Symmetrically dynamic equalized volume and pressure air management system

• US 10,220,665 B2
• Filed: 10/08/2018
• Issued: 03/05/2019
• 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): Condra, Darlene P
• Application Number:
  US16/154,085
• Publication Number:
  US 20190039431A1
• Time in Patent Office: 148 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 17/0525 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 2202/1524 with two air springs per wheel, arranged before and after the wheel axis
• 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 2400/51222 Pneumatic
• 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 2800/914 Height Control System
• CPC Class Codes: F15B 13/0406 for rotary valves

Abstract

An air management system for a vehicle having a supply tank, a system controller integrated with the supply tank, a first pneumatic circuit pneumatically connected to the system controller, and a second pneumatic circuit pneumatically connected to the system controller. The system controller adjusts independently air pressure of the first pneumatic circuit and the second pneumatic circuit without establishing pneumatic communication between the first and second pneumatic circuits. The system controller establishes pneumatic communication between the first and second pneumatic circuits when the system controller is not adjusting independently the air pressure of the first pneumatic circuit and the second pneumatic circuit.

Claims

1. An air management system for leveling a vehicle operated under dynamic driving conditions, the air management system comprising:

a supply tank;

a compressor operatively connected to the supply air tank;

a system controller integrated with the supply tank;

a first pneumatic circuit comprising one or more air springs disposed on a first side of the vehicle and one or more air lines pneumatically connecting the one or more air springs with the system controller;

a second pneumatic circuit comprising one or more air springs disposed on a second side of the vehicle and one or more air lines pneumatically connecting the one or more air springs with the system controller; and

wherein the system controller is configured to adjust independently air pressure of the one or more air springs of the first pneumatic circuit and adjust independently air pressure of the one or more air springs of the second pneumatic circuit without establishing pneumatic communication between the first and second pneumatic circuits;

wherein the system controller is configured to establish pneumatic communication between the first and second pneumatic circuits when the system controller is not adjusting independently the air pressure of the one or more air springs of the first pneumatic circuit and not adjusting independently the air pressure of the one or more air springs of the second pneumatic circuit.

2. The air management system of claim 1, wherein the system controller comprises a housing disposed on an exterior surface of the supply tank, and the housing comprises an internal cross-flow passage pneumatically connecting the first and second pneumatic circuits.

3. The air management system of claim 1, wherein the system controller comprises a housing disposed within the supply tank, and the housing comprises an internal cross-flow passage pneumatically connecting the first and second pneumatic circuits.

4. The air management system of claim 1, wherein the system controller comprises a first port connected to one of the air lines of the first pneumatic circuit, a second port connected to one of the air lines of the second pneumatic circuit, an exhaust port configured to exhaust air to the atmosphere, and one or more tank ports coupled to the supply tank.

5. The air management system of claim 4, wherein the system controller comprises a cross-flow passage pneumatically connecting the first port to the second port.

6. The air management system of claim 1, wherein the system controller comprises a valve unit comprising a plurality of valves configured to selectively supply air from the air tank to at least one of the first and second pneumatic circuits, remove air from at least one of the first and second pneumatic circuits, and establish pneumatic communication between the first and second pneumatic circuits.

7. The air management system of claim 1, wherein at least one air spring of the first and second pneumatic circuits comprises a height sensor configured to monitor the height of its associated air spring and transmit a signal indicating the height of its associated air spring.

8. The air management system of claim 7, wherein the system controller is configured to receive the signal transmitted from each height sensor and calculate a height differential between the air springs of the first pneumatic circuit and the air springs of the second pneumatic circuit based at least on the received signals from the height sensor.

9. The air management system of claim 8, wherein the system controller is configured to adjust independently the air pressure of the first and second pneumatic circuits when the calculated height differential is above a predetermined threshold, and the system controller is configured to establish pneumatic communication between the first and second pneumatic circuits when the calculated height differential is below a predetermined threshold.

10. The air management system of claim 1, wherein each pneumatic circuit comprises at least two proportional control sensors configured to monitor the air pressure of or flow rate to its associated air spring and transmit a signal indicating the air pressure of its associated air spring.

