Patent Publication Number: US-2023158850-A1

Title: Integrated Shock and Suspension Height Sensor

Description:
TECHNICAL FIELD 
     Example embodiments generally relate to vehicle suspension and, more particularly, relate to a suspension system with an integrated shock and suspension height sensor. 
     BACKGROUND 
     Vehicles commonly employ independent suspension that allows each wheel to move relative to the vehicle chassis independent of the other wheels. The components and geometries used for independent suspension designs can vary to some degree. However, a typical independent suspension system will employ dampers or shock absorbers (or simply “shocks”) that are designed to provide damping for pitch (i.e., oscillation about a lateral axis of the vehicle). The shocks generally resist compression and rebound with damping forces that are applied over a range of travel of a piston rod. 
     The shocks selected for a particular vehicle are generally chosen based on the expectation of normal pitch scenarios that are encountered during routine driving conditions. Some typical suspension components that may be considered for selection include springs and dampers (e.g., gas shocks). Moreover, some shocks employ what is referred to as a coil-over design in which a coil spring is provided coaxial with the damper such that the damper is inside the coil spring. Regardless of the specific type of shock, some shock designs include a form of dust gaiter or bellows that is used to prevent dust, dirt or debris from fouling the interface between the rod and the damper tube of the damper or shock. In a typical situation, a bumper cap may also be used to prevent debris from entering the damper tube. These components typically move relative to each other and, in the past, certain designs have been implemented to utilize such components for measuring damper position. However, such designs have typically included many magnets displayed in a linear array that increases complexity of the componentry involved. 
     BRIEF SUMMARY OF SOME EXAMPLES 
     In accordance with an example embodiment, a shock absorber for a vehicle suspension system may be provided. The shock absorber may include a damper tube defining an axis, a rod operably coupled to the damper tube to be movable along the axis relative to the damper tube in response to jounce and rebound events, a dust boot operably coupled to the rod and extending along peripheral sides of the rod and at least a proximal end of the damper tube relative to the rod, the dust boot being movable with the rod, a target disposed on a damper bump cap operably coupled to the proximal end of the damper tube, and a measurement assembly affixed to the dust boot. The measurement assembly may include a PCB elongated parallel to the axis to track relative movement between the target and the measurement assembly responsive to the jounce and rebound events to generate ride height information based on the relative movement. 
     In yet another example embodiment, a suspension system for a vehicle may be provided. The suspension system may include a chassis, a wheel, and a shock absorber operably coupling the chassis and the wheel. The shock absorber may include a damper tube operably coupled to the wheel and defining an axis, a rod operably coupled to the chassis and the damper tube to be movable along the axis relative to the damper tube in response to jounce and rebound events, a dust boot operably coupled to the rod and extending along peripheral sides of the rod and at least a proximal end of the damper tube relative to the rod, the dust boot being movable with the rod, a target disposed on a damper bump cap operably coupled to the proximal end of the damper tube, and a measurement assembly affixed to the dust boot. The measurement assembly may include a PCB elongated parallel to the axis to track relative movement between the target and the measurement assembly responsive to the jounce and rebound events to generate ride height information based on the relative movement. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
       Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
         FIG.  1    illustrates a block diagram of a portion of a vehicle suspension system in accordance with an example embodiment; 
         FIG.  2    illustrates a perspective view of a shock absorber assembly in accordance with an example embodiment; 
         FIG.  3    is a partially exploded view of the shock absorber assembly of  FIG.  2    with a dust boot removed to expose components otherwise covered by the dust boot in accordance with an example embodiment; 
         FIG.  4    is an isolated perspective view of a measurement assembly in accordance with an example embodiment; 
         FIG.  5    illustrates a perspective view of an elongated printed circuit board (PCB) for measuring ride height in accordance with an example embodiment; 
         FIG.  6    shows a perspective view of a bump cap in accordance with an example embodiment; and 
         FIG.  7    is a cross section view of a portion of the shock absorber assembly in accordance with an example embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Some example embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all example embodiments are shown. Indeed, the examples described and pictured herein should not be construed as being limiting as to the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout. Furthermore, as used herein, the term “or” is to be interpreted as a logical operator that results in true whenever one or more of its operands are true. As used herein, operable coupling should be understood to relate to direct or indirect connection that, in either case, enables functional interconnection of components that are operably coupled to each other. 
