Patent Publication Number: US-2023147844-A1

Title: Modular and Expandable Air Management System

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional No. 63,277,526, filed Nov. 9, 2021, the contents of which are incorporated by reference into this utility patent application. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to automotive products, and more specifically to air suspension control systems. 
     BACKGROUND 
     Air suspension systems for vehicles such as cars and trucks are known. Such systems utilize pressurized suspension units to provide suspension forces and often provide for increases or decreases in the air pressure (“air” as used herein includes other compressible gasses) to adjust the height, load capacity or other characteristic of the suspension. Problems arise in known systems when a user wishes to adjust the suspension characteristics of a vehicle, as when a vehicle’s weight or distribution of weight changes, given that adjustment of one suspension unit may affect all other suspension units. Further, installation of additional suspension systems requires coordination with existing units, which is complicated or even not possible with existing systems. 
     Thus, there is a need for an air suspension system that is easily adapted to changes in system configuration and provides distributed data processing from all individual suspension units for system-wide input to electronic control of all suspension units. 
     SUMMARY OF THE INVENTION 
     In accordance with the invention a suspension control system uses one or more individual pneumatic control modules to control one or more selected characteristics of the suspension units of a vehicle. Each individual pneumatic control module has an input control valve and an exhaust control valve, which are preferably electronically controllable, to increase or decrease the pressure in a suspension unit. An increase or decrease in the pressure of a suspension unit may, for example, change the load characteristic of the unit or the height of the unit. 
     The suspension control unit of the invention has a suspension control module that supports a programmable electronic circuit, which can be on a printed circuit board, and electrical connectors for connecting to a harness or other conductor carrying input information regarding selected characteristics of a suspension unit and generating output information to one or more pneumatic control modules to adjust one or more characteristics of a suspension unit to balance all of the suspension units in accordance with a set of algorithms. 
     A suspension control unit of the invention may have an end cap that engages and secures one end of a protective cover of the suspension control unit, provides a hand grip for manipulating the unit, or mounting features for use in securing the unit to a vehicle. 
     In the preferred embodiment, a suspension control unit requires a single suspension control module, a single end cap, and one or more pneumatic control modules. The number of pneumatic control modules depends on the number of suspension units in the particular vehicle. In some cases, one pneumatic control unit may control multiple suspension units. 
     The design of the invention allows for essentially any number of pneumatic control modules to be mounted in serial fashion between a suspension control unit at one end and an end cap at the opposite end. The system is, thus, field expandable to accommodate different air suspension configurations. Each pneumatic control module has a suspension unit pressure sensor, an electrical input for an external suspension unit height sensor, electronically controlled input and exhaust valves, and an electrical connector to communicate with the suspension control unit. This allows the system to adjust the suspension units based on selected characteristics such as suspension unit (or “air spring”) pressure or height depending on user preferred configurations. 
     The suspension control system of the invention is also wireless enabled (e.g., Bluetooth) to provide the system wireless connectivity to smartphone apps and other wireless devices for user interface during operation or adjustment of the system or firmware updating, and the like. 
     A preferred embodiment of the invention is a Bluetooth-enabled, air suspension control system comprising a suspension control module, one or more pneumatic control modules, and an end cap, which can be used in a variety of applications with different arrangements of air springs, such as 1-corner, 2-corner, 3-corner, or 4-corner suspension systems. The invention is modular and expandable, such that it can accommodate different air-suspension configurations and different data sensing options. Providing each pneumatic control module with integrated, electronic air-spring pressure and height sensors enables the system to be programmed to adjust the vehicle based on air-spring pressure or on air-spring height, depending on the customer’s choice. The control system may use smartphone applications or dedicated wireless devices for user interface and updating of system firmware. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG.  1   a    is perspective view of an assembled system according to the invention. 
         FIG.  1   b    is an exploded view of the system of  FIG.  1   a   . 
