Vehicle Suspension Setup Using Image-Based Sag Measurement

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Solution Overview

Problem

Existing vehicle suspension systems often have improper initial settings, such as suspension sag and rebound damping, which can lead to unstable riding experiences due to inadequate adjustment techniques for both front and rear suspensions.

Innovation Solution

A system utilizing sensors, a processor, and a user interface to analyze digital images of the suspension components, determine the o-ring location, and adjust settings based on load and position to achieve optimal suspension performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual suspension adjustment methods are used, then device complexity is reduced, but measurement precision and adjustment accuracy deteriorate

Engineering Contradiction:
Improvesuspension sag measurement accuracyVSAvoidsystem complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical measurement methods with an automated image processing system. A camera captures images of the suspension component, and computer vision algorithms automatically measure the sag distance by detecting the position of the o-ring indicator relative to reference marks. This substitution of mechanical measurement with optical-digital measurement significantly improves measurement precision while the modular software architecture keeps the added complexity manageable.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If automated image analysis is implemented, then measurement precision improves, but device complexity increases

Engineering Contradiction:
Improveo-ring position detection accuracyVSAvoidimage processing system complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses a camera to create a digital copy (image) of the physical suspension component and its indicator marks. This optical copy is then processed through image analysis algorithms to detect the o-ring position. By working with digital copies rather than direct physical measurement, the system achieves high precision while isolating the complexity into software processing rather than complex mechanical measurement devices.

Inventive Principle:
Principle #26Copying

3Reliability

If proper suspension setup procedures are followed, then reliability of riding experience improves, but loss of time increases

Engineering Contradiction:
Improveriding stabilityVSAvoidsetup time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The patent performs suspension setup procedures in advance, capturing images and calculating optimal sag settings before the vehicle is put into service. The system determines the correct o-ring position and provides adjustment recommendations proactively, so that when the vehicle is ready for use, the suspension is already properly configured. This preliminary action ensures reliability of the riding experience while the automated nature of the process minimizes the actual time required.

Inventive Principle:
Principle #10Preliminary action

4Measurement precision

If digital image processing is used, then measurement precision improves, but use of energy increases

Engineering Contradiction:
Improvesuspension parameter measurement accuracyVSAvoidprocessing energy consumption
Core Design Contradiction:
Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The patent applies image processing only to the specific region of interest - the suspension component with the o-ring indicator - rather than processing entire images or performing exhaustive analysis. The system crops and focuses computational resources on detecting the critical marks and measuring the sag distance, achieving high measurement precision while minimizing energy consumption by avoiding unnecessary processing of unrelated data.

Inventive Principle:
Principle #16Partial or excessive action

Data Source

PatentUS12539729B2Methods and apparatus for suspension set up
Publication Date: 2026.02.03 FOX FACTORY INC
  • US12539729B2 patent drawing
  • US12539729B2 patent drawing
  • US12539729B2 patent drawing

AI summary

A method and apparatus are disclosed that assist a user in performing proper setup of a vehicle suspension. A user may utilize a device equipped with an image sensor to assist the user in proper setup of a vehicle suspension. The device executes an application that prompts the user for input and instructs the user to perform a number of steps for adjusting the suspension components. In one embodiment, the application does not communicate with sensors on the vehicle. In another embodiment, the application may communicate with various sensors located on the vehicle to provide feedback to the device during the setup routine. In one embodiment, the device may analyze a digital image of a suspension component to provide feedback about a physical characteristic of the component.