Systems for hydraulic energy delivery

An exemplary energy delivery system includes a housing. The housing includes a linear motor including a translational member and an electromagnetic field generating member. Energization of the electromagnetic field generating member induces translation of the translational member along a longitudinal axis of the linear motor. The housing further includes a first cylinder including a first chamber and a movable first piston and a second cylinder including a second chamber and a movable second piston. The first and second cylinders are coupled in-line with the linear motor within the housing and translation of the translational member along the longitudinal axis translates the first piston within the first chamber in a first direction and translates the second piston within the second chamber in a second direction opposite the first direction.

INTRODUCTION

The present invention relates generally to the field of vehicles and, more specifically, to systems for hydraulic energy delivery using a linear electric motor and one or more directly coupled hydraulic cylinders.

Some vehicles are equipped with active or semi-active vehicle suspension systems that control the vertical movement of the vehicle body relative to the wheels with an onboard system of actuators configured to raise and lower the body independently at each wheel. Typically, these suspension systems utilize electrically-driven pumps and delivery systems that are speed and/or force limited.

SUMMARY

Embodiments according to the present disclosure provide a number of advantages. For example, embodiments according to the present disclosure enable active control of a system, such as a suspension system, using one or more hydraulic cylinders driven by an electric linear motor. Directly coupling one or more hydraulic cylinders to a linear electric motor enables force delivery on demand, which is used, in some embodiments, in active suspension control.

In one aspect, an energy delivery system includes a housing. The housing encloses a linear motor including a translational member and an electromagnetic field generating member, and energization of the electromagnetic field generating member induces translation of the translational member along a longitudinal axis of the linear motor; a first hydraulic cylinder including a first chamber and a movable first piston, the first chamber enclosing a hydraulic fluid; and a second hydraulic cylinder including a second chamber and a movable second piston, the second chamber enclosing a hydraulic fluid. The first and second hydraulic cylinders are coupled in-line with the linear motor within the housing and translation of the translational member along the longitudinal axis translates the first piston within the first chamber in a first direction and translates the second piston within the second chamber in a second direction such that the first and second pistons act on the hydraulic fluid enclosed within the first and second hydraulic cylinders to change an amount of hydraulic fluid contained in each of the first and second hydraulic cylinders.

In some aspects, the energy delivery system includes a controller.

In some aspects, the controller generates a control signal indicative of an adjustment of a position of the translational member such that the position adjustment adjusts a suspension dynamics setting of a vehicle.

In some aspects, the first hydraulic cylinder is coupled to a first suspension component of a vehicle and the second hydraulic cylinder is coupled to a second suspension component of a vehicle.

In some aspects, the first and second pistons are integral with the translational member of the linear motor.

In some aspects, the second direction is opposite the first direction such that a volume of the first chamber increases when a volume of the second chamber decreases.

In another aspect, an automotive vehicle includes a suspension system including an adjustable suspension component, an energy delivery system coupled to the adjustable suspension component, and a controller. The energy delivery system includes a housing, the housing including a linear motor including a translational member and an electromagnetic field generating member, wherein energization of the electromagnetic field generating member induces translation of the translational member along a longitudinal axis of the linear motor; a first cylinder including a first chamber and a movable first piston; and a second cylinder including a second chamber and a movable second piston. The controller is in electronic communication with the energy delivery system. The first and second cylinders are coupled in-line with the linear motor within the housing and translation of the translational member along the longitudinal axis translates the first piston within the first chamber in a first direction and translates the second piston within the second chamber in a second direction such that the adjustable suspension component is adjusted from a first position to a second position.

In some aspects, the first chamber encloses a hydraulic fluid and the second chamber encloses a compressible member.

In some aspects, the compressible member is a spring coupled on one end to the second piston.

In some aspects, each of the first and second chambers encloses a hydraulic fluid.

In some aspects, the controller is in electronic communication with the linear motor and transmits a control signal to the linear motor to adjust a position of the translational member.

In some aspects, the control signal indicates a change in a selective energization of the electromagnetic field generating member.