11. The air management system of claim 10, wherein the system controller is configured to receive the signal transmitted from each proportional control sensor and determine a lag time for air to travel from the system controller to one of the air springs based at least on the received signals from the proportional control sensors.

12. The air management system of claim 1, wherein the air lines have equal lengths and diameters.

13. The air management system of claim 1 comprising a compressor disposed within the supply tank.

14. The air management system of claim 1, wherein each air spring comprises an inertial sensor unit comprising an accelerometer, a gyroscope, and a magnetometer.

15. The air management system of claim 14, wherein the accelerometer is configured to measure an acceleration with respect to three axes of the vehicle;

wherein the gyroscope is configured to measure an angular velocity with respect to three axes of the vehicle; and

wherein the magnetometer is configured to measure the magnetic force with respect to three axes of the vehicle.

16. The air management system of claim 15, wherein the inertial sensor unit is configured to transmit a signal indicating the measured acceleration, the angular velocity, and the magnetic force with respect to the three axes of the vehicle;

wherein the system controller is configured to receive the signal transmitted from the inertial sensor unit and calculate at least one of the vehicle yaw, vehicle pitch, and vehicle roll, and the system controller is configured to determine the desired air pressure of each air spring based on at least on one of the calculated vehicle yaw, vehicle pitch, and vehicle roll.

17. The air management system of claim 1, further comprising one or more sensors configured to monitor at least two conditions of its associated air spring and transmit a measurement signal indicating the at least two conditions of its associated air spring,

wherein the at least two conditions comprise a height of its associated air spring and a pressure of its associated air spring,

wherein, the system controller is configured to (i) receive the signals transmitted from the one or more sensors of each air spring, (ii) detect a height differential between at least one air spring disposed on the first side of the vehicle and at least one air spring disposed on the second side of the vehicle based at least on the received signals from the one or more sensors of each air spring, (iii) independently adjust air pressure of the at least one air spring disposed on the first side of the vehicle such that the first leveling valve is either supplying air from the air supply tank to the at least one air spring disposed on the first side of vehicle or removing air from the at least one air spring disposed on the first side of vehicle to the atmosphere, (iv) independently adjust air pressure of the at least one air spring disposed on the second side of the vehicle by a second leveling valve such that the second leveling valve is either supplying air from the air supply tank to the at least one air spring disposed on the second side of the vehicle or removing air from the at least one air spring disposed on the second side of the vehicle to the atmosphere, (v) detect a pressure differential between the at least one air springs disposed on the first side of the vehicle and the at least one air spring disposed on the second side of the vehicle based at least on the received signals from the one or more sensors of each air spring when both the first leveling valve and the second leveling valve are set in a neutral mode such that the height differential is within a predetermined threshold such that each leveling valve is neither supplying air from the air supply tank or removing air to the atmosphere, and (vi) establish pneumatic communication between the first and second pneumatic circuits when the system controller is not adjusting independently the air pressure of the one or more air springs of the first pneumatic circuit and not adjusting independently the air pressure of the one or more air springs of the second pneumatic circuit.

18. A method for adjusting air pressure of an air management system of a vehicle operated under dynamic driving conditions comprising a supply tank, a first pneumatic circuit disposed on a first side of the vehicle, and a second pneumatic circuit disposed on a second side of the vehicle, the method comprising:

adjusting independently, by a system controller, the air pressure of the first pneumatic circuit such that the system controller is either supplying air from the supply tank to the first pneumatic circuit or removing air from the first pneumatic circuit to the atmosphere;

adjusting independently, by the system controller, the air pressure of the second pneumatic circuit such that the system controller is either supplying air from the supply tank to the second pneumatic circuit or removing air from the second pneumatic circuit to the atmosphere; and

establishing, by the system controller, pneumatic communication between the first pneumatic circuit and the second pneumatic circuit only when the system controller is neither supplying air from the supply tank nor removing air to the atmosphere;

wherein the system controller comprises a housing integrated with the supply tank, and the housing comprises an internal cross-flow passage pneumatically connecting the first and second pneumatic circuits.

