Modular and Expandable Air Management System

Abstract

An air suspension control system utilizes a suspension control module, one or more pneumatic control modules, and an end cap for controlling air-spring suspension units of different configurations. The system is expandable, and each pneumatic control module has an integrated air-spring pressure sensor, and an electrical connector to connect with an electronic height sensor. The system can level the suspension units based on air-spring pressure or air-spring height. The system is wireless enabled to provide connectivity to smartphone apps and dedicated devices for user interface, and allows for wireless updating of firmware.

Claims

1. A pneumatic control unit comprising: a manifold having an input channel for receiving pressurized air and an output channel for exhausting air from said manifold, said input channel being connected to a pneumatic fitting for conducting said pressurized air from said input channel out of said manifold through a pneumatic fitting and said outlet channel being connected to said pneumatic fitting for receiving air directed into said manifold, a first valve for controlling passage of said pressurized air from said input channel to said pneumatic fitting, a second valve for controlling passage of said air from said pneumatic fitting to said output channel, a sensor for detecting the pressure of said pressurized air and providing a pressure electrical signal representing said pressure of said pressurized air at said pneumatic fitting, and a pneumatic control unit electronic control board responsive to said pressure electrical signal and generating a control signal to operate said first and second valves to adjust said pressure of said pressurized air.

2. A pneumatic control unit according to claim 1 wherein said pressure control unit electronic control board receives height-sensor data.

3. A pneumatic suspension control system comprising a plurality of pneumatic control units according to claim 1, and wherein at least two of said plurality of pneumatic control units are connected together such that an input channel of a first of said plurality of pneumatic control units is in pneumatic communication with an input channel of a second of said plurality of pneumatic control units and an output channel of a first of said plurality of pneumatic control units is in pneumatic communication with an output channel of a second of said plurality of pneumatic control units, and further comprising a suspension control unit electronic control board that receives electrical signals from each pressure control unit of said plurality of pneumatic control units and provides suspension control electrical signals to each of said pneumatic control units.

4. A pneumatic suspension control system according to claim 3 wherein said electrical signals contain pressure data.

5. A pneumatic suspension control system according to claim 4 wherein said electrical signals contain height data.

6. A method of controlling an air-spring suspension system comprising the steps of: providing a pneumatic control system according to claim 2, and connecting a said pneumatic fitting of each of said at least two of said plurality of pneumatic control units to an air-spring suspension unit.

7. A device that provides height and pressure control for the air springs in an air suspension equipped vehicle, consisting of: an SCM (Suspension Control Module), an End Cap, and one or more PCMs (Pneumatic Control Modules), where, the one or more PCMs separate the SCM from the End Cap, where the device additionally comprises one or more Exhaust Ports and one or more Inlet Ports, where the SCM is modularly connected to the one or more PCMs, and where at least one of the one or more PCMs is modularly connected to the End Cap.

8. The device of claim 7, where the SCM comprises an SCM housing, two Mounting Threads, a Bluetooth Module, an EU microprocessor, an Inlet or Supply Pressure Sensor, a Voltage Regulator, a Pneumatic Inlet Fitting, and a Pneumatic Exhaust Fitting, where the SCM Housing is attached to a frame by Mounting Threads, and where the SCM further a CANbus Driver, a Power Filtration Components, an Electrical Interconnect to PCMs function, a Tongue and Groove Mating Features to PCM, a Pneumatic Inlet Fitting and a Pneumatic Exhaust Fitting, additionally comprising a manifold having an input channel for receiving pressurized air and an output channel for exhausting air from said manifold, said input channel being connected to a pneumatic fitting for conducting said pressurized air from said input channel out of said manifold through a pneumatic fitting and said outlet channel being connected to said pneumatic fitting for receiving air directed into said manifold.

9. The device of claim 8, where each PCM comprises a Weather-Sealed Coil Cover, one or more Coil Hold Down Nuts which secure a Pneumatic Solenoid Coil and Yoke Assemblies to a Pneumatic Solenoid Armature/Seal Assemblies with one or more Armature Hold Down Screws, where each PCM additionally comprises a Pneumatic Solenoid Armature/Seal Assemblies that fit into cavities in a Manifold, which serves as a mount for a PCB Assembly, which includes a microprocessor, a CANbus, electronic air pressure sensor and a height sensor signal converter with solenoid Coil Drivers).

