The subject matter disclosed herein generally relates to vibration control devices and methods for canceling vibrations and noise. More particularly, the subject matter disclosed herein relates to active vibration and noise control within automobiles and trucks by using force generators and accompanying methods for canceling vibrations and noise.
For internal combustion engine vehicles, manufacturers are continuously trying to improve fuel efficiency. In some instances, the manufacturers intentionally force the vehicle's internal combustion engine to operate in an economy mode or “ECO mode” by using various techniques such as variable engine cylinder displacement control. When doing so, the ECO mode deactivates cylinders to save fuel. Unfortunately, vibration or noise is often created when one or more cylinders are deactivated. In addition, other methods may be employed to save fuel by manipulating the engine firing sequence, gear management, etc. Vibrations or noises created by these fuel saving actions may be transmitted to the driver and passengers.
Reducing the number of operating cylinders, changing the engine firing sequencing, and/or changing gears to save fuel may cause the driver and/or passengers to perceive any change in the normal vibration or noise as there being a problem with the internal combustion engine or the vehicle, even though everything is operating as designed. The driver's physical connection with the steering wheel may further amplify the perceived problem, as well as the driver's perception of the source of the vibration or noise. Thus, when fuel saving techniques are implemented on cars and trucks, an unacceptable vibration and noise may be experienced in the vehicle cab, at the seats, and in the steering column and steering wheel. One of the challenges in reducing the vibration and noise for one part of a vehicle is to avoid introducing vibration and noise into another part of the vehicle with the same vibration and noise canceling devices.
Hybrid vehicles operate with both an internal combustion engine and an electric motor. Hybrid vehicles may experience all the vibration and noise issues found in an internal combustion engine, plus hybrid vehicles may have added vibration and noise issues unique to the internal combustion engine and electric motor operations. For example, the switch-over between the internal combustion engine and electric motor may introduce vibrations and noise, or periodic vibrations possibly overshadowed by the internal combustion engine may be more distinct when operating with the electric motor. Additionally, some hybrid vehicles switch to the battery mode when stopped and during vehicle takeoff the internal combustion engine is started and may introduce sudden vibrations and noise. Thus, the same vibration and noise concerns of the internal combustion engine are present in the hybrid vehicle. In addition, the unique hybrid vehicle issues, and the potential issues associated with electric vehicles may also present vibration and noise problems.
What is needed is a vibration control system that reduces and/or eliminates unwanted vibrations and/or noise felt by the driver and passengers of a vehicle within the vehicle passenger cabin.
In one aspect, a vibration control system (VCS) is provided for a steering column and/or steering wheel of a vehicle, with the steering column having a longitudinal X axis, a lateral Y axis, and a vertical Z axis, and with the steering wheel being coupled to the steering column. The VCS comprises at least one linear force generator (LFG), at least one vibration sensor, and a VCS controller. The at least one LFG being positioned within or coupled to the steering column, and aligned with one of the X, Y, or Z axes or aligned off-axis with one of a X1, Y1, or Z1 axes. The at least one vibration sensor being capable of detecting vibration in or near the steering column and/or the steering wheel. The VCS controller being in electronic communication with the at least one LFG and the at least one vibration sensor. The VCS controller continuously analyzes data from the at least one vibration sensor, determining a vibration canceling force command, and continuously communicating the vibration canceling force command to the at least one LFG. In response to the vibration canceling force command, the at least one LFG generates at least one vibration or noise canceling force in its aligned axis.
In another aspect, a vibration control system (VCS) is provided for a vehicle that has an engine, a frame, a controller area network (CAN) bus, and a steering column positioned within a passenger cabin. The VCS comprises a plurality of circular force generators (CFGs), at least one linear force generator (LFG), vibration sensors, and at least one VCS controller. The plurality of CFGs are coupled to the frame of the vehicle. The at least one LFG is positioned within or coupled to the steering column, wherein the steering column has a longitudinal X axis, a lateral Y axis, and a vertical Z axis, and the at least one LFG is aligned with one of the X, Y, or Z axes or aligned off-axis with one of a X1, Y1, or Z1 axes.
The vibration sensors include at least one vibration sensor positioned to continuously detect a vibration or noise from the engine and/or the frame, and at least one or more additional vibration sensors positioned to continuously detect vibration or noise on or within the steering column and/or a steering wheel. The steering wheel is coupled to the steering column.
