ACTIVE SUSPENSION SYSTEM AND METHOD

• US 20130161921A1
• Filed: 12/22/2011
• Published: 06/27/2013
• Est. Priority Date: 12/22/2011
• Status: Active Grant

• Current Assignee: Hong Kong Productivity Council
• Original Assignee: Automotive Parts And Accessory Systems R&D Centre Limited
• Inventors: Cheng, Ka Wai Eric, Xue, Xiangdang, Zhang, Zhu
• Granted Patent: US 8,833,780 B2
• Time in Patent Office: Days
• US Class Current: 280/124.179
• CPC Class Codes: B60G 11/14 having helical, spiral or coil springs only B60G11/006 takes precedence
• CPC Class Codes: B60G 13/14 having dampers accumulating utilisable energy, e.g. compressing air fluid springs with an accumulator B60G11/30
• CPC Class Codes: B60G 13/18 combined with energy-absorbing means
• CPC Class Codes: B60G 2300/50 Electric vehicles; Hybrid vehicles
• CPC Class Codes: B60G 2300/60 Vehicles using regenerative power
• CPC Class Codes: F16F 15/022 using dampers and springs in combination
• CPC Class Codes: F16F 15/03 using magnetic or electromagnetic means F16F9/53, F16F15/005 take precedence

Abstract

An active suspension system suitable for use with a vehicle, includes a passive suspension element with a first end adapted for rigid engagement to a sprung mass of the vehicle and a second end adapted for rigid engagement to an unsprung mass of the vehicle. Also included is an active suspension element with a linear switched reluctance actuator which has a first end adapted for rigid engagement to the sprung mass of the vehicle and a second end adapted for rigid engagement to the unsprung mass of the vehicle.

Claims

1. An active suspension system suitable for use with a vehicle, comprising:

a passive suspension element having a first end adapted for rigid engagement to a sprung mass of the vehicle and a second end adapted for rigid engagement to an unsprung mass of the vehicle, the passive suspension element being configured for applying a passive force to the sprung mass; and

an active suspension element including a linear switched reluctance actuator having a first end adapted for rigid engagement to the sprung mass of the vehicle and a second end adapted for rigid engagement to the unsprung mass of the vehicle wherein the linear switched reluctance actuator is configured for applying an active force to the sprung mass to substantially maintain a predetermined vertical orientation of the sprung mass when the vehicle traverses a road irregularity.

2. The active suspension system of claim 1 wherein the passive suspension element includes a coil spring.

3. The active suspension system of claim 1 wherein the passive suspension element and the linear switched reluctance actuator are configured for engagement in parallel between the sprung mass and the unsprung mass.

4. The active suspension system of claim 1 wherein the linear switched reluctance actuator includes:

a frame having a peripheral wall, a top surface and a base defining a frame chamber;

a stator rigidly positioned within the frame chamber;

a translator positioned adjacent the stator within the frame chamber, the translator being configured for electromagnetic engagement with the stator to enable slidable movement of the translator relative to the stator; and

a translator shaft rigidly engaged to and slidable with the translator for applying the active force to the sprung mass.

5. The active suspension system of claim 4 wherein:

the top surface of the frame includes an opening and the base of the frame is configured for rigid engagement to the unsprung mass;

the translator shaft includes a first end extending outwardly of the opening in the top surface of the frame, the first end of the translator shaft being configured for rigid engagement to the sprung mass and the translator shaft includes an opposed second end enclosed within the frame chamber, the second end of the translator shaft having a recess disposed therein;

the first end of the coil spring is rigidly engaged to the translator shaft within the recess and the second end of the coil spring is rigidly engaged to the base of the frame wherein the coil spring is able to stretch and compress in axial alignment with the translator shaft.

6. The active suspension system of claim 4 wherein:

an opening is disposed in the top surface of the frame and the base of the frame is configured for rigid engagement to the unsprung mass;

the translator shaft includes a hollow chamber between a first and second end of the translator shaft, the first end of the translator shaft extending outwardly of the opening in the top surface of the frame wherein it is configured for rigid engagement to the sprung mass, an opposed second end of the translator shaft enclosed within the frame chamber, the second end of the translator shaft having an opening disposed therein leading into the hollow chamber of the translator shaft;

the coil spring is disposed within the hollow chamber of the translator shaft wherein a first end of the coil spring is rigidly engaged to the first end of the translator shaft and the second end of the coil spring is rigidly engaged to the base of the frame by an elongate support member wherein the coil spring is able to stretch and compress in axial alignment with the translator shaft within the hollow chamber of the translator shaft.

