Modular Vehicle Control System for Air Suspension Adaptation
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Solution Overview
Problem
Current air suspension systems in the vehicle aftermarket lack flexibility and efficiency, requiring separate engineering for each variation, leading to increased costs and reduced component reuse, while customers seek simple and adaptable control systems for multiple vehicle systems.
Innovation Solution
A modular control system that allows wired or wireless communication for air suspension systems, featuring a single driver interface unit that can control air pressure and height, with modular air control units and an open architecture for easy expansion and interconnection of additional units, enabling flexible installation and adaptation across various vehicle systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate engineering is performed for each air suspension system variation, then system customization and adaptability are improved, but engineering time and costs increase
Solution Approach 1:
The control system is divided into modular components: a controller module, a user interface module, and multiple air suspension units. Each module can be independently designed, tested, and manufactured, then assembled into different system configurations to meet various customization requirements without repeating the entire engineering process.
Solution Approach 2:
The controller module is designed with universal communication capabilities and standardized interfaces that can work with multiple types of air suspension units and integrate with various vehicle systems (engine controllers, damper controllers). This allows a single controller design to serve multiple application scenarios, reducing the need for separate engineering for each variation.
2Adaptability or versatility
If separate engineering is performed for each air suspension system variation, then system adaptability is improved, but manufacturing costs increase
Solution Approach 1:
By segmenting the system into standardized modules, each component can be manufactured independently using optimized processes and then assembled. This modular approach enables economies of scale in manufacturing individual modules while maintaining the ability to create customized system configurations through different module combinations.
Solution Approach 2:
The system allows for parameter customization (such as air pressure levels, suspension height, response characteristics) through software configuration and adjustable parameters rather than requiring different hardware designs for each application. This enables cost-effective adaptation to different vehicle types and suspension requirements.
3Loss of time
If a modular control system with common components is used, then engineering time and costs are reduced, but system flexibility may be limited
Solution Approach 1:
The modular control system incorporates dynamic reconfiguration capabilities where modules can be added, removed, or repositioned based on specific application requirements. The standardized interfaces and communication protocols allow the system to adapt its configuration dynamically, maintaining flexibility while benefiting from the efficiency of common components.
Solution Approach 2:
The controller module serves as an intermediary with universal communication capabilities that can interface with different types of air suspension units, vehicle systems, and user interfaces. This intermediary layer enables common components to work together in diverse configurations, bridging the gap between standardization and customization.
4Reliability
If wired communication is used in the control system, then system reliability is improved, but installation complexity increases
Solution Approach 1:
The wired communication system is designed with universal connectors and standardized communication protocols that can be easily integrated with existing vehicle wiring harnesses. The same controller module can communicate with different vehicle systems using the same interface standards, simplifying installation while maintaining reliable wired communication.
5Device complexity
If wireless communication is used in the control system, then installation simplicity is improved, but communication reliability may decrease
Solution Approach 1:
The wireless communication system uses standardized radio frequency interfaces as intermediaries between control modules. These intermediaries are designed with error correction, redundancy, and fallback mechanisms to maintain reliable communication while preserving the installation simplicity of wireless technology.
Data Source
AI summary
A modular control system is adapted to adjust an aftermarket system in a vehicle via the vehicle head unit. The head unit includes a user interface operable by the user to control the aftermarket system. An aftermarket control unit is in communication with the user interface of the vehicle head unit, the aftermarket control unit receiving an aftermarket control signal from the vehicle head unit as a results of an input by the user at the head unit. The aftermarket control unit is in communication with the aftermarket system, wherein the aftermarket control unit may operate the aftermarket system in response to the user input. The aftermarket system may be an air suspension system.