Hydraulic Suspension Pump Torque Control Without Pressure Sensors
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Solution Overview
Problem
Existing suspension systems rely on pressure sensors for control, which are sensitive to noise and road inputs, leading to deteriorated comfort and performance.
Innovation Solution
A suspension system that controls damper forces using real-time vehicle data from onboard sensors to determine electric torque for the pump motor, eliminating the need for pressure measurements and reducing sensitivity to disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure sensors are used to control damper forces, then the suspension system can regulate damping, but the control becomes sensitive to noise and road inputs, deteriorating comfort and performance
Solution Approach 1:
The patent removes pressure sensors from the control system entirely. Instead of measuring pressure to control damper forces, the system uses a pump that directly generates the required damper force based on vehicle state data from other sensors (accelerometers, gyroscopes, etc.). This extraction of the problematic pressure sensing component eliminates the noise sensitivity while maintaining control capability.
Solution Approach 2:
The patent replaces the mechanical pressure sensing and feedback system with a direct force generation approach. The pump motor is controlled based on vehicle state measurements and desired damping characteristics, generating force directly without relying on pressure measurements. This substitution eliminates the mechanical pressure sensing chain that is vulnerable to noise.
2Productivity
If mechanical stabilizer bars are used to counteract roll moments, then cornering performance improves, but packaging constraints are violated and the system cannot be easily switched off
Solution Approach 1:
The patent replaces mechanical stabilizer bars with an electronically controlled hydraulic pump system. The pump can generate roll counteracting forces by applying different pressures to dampers on opposite sides of the vehicle. This substitution eliminates the need for physical stabilizer bars spanning the vehicle width, freeing up packaging space while maintaining or improving cornering performance through electronic control.
Solution Approach 2:
The patent implements a dynamic, electronically controllable suspension system where the pump can adjust damper forces in real-time based on vehicle state and driving conditions. Unlike fixed mechanical stabilizer bars, this system can be dynamically adjusted or switched off when not needed, providing adaptability while maintaining packaging flexibility.
3Adaptability or versatility
If one pump per damper configuration is used, then independent damper control is achieved, but system complexity and cost increase
Solution Approach 1:
The patent employs a single pump that serves multiple dampers, making the pump perform a universal function. The single pump can independently control multiple dampers by directing pressurized fluid to different damper circuits based on control valve positioning. This multi-functionality achieves independent damper control capability while reducing the number of pumps needed, thereby lowering system complexity and cost.
Solution Approach 2:
The patent introduces control valves as intermediaries between the single pump and multiple dampers. These valves act as mediators that direct the hydraulic fluid flow from the single pump to the appropriate dampers, enabling independent control of each damper without requiring separate pumps. This intermediary mechanism achieves versatility while maintaining system simplicity.
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
Improves comfort and performance by absorbing disturbances from road inputs without relying on pressure sensors, enhancing the control of roll and pitch moments.
Implementation Method 1
a pump motor connected to the pump and configured to operate the pump in either a first, forward direction or a second, reverse direction
Implementation Method 2
the pump can produce a pressure change in the damper(s)... The flow or the speed of the pump is controlled to generate a requested pressure which is translated to a force by the damper
Implementation Method 3
One drawback of suspension systems is that basic spring/damper arrangements will allow the vehicle to roll/lean right or left during cornering
Data Source
AI summary
A suspension system and method of controlling the same is provided. The suspension system includes a damper and a pump assembly fluidly connected with the damper, the pump assembly having a pump and a pump motor. The method includes: (i) monitoring real-time data reflecting at least one of a dynamic state of the vehicle and an input from a vehicle operator; (ii) calculating a damper force based on the real-time data, the damper force being a force to be output by the damper; (iii) determining a hydraulic torque to be output by the pump based on the calculated damper force; (iv) determining a current to be applied to the pump motor based on the determined hydraulic torque; (v) applying the determined current to the pump motor to operate the pump; and (vi) applying a force to the vehicle by the damper.