Suspension Locking Structure for Actuator Energy Reduction

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Solution Overview

Problem

Active suspension systems face challenges in maintaining prolonged compression of suspension springs due to power usage and heat generation by actuators, making it inefficient for operations like lowering the vehicle for passenger ingress or egress.

Innovation Solution

Incorporating locking structures within the suspension components that engage with the actuator to restrain motion and maintain compression when electrical power is discontinued, utilizing screw actuators and linear output actuators with various locking mechanisms such as pins, pawls, and collars to lock the rotatable or translatable components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If continuous operation of the active suspension actuator is used to maintain ride height, then the suspension spring compression can be maintained, but power consumption increases and heat is generated

Engineering Contradiction:

Improvesuspension spring compression maintenanceVSAvoidactuator power consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The system dynamically switches between active actuator operation and passive locking mode. The actuator operates continuously only when height adjustment is needed, then transitions to a locked position where the locking structure maintains suspension compression without requiring continuous power, thus resolving the contradiction between reliable compression maintenance and energy consumption

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent replaces continuous electromagnetic actuation with a mechanical locking structure. The locking structure uses mechanical engagement (teeth, pins, or clamps) to maintain suspension spring compression without requiring continuous electrical power, substituting an energy-consuming electromagnetic system with a passive mechanical system for height maintenance

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If continuous operation of the active suspension actuator is used to maintain ride height, then the suspension spring compression can be maintained, but heat generation increases

Engineering Contradiction:

Improvesuspension spring compression maintenanceVSAvoidactuator heat generation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The system dynamically transitions from continuous actuator operation to a static locked state. Once the desired height is achieved, the actuator stops moving and the locking structure takes over, eliminating continuous heat generation while maintaining the suspension compression, thus resolving the contradiction between reliable compression maintenance and heat generation

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent substitutes the heat-generating electromagnetic actuator with a passive mechanical locking structure for maintaining height. The locking structure maintains suspension spring compression through mechanical engagement without generating heat, resolving the contradiction between reliable compression maintenance and heat generation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If the locking structure engages the rotatable component, then motion is restrained and compression is maintained, but device complexity increases

Engineering Contradiction:

Improvesuspension compression maintenance without powerVSAvoidlocking structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The locking structure is segmented into distinct functional components (locking elements, engagement features, actuation mechanisms) that can be independently designed and optimized. This segmentation allows for simpler individual components that work together to achieve reliable compression maintenance, reducing overall complexity while maintaining functionality

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The locking structure is designed to be self-actuating or automatically engage/disengage based on system state. The locking elements automatically engage when the actuator reaches its target position and automatically disengage when height adjustment is needed, eliminating the need for complex control systems and reducing overall device complexity while maintaining reliable compression maintenance

Inventive Principle:

Principle #25Self-service

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 the maintenance of suspension spring compression without continuous power consumption, reducing energy usage and heat generation, allowing for efficient lowering and raising of vehicles while minimizing actuator load, thereby enhancing operational efficiency and safety.

Implementation Method 1

a stator that is operable to rotate the stator as a result of electromagnetic interaction between the stator and the rotor

Methodology Applied

Scientific EffectElectromagnetic interaction: Electromagnetic Induction

Data Source

PatentUS11173766B1Suspension system with locking structure

Publication Date: 2021.11.16 APPLE INC

AI summary

A suspension component includes a suspension spring, a screw actuator that is operable to compress and decompress the suspension spring upon supply of electrical power to the screw actuator, and locking structure that engages a portion of the screw actuator to restrain motion of the screw actuator to maintain a current degree of compression of the suspension spring.