Search

DE-102019208653-B4 - Sensor module, vibration damper, damping system and vehicle

DE102019208653B4DE 102019208653 B4DE102019208653 B4DE 102019208653B4DE-102019208653-B4

Abstract

Sensor module (1) for a vibration damper with at least one damper unit (10), at least one sensor unit (20) and at least one energy generation unit (30) which is at least partially integrated in the damper unit (10), wherein the energy generation unit (30) is configured to convert mechanical force into electrical energy, such that at least the sensor unit (20) can be operated autonomously with energy from the energy generation unit (30), wherein the energy generation unit (30) is configured as a free-oscillating, electromagnetic energy generation unit (30), wherein the damper unit (10) has a housing (12) and at least one first spring element (14), wherein the energy generation unit (30) is configured with a plurality of permanent magnets (32) in the housing (12) of the damper unit (10), wherein the permanent magnets (32) are arranged for resilient mounting on the first spring element (14) of the damper unit (10), and with at least one stationary, electromagnetic coil (36) on or in the housing (12), for generating electrical energy from an oscillating motion of the permanent magnets (32), characterized in that the damper unit (10) has a second spring element (16) and the permanent magnets (32) are arranged between the first and the second spring element (14, 16) and are received by them.

Inventors

  • Klaus Lepenies
  • Dirk Haney

Assignees

  • THYSSENKRUPP AG
  • THYSSENKRUPP BILSTEIN GMBH

Dates

Publication Date
20260513
Application Date
20190613

Claims (8)

  1. Sensor module (1) for a vibration damper with at least one damper unit (10), at least one sensor unit (20) and at least one energy generation unit (30) which is at least partially integrated in the damper unit (10), wherein the energy generation unit (30) is configured to convert mechanical force into electrical energy, such that at least the sensor unit (20) can be operated autonomously with energy from the energy generation unit (30), wherein the energy generation unit (30) is configured as a free-oscillating, electromagnetic energy generation unit (30), wherein the damper unit (10) has a housing (12) and at least one first spring element (14), wherein the energy generation unit (30) is configured with a plurality of permanent magnets (32) in the housing (12) of the damper unit (10), wherein the permanent magnets (32) are arranged for resilient mounting on the first spring element (14) of the damper unit (10), and with at least one stationary, electromagnetic coil (36) on or in the housing (12), for generating electrical energy from an oscillating movement of the permanent magnets (32), characterized in that the damper unit (10) has a second spring element (16) and the permanent magnets (32) are arranged between the first and the second spring element (14, 16) and are received by them.
  2. Sensor module (1) according to Claim 1 , characterized in that the sensor module (1) has at least one energy storage device (40) for intermediate storage of electrical energy from the energy generation unit (30) and for supplying at least the sensor unit (20) with electrical energy as required.
  3. Sensor module (1) Claim 1 or 2 , characterized in that the sensor unit (20) has at least one acceleration sensor and/or at least one temperature sensor for detecting the wear condition and/or a defect of the vibration damper.
  4. Sensor module (1) according to one of the preceding claims, characterized in that the sensor module (1) has a radio unit (50) for wireless transmission of measurement data from the sensor unit (20).
  5. Sensor module (1) according to one of the preceding claims, characterized in that the energy storage device (40) is designed as at least one capacitor.
  6. Vibration damper with a sensor module (1) according to one of the preceding claims.
  7. Damper system comprising at least one sensor module (1) or a vibration damper according to one of the preceding claims and a control unit (60) configured to receive signals from the at least one sensor module (1).
  8. Vehicle (100) comprising at least one sensor module (1), a vibration damper or a damping system according to any of the preceding claims.

Description

The invention relates to a sensor module for a vibration damper comprising at least one damper unit, at least one sensor unit, and at least one energy generation unit. The invention further relates to a vibration damper, a damper system, and a vehicle. In everyday use, defective shock absorbers or vibration dampers pose a significant safety risk to motor vehicles. Studies show that approximately 22% of all passenger cars in operation have defective shock absorbers. Even at low speeds, the braking distance can increase dramatically, and directional stability and cornering performance can be significantly reduced. It is estimated that defective shock absorbers or vibration dampers contribute to 50% of accidents involving passenger cars with a mileage of more than ten years or 150,000 km. From the DE 10 2010 042 459 A1 A motor vehicle system is known that generates electrical energy through the movement of a motor vehicle suspension device by means of an energy-harvesting device. Additionally, a sensor is attached to the motor vehicle suspension device and coupled to the energy-harvesting device for recording electrical energy. From the DE 10 2010 008 315 A1 A device for energy generation using a vehicle shock absorber is known, wherein a piezoelectric device is coupled with a spring stop. The US 2015 / 0 333 598 A1 discloses a system for energy generation in which vibration energy is converted into electrical energy and used for fault monitoring in bridge construction. In the US 2010 / 0 225 527 A1 is a system for measuring the distance between two vehicle components, such as shock absorbers, using a wireless ultra-wideband (UWB) transreceiver. The EP 3 461 662 A1 Disclosing a damping device for vehicles, wherein a sensor for determining kinetic quantities and a radio device connected to the sensor are provided to achieve continuous monitoring of the damping device with regard to possible damage or wear. From the US 2017 / 0 241 362 A1 A motor monitoring system is known that includes an energy generation unit with an energy converter. Control signals are also generated from measurement signals to protect the motor from damage. Detecting a defect in a shock absorber is extremely difficult for a layperson or end user of motor vehicles. Regular visual inspections for oil leaks or dirt stains on the shock absorber, as well as the observation of uneven (stubbly) tire wear, are only possible for a very experienced and attentive driver. There is a risk that vehicles may have an undetected defect and thus pose a safety hazard on the road. The invention is based on the objective of providing a sensor module that enables simple, independent determination of the wear condition and/or a defect of the vibration damper or the damping function of a chassis, has a compact, space-saving design, and allows for long-term, low-maintenance operation. Furthermore, the invention aims to provide a vibration damper, a damping system, and a vehicle equipped with such a sensor module. According to the invention, this problem is solved with respect to the sensor module by the subject matter of claim 1, with respect to the vibration damper by the subject matter of claim 6, with respect to the damping system by the subject matter of claim 7, and with respect to the vehicle by the subject matter of claim 8. Preferred embodiments are specified in the dependent claims. Specifically, the problem is solved by a sensor module for a vibration damper comprising at least one damper unit, at least one sensor unit, and at least one energy generation unit, which is at least partially integrated into the damper unit. The energy generation unit is designed to convert mechanical force into electrical energy, such that at least the sensor unit can be operated autonomously using energy from the energy generation unit. The invention is based on the fundamental idea of designing a sensor module with an energy generation unit in such a way that the individual components of the sensor module can be supplied with energy permanently and autonomously. It is intended that the energy is derived from mechanical shocks or forces acting on a chassis, and thus The vibration dampers of a vehicle can be utilized via the sensor module. The energy to operate the sensor module can be generated by the energy generation unit during the sensor module's intended operation within a vehicle or at a vibration damper of the vehicle. This should enable a completely independent and self-contained sensor module to be provided. Furthermore, the invention is based on the fact that the sensor module should have a compact design, so that the sensor module according to the invention can preferably also be used in commercially available motor vehicles or expediently attached to commercially available vibration dampers. In this sense, the sensor module according to the invention can be considered as a retrofittable option for existing motor vehicles. According to the present invention, the