Symmetrically dynamic equalized volume and pressure air management system

• US 10,179,496 B1
• Filed: 09/04/2018
• Issued: 01/15/2019
• Est. Priority Date: 06/16/2017
• Status: Active Grant

• Current Assignee: Base Air Management Limited
• Original Assignee: Base Air Management, Inc.
• Inventors: Vaughan, Matthew, Lewis, David Bryan, Calaway, Joseph, Arrants, George
• Primary Examiner(s): Fleming, Faye M
• Application Number:
  US16/121,018
• Publication Number:
  US 20190016189A1
• Time in Patent Office: 133 Days
• CPC Class Codes: B60G 17/0155 pneumatic unit
• CPC Class Codes: B60G 17/0162 mainly during a motion involving steering operation, e.g. cornering, overtaking B60G17/0164 takes precedence
• CPC Class Codes: B60G 17/019 characterised by the type of sensor or the arrangement thereof B60G17/01941 takes precedence
• CPC Class Codes: B60G 17/0525 Height adjusting or levelling valves
• CPC Class Codes: B60G 21/005 transversally
• CPC Class Codes: B60G 21/026 transversally
• CPC Class Codes: B60G 21/067 between wheels on different axles on the same side of the vehicle, i.e. the left or the right side
• CPC Class Codes: B60G 21/106 transversally
• CPC Class Codes: B60G 2202/1524 with two air springs per wheel, arranged before and after the wheel axis
• CPC Class Codes: B60G 2202/42 Electric actuator
• CPC Class Codes: B60G 2204/111 on pneumatic springs
• CPC Class Codes: B60G 2204/82 left and right unit on same axle
• CPC Class Codes: B60G 2204/8304 using a fluid
• CPC Class Codes: B60G 2400/05162 the element being a suspension arm
• CPC Class Codes: B60G 2400/257 transversal with regard to vehicle
• CPC Class Codes: B60G 2400/51222 Pneumatic
• CPC Class Codes: B60G 2500/202 Height or leveling valve for air-springs
• CPC Class Codes: B60G 2500/2021 Arrangement of valves
• CPC Class Codes: B60G 2500/2046 Pressure equalising valves between two units
• CPC Class Codes: B60G 2500/30 Height or ground clearance
• CPC Class Codes: B60G 2800/012 : Rolling condition
• CPC Class Codes: B60G 2800/914 : Height Control System
• CPC Class Codes: B62D 65/12 : the sub-units or components being suspensions, brakes or wheel units
• CPC Class Codes: F16K 11/074 : with flat sealing faces

Abstract

An air management system for a vehicle having a first pneumatic circuit and a second pneumatic circuit, in which the first and second pneumatic circuits are pneumatically connected in a neutral position via a cross-flow mechanism. The first pneumatic circuit includes a first leveling valve configured to adjust independently the height of a first side of the vehicle. The second pneumatic circuit includes a second leveling valve configured to adjust independently the height of a second side of the vehicle. The first and second leveling valves are configured to establish pneumatic communication between the first and second pneumatic circuits when the first leveling valve is not independently adjusting the height of the first side of the vehicle and the second leveling valve is not independently adjusting the height of the second side of the vehicle.

Claims

1. A method for adjusting air pressure of an air management system of a vehicle, the method comprising:

adjusting independently the air pressure of a first pneumatic circuit by a first leveling valve such that the first leveling valve is either supplying air from one or more air supply tanks to the first pneumatic circuit or removing air from the first pneumatic circuit to the atmosphere,

adjusting independently the air pressure of a second pneumatic circuit by a second leveling valve such that the second leveling valve is either supplying air from the one or more air supply tanks to the second pneumatic circuit or removing air from the second pneumatic circuit to the atmosphere, and

establishing pneumatic communication between the first pneumatic circuit and the second pneumatic circuit only when both the first leveling valve and the second leveling valve are set in a neutral mode such that each leveling valve is neither supplying air from the one or more air supply tanks or removing air into the atmosphere, wherein the air management system comprises;

one or more supply air tanks in fluid communication with the first and second pneumatic circuits;

the first pneumatic circuit having the first leveling valve configured to adjust independently the height of at least one air spring on a first side of the vehicle;

the second pneumatic circuit having the second leveling valve configured to adjust independently the height of at least one air spring on a second side of the vehicle; and

a cross-flow line connecting the first pneumatic circuit with the second pneumatic circuit;

wherein each of the first leveling valve and the second leveling valve comprises a plurality of ports including a supply port, an exhaust port, one or more spring ports, and a cross-flow port, and

wherein the first and second leveling valves are configured to establish pneumatic communication between the first and second pneumatic circuits when the first leveling valve is not independently adjusting the height of the first side of the vehicle and the second leveling valve is not independently adjusting the height of the second side of the vehicle.