7. The active suspension system of claim 4 wherein:

an opening is disposed in the top surface of the frame and the base of the frame is configured for rigid engagement to the unsprung mass;

the translator shaft includes a first end extending outwardly of the opening in the top surface of the frame wherein it is configured for rigid engagement to the sprung mass and an opposed second end enclosed within the frame chamber, the second end of the translator shaft being rigidly engaged to the base;

the coil spring is positioned externally of the frame chamber, a first end of the coil spring surrounds the peripheral wall of the frame and abuts against a flanged section extending outwardly from the peripheral wall of the frame, a second end of the coil spring is rigidly engaged to the base of the frame wherein the coil spring is able to stretch and compress in axial alignment with the translator shaft externally of the frame chamber.

8. The active suspension system of claim 4 wherein the stator is rigidly engaged to an inner surface of the peripheral wall within the frame chamber.

9. The active suspension system of claim 4 including a plurality of stators and a plurality of corresponding translators wherein said plurality of translators are rigidly engaged to the translator shaft.

10. The active suspension system of claim 4 wherein the stator includes a double-sided stator.

11. The active suspension system of claim 4 wherein the stator includes a single-sided stator.

12. The active suspension system of claim 10 including a controller unit configured for regulating phased currents provided to phased windings of the linear switched reluctance actuator in order to control the active force applied by the linear switched reluctance actuator to the sprung mass.

13. The active suspension system of claim 12 including a sensor circuit configured for providing input sensor readings to the controller unit, the sensor readings being indicative of at least one of a linear displacement of the translator relative to the stator, a vertical acceleration of the sprung mass, and a vertical acceleration of the unsprung mass, wherein the controller unit regulates the phased currents provided to the phased windings by reference to the sensor readings.

14. The active suspension system of claim 12 wherein the phased windings are disposed on the stator.

15. The active suspension system of claim 2 wherein the coil spring is configured for absorbing vertical motion energy induced in the sprung mass when the vehicle traverses the road irregularity and the linear switched reluctance actuator is configured for dampening the absorbed vertical motion energy by at least one of dissipating the absorbed vertical motion energy and storing the absorbed vertical motion energy in an energy store.

16. The active suspension system of claim 15 including a bi-directional power interface disposed between the controller unit and the linear switched reluctance actuator whereby movement of the translator shaft is able to be converted into energy suitable for storage in the energy store via the bi-directional power interface.

17. The active suspension system of claim 15 wherein the energy store includes a battery of the vehicle.

35. The active suspension system of claim 11 including a controller unit configured for regulating phased currents provided to phased windings of the linear switched reluctance actuator in order to control the active force applied by the linear switched reluctance actuator to the sprung mass.

18. A method of providing active suspension system suitable for use with a vehicle, the method including the steps of:

providing a passive suspension element having a first end adapted for rigid engagement to a sprung mass of the vehicle and a second end adapted for rigid engagement to an unsprung mass of the vehicle, the passive suspension element being configured for applying a passive force to the sprung mass; and

providing an active suspension element including a linear switched reluctance actuator having a first end adapted for rigid engagement to the sprung mass of the vehicle and a second end adapted for rigid engagement to the unsprung mass of the vehicle wherein the linear switched reluctance actuator is configured for applying an active force to the sprung mass to substantially maintain a predetermined vertical orientation of the sprung mass when the vehicle traverses a road irregularity.

19. The method of claim 18 wherein the passive suspension element includes a coil spring.

20. The method of claim 18 including the step of engaging the passive suspension element and the linear switched reluctance actuator in parallel between the sprung mass and the unsprung mass.

21. The method of claim 18 wherein the linear switched reluctance actuator includes:

a frame having a peripheral wall, a top surface and a base defining a frame chamber;

a stator rigidly positioned within the frame chamber;

a translator positioned adjacent the stator within the frame chamber, the translator being configured for electromagnetic engagement with the stator to enable slidable movement of the translator relative to the stator; and

a translator shaft rigidly engaged to and slidable with the translator for applying the active force to the sprung mass.

