INTERNAL GAS SPRING DISPLACEMENT SENSORS AS WELL AS GAS SPRING ASSEMBLIES AND SUSPENSION SYSTEMS INCLUDING SAME
20190111751 ยท 2019-04-18
Inventors
- Larry L. Lockridge (Fishers, IN, US)
- Samuel N. Mbugua (Zionsville, IN, US)
- Bryce A. Carrico (Fort Wayne, IN, US)
- Michael E. Hunley (Fort Wayne, IN, US)
- Erik T. Cowans (Fort Wayne, IN, US)
Cpc classification
B60G17/019
PERFORMING OPERATIONS; TRANSPORTING
F16F2230/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16F9/369
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16F9/05
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16F9/3292
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16F2222/126
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F16F9/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16F9/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
G01S7/481
PHYSICS
Abstract
Displacement sensors can include a photon source and a target surface disposed in spaced relation to the photon source. Displacement sensors can also include a photon receptor disposed along an associated gas spring end member in spaced relation to the target surface. A processor can be communicatively coupled with the photon source and the photon receptor. The photon source can be operable to direct photons toward the target surface. The photon receptor can be operable to generate a signal upon receiving photons reflected off the target surface from the photon source. The processor can operate to determine a distance having a relationship to a time of flight of photons reflected off of the target surface from the photon source and received at the photon receptor. A gas spring assembly including such a displacement sensor, and a suspension system including one or more of such gas spring assemblies are also included.
Claims
1. A gas spring assembly having a longitudinal axis, said gas spring assembly comprising: a flexible spring member including a flexible wall extending peripherally about said longitudinal axis and axially between opposing first and second ends of said flexible spring member to at least partially define a spring chamber therebetween; a first end member secured along said first end of said flexible spring member such that a substantially fluid-tight seal is formed therebetween; a second end member disposed in axially-spaced relation to said first end member, said second end member secured along said second end of said flexible spring member such that a substantially fluid-tight seal is formed therebetween; a photon source operatively disposed along one of said first end member and said second end member; a target surface operatively disposed along one of said first end member and said second end member; a photon receptor operatively disposed along the other of said first end member and said second end member relative to said target surface; and, a processor communicatively coupled with said photon source and said photon receptor; said photon source operable to direct photons toward said target surface through at least a portion of said spring chamber, said photon receptor operable to generate a signal upon receiving photons reflected off said target surface from said photon source, and said processor operable to determine a distance having a relationship a time of flight of photons reflected off of said target surface from said photon source and received at said photon receptor.
2. A gas spring assembly according to claim 1, wherein said photon source includes a laser diode.
3. A gas spring assembly according to claim 2, wherein said laser diode is in the form of a vertical-cavity surface-emitting laser.
4. A gas spring assembly according to claim 1, wherein said photon source emits photons having a wavelength within a range of from approximately 650 nm to approximately 2000 nm.
5. A gas spring assembly according to claim 1, wherein said photon receptor includes a single-photon avalanche diode (SPAD) array.
6. A gas spring assembly according to claim 1, wherein said target surface has a reflectance as low as approximately three (3) percent.
7. A gas spring assembly according to claim 1, wherein said target surface is at least partially formed by a material having a reflectance of at least thirty (30) percent.
8. A gas spring assembly according to claim 1, wherein said target surface is at least partially formed by a material having one of diffuse reflectance, specular reflectance and retroreflectance.
9. A gas spring assembly according to claim 1 further comprising a sensor assembly supported on one of said first end member and said second end member, said sensor assembly including said photon source and said photon receptor.
10. A gas spring assembly according to claim 9, wherein said sensor assembly includes an ambient light sensor communicatively coupled with at least one of said photon source and said photon receptor.
11. A gas spring assembly according to claim 1, wherein said target surface is oriented transverse to said longitudinal axis and supported along said first end member, and said photon source and said photon receptor are supported along said second end member such that photons are emitted and reflected in an approximately longitudinal direction.
12. A gas spring assembly according to claim 11, wherein said second end member includes an end member wall with a passage extending therethrough that is oriented transverse to said longitudinal axis, and said sensor assembly extends into fluid communication with said spring chamber through said passage.
13. A gas spring assembly according to claim 12 further comprising a sealing element fluidically disposed between said end member wall and said sensor assembly such that a substantially fluid-tight seal is formed therebetween.
