AIR MATIC SUSPENSION SYSTEM

- An

innovative technology

AIR MATIC SUSPENSION SYSTEM

ABSTRACT
Suspension system plays a vital role in automobiles especially during the abnormal road and load conditions. The air matic suspension system has special features in addition to the other systems available in the market. This new system incorporates the sensor, sonar, ECU which can ultimately detect each and every vibrations possible in the off road vehicles. This type of suspension is to provide good handling capabilities and smoother ride even on tougher ride conditions. This system meets the suspension effects at varying loads with a single unit totally self-sufficient for its working.

OBJECTIVE:
This unit reduces the vibrations caused during abnormal conditions. Easy maintenance Reliability and accessibility It is highly employable in off road vehicles

Construction:
The constructional unit of this type consists of the following parts suspension unit sonar sensor compressor/ turbine reservoir tank/ air vessel

SUSPENSION UNIT
This unit consists of two chambers A & B. The main chamber casing is fixed to the body and the lower discharge chamber casing is bolted to the axle with rubber bushings. The lower casing is a movable piston like arrangement. This casing moves in a reciprocating manner inside the upper casing. Since the unit is an air operated system the unit is designed with an air tight arrangement. The outer casing is made up of high tensile, temperature withstanding material like aluminium. The unit consists of five valve system through which the exchange of gases takes place. Two valves are situated on either slant sides of the upper casing on the top and the other two are on the top of the inner casing and the remaining one on the lower side of the casing. These valves are solenoid controlled valves controlled by an ECU. The inner casing moves on the guide rod which is attached to the strut at one end. This rod is a strong one designed in a manner that acts as a control unit for the inner casing at its end travel point. Also there is a magnetic sensor on the guide rod on two sides to control the end travel.

SUSPENSION UNIT

AIR COMPRESSOR / TURBINE

Since this is an air suspension, the working medium should be compressed to required Psi, according to the vehicles total loading capacity. Here, the high pressure air is obtained by an air compressor which is a similar arrangement like a turbo charger. Here the compressor vane shaft is attached to the turbine blade shaft. The turbine blade rotates due to expansion of the exhaust gases, this in turn rotates compressor vanes which results in the compression of air.

The inlet of the compressor is attached with a filter and the outlet of the compressor has a pressure relief valve to ensure release of air during blockages. Vanes are made of light weight and hard material like magnesium. The pressure sensor is kept after the pressure relief valve. The signal from this is fed to the ECU to constantly monitor the output pressure from the compressor. An air drier or blower can also be used to remove the moisture from air which is the working medium.

SONAR
This is the sound navigation device which is generally used in ships. This is the device which uses the ultrasonic waves which are generated using a magneto striction circuit. The time taken for the sound wave to cover the to and fro distance from the magneto circuit is used to calculate the height of variation in the road surface. The reflection of the wave is received by a receiving sensor to the ECU, which decides the required pressure to maintain the body stable. Here there are four magneto striction coils (one for each wheel). But the number of sensors to be received will be more in front wheels than the rear wheels ranging by contact areas and angles.

RESERVOIRS
This is a storage tank to maintain same constant air pressure. The outlet of the compressor is fed to the reservoir after relief valve through a solenoid valve which is controlled by the ECU. There is a pressure sensor inside the tank, since the constant pressure should be maintained. Again the sensor is connected to the ECU, the exit valve too is controlled by the ECU. The output is then fed to the separate suspension according to the requirement of the particular suspension by various gas lines. The requirement of each suspension is a result of various inputs given to ECU and the actuating pulses given to the solenoid. The main purpose of this reservoir is that during the off condition of the engine, the air compressor will not work. So, during this condition there will be more or less constant pressure inside the combustion chamber. This air pressurized form is obtained from the reservoir. Even an alternate arrangement of a varying volume reservoir can also be used for special purposes. This can be used as an advantage, since there will be no much impact even while the vehicle is moving down the slope without the engine operating in a slow speed.

