WO2021202665A1

WO2021202665A1 - Damper assembly

Info

Publication number: WO2021202665A1
Application number: PCT/US2021/025089
Authority: WO
Inventors: Michal Andrzej NOWAK; Mateusz BIBRZYCKI; Jan Wojtowicz
Original assignee: DRiV Automotive Inc.
Priority date: 2020-04-01
Filing date: 2021-03-31
Publication date: 2021-10-07

Abstract

A damper assembly includes a piston rod defining a central axis, a sensor mount including a tube and a sensor housing, the tube extending along the central axis of the piston rod and the sensor housing disposed radially offset from the central axis, a sensor supported by the sensor housing, and a reflector. The sensor and the reflector are aligned along an axis parallel to the central axis of the piston rod.

Description

DAMPER ASSEMBLY

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This patent application claims priority to and all the benefits of U.S. Patent Applications No. 63/003,501 filed on April 1, 2020 and No. 63/090,532 filed on October 12, 2020, which are herein incorporated by reference in its entirety.

BACKGROUND

[0002] Detecting a weight of a vehicle can help assess and reduce roadway deterioration. Governmental agencies may require measurements of the weight of the vehicle to be collected periodically to address deteriorating roadways. One way to detect the weight is with a pressure- based measurement of a pressure sensor on an air spring of a suspension. However, a vehicle may use other components in the suspension. There remains an opportunity to measure a weight of a vehicle using components other a pressure sensor.

SUMMARY

[0003] A damper assembly includes a piston rod defining a central axis, a sensor mount including a tube and a sensor housing, the tube extending along the central axis of the piston rod and the sensor housing disposed radially offset from the central axis, a sensor supported by the sensor housing, and a reflector. The sensor and the reflector are aligned along an axis parallel to the central axis of the piston rod. The sensor mount may include a first axial piece having a first edge and a second axial piece having a second edge, the first edge being joinable to the second edge. The piston rod may be connected to an eye mount, the first axial piece may include a first loop connectable to the eye mount, and the second axial piece may include a second loop connectable to the eye mount. The sensor housing may include a first housing in the first axial piece and a second housing in the second axial piece. When the first axial piece is joined to the second axial piece, the sensor may be supported by the first and second housings. The sensor housing may be separately formed from the tube and fixed to the tube. The tube may define a cavity, and the sensor housing may be disposed in the cavity. The sensor may be disposed at a first end of the sensor housing and the reflector may be disposed at a second end of the sensor housing. The sensor may be programmed to emit an ultrasonic pulse and to receive a reflection of the ultrasonic pulse from the reflector. The reflector may define a planar surface facing the sensor. The axis may be radially offset from the central axis of the piston rod.

[0004] A damper assembly may include a piston rod defining a groove and extending along a central axis, a mount including a rod attachment and a sensor attachment, the rod attachment including a tongue mateable with the groove and the sensor attachment defining a slot, and a sensor mateable with the sensor attachment in the slot. The rod attachment is aligned with the central axis of the piston rod and the sensor attachment is radially offset from the central axis of the piston rod. The assembly may further include a shield defining a sensor cavity. The shield may extend around the piston rod and the sensor attachment may be disposed in the sensor cavity of the shield. The mount may include a mount shield extending over the sensor cavity. The sensor may be programmed to emit an ultrasonic pulse toward an upper surface of a damper body and to receive a reflection of the ultrasonic pulse from the upper surface of the damper body. The tongue of the rod attachment and the groove of the piston rod may align the sensor to a specified orientation relative to the piston rod.

BRIEF DESCRIPTION OF THE DRAWINGS [0005] Figure 1 is a perspective view of a vehicle including a damper assembly.

[0006] Figure 2 is a cross-sectional view of the damper assembly.

[0007] Figure 3 is perspective view of a portion of the damper assembly.

[0008] Figure 4 is a perspective view of a mount for a sensor of the damper assembly.

[0009] Figure 5 is a perspective view of the sensor and the mount. [0010] Figure 6 is a perspective view of a second embodiment of the damper assembly. [0011] Figures 7A-7B are cross-sectional views of the second embodiment of the damper assembly.

[0012] Figure 8 is a perspective view of a unitary tube and sensor housing of the damper assembly.

[0013] Figure 9 is a perspective view of another unitary tube and sensor housing of the damper assembly.

[0014] Figure 10 is a perspective view of another unitary tube and sensor housing of the damper assembly.

[0015] Figure 11 is an exploded view of a third embodiment of the damper assembly.

[0016] Figure 12 is an exploded view of the third embodiment of the damper assembly and including a hinge.

[0017] Figures 13A-13B are cross-sectional views of the third embodiment of the damper assembly.

[0018] Figure 14 is a cross-section view of a fifth embodiment of the damper assembly. [0019] Figure 14A is a cross-section view of the fifth embodiment of the damper assembly. [0020] Figure 15 is a cross-section view of a sixth embodiment of the damper assembly. [0021] Figure 16 is a cross-section view of the sixth embodiment of the damper assembly.

[0022] Figure 17 is a cross-section view of a seventh embodiment of the damper assembly.

[0023] Figure 18 is a cross-section view of an eighth embodiment of the damper assembly.

[0024] Figure 19 is a perspective view of a bumper cap and sensor of the damper assembly.

[0025] Figure 20 is a top view of the bumper cap and sensor of the damper assembly.