22. The method of claim 21 wherein:

the top surface of the frame includes an opening and the base of the frame is configured for rigid engagement to the unsprung mass;

the translator shaft includes a first end extending outwardly of the opening in the top surface of the frame, the first end of the translator shaft being configured for rigid engagement to the sprung mass and the translator shaft includes an opposed second end enclosed within the frame chamber, the second end of the translator shaft having a recess disposed therein;

the first end of the coil spring is rigidly engaged to the translator shaft within the recess and the second end of the coil spring is rigidly engaged to the base of the frame wherein the coil spring is able to stretch and compress in axial alignment with the translator shaft.

23. The method of claim 22 wherein:

an opening is disposed in the top surface of the frame and the base of the frame is configured for rigid engagement to the unsprung mass;

the translator shaft includes a hollow chamber between a first and second end of the translator shaft, the first end of the translator shaft extending outwardly of the opening in the top surface of the frame wherein it is configured for rigid engagement to the sprung mass, an opposed second end of the translator shaft enclosed within the frame chamber, the second end of the translator shaft having an opening disposed therein leading into the hollow chamber of the translator shaft;

the coil spring is disposed within the hollow chamber of the translator shaft wherein a first end of the coil is rigidly engaged to the first end of the translator shaft and the second end of the coil spring is rigidly engaged to the base of the frame by an elongate support member wherein the coil spring is able to stretch and compress in axial alignment with the translator shaft within the hollow chamber of the translator shaft.

24. The method of claim 22 wherein:

an opening is disposed in the top surface of the frame and the base of the frame is configured for rigid engagement to the unsprung mass;

the translator shaft includes a first end extending outwardly of the opening in the top surface of the frame wherein it is configured for rigid engagement to the sprung mass and an opposed second end enclosed within the frame chamber, the second end of the translator shaft being rigidly engaged to the base;

the coil spring is positioned externally of the frame chamber, a first end of the coil spring surrounds the peripheral wall of the frame and abuts against a flanged section extending outwardly from the peripheral wall of the frame, a second end of the coil spring is rigidly engaged to the base of the frame wherein the coil spring is able to stretch and compress in axial alignment with the translator shaft externally of the frame chamber.

25. The method of claim 22 including the step of rigidly engaging the stator to an inner surface of the peripheral wall within the frame chamber.

26. The method of claim 25 including the step of providing a plurality of stators and a plurality of corresponding translators wherein said plurality of translators are rigidly engaged to the translator shaft.

27. The method of claim 25 wherein the stator includes a double-sided stator.

28. The method of claim 25 wherein the stator includes a single-sided stator.

29. The method of claim 27 including a controller unit configured for regulating phased currents provided to phased windings of the linear switched reluctance actuator in order to control the active force applied by the linear switched reluctance actuator to the sprung mass.

30. The method of claim 29 including the step of providing the controller unit with input sensor readings from a sensor circuit, the sensor readings being indicative of at least one of a linear displacement of the translator relative to the stator, a vertical acceleration of the sprung mass, and a vertical acceleration of the unsprung mass, wherein the controller unit regulates the phased currents provided to the phased windings by reference to the sensor readings.

31. The method of claim 29 including the step of arranging the phased windings on the stator.

32. The method of claim 19 wherein the coil spring is configured for absorbing vertical motion energy induced in the sprung mass when the vehicle traverses the road irregularity and the linear switched reluctance actuator is configured for dampening the absorbed vertical motion energy by at least one of dissipating the absorbed vertical motion energy and storing the absorbed vertical motion energy in an energy store.

33. The method of claim 32 including the step of providing a bi-directional power interface between the controller unit and the linear switched reluctance actuator whereby movement of the translator shaft is able to be converted into energy suitable for storage in the energy store via the bi-directional power interface.

34. The method of claim 33 including the step of storing the energy in a battery of the vehicle.

36. The method of claim 28 including a controller unit configured for regulating phased currents provided to phased windings of the linear switched reluctance actuator in order to control the active force applied by the linear switched reluctance actuator to the sprung mass.