     Some example embodiments described herein may address the problems described above. In this regard, for example, some embodiments may provide an improved shock or suspension system design that employs position sensors that are configured to measure ride height into existing components. In this regard, for example, some embodiments may provide for a target that may be installed on a first suspension component (e.g., a damper bumper cap (or bump cap)), and a measurement assembly (e.g., in the form of an elongated printed circuit board (PCB) with wiring assemblys thereon) that is provided on another suspension component that moves in a linear fashion (e.g., a dust boot, or dust gaiter). As a result, movement of the first and second suspension components relative to each other may be measured and converted into information on ride height based on such movement to effectively instantiate an integrated ride height sensor that is relatively simple in construction, but also accurate in operation. 
       FIG.  1    illustrates a block diagram of a vehicle suspension system  100  employing a damper  110 . The suspension system  100  employs the damper  110  to dampen jounce and rebound forces that may be initiated between a body or chassis  120  of the vehicle and a wheel  130  (or wheel assembly components). In this regard, the damper  110  operably couples the chassis  120  to the wheel  130 . The damper  110  may include a strut module or damper tube  140  with a rod  142  that extends into the damper tube  140 . The damper tube  140  may be operably coupled to the wheel  130  via a first mechanical interface  144 . The rod  142  may be operably coupled to the body chassis  120  via a second mechanical interface  146 . The rod  142  may also be operably coupled to the damper tube  140  in such a way as to resist movement of the rod  142  via gas, fluid, springs, or other damping media that may be disposed within the damper tube  140 . In some cases, coil-over springs may be further added to enhance such resistance. 
     It may be desirable to prevent any dust or debris from getting into the interface between the rod  142  and the damper tube  140 . To provide a seal against such dust or debris, a damper bump cap  150  may be provided. In some cases, further assistance in prevention of the introduction of dust or debris may be provided by the provision of a dust boot (or dust gaiter or bellows)  160 . The dust boot  160  may be affixed to the damper tube  140  via the second mechanical interface  146  and extend to cover all exposed portions of the rod  142  and beyond the damper bump cap  150  alongside the damper tube  140 . 
     As the suspension system  100  encounters compression and extension due to jounce and rebound associated with traversing uneven surfaces, the rod  142  may be plunged further into the damper tube  140  and alternately extend farther out of the damper tube  140 , respectively, relative to the position shown in  FIG.  1   . Such movements will therefore carry the dust boot  160  down and up according to the alternate directions of double arrow  165 . By measuring such movement, it may be possible to determine ride height for the corresponding wheel or corner of a vehicle employing the suspension system  100 . 
     As noted above, some complicated designs are already in place to try to measure this movement. However, such designs add many parts to those generally shown in  FIG.  1   , and are therefore complicated and expensive to employ. Moreover, many such designs do not provide linear outputs that are reliably accurate. Meanwhile, example embodiments may integrate measurement components into the components shown in  FIG.  1    to provide cheaper and better performing ride height measurement for the suspension system  100 . 
     In this regard, as shown in  FIG.  1   , a target  170  may be installed in or attached to the damper bump cap  150 . The target  170  may, for example, generate a magnetic field that is of a known magnitude, and at a known location (i.e., at the corresponding portion of the damper bump cap  150 , and at a fixed position relative to the damper tube  140 ). Meanwhile, a measurement assembly  180  may be disposed along a length of the dust boot  160 . As the dust boot  160  moves up or down responsive to jounce and rebound, the location of the target  170  correspondingly moves relative to the measurement assembly  180 . The measurement assembly  180  may be configured to track such movement and ride height information may correspondingly be determined based on such movement. 