2. The method of claim 1, wherein each of the first and second leveling valves is configured to pivot from a neutral position to one or more response positions.

3. The method of claim 1, the first and second leveling valves each include a valve element configured to move between a plurality of positions to alter communication between the plurality of ports.

4. The method of claim 3, wherein the plurality of positions include a neutral position to establish pneumatic communication between the first and second pneumatic circuits, a supply position to supply air from the one or more air supply tanks to a respective pneumatic circuit, and an exhaust position to remove air from the respective pneumatic circuit into the atmosphere.

5. The method of claim 4, wherein the valve element is configured to pivot from a neutral position to one or more response positions, and each leveling valve is set in the neutral mode when the valve element is set in the neutral position, and each leveling valve is adjusting independently the air pressure of a respective pneumatic circuit when the valve element is set to the one or more response positions.

6. The method of claim 1, wherein the first pneumatic circuit comprises a first set of air springs disposed on the first side of the vehicle, a first plurality of air lines pneumatically connecting the first set of air springs with the first leveling valve, and a first supply line pneumatically connecting the first leveling valve with at least one of the one or more air supply tanks;

and

the second pneumatic circuit comprises a second set of air springs disposed on the second side of the vehicle, a second plurality of air lines pneumatically connecting the second set of air springs with the second leveling valve, and a second supply line pneumatically connecting the second leveling valve with at least one of the one or more air supply tanks.

7. The method of claim 3, wherein the valve element alters communication between the supply port, the exhaust port, the one or more spring ports, and the cross-flow port, by pivoting between a plurality of positions include (i) a neutral position, in which the one or more spring ports pneumatically communicate with the cross-flow port, and neither the supply port nor the exhaust port pneumatically communicates with the one or more spring ports, (ii) a supply position, in which the one or more spring ports pneumatically communicate with the supply port, and neither the exhaust port nor the cross-flow port pneumatically communicates with the one or more spring ports, and (iii) an exhaust position, in which the one or more spring ports pneumatically communicate with the exhaust port, and neither the supply port nor the cross-flow port pneumatically communicates with the one or more spring ports.

8. The method of claim 1, wherein the air management system further comprises each of said first and second leveling valves provided in a control unit, each control unit comprising:

a housing configured to be mounted to a top plate of an associated air spring, wherein the housing comprises a valve chamber;

a respective leveling valve disposed in the valve chamber, wherein the respective leveling valve is configured to switch between a plurality of modes including;

(i) an active mode wherein the respective leveling valve is adjusting independently a height of the associated air spring, and (ii) a neutral mode wherein the respective leveling valve is establishing pneumatic communication between the associated air spring and a respective cross-flow line when the respective leveling valve is not in the active mode;

said control unit operatively connected to one or more sensors configured to monitor at least one condition of the associated air spring and generate a measurement signal indicating the at least one condition of the associated air spring;

said control unit operatively connected to a communication interface configured to directly transmit and receive data signals to and from other control units associated with other air springs of the suspension system; and

said control unit operatively connected to a processing module operatively linked to the respective leveling valve, the one or more sensors, and the communication interface;

wherein the processing module is configured to;

(i) receive measurement signals from the one or more sensors and data signals from the communication interface, and (ii) actuate the respective leveling valve to switch between the active mode and the neutral mode based on the received measurement signals from the one or more sensors and the data signals from the communication interface.

9. The method of claim 8, wherein the air management system further comprises a system controller in electrical communication with the communication interface of each control unit of the air management system, and

wherein the system controller is configured to:

(i) receive measurement signals from each control unit of the air management system, (ii) determine a desired volumetric flow rate for removing or supplying air to and from a chamber of each air spring of the air management system based on the received measurement signals, and (iii) transmit commands to each control unit of the air management system such that each control unit actuates its associated leveling valve between the active mode and the neutral mode.

10. The method of claim 8, wherein the air management system further comprises a compressor operatively connected to the one or more supply air tanks.

11. The method of claim 8, wherein the housing comprises:

a housing inlet port configured to receive air flow from an air source,

a housing outlet port configured to release air to the atmosphere,

a housing cross-flow port configured to connect to the cross-flow line connected to the second air spring of the air management system and

a housing delivery port configured to supply or release air to and from a chamber of the air spring,

wherein the valve chamber is connected to the housing inlet port, the housing outlet port, and the housing delivery port by a plurality of passages.