The at least one VCS controller is in electronic communication with the CAN bus, the plurality of CFGs, the at least one LFG, and all vibration sensors. The VCS controller providing electronic control to the plurality of CFGs and the at least one LFG. The VCS controller continuously analyzes data from the CAN bus, all the vibration sensors, the plurality of CFGs, and the at least one LFG, and wherein the VCS controller calculates and communicates a vibration canceling force command for each of the plurality of CFGs and the at least one LFG. Each of the plurality of CFGs generates a vibration canceling force having a magnitude and a phase that attenuates the vibration and/or noise within the passenger cabin, and the VCS controller continuously updating and communicating vibration canceling force commands to each of the plurality of CFGs. The at least one LFG generates a linear vibration canceling force that attenuates the noise and/or vibration on or within the steering column and/or steering wheel, with the VCS controller continuously updating and communicating vibration canceling force commands to the at least one LFG.
In still another aspect, a method of controlling vibrations in a steering column positioned in a passenger cabin of a vehicle having an engine, a frame, and a controller area network (CAN) bus is provided. The method comprises integrating a vibration control system (VCS) with the steering column, the steering column having a longitudinal X axis, a lateral Y axis, and a vertical Z axis, the VCS including at least one linear force generator (LFG) positioned within or coupled to the steering column, the at least one LFG being aligned with one of the X, Y, or Z axes or aligned off-axis with one of a X1, Y1, or Z1 axes. The VCS further including at least one vibration sensor capable of detecting vibration in the steering column, and a VCS controller in electronic communication with the at least one LFG, the at least one vibration sensor, and the CAN bus. The VCS controller continuously analyzes data from the at least one vibration sensor, the at least one LFG, and the CAN bus. The method further comprises detecting a vibration or noise with the at least one vibration sensor, communicating the detected vibrations or noise to the VCS controller, analyzing the detected vibration within the VCS controller, calculating a vibration canceling force command within the VCS controller, communicating the calculated vibration canceling force command from the VCS controller to the at least one LFG, generating the vibration canceling force with the at least one LFG in the LFG's aligned axis and canceling the detected vibration or noise, and continuously repeating.
As used herein, the terms automobile and vehicle are meant to address the entire spectrum of vehicles having an internal combustion engine running on combustible fuel such as gas, diesel, natural gas, hydrogen, etc., as well as hybrid vehicles having both an internal combustion engine and an electric motor. The use of the terms automobile and vehicle are meant to include, but not limited to passenger cars, light trucks, and medium-to-heavy trucks, including heavy, off-road vehicles. As used herein, the term engine is inclusive of an internal combustion engine. And, when applicable to a hybrid vehicle, the term engine used herein is inclusive of both an internal combustion engine and an electric motor. As used herein, the term transmission is meant to cover all references to a transmission, gears, drive unit, or other component transferring energy from the vehicle's engine directly or indirectly to the vehicle's wheels.
Vehicle vibrations and noise are generated by a variety of different components and dynamic forces in the vehicle such as the engine, transmission, frame, mechanical linkages, wheel assemblies, etc. and can be transmitted into the vehicle's passenger cabin. In some cases, the vibration and noise is transmitted through the steering column and/or steering wheel. The driver and passengers feel the vibrations and/or hear the noises. Vehicle manufacturers have tried to address the vibrations and noises by using several different technologies. One technology has been to use large linear force generators (LFGs) and circular force generators (CFGs) to mitigate the source of the vibrations and noise.
LFGs employ a rare earth magnet supported by a spring and they are driven by a voice coil via electromagnetic force. LFGs are designed without rotating bearings. The moving mass of the LFG creates a controllable dynamic linear force along an axis of the LFG to mitigate noise and vibration. LFGs are able to generate a dynamic linear force at multiple frequencies simultaneously. Thereby, the LFG is able to produce multiple frequency simultaneous vibration and noise control long the linear axis of the LFG.
Vehicle manufacturers have used large LFGs to address the large dynamic vibration and noise from the vehicle's engine, transmission, and/or frame. However, this requires the manufacturer to place large LFGs at different points on the vehicle frame for each vehicle model. Due to the different placement of the large LFGs, and because assembly lines have different vehicle models being manufactured on the same production line, changing the placement for each large LFG on each model slows down the production line.
Each large LFG must also be large enough to cancel the large dynamic vibration and noise from the engine, transmission, and/or frame. This increased size translates into significantly increased weight and power requirements for each LFG. Each large LFG is only able to produce a linear force along the axis of the LFG relative to its position on the vehicle. Thus, large LFGs are unable to control complex motions that are not along the LFG linear axis over a wide frequency range. Due to the size and extra weight of the large LFGs, the large volume of rare earth magnetic material and high-quality metals contained within each large LFG, the limitation of only producing linear force along the axis of the LFG, and the time it takes to change the placement of the LFG on the vehicle frame, increasingly makes the use of large LFGs an undesirable solution to address vibrations and noises.
