Active Vehicle Suspension System

• US 20070120332A1
• Filed: 11/17/2006
• Published: 05/31/2007
• Est. Priority Date: 11/29/2005
• Status: Active Grant

• Current Assignee: ClearMotion Acquisition I LLC
• Original Assignee: Bose Corporation
• Inventors: Bushko, Dariusz, Pare, Christopher
• Granted Patent: US 7,823,891 B2
• Time in Patent Office: Days
• US Class Current: 280/5.508
• CPC Class Codes: B60G 17/0157 non-fluid unit, e.g. electric motor
• CPC Class Codes: B60G 2200/14 with lateral arms
• CPC Class Codes: B60G 2202/422 Linear motor
• CPC Class Codes: B60G 2204/202 of cables
• CPC Class Codes: B60G 2204/416 Ball or spherical joints
• CPC Class Codes: B60G 2204/418 Bearings, e.g. ball or roller bearings
• CPC Class Codes: B60G 2204/421 Pivoted lever mechanisms for mounting suspension elements, e.g. Watt linkage
• CPC Class Codes: B60G 2204/423 Rails, tubes, or the like, for guiding the movement of suspension elements
• CPC Class Codes: B60G 2204/4502 using resilient buffer
• CPC Class Codes: B60G 3/01 the wheel being mounted for sliding movement, e.g. in or on a vertical guide camber maintaining means B60G3/26
• CPC Class Codes: B60G 3/06 the arm being rigid

Abstract

An active suspension system for a vehicle includes an active suspension element that is substantially rigidly attached to a frame of the vehicle such that a motion of an armature of the active suspension element is mechanically decoupled from a lateral motion of a wheel of the vehicle. A control rod is attached between the active suspension element and the wheel of the vehicle.

Claims

1. An active suspension system for a vehicle comprising:

an active suspension element that is substantially rigidly attached to a frame of the vehicle such that a motion of an armature of the active suspension element is substantially mechanically decoupled from a lateral motion of a wheel of the vehicle; and

a control rod that is attached between the armature of the active suspension element and the wheel of the vehicle.

2. The active suspension system of claim 1 wherein the active suspension element is substantially mechanically decoupled from a suspension linkage of the vehicle.

3. The active suspension system of claim 1 wherein the active suspension element is substantially mechanically decoupled from a suspension linkage of the vehicle.

4. The active suspension system of claim 1 wherein the lateral motion comprises at least one of fore-aft and side-side motion.

5. The active suspension system of claim 1 further comprising a passive suspension element that is configured to support a portion of a mass of the vehicle.

6. The active suspension system of claim 1 wherein a first end of the control rod is attached to the active suspension element through one of a ball joint and a bushing.

7. The active suspension system of claim 1 wherein a distance between the active suspension element and a tire of the vehicle is at least two centimeters.

8. A method for actively suspending a chassis of a vehicle, the method comprising:

attaching an active suspension element to a frame of the vehicle such that a motion of an armature of the active suspension element is substantially mechanically decoupled from a lateral motion of a wheel of the vehicle; and

attaching a control rod between the armature of the active suspension element and the wheel of the vehicle.

9. The method of claim 8 further comprising attaching a passive suspension element to a frame of the vehicle.

10. The method of claim 8 wherein the attaching the active suspension element to the frame comprises attaching the active suspension element through a bushing.

11. The method of claim 8 wherein the active suspension element is substantially mechanically decoupled from a suspension linkage of the vehicle.

12. The method of claim 8 wherein the mass of the active suspension element is substantially mechanically decoupled from a steering linkage of the vehicle.

13. The method of claim 8 wherein the lateral motion comprises at least one of fore-aft or side-side motion.

14. An active suspension system for a vehicle comprising:

a linear electromagnetic actuator comprising a stator and an armature that is movable relative to the stator, the stator being substantially rigidly attached to a frame of the vehicle; and

a control rod having a first end that is attached to the armature and having a second end that is attached to a wheel of the vehicle such that a movement of the armature causes the wheel of the vehicle to move relative to the frame of the vehicle.

15. The active suspension system of claim 14 further comprising a passive suspension element that is coupled between the frame of the vehicle and the wheel of the vehicle.

16. The active suspension system of claim 15 wherein the passive suspension element is chosen from the group comprising a spring and a damper.

17. The active suspension system of claim 14 wherein the linear electromagnetic actuator comprises a moving magnet electromagnetic actuator.

18. The active suspension system of claim 14 further comprising a passive suspension element that is coupled between a chassis of the vehicle and the wheel of the vehicle.

19. The active suspension system of claim 14 wherein the stator is attached to the frame of the vehicle through a bushing.

20. The active suspension system of claim 14 wherein the first end of the control rod is attached to the armature through a ball joint.

21. The active suspension system of claim 14 wherein the first end of the control rod is attached to the armature through a bushing.

22. The active suspension system of claim 14 wherein the movement of the armature causes the wheel of the vehicle to move in a substantially vertical direction relative to a horizontal plane of the vehicle.