14. (canceled)
15. A displacement sensor comprising: a photon source and a target surface disposed in spaced relation to said photon source; a photon receptor disposed along an associated gas spring end member in spaced relation to said target surface; and, a processor communicatively coupled with said photon source and said photon receptor; said photon source operable to direct photons toward said target surface, said photon receptor operable to generate a signal upon receiving photons reflected off said target surface from said photon source, and said processor operable to determine a distance having a relationship to a time of flight of photons reflected off of said target surface from said photon source and received at said photon receptor.
16. A displacement sensor according to claim 15, wherein said photon source includes a laser diode.
17. A displacement sensor according to claim 16, wherein said laser diode is in the form of a vertical-cavity surface-emitting laser.
18. A displacement sensor according to claim 15, wherein said photon source emits photons having a wavelength within a range of from approximately 650 nm to approximately 2000 nm.
19. A displacement sensor according to claim 15, wherein said photon receptor includes a single-photon avalanche diode (SPAD) array.
20. A displacement sensor according to claim 15 further comprising an ambient light sensor communicatively coupled with at least one of said photon source and said photon receptor.
21. A displacement sensor according to claim 15 further comprising a sensor body containing at least a portion of at least one of said photon source and said photon receptor.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0023] Turning now to the drawings, it is to be understood that the showings are for purposes of illustrating examples of the subject matter of the present disclosure and are not intended to be limiting. Additionally, it will be appreciated that the drawings are not to scale and that portions of certain features and/or elements may be exaggerated for purpose of clarity and ease of understanding.
[0024]
[0025] The suspension system can also include a plurality of gas spring assemblies supported between the sprung and unsprung masses of the associated vehicle. In the arrangement shown in
[0026] Suspension system 100 also includes a pressurized gas system 104 operatively associated with the gas spring assemblies for selectively supplying pressurized gas (e.g., air) thereto and selectively transferring pressurized gas therefrom. In the exemplary embodiment shown in
[0027] Valve assembly 108 is in communication with gas spring assemblies 102 through suitable gas transfer lines 118. As such, pressurized gas can be selectively transferred into and/or out of the gas spring assemblies through valve assembly 108 by selectively operating valves 112, such as to alter or maintain vehicle height at one or more corners of the vehicle, for example.
[0028] Suspension system 100 can also include a control system 120 that is capable of communication with any one or more systems and/or components (not shown) of vehicle VHC and/or suspension system 100, such as for selective operation and/or control thereof. Control system 120 can include a controller or electronic control unit (ECU) 122 communicatively coupled with compressor 106 and/or valve assembly 108, such as through a conductor or lead 124, for example, for selective operation and control thereof, which can include supplying and exhausting pressurized gas to and/or from gas spring assemblies 102. Controller 122 can be of any suitable type, kind and/or configuration.
[0029] In accordance with the subject matter of the present disclosure, control system 120 can also include one or more height (or distance) sensing devices 126 (which are also referred to herein by terms such as displacement sensors and the like), such as, for example, may be operatively associated with the gas spring assemblies and capable of outputting or otherwise generating data, signals and/or other communications having a relation to a height of the gas spring assemblies or a distance between other components of the vehicle. Height sensing devices 126 can be in communication with ECU 122, which can receive the height or distance signals therefrom. The height sensing devices can be in communication with ECU 122 in any suitable manner, such as through conductors or leads 128, for example. In a preferred arrangement, in accordance with the subject matter of the present disclosure, height sensing devices 126 can be of a type, kind and/or construction that utilize time-of-flight measurement of photons to generate data, signals and/or other communications having a relation to a height of the gas spring assemblies or to a distance between other components of the vehicle.
[0030] One example of a gas spring assembly 200 in accordance with the subject matter of the present disclosure is shown in
[0031] Gas spring assembly 200 can be disposed between associated sprung and unsprung masses of an associated vehicle in any suitable manner. For example, one end member can be operatively connected to the associated sprung mass with the other end member disposed toward and operatively connected to the associated unsprung mass. In the arrangement shown in
[0032] Additionally, a fluid communication port, such as a transfer passage 214 (
[0033] End member 204 can be secured along a second or lower structural component LSC, such as an axle AXL in
[0034] It will be appreciated that the one or more end members can be of any suitable type, kind, construction and/or configuration, and can be operatively connected or otherwise secured to the flexible wall in any suitable manner. In the exemplary arrangement shown in
[0035] As identified in
[0036] Body 226 also includes a second inner side wall 246 that extends longitudinally inward into the body from along end wall 234. Second inner side wall 246 terminates at an end or bottom wall 248 that is approximately planar and disposed transverse to axis AX such that second inner side wall 246 and bottom wall 248 at least partially define a cavity 250 within body 226. In some cases, bridge walls 252 can, optionally, extend between and operatively interconnect outer side wall 232 and second inner side wall 246.