ECU, SENSORS AND ACTUATORS

An ECU is an electronic control unit which controls the actuators like pressure valves by the input fed from the various sensors. A reliable, suitable, cheap ECU can be chosen. Actuators are used to operate the valve mechanism in the suspension and in various parts and also to actuate the particular sonar sensor receiver circuit according to the angle of turn of the front wheels. But the rear sonar are permanent until the vehicle is moving. Here, the sonar actuators are a simple electronic regulator circuit which connects and disconnects the supply to the sonar sensor circuit. The solenoid actuators are simple coil wound on a rod which gives the electric impulse to be magnetized causing the opening of the valve. This system includes a number of sensors whose output is fed as an input to the ECU. These values from the sensors play a major role in the signals sent to the actuators. The specifically programmed microprocessor transmits the input from the sensors, which are then analyzed, processed and then signaled. These signals in the form of electronic pulses are sent to the actuators at a right time and in co ordination for the particular operation of the suspension to take place. The various sensors included in the system are

wheel rpm sensor (axle) Wheel turning angle sensor. Body load sensor ( one on each wheel suspension). Brake pedal sensor to detect braking rate. Ignition key sensor Sonar wave receiver. Magnetic sensor. Accelerator pedal sensor. Pressure sensor inside the main chamber. Engine sensor (to know whether it is operating or not). Body level sensor. Tyre pressure sensor.

So these sensors operate at different conditions and send signals to the ECU requesting for the particular actuation of the actuators for a specific condition of ride to be satisfied.

ACCESSORIES
Firm, non leaking heat resistant tubes for transporting compressed air. Sensor signals and actuator signal cables.

WORKING MECHANISM
The three major conditions of working are to be considered here. 1. 2. 3. 4. vehicle stationery with engine not running Sensor OFF vehicle stationery with engine running -------- Sensor ON vehicle is mobile with normal road surface with engine not runningSensor OFF vehicle is mobile with normal road surface with engine runningSensor ON If the engine is suddenly off when the vehicle is running at a good speed, the valves of the main chamber is closed and when the sudden brake is applied during that condition, the reservoir air is used to counteract the impact provided. The brake sensors are always ON when the wheels are rolling, the load sensors are also ON and sudden acceleration during that condition with engine ON, it is back to its normal operation. Load sensors are always ON when the ignition key is ON. The vehicle when remain stationery, when the engine is off, the sonar and load sensor is OFF. When the vehicle comes to its STOP position, the suspensions are set with the particular air pressure, which is enough to keep the body stable. This condition is disturbed only when there is loading done on stationery vehicle. At this stage, when the pressure inside the main chamber increases by an optimum pressure which automatically activates the whole system except sonar to regain the stability. This is only when the key is in OFF condition during which all the system will be OFF. But when the ignition key is ON, totally all the system will be ON except the SONAR. So when the vehicle comes finally to rest and the engine is

switched OFF. The final analysis is done and a constant suspension conditions are maintained.

RESERVOIR

COMPRESSOR/ TURBINE

SUSPENSION UNIT

ECU

SONAR Receivers

To various sensors

When the vehicle is moving, the system is totally ON when the engine is ON. So, during the normal road surface, the load sensor signals and the level sensor signals are used and a constant pressure inside the main chamber is maintained providing the clearance between the body and the wheels. Here the inlet valve of A is opened and the outlet is also opened. But the valves of chamber B are closed. As a result, the constant pressure inside the cylinder is attained. Here the air from outlet is again fed into the reservoir.

CONCLUSION
When the vehicle runs in abnormal road conditions, the suspension requires various operations to be done such as: The operation of the SONAR Sensors varies with the varying angles of front wheels. There are poly number of SONAR sensors for the front wheel which are actuated by the ECU, receiving the signals from the wheel and the sensor. So, when the wheels are turning, the reflections of the waves are received by the right sensor as assigned by the ECU.

The signal from the sensor is fed back to the ECU, where it decides the variation in the road surface such as increase in time of travel of SONAR indicating a pot hole and vice versa. So according to these variations, the valves of the unit is closed or opened with help of sensors resulting in the stable conditions of the vehicle.

ADVANTAGES
The air matic suspension being an active suspension, it requires those ECU, Sensors etc. since, it is an active suspension, it can provide a soft and comfort ride to the passengers and also a good maneuverability of the car. Maintenance is easy It is cost effective The air matic system will be very useful for military vehicles and other off road vehicles The signals from the sensors are very accurate. This results in better stability of the vehicle. This is very effective for varying load conditions.