Smaller LFGs have significantly lower weight, power, and cost constraints when compared to large LFGs. Thus, using smaller LFGs to control small vibrations and noises elsewhere in the vehicle, such as in the steering column and/or steering wheel, is advantageous over larger LFGs. These smaller LFGs are inherently quiet, generate a low audible noise signature, and are well suited to control vibration and noise in a confined space such as a vehicle passenger cabin. The form factor of smaller LFGs also provides more flexibility when mounting them to or within the steering column.
Instead of using smaller LFGs, small CFGs will also fit within the available space within the steering column. However, the spinning of the imbalance masses within the CFG may create an unwanted noise that can be bothersome to the driver and passengers. Thus, the use of smaller LFGs on or within the steering column and/or steering wheel provides a satisfactory lower noise solution than using small CFGs.
CFGs can generate a planar force and moment that can more easily control vibration in a complex structural response when compared to LFGs, especially over large ranges of operating frequencies. This makes CFGs ideal for mounting to a vehicle frame. Also, CFGs mounted to the frame are smaller and lighter than any LFGs used for the same purpose, and they do not need to be placed differently for each vehicle model. CFGs are also able to create larger forces than comparably sized LFGs. Thus, using CFGs on the frame to control vibration and noise transmitted to vehicle passenger cabin allows for canceling the large vibration or noise input to the occupants of the passenger cabin.
The system disclosed herein is a vibration control system (VCS) for a vehicle that has at least one vibration control force generator, along with at least one vibration/noise sensor and a VCS controller. The system is attached to or integrated with the vehicle. For the vibration control force generator, the VCS may have at least one LFG, at least one CFG, or a combination of at least one LFG and at least one CFG. Depending upon the vibrations and/or noise being controlled, the LFG and/or the CFG are positioned to control vibration and/or noise from a variety of vibration sources. The vibration sources may be from the engine, transmission, frame, steering column, and/or steering wheel, as well as other sources of vibration and noise.
The combination of LFGs and CFGs may simultaneously address vibration and noise from the frame and the steering column. The combination of LFGs and CFGs are ideal in many vehicle applications where CFGs are used to generate the larger forces required to control vibration and noise from the engine, transmission, frame, and the LFGs are used in locations where small controlling forces are required, such as within or on the steering column where a low operating vibration or noise is desired.
Referring to the drawings,
LFGs 28, 28a, 28b, 28c are illustrated in
Power for LFGs 28, CFGs 30, sensors 32, and VCS controller 34 is provided by the vehicle power system (not shown) which may include a battery (not shown) and/or CAN bus 20. When CAN bus 20 is used, it may directly or indirectly supply power to LFGs 28, CFGs 30, vibration sensor 32, and VCS controller 34. Power may also be directly supplied from the vehicle to LFGs 28, CFGs 30, vibration sensor 32, and VCS controller 34. A combination of CAN bus 20 power and direct power from the vehicle power system may also be used.
Focusing VCS 10 without using any CFGs 30, VCS 10 is illustrated in
Referring to
Although, LFGs 28a-28c are illustrated in
Referring to
Vibration sensor 32 selection depends upon the type of sensor and how many axes of vibration are being detected. In the non-limiting exemplary embodiment illustrated, at least two axes of vibration are being detected in steering column 22 and at least two axes of vibration are being detected in steering wheel 26. In an embodiment, vibration sensors 32 are selected from the group consisting of single axis vibration sensors, two-axis vibration sensors, three-axis vibration sensors, and combinations thereof. In another embodiment, at least one vibration sensor 32 is capable of detecting vibration and/or noise in two of three axes. In still another embodiment, at least one vibration sensor 32 is capable of detecting vibration and/or noise in two of three axes in steering column 22.
