Integrated Shock Height Sensing With Dust-Boot PCB Assembly
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Solution Overview
Problem
Existing vehicle suspension systems face complexity and inaccuracy in measuring ride height due to cumbersome designs that incorporate multiple magnets and components, leading to increased costs and reduced reliability.
Innovation Solution
An integrated ride height sensor system is implemented using a target on the damper bump cap and a measurement assembly on the dust boot, featuring an elongated PCB that tracks relative movement between the target and the measurement assembly, generating accurate ride height information through magnetic field interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple magnets are displayed in a linear array to measure damper position, then measurement capability is provided, but device complexity increases
Solution Approach 1:
The patent combines the measurement assembly with the dust boot into a single integrated unit. The PCB is mounted within the dust boot structure, eliminating the need for separate measurement components. This merging reduces device complexity while maintaining measurement capability through the magnetic field sensing arrangement.
Solution Approach 2:
The dust boot serves multiple functions: it protects the rod from contamination and houses the measurement assembly. By making the dust boot multi-functional, the patent eliminates the need for separate protective and measurement components, thereby reducing overall device complexity while preserving measurement precision.
2Measurement precision
If multiple magnets are displayed in a linear array to measure damper position, then measurement capability is provided, but manufacturing cost increases
Solution Approach 1:
By integrating the measurement assembly into the dust boot, the patent reduces the total number of components that need to be manufactured and assembled. This consolidation lowers manufacturing costs while maintaining the magnetic field-based measurement capability through optimized PCB design within the unified structure.
Solution Approach 2:
The patent uses a PCB-based measurement assembly that can be manufactured more economically than traditional multi-magnet arrays. The integrated design allows for cost-effective production while achieving the required measurement precision through alternative sensing methods.
3Measurement precision
If multiple magnets are displayed in a linear array to measure damper position, then measurement capability is provided, but system reliability decreases
Solution Approach 1:
The integration of the measurement assembly into the dust boot reduces the number of separate components and connection points, thereby reducing potential failure points. The unified structure improves system reliability while maintaining measurement capability through the consolidated magnetic field sensing design.
4Device complexity
If existing components are utilized for measuring damper position, then component count is reduced, but measurement accuracy decreases
Solution Approach 1:
The patent merges the measurement assembly with the dust boot structure, creating an integrated unit that provides both protection and precise measurement capabilities. This combination maintains low component count while achieving improved measurement accuracy through the optimized PCB and magnetic field sensing arrangement within the unified structure.
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
This solution simplifies the design, reduces costs, and provides accurate ride height measurements by integrating the target and measurement assembly into existing suspension components, enhancing the reliability and efficiency of the suspension system.
Implementation Method 1
generating accurate ride height information through magnetic field interactions
Data Source
AI summary
A shock absorber for a vehicle suspension system may include a damper tube defining an axis, a rod operably coupled to the damper tube to be movable along the axis relative to the damper tube in response to jounce and rebound events, a dust boot operably coupled to the rod and extending along peripheral sides of the rod and at least a proximal end of the damper tube relative to the rod, the dust boot being movable with the rod, a target disposed on a damper bump cap operably coupled to the proximal end of the damper tube, and a measurement assembly affixed to the dust boot. The measurement assembly may include a PCB elongated parallel to the axis to track relative movement between the target and the measurement assembly responsive to the jounce and rebound events to generate ride height information based on the relative movement.