[0037] An inner support wall 254 is disposed radially inward from outer side wall 232 and extends peripherally about axis AX. In some cases, inner support wall 254 can form a hollow column-like structure that projects from along bottom wall 248 in a longitudinal direction toward end 230. In some cases, the distal end of outer side wall 232 and/or the distal end of inner support wall 254 can at least partially define a mounting plane MP formed along end 230 of the end member body. In this manner, body 226 can be supported at least in part by outer side wall 232 and/or inner support wall 254, such as on or along an associated structural member (e.g., lower structural component LSC in
[0038] Body 226 can also include a central or support post wall 256 that is disposed radially inward from inner support wall 254 and forms a post-like structure that projects from along bottom wall 248 in a direction toward end 230. In some cases, central wall 256 can terminate in approximate alignment with mounting plane MP, such as is illustrated in
[0039] Additionally, end member body 226 of end member 204 can include a bumper mount 258 that is disposed along bottom wall 248 and projects outwardly therefrom in an axial direction toward end 228 of the end member body. Additionally, as indicated above, end member 204 can include any number of one or more features and/or components. For example, end member 204 can include an insert 260 that is embedded (e.g., molded) into or otherwise captured and retained within end member body 226. Insert 260 can function to assist in securing the end member on or along an associated structural component, such as providing a mounting and/or securement point for the end member. As one example, insert 260 can include a hole or opening 262 that can extend into the insert body from along an end surface 264. In a preferred arrangement, the insert body can include a securement feature. In the arrangement shown, the securement feature can take the form of one or more helical threads that are cooperative with corresponding securement features (e.g., one or more helical threads formed on or along threaded fastener 216.
[0040] Gas spring assembly 200 can also, optionally, include a jounce bumper 266 that can be supported within spring chamber 208, such as to inhibit direct contact between end members 202 and 204, for example. It will be appreciated that the jounce bumper, if included, can be supported on or along an end member in any suitable manner. For example, jounce bumper 266 is shown as being received on and retained in position on or along end member 204 by bumper mount 258.
[0041] Gas spring assembly 200 is also shown in
[0042] Additionally, it will be appreciated that displacement sensor 268 can be connected to other systems and/or components of a vehicle suspension system in any suitable manner. For example, displacement sensor 268 could include one or more leads or conductors 276 that can be used to provide electrical power to the displacement sensor and/or for communication purposes (e.g., signals, data and/or communication transfer to and/or from the displacement sensor), such as is indicated by leads 128 of control system 120 in
[0043] During use, in accordance with the subject matter of the present disclosure, displacement sensor 268 is shown in
[0044] For example, though optional, gas spring assembly 200 and/or displacement sensor 268 can include a reflective target 282 having a target surface 284 off of which photons can be reflected from photon source 272 toward photon receptor 274, such as is shown in
[0045] Another example of a gas spring assembly in accordance with the subject matter of the present disclosure can take the form of a gas spring and damper assembly 300, as is shown in
[0046] Gas spring and damper assembly 300 is shown in
[0047] Elongated rod 322 is shown in
[0048] It will be appreciated that gas spring and damper assembly 300 can be operatively connected between associated sprung and unsprung masses of an associated vehicle (or other construction) in any suitable manner. For example, one end of the assembly can be operatively connected to the associated sprung mass with the other end of the assembly disposed toward and operatively connected to the associated unsprung mass. As shown in
[0049] Gas spring assembly 304 includes an end member 334, such as a top cap, bead plate or reservoir enclosure, for example. Gas spring assembly 304 also includes an end member 336, such as a roll-off piston or piston assembly, for example, that is disposed in axially-spaced relation to end member 334. A flexible spring member 338, in accordance with the subject matter of the present disclosure, can be operatively connected between end members 334 and 336 in a substantially fluid-tight manner such that a spring chamber 340 is at least partially defined therebetween. In some cases, flexible spring member 338 can form a rolling lobe 342 that is displaced along an outer surface 344 of end member 336 as gas spring and damper assembly 300 moves between extended (i.e., rebound) and compressed (i.e., jounce) conditions. As shown in
