Self-Powered Wireless Switch for Vehicle Suspension Control

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Solution Overview

Problem

Current vehicle control switches require electrical connections via cables or slip-ring connections, and aftermarket wireless switches rely on batteries that need frequent replacement or recharging, posing limitations in convenience and durability.

Innovation Solution

An energy harvesting switch that enables wireless communication with vehicle suspension systems, allowing for remote digital suspension adjustments using a mobile device, eliminating the need for physical connections and battery-powered components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If wireless switches use batteries, then wireless communication is enabled, but batteries need frequent replacement or recharging

Engineering Contradiction:
Improvewireless operationVSAvoidbattery life
Core Design Contradiction:
Ease of operationVSDuration of action of moving object

Solution Approach 1:

The switch harvests energy from the vehicle's electrical system through the cable connection to power its wireless communication and LED indicators, eliminating the need for separate batteries. The cable that provides data/power connection also serves as the energy source, making the system self-sufficient without external power replacement.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The cable connection serves multiple functions simultaneously: it provides data communication between switches, supplies electrical power to wireless components, and enables the override function. This multi-functionality eliminates the need for separate battery power sources.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Reliability

If control switches require cable connections, then reliable electrical connection is achieved, but installation complexity and maintenance increase

Engineering Contradiction:
Improveelectrical connectionVSAvoidphysical connections
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical wireless switches with batteries using cable connections with this invention: a wireless switch that uses a cable connection solely for data communication and energy harvesting, while the control signals are transmitted wirelessly. This substitutes the need for complex battery power systems with a simpler energy harvesting approach.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If aftermarket wireless switches are used, then installation simplicity is improved, but durability decreases due to battery limitations

Engineering Contradiction:
Improveinstallation simplicityVSAvoiddurability
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The switch automatically harvests energy from the vehicle's electrical system through the existing cable connection, eliminating the need for battery installation and replacement. This self-powered approach significantly improves durability while maintaining the simple wireless installation advantage.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The cable connection acts as an intermediary that simultaneously provides data communication and energy transfer. This mediator approach allows the switch to be wired for reliability but wireless for operation, combining the advantages of both approaches while eliminating their respective disadvantages.

Inventive Principle:
Principle #24Intermediary (Mediator)

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

Enables convenient, battery-free, and durable wireless control of vehicle suspension settings, enhancing user experience and reducing maintenance costs by harnessing energy for continuous operation.

Implementation Method 1

The wireless switch includes an energy harvesting circuit that harvests energy from the vehicle's electrical system to power the wireless switch and LED indicators

Methodology Applied
Scientific EffectEnergy harvesting:

Data Source

PatentUS12138977B2Energy harvesting switch
Publication Date: 2024.11.12 FOX FACTORY INC
  • US12138977B2 patent drawing
  • US12138977B2 patent drawing
  • US12138977B2 patent drawing

AI summary

An energy harvesting switch is disclosed. The energy harvesting switch includes a magnet, a coil, and a mechanical switch. The manipulation of the mechanical switch causes the magnet to move with respect to the coil and generate an amount of energy. The energy harvesting switch also includes a transmitter configured to use the generated amount of energy to transmit a signal to at least one component coupled with a vehicle, the signal configured to cause a change to at least one characteristic of the at least one component.