         FIG.  2    is a longitudinal cross section of the system shown in  FIG.  1   a   . 
         FIG.  3    is an exploded view of the components of one pneumatic control module shown in  FIG.  1   b   . 
         FIG.  4    is a transverse cross section of a pneumatic control module shown in  FIG.  1   b   . 
         FIG.  5   a    is a perspective of top of a printed circuit board shown in  FIG.  3   . 
         FIG.  5   b    is a perspective of the bottom of the printed circuit board shown in  FIG.  5   a   . 
         FIG.  6    is an exploded perspective of a suspension control module of the system shown in  FIG.  1   . 
         FIG.  7   a    is a perspective of a front side of a printed circuit board shown in  FIG.  6   . 
         FIG.  7   b    is a perspective of a rear side of the printed circuit board shown in  FIG.  7   a   . 
     
    
    
     DETAILED DESCRIPTION OF THE FIGURES 
       FIG.  1   a    shows a suspension control system  1  according to the invention completely assembled. System  1  is designed to be connected to and control four known air-suspension units that are mounted to a vehicle in a known manner; neither the vehicle nor an air-suspension unit is illustrated in these drawings. Suspension control system  1  as shown in  FIGS.  1   a  and  1   b    has four pneumatic control units  3  (also referred to herein as modules). As will be explained in more detail below, air under pressure is introduced to the system  1  from a pump (not shown) at supply port  14 , and excess air is discharged at exhaust port  15 . 
       FIG.  2    illustrates the serial connection of four pneumatic control modules  3 , as illustrated in  FIG.  1   a   . Screws  12  are shown holding each pair of modules  3  together, but other means, such as clamps or adhesives may be employed. Pressure sensors  10  and their associated internal channels are also seen in this figure. 
       FIG.  3    is an exploded perspective of a single pneumatic control unit  3 . Control unit  3  includes two pneumatic solenoid valve armatures  17 , each of which is electrically controlled by a respective solenoid coil and yoke assembly  16 . The pneumatic solenoid valve armatures  17  are mounted on a pneumatic control manifold  19  by screws  8 . Manifold  19  includes internal channels to connect pneumatic fitting  21 , selectively, to supply port  14  and exhaust port  15 . Pneumatic fitting  21  is in turn connected to an air-spring suspension unit on a vehicle. A printed circuit board  18  is mounted to the manifold  19  with screws  9  between the pneumatic solenoid valve armatures and the manifold. 
       FIG.  4    is a transverse cross section of a module  3 . 
     The printed circuit board  18  is shown in more detail in  FIGS.  5   a  and  5   b   . Board  18  gathers data from its pressure and height sensors and communicates these signals to the suspension control module. In turn, the suspension control module calculates the current versus desired state of the air spring suspension based on conditions and user input and commands board  18  to control the operation of the solenoids  16  resulting in a change in pressure and height of the air spring. Thus, a pneumatic solenoid valve armature  17  that controls air flow between supply port  14  and pneumatic fitting  21  can be opened by activation of the coil and yoke assembly  16  that controls that armature to increase the pressure in an air-spring suspension. Conversely the pneumatic solenoid valve armature  17  controlling air flow between the exhaust port  15  and pneumatic fitting  21  can be opened by activation of the other coil and yoke assembly  16  to reduce the pressure in the air-spring suspension. 
     Board  18  includes air-spring suspension pressure sensor  10  which communicates with the pneumatic fitting  21  to provide electronic data to microprocessor  21  of the pressure in the air-spring suspension. Electrical interconnectors  22  provide electrical connection between one or more other pneumatic control modules  3  and the suspension control module. 
     Referring to  FIG.  3   , a pneumatic control module  3  further includes a cover  5 , which is attached to the manifold by screws  7  at holes  6  to render the module weatherproof. Also, as shown in  FIG.  3   , the supply port  14  and exhaust port  15  have nipples that allow these ports to connect with an adjacent manifold or module, and interconnect seals  13  are provided to prevent leakage. A height sensor, not shown, is provided to sense the height of the air-spring suspension and can be physical or otherwise. The height sensor provides electronic data regarding height, the data being supplied to board  18  by a connector  11 . 