10. The device of claim 9, where each PCM additionally comprises a PCM Manifold, which serves as a bottom part of a waterproofing assembly, and where one or more Coil Cover Screws secure a Weather-Sealed Coil Cover to the PCM Manifold, where the PCM manifold has a PCM input channel for receiving pressurized air and a PCM output channel for exhausting air from said PCM manifold, said input channel being connected to a pneumatic fitting for conducting said pressurized air from said input channel out of said manifold through a pneumatic fitting and said outlet channel being connected to said pneumatic fitting for receiving air directed into said manifold, a first valve for controlling passage of said pressurized air from said input channel to said pneumatic fitting, a second valve for controlling passage of said air from said pneumatic fitting to said output channel, a sensor for detecting the pressure of said pressurized air and providing a pressure electrical signal representing said pressure of said pressurized air at said pneumatic fitting, and a pressure control unit electronic control board responsive to said pressure electrical signal and generating a control signal to operate said first and second valves to adjust said pressure of said pressurized air.

11. The device of claim 9, where each PCM additionally comprises an Electrical Interconnect with O-ring Seals, a Height Sensor Connector, a PCM Interconnect Fastener, a Pressure Sealed Pneumatic Supply and an Exhaust Port, where a Pneumatic Fitting to Vehicle Air Spring Port conveys a quantity of air pressure to one or more vehicle air springs, where each PCM additionally comprises a PCB Assembly, where the PCB Assembly comprises one or more Electrical Connectors, a Coil Driver Module, two or more Coil Connectors, a CANbus Module, a Pressure Sensor, and a Microprocessor.

12. A device that provides height and pressure control for the air springs an air suspension equipped vehicle, comprising: an SCM (Suspension Control Module), an End Cap, and one or more PCMs (Pneumatic Control Modules), where, the one or more PCMs separate the SCM from the End Cap, where the device additionally comprises one or more Exhaust Ports and one or more Inlet Ports, where the SCM is modularly connected to the one or more PCMs, and where at least one of the one or more PCMs is modularly connected to the End Cap.

13. The device of claim 12, where the SCM comprises an SCM housing, two Mounting Threads, a Bluetooth Module, an EU microprocessor, an Inlet or Supply Pressure Sensor, a Voltage Regulator, a Pneumatic Inlet Fitting, and a Pneumatic Exhaust Fitting.

14. The device of claim 13, where the SCM Housing is attached to a frame by Mounting Threads, and where the SCM further a CANbus Driver, a Power Filtration Components, an Electrical Interconnect to PCMs function, a Tongue and Groove Mating Features to PCM, a Pneumatic Inlet Fitting and a Pneumatic Exhaust Fitting.

15. The device of claim 14, where each PCM comprises a Weather-Sealed Coil Cover, one or more Coil Hold Down Nuts which secure a Pneumatic Solenoid Coil and Yoke Assemblies to a Pneumatic Solenoid Armature/Seal Assemblies with one or more Armature Hold Down Screws.

16. The device of claim 15 where each PCM additionally comprises a Pneumatic Solenoid Armature/Seal Assemblies that fit into cavities in a Manifold, which serves as a mount for a PCB Assembly, which includes a microprocessor, a CANbus, electronic air pressure sensor and a height sensor signal converter with solenoid Coil Drivers).

17. The device of claim 16, where each PCM additionally comprises a Manifold, which serves as a bottom part of a waterproofing assembly, and where one or more Coil Cover Screws secure a Weather-Sealed Coil Cover to a Manifold.

18. The device of claim 17, where each PCM additionally comprises an Electrical Interconnect with O-ring Seals, a Height Sensor Connector, a PCM Interconnect Fastener, a Pressure Sealed Pneumatic Supply and an Exhaust Port, where a Pneumatic Fitting to Vehicle Air Spring Port conveys a quantity of air pressure to one or more vehicle air springs.