[0050] As discussed above, gas spring and damper assembly 300 can be operatively connected between associated sprung and unsprung masses of an associated vehicle (or other structure) in any suitable manner. As shown in
[0051] A fluid communication port can optionally be provided to permit fluid communication with spring chamber 340, such as may be used for transferring pressurized gas into and/or out of the spring chamber, for example. It will be appreciated that such a fluid communication port can be provided in any suitable manner. As one example, a fluid communication port could extend through one or more of mounting studs 352. As another example, end member 334 can include a transfer passage 354 extending therethrough that is in fluid communication with spring chamber 340. It will be appreciated, however, that any other suitable fluid communication arrangement could alternately be used. In some cases, passage 354 can be adapted to receive a suitable connector fitting 356, such as may be suitable for operatively connecting gas transfer lines 118 in
[0052] An opposing end 358 of flexible sleeve 338 can be secured on or along end member 334 in any suitable manner. As one example, a portion of the flexible sleeve can be secured in abutting engagement along a wall portion of end member 334 by way of a retaining ring 360 that can be crimped radially inward or otherwise deformed to form a substantially fluid-tight connection therebetween. Additionally, gas spring and damper assembly 300 can, optionally, include an external sleeve or support, such as a restraining cylinder 362, for example, that can be secured on or along the flexible sleeve in any suitable manner. As one example, a portion of the flexible sleeve can be secured in abutting engagement along a wall portion of restraining cylinder 362 by way of a retaining ring 364 that can be crimped radially outward or otherwise deformed to form engagement between the restraining cylinder and the flexible sleeve. It will be appreciated, however, that other arrangements could alternately be used.
[0053] Gas spring and damper assembly 300 can also, optionally, include one or more additional components and/or features. For example, an accordion-type bellows 366 can extend along at least a portion of the gas spring and damper assembly and can be secured to one or more components thereof in any suitable manner, such as by way of retaining rings 368, for example. As another example, a seal assembly 370 can be disposed in fluid communication between damper housing 306 and end member 336, such that a substantially fluid-tight seal can be formed therebetween. As a further example, a jounce bumper 372 can be disposed within spring chamber 340 and can be supported on or along one of end members 334 and 336 in a suitable manner. In the arrangement shown in
[0054] Gas spring assembly 304 of gas spring and damper assembly 300 is also shown in
[0055] Additionally, it will be appreciated that displacement sensor 376 can be communicatively coupled or otherwise connected to other systems and/or components of a vehicle suspension system in any suitable manner. For example, displacement sensor 376 could include one or more leads or conductors 386 that can be used to provide electrical power to the displacement sensor and/or for communication purposes (e.g., signals, data and/or communication transfer to and/or from the displacement sensor), such as is indicated by leads 128 of control system 120 in
[0056] During use, in accordance with the subject matter of the present disclosure, displacement sensor 376 is shown in
[0057] Again, depending upon the anticipated conditions of use in a particular application and the desired performance characteristics and/or robustness of operation, the target surface (whether a surface of the target feature or component or a dedicated reflective surface, such as reflective surface 390) can have a diffuse reflectance, a specular reflectance or a retroreflectance. As will be discussed in greater detail hereinafter, displacement sensor 376, or a system or component operatively associated with the displacement sensor, can be operable to determine time of flight of photons traveling at the speed of light (i.e., 299,700,000 meters per second in air) from the photon source, to the reflective surface and then to the photon receptor. It will be appreciated that the roundtrip distance traveled by the photons will have a relation to the time of flight. Thus, by determining the time of flight of the photons, displacement sensor 376, or a system or component operatively associated with the displacement sensor, can then determine a height or distance associated with the gas spring assembly or other components of a suspension system.