     In an example embodiment, the measurement assembly  180  may be embodied as an elongated PCB that extends along a surface of the dust boot  160 . Moreover, in some cases, the PCB may include, carry or be in communication with a wiring assembly  182 . The wiring assembly  182  may have a current run therethrough, and the current may generate a corresponding magnetic field. The magnetic field generated by the wiring assembly  182  may be interacted with by the magnetic field of the target  170 . For example, the target  170  may distort the magnetic field generated by the wiring assembly  182 . The distortion or modification of the magnetic field of the wiring assembly  182  may be measured/monitored by the PCB of the measurement assembly  180 , and a corresponding ride height information determination may be made by the PCB (or another processing component operably coupled thereto). 
     In an example embodiment, the target  170  may be integrated into the damper bump cap  150 , and the measurement assembly  180  may be integrated into the dust boot  160 . Integration of the target  170  into the damper bump cap  150 , and the measurement assembly  180  into the dust boot  160  may simplify the design of the corresponding integrated ride height sensor that results from the structures described above. 
       FIGS.  2 - 7    illustrate one example structure that may implement the elements discussed above in reference to  FIG.  1   . In this regard,  FIG.  2    illustrates a perspective view of a shock absorber assembly  200  of an example embodiment.  FIG.  3    is a partially exploded view of the shock absorber assembly  200  of  FIG.  2    with a dust boot  220  (e.g., an example of dust boot  160 ) removed to expose components otherwise covered by the dust boot  220 .  FIG.  4    is an isolated perspective view of a measurement assembly  240  (e.g., an example of measurement assembly  180 ) that may be operably coupled to the dust boot  210 .  FIG.  5    illustrates a perspective view of a PCB  250  (e.g., an example of the PCB described above in reference to  FIG.  1   ). Meanwhile,  FIG.  6    shows a perspective view of a bump cap  260 , and  FIG.  7    is a cross section view of a portion of the shock absorber assembly  200 . 
     Referring now to  FIGS.  2 - 7   , the shock absorber assembly  200  (e.g., an example of damper  110 ) may include a damper tube  202  with a rod  204  that extends into the damper tube  202 . The damper tube  202  may be operably coupled to a wheel (e.g., wheel  130 ) via a first mechanical interface  206 . The rod  204  may be operably coupled to a chassis (e.g., body chassis  120  of  FIG.  1   ) via a second mechanical interface  208 . The rod  204  may also be operably coupled to the damper tube  202  in such a way as to resist movement of the rod  204  for jounce and rebound, as described above. 
     In this example, the rod  204 , and/or the second mechanical interface  208  may be further operably coupled to a cap member  210 . The cap member  210  may in turn be operably coupled to the dust boot  220  via threaded fasteners  212  (or other fastening means). The dust boot  220  may be formed from a first side member  222 , a second side member  224 , a third side member  226 , and a fourth side member  228 , which may form the peripheral sides of the dust boot  220  and define a substantially hollow space therebetween. The first, second, third and fourth side members  222 ,  224 ,  226  and  228  may define elongated flat external surfaces, although some (e.g., the first and third side members  222  and  226  in this example) may be slightly curved in the transverse direction. The dust boot  220  may be molded from plastic or composite materials in some cases. The threaded fasteners  212  may be inserted into receivers formed at respective corners defined between adjacent ones of the first, second, third and fourth side members  222 ,  224 ,  226  and  228  on a first end  230  of the dust boot  220 . Meanwhile, a second end  232  of the dust boot  220  may be enabled to move up and down with rebound and jounce events relative to the damper tube  202 . 
     An elongated compartment  234  may be attached to (or formed integrally with) one of the side members to house the measurement assembly  240 . In this example, the elongated compartment  234  is formed to be coextensive with and attached to the fourth side member  228 . However, alternative locations could be defined in some cases. The measurement assembly  240  may be retained in the elongated compartment  234  and may thereby be protected from dust and debris. Meanwhile, since the measurement assembly  240  is configured to operate via magnetic or electric field interactions, the physical isolation will otherwise not affect the operation of the measurement assembly  240 . Given that sides of the dust boot  220  may be made of materials that do not influence or block magnetic or electric fields, the elongated compartment  234  may be positioned on the outside (e.g., an external surface) of the dust boot  220  thereby providing easier access to the measurement assembly  240  for installation, maintenance or replacement. Connections to external componentry to which the ride height information is provided may also be correspondingly enhanced. 