19. The device of claim 18, where each PCM additionally comprises a PCB Assembly, where the PCB Assembly comprises one or more Electrical Connectors, a Coil Driver Module, two or more Coil Connectors, a CANbus Module, a Pressure Sensor, and a Microprocessor.

20. A modular assembly that provides height and pressure control for the air springs an air suspension equipped vehicle, comprising: an SCM (Suspension Control Module), an End Cap, and one or more PCMs (Pneumatic Control Modules), where, the one or more PCMs separate the SCM from the End Cap, where the device additionally comprises one or more Exhaust Ports and one or more Inlet Ports, where the SCM is modularly connected to the one or more PCMs, and where at least one of the one or more PCMs is modularly connected to the End Cap.

21. The modular assembly of claim 20, where the SCM comprises an SCM housing, two Mounting Threads, a Bluetooth Module, an EU microprocessor, an Inlet or Supply Pressure Sensor, a Voltage Regulator, a Pneumatic Inlet Fitting, and a Pneumatic Exhaust Fitting, where the SCM Housing is attached to a frame by Mounting Threads, and where the SCM further a CANbus Driver, a Power Filtration Components, an Electrical Interconnect to PCMs function, a Tongue and Groove Mating Features to PCM, a Pneumatic Inlet Fitting and a Pneumatic Exhaust Fitting.

22. The modular assembly of claim 21, where each PCM comprises a Weather-Sealed Coil Cover, one or more Coil Hold Down Nuts which secure a Pneumatic Solenoid Coil and Yoke Assemblies to a Pneumatic Solenoid Armature/Seal Assemblies with one or more Armature Hold Down Screws, where each PCM additionally comprises a Pneumatic Solenoid Armature/Seal Assemblies that fit into cavities in a Manifold, which serves as a mount for a PCB Assembly, which includes a microprocessor, a CANbus, electronic air pressure sensor and a height sensor signal converter with solenoid Coil Drivers).

23. The modular assembly of claim 22, where each PCM additionally comprises a Manifold, which serves as a bottom part of a waterproofing assembly, and where one or more Coil Cover Screws secure a Weather-Sealed Coil Cover to a Manifold, where the manifold has an input channel for receiving pressurized air and an output channel for exhausting air from said manifold, said input channel being connected to a pneumatic fitting for conducting said pressurized air from said input channel out of said manifold through a pneumatic fitting and said outlet channel being connected to said pneumatic fitting for receiving air directed into said manifold, a first valve for controlling passage of said pressurized air from said input channel to said pneumatic fitting, a second valve for controlling passage of said air from said pneumatic fitting to said output channel, a sensor for detecting the pressure of said pressurized air and providing a pressure electrical signal representing said pressure of said pressurized air at said pneumatic fitting, and a pressure control unit electronic control board responsive to said pressure electrical signal and generating a control signal to operate said first and second valves to adjust said pressure of said pressurized air.

24. The modular assembly of claim 23, where each PCM additionally comprises an Electrical Interconnect with O-ring Seals, a Height Sensor Connector, a PCM Interconnect Fastener, a Pressure Sealed Pneumatic Supply and an Exhaust Port, where a Pneumatic Fitting to Vehicle Air Spring Port conveys a quantity of air pressure to one or more vehicle air springs.

25. The modular assembly of claim 24, where each PCM additionally comprises a PCB Assembly, where the PCB Assembly comprises one or more Electrical Connectors, a Coil Driver Module, two or more Coil Connectors, a CANbus Module, a Pressure Sensor, and a Microprocessor. wherein said pressure control unit electronic control board receives height-sensor data, wherein at least two of a plurality of pneumatic control units are connected together such that an input channel of a first of said plurality of pneumatic control units is in pneumatic communication with an input channel of a second of said plurality of pneumatic control units and an output channel of a first of said plurality of pneumatic control units is in pneumatic communication with an output channel of a second of said plurality of pneumatic control units, and further comprising a suspension control unit electronic control board that receives electrical signals from each pressure control unit of said plurality of pneumatic control units and provides suspension control electrical signals to each of said pneumatic control units.