23. The active suspension system of claim 14 wherein a ratio between a motion of the armature and a motion of the wheel is substantially one-to-one.

24. The active suspension system of claim 14 wherein a ratio between a motion of the armature and a motion of the wheel is less than one-to-one.

25. The active suspension system of claim 14 further comprising a sensor that is attached to one of the linear electromagnetic actuator, the frame, and the wheel.

26. The active suspension system of claim 25 wherein the sensor is integrated with the linear electromagnetic actuator.

27. The active suspension system of claim 14 wherein the control rod comprises a bent portion.

28. The active suspension system of claim 14 wherein the motion of the armature is substantially mechanically decoupled from a lateral motion of the wheel.

29. The active suspension system of claim 14 further comprising a cover that substantially shields the armature.

30. The active suspension system of claim 14 further comprising a bellows that surrounds at least a portion of the control rod.

31. The active suspension system of claim 14 wherein the linear electromagnetic actuator is substantially mechanically decoupled from a steering linkage of the vehicle.

32. A method for actively suspending a chassis of a vehicle comprising:

attaching a stator of a linear electromagnetic actuator to a frame of the vehicle, the chassis of the vehicle being attached to the frame;

attaching a first end of a control rod to an armature of the linear electromagnetic actuator, the armature being movable relative to the stator; and

attaching a second end of the control rod to a wheel of the vehicle such that a movement of the armature causes the wheel of the vehicle to move relative to the frame of the vehicle.

33. The method of claim 32 further comprising attaching a passive suspension element between the frame of the vehicle and the wheel of the vehicle.

34. The method of claim 32 wherein the passive suspension element is chosen from the group comprising a spring and a damper.

35. The method of claim 32 wherein the linear electromagnetic actuator comprises a moving magnet electromagnetic actuator.

36. The method of claim 32 further comprising attaching a passive suspension element between a chassis of the vehicle and the wheel of the vehicle.

37. The method of claim 32 further comprising bushing the stator to the frame of the vehicle.

38. The method of claim 32 further comprising ball joining the first end of the control rod to the armature.

39. The method of claim 32 further comprising bushing the first end of the control rod to the armature.

40. The method of claim 32 wherein the movement of the armature causes the wheel of the vehicle to move in a substantially vertical direction relative to a horizontal plane of the vehicle.

41. A linear electromagnetic actuator of an active suspension system of a vehicle, the actuator comprising:

a stator;

an armature that is magnetically coupled to the stator;

a first bearing that is mechanically coupled to the armature, the first bearing maintaining an air gap between the armature and the stator; and

a second bearing that is mechanically coupled to the stator and substantially mechanically decoupled from the armature, the second bearing absorbing suspension related bending loads, thereby minimizing the suspension related bending loads on the armature.

42. The actuator of claim 41 wherein the stator comprises at least one coil.

43. The actuator of claim 41 wherein the armature comprises at least one magnet.

44. The actuator of claim 41 wherein the first bearing supports a magnetic load from an interaction of the armature and the stator.

45. The actuator of claim 41 wherein the first bearing is mechanically coupled to the second bearing through one of a pin and a flexure.

46. The actuator of claim 41 further comprising a carriage that is mechanically coupled to the second bearing.

47. The actuator of claim 46 wherein the carriage is mechanically coupled to the first bearing through one of a pin and a flexure.

48. The actuator of claim 47 wherein the one of the pin and the flexure allows the carriage to move relative to the first bearing.

49. The actuator of claim 46 wherein the carriage is mechanically coupled to a wheel of the vehicle through a control rod.

50. The actuator of claim 49 wherein one end of the control rod is coupled to the carriage through one of a ball joint and a bushing.

51. A linear electromagnetic actuator for an active suspension system of a vehicle, the actuator comprising:

a stator;

an armature that is magnetically coupled to the stator, the armature being movable relative to the stator;

a housing that surrounds the stator and the armature, an envelope of the housing remaining fixed regardless of the position of the armature relative to the stator.

52. The linear electromagnetic actuator of claim 51 wherein the housing is substantially rigidly attached to a frame of the vehicle.

53. The linear electromagnetic actuator of claim 51 wherein the envelope of the housing comprises the dimensions of the housing.

54. The linear electromagnetic actuator of claim 51 further comprising a control rod having a first end that is attached to the armature and having a second end that is attached to a wheel of the vehicle such that a movement of the armature causes the wheel of the vehicle to move relative to a frame of the vehicle.

55. The linear electromagnetic actuator of claim 51 wherein the armature is mechanically coupled to the stator through a bearing.

56. An active suspension system for a vehicle comprising:

a linear electromagnetic actuator comprising a stator and an armature that is movable relative to the stator, the stator being substantially rigidly attached to a frame of the vehicle; and

a controller that is electrically coupled to the linear electromagnetic actuator through one or more non-flexing cables.

57. The active suspension systme of claim 56 wherein the one or more non-flexing cables comprises at least one of a signal cable and a power cable.

