Suspension Lever Rotation Sensor Shielded From Dirt and Water
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Solution Overview
Problem
Existing vehicle suspension systems with integrated sensors are complex, expensive, and lack accuracy and reliability due to exposure to environmental influences like dirt and water, which affects the precision of measurements.
Innovation Solution
A vehicle suspension system incorporating a rotation sensor with rotatable first and second sensor portions, protected by a cylindrical design where one portion is a pin and the other a body with a hole, aligned symmetrically with the sensor rotation axis, minimizing gaps and exposure to contaminants, and potentially fixed to a U-shaped bracket for enhanced protection and calibration reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is integrated into the suspension system to monitor wheel position, then measurement capability is improved, but the sensor is exposed to environmental influences like dirt and water which worsens measurement precision and reliability
Solution Approach 1:
The patent employs a rotary encoder with a protected sensor housing that shields the measurement components from environmental contaminants. The encoder measures the rotary movement of the suspension lever while remaining enclosed, preventing direct exposure to dirt and water that would otherwise degrade measurement precision.
Solution Approach 2:
The patent introduces a magnetic coupling mechanism as an intermediary between the moving suspension lever and the stationary sensor. Magnets on the lever interact with Hall effect sensors through a non-magnetic barrier, allowing measurement of lever position without direct mechanical contact or exposure of the sensor to environmental factors.
2Measurement precision
If complex sensor assemblies are used to achieve accurate measurements, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the measurement function from complex multi-component sensor assemblies and implements it through a simplified rotary encoder or magnetic sensing system. The essential measurement capability is isolated into a single integrated unit that rotates with the suspension lever, eliminating the need for complex wiring and multiple sensors.
Solution Approach 2:
The rotary encoder serves multiple functions simultaneously: it measures the angular position of the suspension lever, provides electrical connection between moving and stationary parts, and shields internal components from environmental factors. This multi-functionality reduces the need for separate components and simplifies the overall assembly.
3Ease of manufacture
If sensors are exposed to the environment for direct measurement, then ease of installation is improved, but reliability of measurements deteriorates due to contamination
Solution Approach 1:
The patent merges the sensor housing with the suspension lever assembly, integrating the measurement device directly into the moving component. This unified design simplifies installation as a single assembly while the housing simultaneously protects the sensor from environmental contamination during operation.
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
The solution provides a robust, accurate, and reliable suspension system with minimized environmental interference, ensuring high reproducibility and reliability of measurement results without the need for extensive calibration.
Implementation Method 1
the sensor is a rotation sensor and wherein a first sensor portion of the sensor is fixedly connected to the vehicle body portion and a second sensor portion is fixedly connected to the first suspension lever, wherein the first and second sensor portions are rotatable with respect to each other about a sensor rotation axis, and wherein the rotation angle between the first and second sensor portions with respect to each other indicates a pivot angle of the first suspension lever
Data Source
AI summary
A vehicle suspension system including a vehicle body portion is provided herein. The vehicle suspension system further includes a first suspension lever which is pivotally mounted with respect to a first pivot axis on a first region of the vehicle body portion and pivotally connects a wheel hub or a steering knuckle to the vehicle body portion. The vehicle suspension system further includes a rotation sensor with a first sensor portion of the sensor is fixedly connected to the vehicle body portion and a second sensor portion is fixedly connected to the first suspension lever, where the first and second sensor portions are rotatable with respect to each other about a sensor rotation axis, and the rotation angle between the first and second sensor portions with respect to each other indicates a pivot angle of the first suspension lever.