26. The modular assembly of claim 25, wherein said electrical signals contain pressure data.

27. The modular assembly of claim 26, wherein said electrical signals contain height data.

28. A method of assembling a device that provides height and pressure control for the air springs in an air suspension equipped vehicle, consisting of: a first step of obtaining an SCM (Suspension Control Module), an End Cap, and one or more PCMs (Pneumatic Control Modules), a second step of installing the one or more PCMs on between the SCM and the End Cap, where the device additionally comprises one or more Exhaust Ports and one or more Inlet Ports, where the SCM is modularly connected to the one or more PCMs, and where at least one of the one or more PCMs is modularly connected to the End Cap.

29. The method of claim 28, where the SCM comprises an SCM housing, two Mounting Threads, a Bluetooth Module, an EU microprocessor, an Inlet or Supply Pressure Sensor, a Voltage Regulator, a Pneumatic Inlet Fitting, and a Pneumatic Exhaust Fitting, where the SCM Housing is attached to a frame by Mounting Threads, and where the SCM further a CANbus Driver, a Power Filtration Components, an Electrical Interconnect to PCMs function, a Tongue and Groove Mating Features to PCM, a Pneumatic Inlet Fitting and a Pneumatic Exhaust Fitting.

30. The method of claim 29, where each PCM comprises a Weather-Sealed Coil Cover, one or more Coil Hold Down Nuts which secure a Pneumatic Solenoid Coil and Yoke Assemblies to a Pneumatic Solenoid Armature/Seal Assemblies with one or more Armature Hold Down Screws, where each PCM additionally comprises a Pneumatic Solenoid Armature/Seal Assemblies that fit into cavities in a Manifold, which serves as a mount for a PCB Assembly, which includes a microprocessor, a CANbus, electronic air pressure sensor and a height sensor signal converter with solenoid Coil Drivers).

31. The method of claim 30, where each PCM additionally comprises a Manifold, which serves as a bottom part of a waterproofing assembly, and where one or more Coil Cover Screws secure a Weather-Sealed Coil Cover to a Manifold.

32. The method of claim 31, where the manifold has an input channel for receiving pressurized air and an output channel for exhausting air from said manifold, said input channel being connected to a pneumatic fitting for conducting said pressurized air from said input channel out of said manifold through a pneumatic fitting and said outlet channel being connected to said pneumatic fitting for receiving air directed into said manifold, a first valve for controlling passage of said pressurized air from said input channel to said pneumatic fitting, a second valve for controlling passage of said air from said pneumatic fitting to said output channel, a sensor for detecting the pressure of said pressurized air and providing a pressure electrical signal representing said pressure of said pressurized air at said pneumatic fitting, and a pressure control unit electronic control board responsive to said pressure electrical signal and generating a control signal to operate said first and second valves to adjust said pressure of said pressurized air.

33. The method of claim 32 wherein said pressure control unit electronic control board receives height-sensor data.

34. The method of claim 33, where there is a plurality of pneumatic control units, and, wherein at least two of said plurality of pneumatic control units are connected together such that an input channel of a first of said plurality of pneumatic control units is in pneumatic communication with an input channel of a second of said plurality of pneumatic control units and an output channel of a first of said plurality of pneumatic control units is in pneumatic communication with an output channel of a second of said plurality of pneumatic control units, and further comprising a suspension control unit electronic control board that receives electrical signals from each pressure control unit of said plurality of pneumatic control units and provides suspension control electrical signals to each of said pneumatic control units, wherein said electrical signals contain pressure data, wherein said electrical signals contain height data.

35. The method of claim 34, where each PCM additionally comprises an Electrical Interconnect with O-ring Seals, a Height Sensor Connector, a PCM Interconnect Fastener, a Pressure Sealed Pneumatic Supply and an Exhaust Port, where a Pneumatic Fitting to Vehicle Air Spring Port conveys a quantity of air pressure to one or more vehicle air springs.