[0058]
[0059] In the configuration shown in
[0060] Additionally, it will be appreciated that displacement sensor 376 can be secured on or along the associated end member (e.g., one of end members 334 and 336) in any suitable manner. As one example, sensor body 378 can include one or more mounting holes 408, such as may be suitable for receiving securement devices (not shown) dimensioned to cooperatively engage the associated end member to attach or otherwise secure the displacement sensor thereon. In a preferred arrangement, sensor body 378 can include one or more compression limiting features, such as compression limiting cylinders 410, for example, that are operative to substantially inhibit inadvertent deflection and/or deformation of sensor body 378 and/or other components of displacement sensor 376, such as might otherwise occur during installation, for example.
[0061]
[0062] Sensor 500 includes a photon source 506 that is operable to emit photons through a lens 508 toward target surface 504, as is represented in
[0063] Delay detector 516 can be constructed or otherwise provided in any suitable manner. As one example, a delay detection circuit could be used, such as is described in detail in U.S. Patent Publication No. 2016/0291316, which was published on Oct. 6, 2016 in the names of STMicroelectronics Limited of Marlow Bucks, Great Britain and STMicroelectronics SAS of Grenoble, France, and entitled OPTICAL SIGNAL GENERATION IN A SPAD ARRAY. Alternately, the delay detector could include a combination of hardware, firmware and/or software operable to determine a time difference between the emission of photons from photon source 506 and the detection of emitted photons at photon receptor 510. For example, displacement sensor 500 is shown in
[0064] Additionally, displacement sensor 500 can include a non-transitory storage device or memory, which can be of any suitable type, kind and/or configuration that can be used to store data, values, settings, parameters, inputs, software, algorithms, routines, programs and/or other information or content for any associated use or function, such as use in association with the determination of a time difference between the emission of photons from photon source 506 and the detection of emitted photons at photon receptor 510 and/or with the performance and/or operation of the displacement sensor 500 as well as any systems, components and/or features of the gas spring assemblies and/or suspension system with which the displacement sensor may be operatively associated.
[0065] As such, displacement sensor 500 can include a non-transitory storage device or memory, which is represented in
[0066] Displacement sensor 500 can also include any other components, circuits, data, values, settings, parameters, inputs, software, algorithms, routines, programs and/or other information or content for operation and use of the displacement sensor. For example, displacement sensor 500 can include a frequency generator 522 that can be implemented as any combination of circuitry and software. A clock signal CLK can be provided to frequency generator 522, which can generate a voltage signal 524 that is provided to a driver 526 for generating a signal for driving photon source 506. Delay detector 516 can also be operative to generate and communicate phase control signals 528 to frequency generator 522, such as is described in detail in U.S. Patent Publication No. 2016/0291316 discussed above.
[0067] Displacement sensor 500 can further include an ambient light sensor 530 that is operable to detect a level of ambient light in a surrounding environment through lens 532, such as is represented by arrows ABL in
[0068] Using such an arrangement, displacement sensor 500 can function as an extremely accurate ride height sensor that is capable of providing signals, data and/or other information regarding an average relative distance between gas spring end members and/or other components of a vehicle or other structure. Advantageously, displacement sensor 500 can accomplish these and other functions from the enclosed environment of the interior of a gas spring assembly (e.g., gas spring assemblies 102, 200 and 304), thereby isolating the displacement sensor and any reflector target, if provided, from the deleterious effects of environments to which vehicle suspension systems are commonly exposed.
[0069] It will be appreciated that photon source 506 can take the form of any suitable type and/or kind of device. As one example, photon source 506 can include a laser diode. In a preferred arrangement, the laser diode can take the form of a vertical-cavity surface-emitting laser (VCSEL). It will be appreciated that photon source 506 can emit photons having any suitable wavelength, such as a wavelength in a range of from approximately six hundred fifty (650) nanometers to approximately two thousand (2000) nanometers, for example. Additionally, it will be appreciated that photon receptor 510 and reference photon detector 514 can be of any suitable type, kind and/or construction. In a preferred construction, photon receptor 510 and reference photon detector 514 can include single-photon avalanche diode (SPAD) arrays, such as are described in U.S. Patent Publication No. 2016/0291316 discussed above.
[0070] As discussed above, the subject matter of the present disclosure can include an integrated circuit that measures instantaneous, absolute displacement based measurements using the time of flight of emitted photons. Such a construction will allow absolute distance measurement independent of target reflectance by precisely measuring the time the light takes to travel to the target reflector. Displacement sensors in accordance with the subject matter of the present disclosure can operate within a range of from approximately zero (0) centimeters to approximately twenty (20) centimeters, with one hundred (100) centimeter ranging being possible using specific reflected target material.