19. The method of claim 18, further comprising:

(i) monitoring, by one or more sensors, at least one condition of at least one air spring disposed on each of the first and second sides of the vehicle;

(ii) transmitting, by the one or more sensors, at least one signal indicating the at least one condition of the at least one air spring disposed on each of the first and second sides of the vehicle;

(iii) receiving, by a processing module, at least one signal indicating the at least one condition of the at least one air spring disposed on each of the first and second sides of the vehicle;

(iv) detecting, by the processing module, a height differential between the at least one air spring disposed on each of the first and second sides of the vehicle based at least on the received signals;

(v) independently adjusting, by a first leveling valve, air pressure of the at least one air spring disposed on the first side of the vehicle such that the first leveling valve is either supplying air from the air supply tank to the at least one air spring disposed on the first side of the vehicle or removing air from the at least one air spring disposed on the first side of the vehicle to the atmosphere;

(vi) independently adjusting, by a second leveling valve, air pressure of the at least one air spring disposed on the second side of the vehicle such that the second leveling valve is either supplying air from the air supply tank to the at least one air spring disposed on the second side of the vehicle or removing air from the at least one air spring disposed on the second side of the vehicle to the atmosphere;

(vii) detecting, by the processing module, an air pressure differential between at least one air spring disposed on each of the first and second sides of the vehicle based at least on the received signals when both the first leveling valve and the second leveling valve are set in a neutral mode such that the height differential is within a predetermined threshold such that first and second leveling valves are neither supplying air from the air supply tank nor removing air to the atmosphere; and

(viii) 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 via an internal cross-flow passage pneumatically connecting the first and second pneumatic circuits extending through the supply tank.

20. The method of claim 18, wherein the one or more sensors comprises a height sensor configured to monitor the height of the air spring and transmit a signal indicating the height of the air spring.

21. The method of claim 20, wherein the height sensor is an ultrasonic sensor, a laser sensor, an infrared sensor, an electromagnetic wave sensor, or a potentiometer.

22. The method of claim 18, wherein the one or more sensors comprise a pressure sensor configured to monitor the internal air pressure of the air spring and transmit a signal indicating the internal air pressure of the air spring.

23. The method of claim 18, wherein the system controller comprises a housing disposed on an exterior surface of the supply tank.

24. The method of claim 18, wherein the system controller comprises a housing disposed within the supply tank.

25. The method of claim 18 comprising a compressor disposed within the supply tank.

26. A system controller for an air management system comprising a supply tank, a first pneumatic circuit disposed on a first side of a vehicle, and a second pneumatic circuit disposed on a second side of a vehicle, the system controller comprising:

a housing integrated with the supply tank, wherein the housing comprises at least one tank port pneumatically connected to the supply tank, a first port pneumatically connected to the first pneumatic circuit, a second port pneumatically connected to the second pneumatic circuit, and an exhaust port pneumatically connected to the atmosphere; and

a set of valves configured to selectively supply air from the air tank to at least one of the first and second pneumatic circuits, remove air from at least one of the first and second pneumatic circuits to the atmosphere, and establish pneumatic communication between the first and second pneumatic circuits;

wherein the system controller is configured to adjust independently air pressure of the first pneumatic circuit and adjust independently air pressure of the second pneumatic circuit without establishing pneumatic communication between the first and second pneumatic circuits;

wherein the system controller is configured to establish pneumatic communication between the first and second pneumatic circuits when the system controller is not adjusting independently the air pressure of the first pneumatic circuit and not adjusting independently the air pressure of the second pneumatic circuit.

27. The system controller of claim 26, wherein the housing is disposed on an exterior surface of the supply tank.

28. The system controller of claim 26, wherein the housing is disposed within the supply tank.

29. The system controller of claim 26, wherein the at least one tank port comprises a first tank port and a second tank port, and

wherein the housing comprises:

a first passage pneumatically connecting the first port with the first tank port,

a second passage pneumatically connecting the second port with the second tank port,

a cross-flow passage pneumatically connecting the first passage with the second passage, and

an exhaust passage pneumatically connecting the exhaust port to the cross-flow passage.

30. The system controller of claim 29, wherein the set of valves is a valve unit comprising:

a first valve disposed at an intersection between the first passage and the cross-flow passage,

a second valve disposed at an intersection between the second passage and the cross-flow passage, and

a third valve disposed at an intersection between the exhaust passage and the cross-flow passage.