AI summary
A vehicle load-limiting suspension apparatus comprises at least one shear tab for controlling an amount of impact load applied to a vehicle structure when a vehicle impact event occurs. The vehicle load-limiting suspension apparatus further comprises at least one crush tube for limiting the amount of impact load applied to the vehicle structure after the at least one shear tab shears in response to occurrence of the vehicle impact event.