[0071] It has been determined that ambient light conditions within a gas spring assembly can be as low as 0.5 lumens. As such, a displacement sensor in accordance with the subject matter of the present disclosure is preferably designed to function properly under ambient light conditions within a range of from approximately zero (0) lumens to full sunlight. Additionally, as it concerns target reflectors and the reflectance of target surfaces, it will be appreciated that any one of various reflector surfaces can be used. In some cases, a natural or untreated surface of an existing component having a reflectance of as low as three (3) percent could be used. In other cases, reflector surfaces can be utilized that provide improved accuracy and/or robustness of operation, such as accuracy resolution for the displacement of less than one (1) millimeter can be used. Such an internal height sensor can be powered by a 5V voltage regulated and coupled source, with an adjustable digital output rate, such as a 16-bit digital output rate, for example, of the signal with an adjustable sample rate, such as ten (10) averaged samples. An intended operation range of this internal height sensor can be within a temperature range of approximately 40 C. to approximately 85 C.
[0072] In some cases, details and/or specifications such as those described below can correspond to additional operating parameters and/or performance characteristics of a displacement sensor in accordance with the subject matter presented in this application. For example, in some cases an absolute accuracy within a range of +/4 millimeters can be used with a range of +/1 millimeter being achieved under certain conditions of use. As another example, in some cases a relative accuracy within a range of +/2 millimeter can be used. As a further example, in some cases a sampling period of approximately 10 milliseconds can be used in which case the displacement sensor can report a new height or distance measurement every 10 milliseconds.
[0073] In order to meet the difficult environmental requirements associated with certain applications and/or conditions of use, a displacement sensor assembly in accordance with the subject matter of the present disclosure can include one or more of an injection molded housing and an over-molded housing of the sensor's circuitry. In the case of injection molded housings, a single-piece clear polymeric (e.g., polycarbonate) part can be used where the printed circuit board was populated, then inserted into the housing. A potting compound can be shot into the housing to seal the unit. The housing can have a gasket on the end nearest to the optics sensor that prevents the potting compound from entering that part of the housing and to aid against corrupting the optics and thereby creating an air cavity around the optics.
[0074] With regard to the over-molded housings, a new process was developed since a standard over-molding process would likely damage the sensitive electronic and optical parts via the application of high pressure and high temperature. To overcome this challenge, a low pressure over-molding solution that also used temperatures low enough to prevent damage to the PCB and other components. These parts have shown excellent precision unit to unit since any variances in the over-molded material (e.g., acrylic) can be controlled.
[0075] As an alternative, a combination of the two foregoing methods of forming a displacement sensor body or housing could be used. In such a method of manufacture, an injection molded polycarbonate housing could be formed. Such an injection molded polycarbonate housing will form a hard enclosure that will withstand environmental conditions and satisfy performance requirements for robustly protecting any sensitive internal components of the displacement sensor. Examples of such environmental conditions and performance requirements that an injection molded polycarbonate housing can provide include pressure, temperature, impact, vibration, chemical resistance and infrared transparency. As discussed above, the displacement sensor body can include one or more sealing elements to form a substantially fluid-tight seal with the end member of the gas spring assembly.
[0076] A printed circuit board assembly (PCBA) with wires attached can then be over-molded and inserted in to the injection molded polycarbonate housing and sealed with an end cap. The over-molded material can serve as a strain relief for the wires. The over-molded material can also seal the wires to the polycarbonate housing, and fill the interior of the housing with over-molded material to reduce the internal air volume of the assembled displacement sensor. This advantageously reduces amount of moisture that can be present inside the displacement sensor to potentially condense therein. Two or more of the components can be mechanically secured together using molded-in interlocking features.
[0077] This development of a process of the packaging a time of flight internal height sensor in accordance with the subject matter of the present disclosure is beneficial since various characteristics and/or features of the packaging material, such as the optical clarity, the distance between the time of flight sensor and the material used, for example, can have a direct effect on the successful operation of the sensor.