In yet another aspect, an energy delivery system includes a housing, the housing including a linear motor including a translational member and an electromagnetic field generating member, wherein energization of the electromagnetic field generating member induces translation of the translational member along a longitudinal axis of the linear motor; a first cylinder including a first chamber and a movable first piston, the first chamber enclosing a hydraulic fluid; and a second cylinder including a second chamber and a movable second piston. The first and second cylinders are coupled in-line with the linear motor within the housing and translation of the translational member along the longitudinal axis translates the first piston within the first chamber in a first direction and translates the second piston within the second chamber in a second direction such that the first and second pistons act on the hydraulic fluid enclosed within the first cylinder to change an amount of hydraulic fluid contained in the first cylinder.

In some aspects, the first and second pistons are integral with the translational member of the linear motor.

In some aspects, the second direction is opposite the first direction such that a volume of the first chamber increases when a volume of the second chamber decreases.

In some aspects, the first chamber encloses a hydraulic fluid and the second chamber encloses a compressible member.

In some aspects, the compressible member is a spring coupled on one end to the second piston.

In some aspects, the energy delivery system includes a controller.

In some aspects, the controller generates a control signal indicative of an adjustment of a position of the translational member such that the position adjustment adjusts a suspension dynamics setting of a vehicle.

In some aspects, the first cylinder is coupled to a first suspension component of a vehicle and the second cylinder is coupled to a second suspension component of a vehicle.

The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through the use of the accompanying drawings. Any dimensions disclosed in the drawings or elsewhere herein are for the purpose of illustration only.

DETAILED DESCRIPTION

FIG. 1schematically illustrates an automotive vehicle10according to the present disclosure. The vehicle10generally includes a body11and wheels15. The body11encloses the other components of the vehicle10. The wheels15are each rotationally coupled to the body11near a respective corner of the body11. The vehicle10is depicted in the illustrated embodiment as a passenger car, but it should be appreciated that any other vehicle, including motorcycles, trucks, sport utility vehicles (SUVs), or recreational vehicles (RVs), etc., can also be used.

The vehicle10includes a propulsion system13, which may in various embodiments include an internal combustion engine, an electric machine such as a traction motor, and/or a fuel cell propulsion system. The vehicle10also includes a transmission14configured to transmit power from the propulsion system13to the plurality of vehicle wheels15according to selectable speed ratios. According to various embodiments, the transmission14may include a step-ratio automatic transmission, a continuously-variable transmission, or other appropriate transmission. The vehicle10additionally includes wheel brakes (not shown) configured to provide braking torque to the vehicle wheels15. The wheel brakes may, in various embodiments, include friction brakes, a regenerative braking system such as an electric machine, and/or other appropriate braking systems. The vehicle10additionally includes a steering system16. While depicted as including a steering wheel and steering column for illustrative purposes, in some embodiments, the steering system16may not include a steering wheel.

The vehicle10also includes a suspension system18. The suspension system18includes a plurality of suspension components including, for example and without limitation, dampers, shock absorbers, sway bar linkages, etc. that may be mounted adjacent to the wheels15. In some embodiments, the suspension system18is an active or semi-active suspension system. An active suspension is a type of automotive suspension that controls the vertical movement of the wheel relative to the chassis or vehicle body with an onboard system. Active or semi-active suspension systems can vary shock absorber firmness to match changing road or dynamic conditions or use an actuator to raise and lower the chassis independently at each wheel. In some embodiments, the suspension system18includes one or more suspension components, such as the suspension components28. In some embodiments, as shown inFIG. 1, a suspension component28is positioned adjacent to each of the wheels15. In some embodiments, the suspension component28is a vehicle damper. In some embodiments, the vehicle10includes other actively-controlled suspension components, such as a sway bar linkage, etc., for example and without limitation.

With further reference toFIG. 1, the vehicle10also includes a plurality of sensors26configured to measure and capture data on one or more vehicle characteristics, including but not limited to vehicle speed, vehicle heading, and suspension displacement. In the illustrated embodiment, the sensors26include, but are not limited to, an accelerometer, a speed sensor, a heading sensor, gyroscope, steering angle sensor, or other sensors that sense observable conditions of the vehicle or the environment surrounding the vehicle and may include RADAR, LIDAR, optical cameras, thermal cameras, ultrasonic sensors, infrared sensors, light level detection sensors, and/or additional sensors as appropriate. In some embodiments, the vehicle10also includes a plurality of actuators30configured to receive control commands to control steering, shifting, throttle, braking, suspension dynamics, or other aspects of the vehicle10.