12. The method of claim 8, wherein the valve chamber, the respective leveling valve, and the processing module are mounted below the top plate and disposed in the chamber of the air spring.

13. The method of claim 10, wherein the valve chamber, the respective leveling valve, the processing module, and the compressor are disposed outside the chamber of the air spring.

14. An air management system for a vehicle, the air management system comprising:

one or more supply air tanks in fluid communication with a first pneumatic circuit and a second pneumatic circuit;

a compressor operatively connected to the one or more supply air tanks;

the first pneumatic circuit having a first leveling valve configured to adjust independently the height of at least one air spring on a first side of the vehicle;

the second pneumatic circuit having a second leveling valve configured to adjust independently the height of at least one air spring on a second side of the vehicle; and

a cross-flow line connecting the first pneumatic circuit with the second pneumatic circuit;

wherein each of the first leveling valve and the second leveling valve comprises a plurality of ports including a supply port, an exhaust port, one or more spring ports, and a cross-flow port, and

wherein the first and second leveling valves are configured to establish pneumatic communication between the first and second pneumatic circuits when the first leveling valve is not independently adjusting the height of the first side of the vehicle and the second leveling valve is not independently adjusting the height of the second side of the vehicle.

15. The air management system of claim 14, further comprising at least one control unit in communication with said first and second leveling valves, wherein said at least one control unit transmits signals to one or both of the first and second leveling valves, respectively, to switch between a plurality of modes including:

(i) an active mode wherein the respective leveling valve is adjusting independently a height of the associated air spring, and (ii) a neutral mode wherein the respective leveling valve is establishing pneumatic communication between the associated air spring and a respective cross-flow line when the respective leveling valve is not in the active mode.

16. The air management system of claim 15, further comprising one or more sensors configured to monitor at least one condition of the associated air spring and generate a measurement signal indicating the at least one condition of the associated air spring;

a communication interface configured to directly transmit and receive data signals to and from other control units associated with other air springs of the suspension system; and

a processing module operatively linked to each of the first and second leveling valves, the one or more sensors, and the communication interface;

wherein the processing module is configured to;

(i) receive measurement signals from the one or more sensors and data signals from the communication interface, and (ii) actuate one or both of the first and second leveling valves to switch between the active mode and the neutral mode based on the received measurement signals from the one or more sensors and the data signals from the communication interface.

17. The air management system of claim 16, further comprising a system controller in electrical communication with the communication interface of each control unit of the air management system, and

wherein the system controller is configured to:

(i) receive measurement signals from each control unit of the air management system, (ii) determine a desired volumetric flow rate for removing or supplying air to and from the chamber of each air spring of the air management system based on the received measurement signals, and (iii) transmit commands to each control unit of the air management system such that each control unit actuates its associated leveling valve between the active mode and the neutral mode.

18. The air management system of claim 14, wherein the air management system further comprises each of said first and second leveling valves provided in a control unit, each control unit comprising:

a housing configured to be mounted to a top plate of an associated air spring, wherein the housing comprises a valve chamber;

a respective leveling valve disposed in the valve chamber, wherein the respective leveling valve is configured to switch between a plurality of modes including;

(i) an active mode wherein the respective leveling valve is adjusting independently a height of the associated air spring, and (ii) a neutral mode wherein the respective leveling valve is establishing pneumatic communication between the associated air spring and a respective cross-flow line when the respective leveling valve is not in the active mode;

said control unit operatively connected to one or more sensors configured to monitor at least one condition of the associated air spring and generate a measurement signal indicating the at least one condition of the associated air spring;

said control unit operatively connected to a communication interface configured to directly transmit and receive data signals to and from other control units associated with other air springs of the suspension system; and

said control unit operatively connected to a processing module operatively linked to the respective leveling valve, the one or more sensors, and the communication interface;

wherein the processing module is configured to;

(i) receive measurement signals from the one or more sensors and data signals from the communication interface, and (ii) actuate the respective leveling valve to switch between the active mode and the neutral mode based on the received measurement signals from the one or more sensors and the data signals from the communication interface.

19. The air management system of claim 18, wherein the housing comprises:

a housing inlet port configured to receive air flow from an air source,

a housing outlet port configured to release air to the atmosphere,

a housing cross-flow port configured to connect to the cross-flow line connected to the second air spring of the air management system and

a housing delivery port configured to supply or release air to and from a chamber of the air spring,

wherein the valve chamber is connected to the housing inlet port, the housing outlet port, and the housing delivery port by a plurality of passages.

20. The method of claim 18, wherein the valve chamber, the respective leveling valve, and the processing module are mounted below the top plate and disposed in the chamber of the air spring.