58. The active suspension system of claim 56 wherein the linear electromagnetic actuator further comprises an amplifier that is electrically coupled to the controller.

59. The active suspension system of claim 56 wherein the stator is attached to the frame of the vehicle through a bushing.

60. The active suspension system of claim 56 further comprising a control rod having a first end that is attached to the armature and having a second end that is attached to a wheel of the vehicle such that a movement of the armature causes the wheel of the vehicle to move relative to the frame of the vehicle.

61. An active suspension system for a vehicle comprising:

means for attaching an active suspension element to a frame of the vehicle such that a motion of an armature of the active suspension element is substantially mechanically decoupled from a lateral motion of a wheel of the vehicle; and

means for attaching a control rod between the armature of the active suspension element and the wheel of the vehicle.

62. An electromagnetic actuator for an active suspension system of a vehicle, the actuator comprising:

a stator;

an armature that is magnetically coupled to the stator, the armature being movable relative to the stator;

a housing that surrounds the stator and the armature; and

a first mechanical stop located within the housing, wherein there is relative movement between the armature and the stop when the armature moves, the stop limiting movement of the armature in a first direction.

63. The actuator of claim 62, further including a second mechanical stop located within the housing, wherein there is relative movement between the armature and the second stop when the armature moves, the second stop limiting movement of the armature in a second direction opposite the first direction.

64. The actuator of claim 63, further including a third mechanical stop located within the housing, wherein there is relative movement between the armature and the third stop when the armature moves, the third stop limiting movement of the armature in the second direction.

65. The actuator of claim 62, wherein the stop has a round cross-section.

66. The actuator of claim 62, wherein the stop has a groove.

67. The actuator of claim 62, further including a bearing rail which guides movement of the armature, the stop encircling the bearing rail.

68. The actuator of claim 62, wherein the stop includes neoprene.

69. The actuator of claim 62, wherein the stop includes ethylene propylene diene monomer.

70. An electromagnetic actuator for an active suspension system of a vehicle, the actuator comprising:

a stator;

an armature that is magnetically coupled to the stator, the armature being movable relative to the stator;

a housing that surrounds the stator and the armature; and

a mechanical stop located within the housing, wherein the mechanical stop is made of a material including a polymeric elastomer.

71. The actuator of claim 70, wherein the elastomer is a thermoset polymeric elastomer.

72. The actuator of claim 71, wherein the thermoset polymeric elastomer includes a material chosen from the group consisting of ethylene propylene diene monomer, neoprene, nitrile rubber, polyurethane, silicone rubber, natural rubber, styrene butadiene rubber and fluorocarbons.

73. The actuator of claim 70, wherein the elastomer is a thermoplastic polymeric elastomer.

74. The actuator of claim 73, wherein the thermoplastic polymeric elastomer includes a dynamically vulcanized elastomer.

75. The actuator of claim 70, wherein the polymeric elastomer is in the form selected from a group of forms consisting of a solid foam or a cellular foam.

76. An electromagnetic actuator for an active suspension system of a vehicle, the actuator comprising:

a stator;

an armature that is magnetically coupled to the stator, the armature being movable relative to the stator;

a housing that surrounds the stator and the armature; and

a mechanical stop located within the housing, wherein the mechanical stop has a thickness of from about 10 mm to about 60 mm.

77. The actuator of claim 76, wherein the mechanical stop has a thickness of from about 20 mm to about 50 mm.

78. The actuator of claim 76, wherein the mechanical stop has a thickness of from about 30 mm to about 40 mm.

79. The actuator of claim 76, wherein the mechanical stop has a thickness of about 35 mm.

80. An electromagnetic actuator for an active suspension system of a vehicle, the actuator comprising:

a stator;

an armature that is magnetically coupled to the stator, the armature being movable relative to the stator;

a first bearing rail that guides movement of the armature; and

a first support for supporting a first end of the bearing rail, the support allowing the first end of the bearing rail to move away from a first home position when a first force is applied to the bearing rail, the support returning the first end of the bearing rail to the home position when the force is removed from the first bearing rail.

81. The actuator of claim 80, further including a second support for supporting a second end of the bearing rail, the second support allowing the second end of the bearing rail to move away from a second home position when the force is applied to the bearing rail, the second support returning the second end of the bearing rail to the second home position when the force is removed from the first bearing rail.

82. The actuator of claim 81, further comprising:

a second bearing rail that guides movement of the armature; and

a third support for supporting a first end of the second bearing rail, the third support allowing the first end of the second bearing rail to move away from a third home position when a second force is applied to the second bearing rail, the third support returning the first end of the second bearing rail to the third home position when the second force is removed from the second bearing rail.

83. The actuator of claim 82, further including a fourth support for supporting a second end of the second bearing rail, the fourth support allowing the second end of the second bearing rail to move away from a fourth home position when the second force is applied to the second bearing rail, the fourth support returning the second end of the second bearing rail to the fourth home position when the force is removed from the second bearing rail.

84. The actuator of claim 80, wherein the support includes a mechanical stop which limits movement of the armature.