Sensors 32 may be any type of vibration or noise sensor to include but not be limited to accelerometers, biaxial sensors, inertial sensors, displacement sensors, piezoelectric sensors, strain gauges, acoustic sensors, microphones, etc. The embodiments may include the use of one or more different types of vibration sensors 32 at one or more locations on or within steering column 22 and/or steering wheel 26. Additionally, the embodiments may include the use of a single vibration sensor 32 at a single location in or on steering column 22 or steering wheel 26. The foregoing vibration sensors 32 are positioned away from LFGs 28. However, for production efficiencies it may be desirable to position vibration sensors 32 integrally on or within LFGs 28, as is illustrated in
VCS controller 34 is in electronic communication with CAN bus 20. In addition to being in electronic communication with CAN bus 20, VCS controller 34 is in electronic communication with each LFG 28 and with each vibration sensor 32. VCS controller 34 continuously analyzes data electronically communicated from each vibration sensor 32, determines a vibration canceling force command, and continuously communicates the vibration canceling force command to each LFG 28. Each LFG 28 generates a vibration or noise canceling force in its aligned axis in response to the vibration canceling force command.
Although a single VCS controller 34 is illustrated in
Referring to
LFG 28 components are placed and operate as described above and illustrated in
In general, CFGs 30 can be placed at any location on vehicle 12, and the number and location of CFGs 30 are selected to meet vibration and noise canceling needs for individual vehicle types. In the non-limiting examples of
CFG designs vary.
The non-limiting examples of prior art CFGs illustrated in
Vibration sensors 32 for CFGs 30 are illustrated in
As described above, in addition to being in electronic communication with each LFG 28, each vibration sensor 32, and CAN bus 20, VCS controller 34 is in electronic communication with each CFG 30. Using the data it receives from all electronic communication, the VCS controller 34 calculates a vibration canceling force command for each LFG 28 and each CFG 30 to enable each LFG 28 and each CFG 30 to generate the vibration canceling force.
In operation with both LFGs 28 and CFGs 30, vibration sensors 32 in electronic communication with at least one LFG 28 detect a noise or vibration such as those measuring vibration and noise in or around steering column 22 and/or steering wheel 26. Vibration sensors 32 in electronic communication with CFGs 30 detect a noise or vibration such as those measuring vibration and noise in passenger cabin 24 as well as vibrations and noise from engine 14, transmission 16, frame 18, and/or any other source of vibration and noise generated on or by vehicle 12. Vibration sensors 32 transmit the detected noise or vibration to VCS controllers 34. VCS controller(s) 34 analyze the electronically communicated data from each vibration sensor 32 and CAN bus 20. Using vibration canceling algorithms known to those having skill in the art (e.g., Filtered-X algorithm, etc.), VCS controller(s) 34 calculate vibration or noise canceling force command(s) and transmit the vibration or noise canceling force command(s) to the at least one LFG 28 and/or CFGs 30. VCS controller(s) 34 calculate if LFG 28 or CFGs 30 need to generate simultaneous vibration and/or noise canceling forces in multiple frequencies. Upon receiving the vibration or noise canceling force command(s), each LFG 28, when there is more than one LFG 28, and/or each CFG 30 generates one or more vibration or noise canceling forces in its aligned axis. The process is continuously repeated.
Referring to
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The system illustrated in
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Although not illustrated, other combinations of VCS controllers 34 providing control to LFGs 28 and CFGs 30 include a VCS controller 34 associated with each CFG 30 and one VCS controller 34 associated all LFGs 28. Similarly, a VCS controller 34 associated with each LFG 28 and one VCS controller 34 associated all CFGs 30 may be used. In either of these cases, VCS controllers 34 may be in a distributed dominate/subordinate configuration and all have two-way communication between them. Variations of these non-illustrated configurations of VCS controllers 34 may also be used.
Referring still to
When used with CFGs 30, VCS 10 at least two CFGs 30 and VCS controller 34 communicate with vibration sensors 32 and vehicle computer (not shown) commands via CAN bus 20 detect and generate vibration canceling forces. The resulting vibration canceling forces from CFGs 30 reduce the vibration and noise experienced by the driver and passengers within passenger cabin.
VCS 10 operates in a closed loop system or an open loop system. A closed loop system relies upon data from vibration sensors 32. In addition to relying upon vibration sensors 32, an open loop system also requires populating or entering data in VCS controller 34 related to various vehicle 12 performance and operating conditions.
A test vehicle (not shown) was configured with VCS 10 having only two LFGs 28. The results of the tests are illustrated in
Other embodiments of the present invention will be apparent to one skilled in the art. As such, the foregoing description merely enables and describes the general uses and methods of the present invention. Accordingly, the following claims define the true scope of the present invention.
The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/109,477, filed on Nov. 4, 2020, the disclosure of which is incorporated herein by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US2021/056923 | 10/28/2021 | WO |
Number | Date | Country | |
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63109477 | Nov 2020 | US |