36. The method of claim 35, where each PCM additionally comprises a PCB Assembly, where the PCB Assembly comprises one or more Electrical Connectors, a Coil Driver Module, two or more Coil Connectors, a CANbus Module, a Pressure Sensor, and a Microprocessor.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0012] FIG. 1a is perspective view of an assembled system according to the invention.

[0013] FIG. 1b is an exploded view of the system of FIG. 1a.

[0014] FIG. 2 is a longitudinal cross section of the system shown in FIG. 1a.

[0015] FIG. 3 is an exploded view of the components of one pneumatic control module shown in FIG. 1b.

[0016] FIG. 4 is a transverse cross section of a pneumatic control module shown in FIG. 1b.

[0017] FIG. 5a is a perspective of top of a printed circuit board shown in FIG. 3.

[0018] FIG. 5b is a perspective of the bottom of the printed circuit board shown in FIG. 5a.

[0019] FIG. 6 is an exploded perspective of a suspension control module of the system shown in FIG. 1.

[0020] FIG. 7a is a perspective of a front side of a printed circuit board shown in FIG. 6.

[0021] FIG. 7b is a perspective of a rear side of the printed circuit board shown in FIG. 7a.

DETAILED DESCRIPTION OF THE FIGURES

[0022] FIG. 1a shows a suspension control system 1 according to the invention completely assembled. System 1 is designed to be connected to and control four known air-suspension units that are mounted to a vehicle in a known manner; neither the vehicle nor an air-suspension unit is illustrated in these drawings. Suspension control system 1 as shown in FIGS. 1a and 1b has four pneumatic control units 3 (also referred to herein as modules). As will be explained in more detail below, air under pressure is introduced to the system 1 from a pump (not shown) at supply port 14, and excess air is discharged at exhaust port 15.

[0023] FIG. 2 illustrates the serial connection of four pneumatic control modules 3, as illustrated in FIG. 1a. Screws 12 are shown holding each pair of modules 3 together, but other means, such as clamps or adhesives may be employed. Pressure sensors 10 and their associated internal channels are also seen in this figure.

[0024] FIG. 3 is an exploded perspective of a single pneumatic control unit 3. Control unit 3 includes two pneumatic solenoid valve armatures 17, each of which is electrically controlled by a respective solenoid coil and yoke assembly 16. The pneumatic solenoid valve armatures 17 are mounted on a pneumatic control manifold 19 by screws 8. Manifold 19 includes internal channels to connect pneumatic fitting 21, selectively, to supply port 14 and exhaust port 15. Pneumatic fitting 21 is in turn connected to an air-spring suspension unit on a vehicle. A printed circuit board 18 is mounted to the manifold 19 with screws 9 between the pneumatic solenoid valve armatures and the manifold.

[0025] FIG. 4 is a transverse cross section of a module 3.

[0026] The printed circuit board 18 is shown in more detail in FIGS. 5a and 5b. Board 18 gathers data from its pressure and height sensors and communicates these signals to the suspension control module. In turn, the suspension control module calculates the current versus desired state of the air spring suspension based on conditions and user input and commands board 18 to control the operation of the solenoids 16 resulting in a change in pressure and height of the air spring. Thus, a pneumatic solenoid valve armature 17 that controls air flow between supply port 14 and pneumatic fitting 21 can be opened by activation of the coil and yoke assembly 16 that controls that armature to increase the pressure in an air-spring suspension. Conversely the pneumatic solenoid valve armature 17 controlling air flow between the exhaust port 15 and pneumatic fitting 21 can be opened by activation of the other coil and yoke assembly 16 to reduce the pressure in the air-spring suspension.

[0027] Board 18 includes air-spring suspension pressure sensor 10 which communicates with the pneumatic fitting 21 to provide electronic data to microprocessor 21 of the pressure in the air-spring suspension. Electrical interconnectors 22 provide electrical connection between one or more other pneumatic control modules 3 and the suspension control module.