The vehicle10includes at least one controller22. While depicted as a single unit for illustrative purposes, the controller22may additionally include one or more other controllers, collectively referred to as a “controller.” The controller22may include a microprocessor or central processing unit (CPU) or graphical processing unit (GPU) in communication with various types of computer readable storage devices or media. Computer readable storage devices or media may include volatile and nonvolatile storage in read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM), for example. KAM is a persistent or non-volatile memory that may be used to store various operating variables while the CPU is powered down. Computer-readable storage devices or media may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMs (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used by the controller22in controlling the vehicle.

Typically, adjustments to active suspension system components, such as the components28, are enabled by electrically-driven pumps and delivery systems that are speed and/or force limited. The systems discussed herein allow efficient fluid volume and/or force delivery to active suspension system components using linear motors coupled with one or more hydraulic drive cylinders.

FIG. 2is a schematic illustration of an energy delivery system150, according to an embodiment. In some embodiments, the energy delivery system150is integrated with or physically and/or electronically connected to the suspension system18of the vehicle10. The energy delivery system150includes a housing151. The housing151encloses a linear motor152and first and second hydraulic cylinders162,164.

As is known to those skilled in the art, the linear motor152is a linear induction motor. The linear motor152includes electromagnets153surrounding a translational member154. Translational motion of the translational member154is driven by changes to an electromagnetic field generated by the electromagnets153that encircle the translational member154. Selective energization of the electromagnets153generates a direct translational movement of the translational member154that can be used to provide a discrete and precise adjustment to the position of one or more pistons within one or more directly-mounted, inline hydraulic cylinders, for example and without limitation.

In the embodiment shown inFIG. 2, the linear motor152is longitudinally positioned between two hydraulic cylinders162,164. A longitudinal axis of each of the hydraulic cylinders162,164is aligned with the longitudinal axis of the linear motor152. Each of the hydraulic cylinders162,164includes a cylinder chamber163,165. The cylinder chambers163,165each enclose hydraulic fluid. Activation of the linear motor152causes the translational member154to act as a piston on the hydraulic fluid enclosed within the chambers163,165. Piston faces166,168are integral with or coupled to the translational member154. The piston faces166,168travel longitudinally within the chambers163,165to displace the hydraulic fluid enclosed within. A sealing member155separates the two chambers163,165of the hydraulic cylinders192,194.

Hydraulic lines172,174connect the chambers163,165with hydraulic chambers of the components28. The components28are part of the suspension system18of the vehicle10. In some embodiments, a hydraulic line176and an accumulator178connect the chambers163,165to provide load balance to the energy delivery system150. In some embodiments, one or more valves179assist to regulate the flow between the chambers163,165and bleed the system150of air.

The energy delivery system150is in electrical communication with a controller, such as the controller22. In some embodiments, as shown inFIG. 2, the energy delivery system150is used to provide active roll control for a vehicle suspension system, such as the suspension system18of the vehicle10. In some embodiments, the linear motor152receives a control signal from the controller22. The control signal represents a desired change in an active suspension setting, such as active roll control, and selectively energizes the electromagnets153to move translational member154in the desired direction(s) to adjust a suspension dynamics setting of each of the components28.

The translational member154travels longitudinally either left or right (as viewed inFIG. 2) in response to the control signal received from the controller22. As the translational member154travels from left to right, the volume of the chamber165is decreased and the volume of the chamber163is increased. Hydraulic fluid in the chamber165is transferred to the component28via the hydraulic line174and simultaneously hydraulic fluid is drawn from the other component28to adjust a suspension dynamics setting of the components28. Similarly, as the translational member154the linear motor152travels from right to left, the volume of the chamber163is decreased and the volume of the chamber165is increased. Hydraulic fluid in the chamber163is transferred to the component28via the hydraulic line172while the increased volume of the chamber165draws hydraulic fluid from the other component28. As a result of the linear translation of the linear motor152, adjustment of both of the components28is affected to provide active roll control of the vehicle10.

