Modular Air Suspension Manifold With Integrated Electronics
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Solution Overview
Problem
Conventional electronically controlled air suspension systems are complex, expensive, and lack reconfigurability, making them difficult to manufacture and integrate into various vehicle configurations, with challenges in reducing the number of operations for internal component coupling and achieving low per-unit costs for robust electronic control units.
Innovation Solution
A modular electronically controlled air suspension system with a manifold, actuator, pressure sensor, and electronics module that allows for flexible reconfiguration, reduced part count, and single-operation coupling of components, utilizing injection-moldable materials and simplified assembly to decrease complexity and cost, while enabling efficient control of air flow to air springs and dampers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electronically controlled air suspension systems are used, then reliable suspension control is achieved, but system complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple control functions (electronic control unit, manifolds, valves, sensors) into an integrated assembly where the electronic control unit directly interfaces with control valves through simplified coupling mechanisms, reducing the number of discrete components and interconnections while maintaining control reliability
Solution Approach 2:
The electronic control unit is designed with a standardized interface that can control multiple air springs and dampers across different vehicle configurations, allowing a single design to serve multiple functions and applications without requiring complex reconfiguration
2Reliability
If conventional electronically controlled air suspension systems are used, then suspension control is achieved, but manufacturing cost increases due to extensive machining and assembly operations
Solution Approach 1:
The patent integrates the electronic control unit with manifold assemblies in a way that reduces the number of separate machining operations and assembly steps, combining functions that were previously requiring multiple discrete manufacturing processes into unified components
Solution Approach 2:
The system is divided into modular components (electronic control unit, manifolds, valves, sensors) that can be manufactured separately using optimized processes and then assembled through simplified coupling mechanisms, reducing overall manufacturing complexity and cost
3Reliability
If conventional electronically controlled air suspension systems are used, then active suspension control is achieved, but reconfigurability for different vehicle configurations is limited
Solution Approach 1:
The electronic control unit employs a standardized universal interface design that can accommodate different vehicle configurations and suspension arrangements, allowing the same control unit to be reconfigured for various applications without requiring specialized designs for each configuration
4Reliability
If robust electronic control units with complex manifolds are manufactured, then reliable control is achieved, but per-unit manufacturing cost decreases are difficult to achieve
Solution Approach 1:
The patent combines the electronic control unit with manifold functions in an integrated assembly, eliminating the need for separate complex manifold manufacturing and reducing the total number of parts that require individual manufacturing operations
Solution Approach 2:
The control system is segmented into modular functional units that can be manufactured using cost-effective processes and then assembled through simplified coupling, reducing the overall per-unit manufacturing cost while maintaining reliability
5Productivity
If the number of operations for internally coupling electronic control unit components is reduced, then manufacturing efficiency increases, but integration of sub-system components becomes more challenging
Solution Approach 1:
The patent integrates sub-system components (electronic control unit, manifolds, valves, sensors) into a unified assembly with standardized interfaces, allowing multiple components to be coupled through simplified operations while maintaining proper integration and functionality
Data Source
AI summary
An air suspension system, comprising a manifold, defining a first and second port, each port defining a receiving region at the second end, wherein the first and second ports are arranged in a common plane, a channel intersecting the first and second port, a cavity intersecting each port, and a pressure sensor port, positioned between the first and second port, defining a sensor insertion axis normal to the common plane, the pressure sensor port separated from the first port, the second port, and the channel by a thickness; a first and second solenoid valve, each solenoid valve arranged within the cavity and coaxially arranged with the first and second ports, each solenoid valve comprising a connector; a pressure sensor arranged within the pressure sensor port, the pressure sensor comprising a connector; and an electronics module arranged parallel the common plane, the electronics module configured to electrically couple to the connectors.