     The measurement assembly  240  may include (as shown in  FIGS.  4  and  5   ) a PCB  242  operably coupled to a coupling assembly  244  and a measuring surface  246 . The measurement assembly  240  may also include a housing  248  inside which the PCB  242  may be housed. The housing  248  may be about as long as the elongated compartment  234  and may be sized and shaped to fit relatively snugly inside the elongated compartment  234 . The coupling assembly  244  may include leads, wires, or other electrical connections to enable the PCB  242  to be operably coupled to external componentry. The PCB  242  may extend nearly as long as the housing  248  (and therefore also the elongated compartment  234 ). Thus, for example, the PCB  242  may be at least 90% as long as the elongated compartment  234 . The PCB  242  may include processing circuitry that enables magnetic/electrical field disruption and/or electrical signals generated based on such disruptions to be calculated or monitored for the purpose of measuring motion (or determining a position) of the rod  204  relative to the damper tube  202 . In this regard, the measuring surface  246  may include a wiring assembly (e.g., wiring assembly  182  from  FIG.  1   ) that generates an electric field when a current (e.g., provided from a source via the coupling assembly  244 ) is run through one side (e.g., a transmit loop) of the wiring assembly and receives the field at another side (e.g., a receive loop) of the wiring assembly. The measuring surface  246  may therefore define a range of motion of the dust boot  220  (and therefore also the measuring surface  246 ) that can be compared to a fixed reference point on the damper tube  202  to determine ride height information based on the measured changes in the fields caused by the target  170  and measured at the wiring assembly. 
     The fixed reference point may be defined as the target  170  of  FIG.  1   . In an example embodiment, the fixed reference point may be disposed on a portion of the bump cap  260  that faces the fourth side member  228  (and consequently also faces the measuring surface  246 ). In this example, the target  170  of  FIG.  1    is embodied as a pair of magnets  262  that are retained in magnet retainers  264  formed in the bump cap  260 . The pair of magnets  262  may be spaced apart from each other by, for example, the distance between wires in the wiring assembly in order to maximize interaction between the pair of magnets  262  and the wiring assembly. The PCB  242  may be configured to provide a linear measurement of position change through the range of motion between max jounce and max rebound. In this regard, for example, the measuring surface  246  may act as an inductive sensor, enable measurements in changed resistance or frequency of signals generated in the wiring assembly, and/or directly measure changes in the magnetic field of the wiring assembly based on proximity to the target  170 . In other examples, the measuring surface  246  may include a coating that enhances the ability to accurately locate and detect magnetic or electric fields (e.g., to saturation) when proximity is provided to the pair of magnets  262 . The position of the target  170  relative to the measuring surface  246  may therefore be determined accordingly by the PCB  242 . In some cases, the changes may be linearly changing based on the position of the pair of magnets  262  along the wiring assembly such that ride height information may be linearly also determined. The use of two magnets as opposed to a single magnet, where the pair of magnets  262  are arranged to define a plane perpendicular to the axis of jounce-rebound travel, makes the sensing area larger by creating a larger field. Having a larger area may be helpful to account for possible movement of the dust boot  220 , assembly tolerances, and damper top to damper bottom relative rotation that may be experienced in some cases. The structures provided may also allow accurate measurement in the presence of a relatively large, and potentially varying air gap between the target  170  and the PCB  242 . 
     Although not required, in some cases, the magnet retainers  264  may be provided on a tab extension  266  that extends partially down a side of the damper tube  202  proximate the fourth side member  228 . The tab extension  266  may enable the pair of magnets  262  to be moved closer to the a center of the measuring surface  246 , if not otherwise centered, in order to maximize the amount of travel in both rebound and jounce directions that can be measured. 