FIG. 3illustrates an energy delivery system150′, according to an embodiment. In some embodiments, the energy delivery system150′ is part of the suspension system18of the vehicle10. The energy delivery system150′ includes a housing151. The housing151encloses a linear motor152, a hydraulic cylinder162′, and a mechanical cylinder164′.

In the embodiment shown inFIG. 3, the linear motor152is longitudinally positioned between the hydraulic cylinder162′ and the mechanical cylinder164′. The hydraulic cylinder162′ includes a chamber163′ and the mechanical cylinder164′ includes a chamber165′. The cylinder chamber163′ encloses hydraulic fluid. The chamber165′ encloses a compressive member or fluid that provides energy balance to the system150. In one embodiment, the chamber165′ encloses a compressive member169. In some embodiments, the compressive member169is a spring, for example and without limitation. In other embodiments, the chamber165′ encloses air or any other compressible fluid that exerts a force against the piston face168′ to balance the force exerted by the hydraulic fluid on the piston face166′. Piston faces166′,168′ travel longitudinally within the chambers163,165to displace the hydraulic fluid enclosed within the chamber163′ and exert either a compressive or tensile force on the compressive member or fluid within the chamber165′. A sealing member155separates the two chambers163′,165′.

Hydraulic lines172′,174′ connect the chamber163′ with the hydraulic chambers of the components28. The components28are part of the suspension system18of the vehicle10. In some embodiments, the components28are vehicle dampers or any other suspension component that assists to adjust a ride height of the vehicle10.

The energy delivery system150′ is in electrical communication with a controller, such as the controller22. In some embodiments, as shown inFIG. 3, the energy delivery system150′ is used to provide ride height control for a vehicle suspension system, such as the suspension system18of the vehicle10. In some embodiments, the linear motor152receives a control signal from the controller22. The control signal represents a desired change in an active suspension setting, such as a ride height adjustment.

The linear motor152travels longitudinally either left or right (as viewed inFIG. 3) in response to the control signal received from the controller22. As the translational member154of the linear motor152travels from left to right, the volume of the chamber165′ is decreased and the volume of the chamber163′ is increased. As the compressive member169compresses in response to the force applied by the linear motor152, hydraulic fluid is redistributed in the chamber163′ and the components28via the lines172′,174′ to adjust a vehicle ride height. Similarly, as the translational member154of the linear motor152travels from right to left, the volume of the chamber163′ is decreased and the volume of the chamber165′ is increased. Hydraulic fluid in the chamber163′ is transferred to the components28via the hydraulic lines172′,174′. As a result of the linear translation of the linear motor152, adjustment of both of the components28is affected to provide active roll control of the vehicle10.

WhileFIGS. 2 and 3illustrate two configurations of a linear motor coupled to one or more hydraulic cylinders. However, other configurations, such as the placement and orientation of the hydraulic cylinder(s) and/or a compressive member are contemplated as within the scope of the embodiments discussed herein. Additionally, while discussed in the context of an active suspension system, the energy delivery system may be used for any application in which discrete adjustment of one or more components is desired.

It should be emphasized that many variations and modifications may be made to the herein-described embodiments, the elements of which are to be understood as being among other acceptable examples. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims. Moreover, any of the steps described herein can be performed simultaneously or in an order different from the steps as ordered herein. Moreover, as should be apparent, the features and attributes of the specific embodiments disclosed herein may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure.

Numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also interpreted to include all of the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 1 to 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but should also be interpreted to also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3 and 4 and sub-ranges such as “about 1 to about 3,” “about 2 to about 4” and “about 3 to about 5,” “1 to 3,” “2 to 4,” “3 to 5,” etc. This same principle applies to ranges reciting only one numerical value (e.g., “greater than about 1” and should apply regardless of the breadth of the range or the characteristics being described. A plurality of items may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary. Furthermore, where the terms “and” and “or” are used in conjunction with a list of items, they are to be interpreted broadly, in that any one or more of the listed items may be used alone or in combination with other listed items. The term “alternatively” refers to selection of one of two or more alternatives, and is not intended to limit the selection to only those listed alternatives or to only one of the listed alternatives at a time, unless the context clearly indicates otherwise.