Integrated Shock Height Sensing With Dust Boot PCB Tracking
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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 introduced, featuring a target on the damper bump cap and a measurement assembly on the dust boot, utilizing an elongated PCB to track 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 multiple magnets into a single magnet assembly that integrates the magnetic field generation function previously requiring multiple separate magnets. This single assembly maintains the necessary magnetic field characteristics for accurate position measurement while eliminating the complexity of arranging and maintaining multiple individual magnets in a linear array.
Solution Approach 2:
The bump cap is designed to serve multiple functions: it provides structural support for the damper assembly, houses the single magnet assembly for position measurement, and acts as a mounting structure for the dust boot. This multi-functionality eliminates the need for separate components, reducing overall device complexity while maintaining measurement capability.
2Reliability
If traditional separate components are used for dust protection and position measurement, then protection is provided, but manufacturing cost increases
Solution Approach 1:
The dust boot is integrated directly with the bump cap structure, forming a unified component that provides both dust protection and serves as the mounting structure for the magnet assembly. This integration eliminates the need for separate dust boot and bump cap components, reducing part count and manufacturing cost while maintaining reliable dust protection.
Solution Approach 2:
The integrated bump cap assembly serves multiple functions simultaneously: it provides structural support, houses the magnet assembly for measurement, mounts the dust boot for protection, and facilitates assembly. This multi-functionality reduces the total number of components that need to be manufactured and assembled, lowering overall manufacturing cost.
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
utilizing an elongated PCB to track relative movement between the target and the measurement assembly, 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.