[0028] Referring to FIG. 3, a pneumatic control module 3 further includes a cover 5, which is attached to the manifold by screws 7 at holes 6 to render the module weatherproof. Also, as shown in FIG. 3, the supply port 14 and exhaust port 15 have nipples that allow these ports to connect with an adjacent manifold or module, and interconnect seals 13 are provided to prevent leakage. A height sensor, not shown, is provided to sense the height of the air-spring suspension and can be physical or otherwise. The height sensor provides electronic data regarding height, the data being supplied to board 18 by a connector 11.

[0029] FIG. 6 is an exploded view of a suspension control module 2. This module includes a manifold 28 with pneumatic inlet through hole 37 and exhaust through hole 38, which connect with inlet 14 and exhaust 15, respectively, of an adjacent pneumatic control module. Projections 39 ensure alignment with an adjacent module 3. A weather sealed housing 27 is secured to the manifold 28 by screws 29. A printed circuit board 31 is carried in the housing 27, the board 31 having a supply pressure sensor 36, which communicates with air channel 36′, and an electrical connector 35 to receive electronic data from the pneumatic control units, and send commands to the pneumatic control units in order to cause increased or decreased pressure in the air-spring suspension units. A cover 32 encloses the housing by screws 33 and provides opening 34 for the connector 35.

[0030] FIGS. 7a and 7b show the front and back of the board 31. The board 31 includes wireless (e.g., Bluetooth) module 40, microprocessor 41, voltage regulator 42, driver 43, and electronic filters 44.

[0031] It will be appreciated that a system as described above provides one or more of the following advantages:

[0032] The modularity and expansion capability of the invention allows the suspension control module, any number of pneumatic control modules, and an end cap to be used in a variety of applications having different numbers of air-spring suspension units. For example, several common uses are:

[0033] Two rear air-spring suspension units can be operated in unison by using a tee to divide a single pressure supply between left and right air-spring units. This arrangement works well if there is no offset load or tall center of mass that will allow too much sway around corners. Such a use would require only a single pneumatic control unit along with a suspension control module and an end cap and is often termed a “1-corner system”.

[0034] Two rear air-spring suspension units can be operated independently in order to balance an offset load or prevent sway around corners. This use would require two pneumatic control modules, in addition to a suspension control module and an end cap. This arrangement is often termed a “2-corner system.”

[0035] A system having four air-spring suspension units can place two units at the left and right sides of a vehicle and two air-spring suspension system toward the rear left and right sides of the vehicle. The two rear two air-spring suspension units may be connected by a tee to a common source of air from a single pneumatic control module, while the front two units are individually controlled, respectively by two pneumatic control units. This arrangement requires three pneumatic control units, as well as a suspension control module and an end cap and is often termed a “3-corner system”.

[0036] A system having four air-spring suspension units as described above may use separate air sources for each of the four air-spring suspension units. This arrangement would require four pneumatic control modules, a suspension control module, and an end cap. Such a system is often termed a “four-corner system”.

[0037] Trucks, buses, or military vehicles with air suspension and more than 2-axles, or any towing vehicle with air suspension that pulls a trailer that also has air suspension could utilize more than 4 pneumatic control modules, a suspension control unit, and an end cap.

[0038] Field Expandable - The simple mechanical interconnect solutions allow simple field upgradability or service of a single pneumatic control module in the case of a failure.

[0039] Multiple Sensing Options - Each pneumatic control module has an integrated air-spring pressure sensor and an electrical plug to connect with an electronic height sensor. This capability allows the system to level a vehicle based on air spring pressure or air spring height depending on the customer use case.

[0040] Bluetooth Enabled SCM - The Bluetooth Low Energy (BLE) module located inside of the SCM gives the system wireless connectivity, for example, to smartphone apps and dedicated BLE devices for user interface. This communication gateway also allows for Over the Air (OTA) updating of the firmware inside of the suspension control module and pneumatic control module(s) in order to bring enhanced features and functionality to the system over time.

[0041] Sleek and Compact - The industrial design with optional aluminum cover makes for a visually attractive solution for display in visual installations. The compact packaging design allows for minimal space consumption (approximately 3.3″× 3.0″× 8.0″ for the 4-Corner configuration).