[0078] In some cases, temperature compensation can be included that will permit an output of a time of flight sensor (e.g., displacement sensor 500) to be variable over different temperature ranges. In some cases, such adjustments can include compensating any data from the sensor via a compensation algorithm. This algorithm may be derived from taking distance/displacement data from multiple distances on multiple sensors over the entire operation temperature range (40 C. to 85 C.). The temperature compensation algorithm, as part of the operational software for this internal height sensor as utilized can, in some cases, contribute to the successful operation of the present invention. In some cases, such a temperature compensation algorithm can be stored in memory stores 520A and 520B and executed by processing device 518.
[0079] It is a possibility that as the displacement range increases, the linearity of the sensor is affected in that non-linearity is evident as different ranges. For that reason, it may be desirable to include a range compensation algorithm to ensure that the displacement readings are linear throughout the range. For example, it may be found that the internal height sensors are sensing a displacement of 300 millimeters while the actual displacement is 310 millimeters. Under such conditions of use, a compensation algorithm could be used that is capable of automatically correcting this difference across the entire range of detection. In some cases, such a linearity compensation algorithm can be stored in memory stores 520A and 520B and executed by processing device 518.
[0080] As described above in detail, the subject matter of the present disclosure can utilize a proximity and ambient light sensing module that is capable of performing time of flight based displacement measurements of emitted photons. Such sensing modules can include one or more devices that can utilize an infrared transmitter, a range sensor, and an ambient light sensor in one package. One example of such a construction is available from STMicroelectronics of Geneva, Switzerland under the component designation VL6180X and commercially referred to as a FLIGHTSENSE module. It will be appreciated, however, that other devices could alternately be used.
[0081] As used herein with reference to certain features, elements, components and/or structures, numerical ordinals (e.g., first, second, third, fourth, etc.) may be used to denote different singles of a plurality or otherwise identify certain features, elements, components and/or structures, and do not imply any order or sequence unless specifically defined by the claim language. Additionally, the terms transverse, and the like, are to be broadly interpreted. As such, the terms transverse, and the like, can include a wide range of relative angular orientations that include, but are not limited to, an approximately perpendicular angular orientation. Also, the terms circumferential, circumferentially, and the like, are to be broadly interpreted and can include, but are not limited to circular shapes and/or configurations. In this regard, the terms circumferential, circumferentially, and the like, can be synonymous with terms such as peripheral, peripherally, and the like.
[0082] Furthermore, the phrase flowed-material joint and the like, if used herein, are to be interpreted to include any joint or connection in which a liquid or otherwise flowable material (e.g., a melted metal or combination of melted metals) is deposited or otherwise presented between adjacent component parts and operative to form a fixed and substantially fluid-tight connection therebetween. Examples of processes that can be used to form such a flowed-material joint include, without limitation, welding processes, brazing processes and soldering processes. In such cases, one or more metal materials and/or alloys can be used to form such a flowed-material joint, in addition to any material from the component parts themselves. Another example of a process that can be used to form a flowed-material joint includes applying, depositing or otherwise presenting an adhesive between adjacent component parts that is operative to form a fixed and substantially fluid-tight connection therebetween. In such case, it will be appreciated that any suitable adhesive material or combination of materials can be used, such as one-part and/or two-part epoxies, for example.
[0083] Further still, the term gas is used herein to broadly refer to any gaseous or vaporous fluid. Most commonly, air is used as the working medium of gas spring devices, such as those described herein, as well as suspension systems and other components thereof. However, it will be understood that any suitable gaseous fluid could alternately be used.
[0084] It will be recognized that numerous different features and/or components are presented in the embodiments shown and described herein, and that no one embodiment may be specifically shown and described as including all such features and components. As such, it is to be understood that the subject matter of the present disclosure is intended to encompass any and all combinations of the different features and components that are shown and described herein, and, without limitation, that any suitable arrangement of features and components, in any combination, can be used. Thus it is to be distinctly understood claims directed to any such combination of features and/or components, whether or not specifically embodied herein, are intended to find support in the present disclosure.
[0085] Thus, while the subject matter of the present disclosure has been described with reference to the foregoing embodiments and considerable emphasis has been placed herein on the structures and structural interrelationships between the component parts of the embodiments disclosed, it will be appreciated that other embodiments can be made and that many changes can be made in the embodiments illustrated and described without departing from the principles hereof. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. Accordingly, it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the subject matter of the present disclosure and not as a limitation. As such, it is intended that the subject matter of the present disclosure be construed as including all such modifications and alterations.