       FIG.  7    illustrates a cross section view taken through an axis of the rod  204  and the damper tube  202 . The extension tab  266  can be seen in  FIG.  7    to be located such that the magnet retainers  264  (and therefore the target  170  of  FIG.  1   ) are located substantially at a midpoint of the full range of motion (R M ) measurable by the PCB  242  and the measuring surface  246 . As a jounce event occurs, the rod  204  may be compressed farther into the damper tube  202 . Dust boot  220 , carried by the cap member  210  and the rod  204 , may then move in the direction of arrow  300 . As the dust boot  220  moves in the direction of arrow  300 , the pair of magnets  262  will be proximate to a different portion of the measuring surface  246  and influence the field generated by the wiring assembly differently. The change in fields or currents associated with the wiring assembly may then be used by the PCB  242  to calculate a precise location of the target  170  (e.g., the pair of magnets  262 ) along the range of motion (R M ) measurable by the PCB  242 . The field changes may therefore be converted (e.g., by the PCB  242 ) into ride height information that can provide real time ride height data for the corresponding wheel or corner of the vehicle to a vehicle suspension system controller or other vehicle control systems. Movement for rebound is substantially opposite the direction of arrow  300  and responses to such movement are correspondingly changed from the descriptions above. 
     A shock absorber for a vehicle suspension system of an example embodiment may therefore be provided (along with a suspension system including such shock absorber). The shock absorber may include a damper tube defining an axis, a rod operably coupled to the damper tube to be movable along the axis relative to the damper tube in response to jounce and rebound events, a dust boot operably coupled to the rod and extending along peripheral sides of the rod and at least a proximal end of the damper tube relative to the rod, the dust boot being movable with the rod, a target disposed on a damper bump cap operably coupled to the proximal end of the damper tube, and a measurement assembly affixed to the dust boot. The measurement assembly may include a PCB elongated parallel to the axis to track relative movement between the target and the measurement assembly responsive to the jounce and rebound events to generate ride height information based on the relative movement. 
     The shock absorber of some embodiments may include additional features, modifications, augmentations and/or the like to achieve further objectives or enhance performance of the device. The additional features, modifications, augmentations and/or the like may be added in any combination with each other. Below is a list of various additional features, modifications, and augmentations that can each be added individually or in any combination with each other. For example, the target may include one or more magnets. In an example embodiment, the measurement assembly may include a measuring surface operably coupled to the PCB and coextensive with a portion thereof to define a range of motion over which relative movement between the target and the measuring surface is determinable. In some cases, a wiring assembly may be disposed at the measuring surface and a current may be run through the wiring assembly, and the relative movement may be detected based on the target disrupting the current or an electromagnetic field associated with the wiring assembly. In an example embodiment, the target comprises a first magnet and a second magnet corresponding to a transmit loop of the wiring assembly and a receive loop of the wiring assembly. In some cases, the damper bump cap may include an extension tab extending away from the proximal end, and magnet receptacles may be disposed in the extension tab to receive the first and second magnets. In an example embodiment, the extension tab may be disposed to position the magnet receptacles substantially at a midpoint of the range of motion defined by the measuring surface. In some cases, the dust boot may include an elongated compartment attached to one peripheral side of the dust boot, and the measurement assembly may be disposed in the elongated compartment. In an example embodiment, the elongated compartment may be approximately equal in length to a length of the dust boot, and the PCB may be at least 90% as long as the elongated compartment. In some cases, the measurement assembly may be disposed at an external surface of the dust boot. 
     Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although the foregoing descriptions and the associated drawings describe exemplary embodiments in the context of certain exemplary combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated as may be set forth in some of the appended claims. In cases where advantages, benefits or solutions to problems are described herein, it should be appreciated that such advantages, benefits and/or solutions may be applicable to some example embodiments, but not necessarily all example embodiments. Thus, any advantages, benefits or solutions described herein should not be thought of as being critical, required or essential to all embodiments or to that which is claimed herein. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.