       FIG.  6    is an exploded view of a suspension control module  2 . This module includes a manifold  28  with pneumatic inlet through hole  37  and exhaust through hole  38 , which connect with inlet  14  and exhaust  15 , respectively, of an adjacent pneumatic control module. Projections  39  ensure alignment with an adjacent module  3 . A weather sealed housing  27  is secured to the manifold  28  by screws  29 . A printed circuit board  31  is carried in the housing  27 , the board  31  having a supply pressure sensor  36 , which communicates with air channel  36 ′, and an electrical connector  35  to receive electronic data from the pneumatic control units, and send commands to the pneumatic control units in order to cause increased or decreased pressure in the air-spring suspension units. A cover  32  encloses the housing by screws  33  and provides opening  34  for the connector  35 . 
       FIGS.  7   a  and  7   b    show the front and back of the board  31 . The board  31  includes wireless (e.g., Bluetooth) module  40 , microprocessor  41 , voltage regulator  42 , driver  43 , and electronic filters  44 . 
     It will be appreciated that a system as described above provides one or more of the following advantages: 
     The modularity and expansion capability of the invention allows the suspension control module, any number of pneumatic control modules, and an end cap to be used in a variety of applications having different numbers of air-spring suspension units. For example, several common uses are: 
     Two rear air-spring suspension units can be operated in unison by using a tee to divide a single pressure supply between left and right air-spring units. This arrangement works well if there is no offset load or tall center of mass that will allow too much sway around corners. Such a use would require only a single pneumatic control unit along with a suspension control module and an end cap and is often termed a “1-corner system”. 
     Two rear air-spring suspension units can be operated independently in order to balance an offset load or prevent sway around corners. This use would require two pneumatic control modules, in addition to a suspension control module and an end cap. This arrangement is often termed a “2-corner system.” 
     A system having four air-spring suspension units can place two units at the left and right sides of a vehicle and two air-spring suspension system toward the rear left and right sides of the vehicle. The two rear two air-spring suspension units may be connected by a tee to a common source of air from a single pneumatic control module, while the front two units are individually controlled, respectively by two pneumatic control units. This arrangement requires three pneumatic control units, as well as a suspension control module and an end cap and is often termed a “3-corner system”. 
     A system having four air-spring suspension units as described above may use separate air sources for each of the four air-spring suspension units. This arrangement would require four pneumatic control modules, a suspension control module, and an end cap. Such a system is often termed a “four-corner system”. 
     Trucks, buses, or military vehicles with air suspension and more than 2-axles, or any towing vehicle with air suspension that pulls a trailer that also has air suspension could utilize more than 4 pneumatic control modules, a suspension control unit, and an end cap. 
     Field Expandable - The simple mechanical interconnect solutions allow simple field upgradability or service of a single pneumatic control module in the case of a failure. 
     Multiple Sensing Options - Each pneumatic control module has an integrated air-spring pressure sensor and an electrical plug to connect with an electronic height sensor. This capability allows the system to level a vehicle based on air spring pressure or air spring height depending on the customer use case. 
     Bluetooth Enabled SCM - The Bluetooth Low Energy (BLE) module located inside of the SCM gives the system wireless connectivity, for example, to smartphone apps and dedicated BLE devices for user interface. This communication gateway also allows for Over the Air (OTA) updating of the firmware inside of the suspension control module and pneumatic control module(s) in order to bring enhanced features and functionality to the system over time. 
     Sleek and Compact - The industrial design with optional aluminum cover makes for a visually attractive solution for display in visual installations. The compact packaging design allows for minimal space consumption (approximately 3.3″× 3.0″× 8.0″ for the 4-Corner configuration).