Solid Axle Damper Velocity Estimation Using 3D Sensor Maps
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Solution Overview
Problem
Determining damper velocity in vehicles with solid rear axles is challenging due to wheel hop, tramp, and non-symmetrically splayed dampers, which complicate the calibration of damper velocities for left and right wheels.
Innovation Solution
A system using distance sensors and three-dimensional look-up tables to determine damper velocity by correlating sensor measurements with damper lengths, employing controllers to derive damper length over time based on kinematic studies of the solid axle suspension in curb, compression, and rebound positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional mechanical or electrical rework methods are used to determine damper velocity, then measurement precision may be improved, but device complexity and ease of manufacture deteriorate
Solution Approach 1:
The patent replaces mechanical velocity sensing methods with a software-based calculation system. The controller determines damper velocity by mathematically differentiating damper position data obtained from existing distance sensors, eliminating the need for mechanical velocity sensors or complex electrical rework while maintaining measurement precision
Solution Approach 2:
The patent creates a virtual model of damper velocity through software calculation rather than physical measurement. By using the relationship between damper position and time derived from existing sensor data, the system generates accurate velocity information without adding physical measurement devices
2Ease of manufacture
If traditional calibration methods are used for dampers, then manufacturing processes remain simple, but measurement precision deteriorates due to wheel hop, tramp, and non-symmetric damper splay
Solution Approach 1:
The patent performs preliminary software configuration and look-up table generation during the manufacturing phase. The controller is pre-programmed with the mathematical relationships and calibration data needed to accurately calculate damper velocity, allowing the physical suspension components to remain simple while ensuring measurement precision is achieved through software preparation
Solution Approach 2:
The patent changes the approach from mechanical calibration to software-based parameter calculation. By using mathematical differentiation and pre-configured look-up tables that account for wheel hop, tramp, and non-symmetric splay, the system achieves accurate velocity measurement without modifying physical calibration procedures
3Ease of manufacture
If existing distance sensors are used without modification, then ease of manufacture is maintained, but measurement precision of damper velocity deteriorates due to inability to directly measure velocity
Solution Approach 1:
The patent replaces direct mechanical velocity measurement with software-based differentiation of position data. The controller calculates velocity by differentiating damper position with respect to time, transforming existing distance sensor data into accurate velocity information without adding or modifying physical sensors
Solution Approach 2:
The patent introduces software calculation as an intermediary between position measurement and velocity determination. The controller acts as a mediator that transforms position data from distance sensors into velocity information through mathematical operations, bridging the gap without requiring direct velocity sensing
Data Source
AI summary
A system for determining a damper velocity in solid axle suspension for a vehicle includes a solid axle, a pair of dampers corresponding to a left wheel and a right wheel of the vehicle, and a pair of distance sensors. The pair of distance sensors each generate sensor signals that are indicative of respective distances between respective portions of the frame of the vehicle and the solid axle. The system also includes one or more controllers in electronic communication with the pair of distance sensors. The one or more controllers access a pair of three-dimensional look-up tables that each correspond to one of the dampers of the pair of dampers, wherein each three-dimensional look-up table defines a relationship between the respective distances measured by the pair of distance sensors and the respective damper length of each damper.