DETAILED DESCRIPTION

[0026] To provide the weight measurements of the vehicle, a sensor in a damper assembly can emit an ultrasonic pulse, receive a reflection of the ultrasonic pulse, and based on an elapsed time between emission of the ultrasonic pulse and receipt of the reflection, determine a height of the damper assembly. Based on the height of the damper assembly, the sensor can determine a weight of the vehicle and transmit the weight to a vehicle computer. Using the sensor to emit the ultrasonic pulse allows fast and accurate weight measurements that can be collected by the sensor for use by, e.g., a government agency, to address roadway deterioration.

[0027] Inserting the sensor in a tube or a shield of the damper assembly may provide compact installation of the damper assembly, reducing overall space used by the damper assembly while collecting weight measurements. The tube or shield protects the sensor from debris, e.g., dust, precipitation, dirt, etc. Thus, the sensor may emit ultrasonic pulses with reduced or no interference by debris, improving accuracy of the weight measurements. The damper assembly may be used with an air spring suspension and/or a leaf suspension.

[0028] With reference to the Figures, wherein like numerals indicate like parts throughout the several views, a damper assembly 10 in a vehicle 12 includes a piston rod 14 defining a groove 16 and extending along a central axis A, a mount 18 including a rod attachment 20 and a sensor attachment 22, and a sensor 24. The rod attachment 20 includes a tongue 26 mateable with the groove 16. The sensor attachment 22 defines a slot 28. The sensor 24 is mateable with the sensor attachment 22 in the slot 28. The rod attachment 20 is aligned with the central axis A of the piston rod 14 and the sensor attachment is radially offset from the central axis A of the piston rod 14.

[0029] A damper assembly 10a, 10b in the vehicle 12 includes the piston rod 14a, 14b defining the central axis A, a sensor mount 32, 34 including a tube 36, 38 and a sensor housing 40, 42, a sensor 24 supported by the sensor housing 40, 42, and a reflector 44. The tube 36, 38 extends along the central axis A of the piston rod 14 and the sensor housing 40, 42 is disposed radially offset from the central axis A. The sensor 24 and the reflector 44 are aligned along an axis B parallel to the central axis A of the piston rod 14.

[0030] As shown in Figure 1, the vehicle 12 may be any type of passenger or commercial vehicle such as a car, a truck, a truck tractor, a truck trailer, a sport utility vehicle, a crossover vehicle, a van, a minivan, a taxi, a bus, etc. The vehicle 12 includes a body 46 and a frame. The body 46 and frame may be of a unibody construction. In the unibody construction, the body 46, e.g., rockers, serves as the vehicle frame, and the body 46 (including the rockers, pillars, roof rails, etc.) is unitary, i.e., a continuous one-piece unit. As another example, the body 46 and frame may have a body-on-frame construction (also referred to as a cab-on-frame construction). In other words, the body 46 and frame are separate components, i.e., are modular, and the body is supported on and affixed to the frame. Alternatively, the body 46 and frame may have any suitable construction. The body 46 and/or the frame may be formed of any suitable material, for example, steel, aluminum, etc.

[0031] Figure 2 is a cross-sectional view of the damper assembly 10. The damper assembly 10 controls motion of wheels 48 of the vehicle 12 relative to the body 46 of the vehicle 12. The damper assembly 10 may resist motion of the wheels 48 relative to the body 46 based on a speed and direction of such motion. The damper assembly 10 includes the piston rod 14, a shield 50, and a damper body 52. The piston rod 14 defines the central axis A. The piston rod 14 may move toward and away from the damper body 52 along the central axis A. [0032] The damper assembly 10 includes the shield 50, as shown in Figures 2-3. The shield 50 extends around the piston rod 14. The shield 50 may define a cavity 54. The piston rod 14 may be disposed in the cavity 54. The sensor attachment 22 may be disposed in the cavity 54. The shield 50 prevents debris from reaching and interfering with the piston rod 14 and the sensor attachment 22. The shield 50 may be, e.g., steel, aluminum, plastic, or other suitable material.

[0033] The damper assembly 10 includes the damper body 52. The damper body 52 receives movement from the wheel 48. The piston rod 14 moves along the damper body 52. The damper body 52 is at least partially disposed in the shield 50. The shield 50 and the damper body 52 extend according to movement of the wheel 48 and the body 46 of the vehicle 12. The damper body 52 has an upper surface 56, as shown in Figure 2. The upper surface 56 is substantially planar, i.e., flat. That is, the upper surface 56 may extend substantially perpendicular to the central axis A.

[0034] The damper assembly 10 includes the sensor 24. The sensor 24 may be an ultrasonic sensor. That is, the sensor 24 may be programmed to emit an ultrasonic pulse and to receive a reflection of the ultrasonic pulse. An “ultrasonic pulse” is an emission of sound at a frequency above human hearing range, e.g., above 20,000 Hertz. The ultrasonic pulse reflects off the upper surface 56 of the damper body 52. That is, the upper surface 56 of the damper body 52 may be a reflection surface that reflects the ultrasonic pulse. Based on an elapsed time between emission of the ultrasonic pulse and receipt of the reflected ultrasonic pulse and the speed of sound, the sensor 24 can determine a distance between the sensor 24 and the upper surface 56 of the damper body 52. That is, the sensor 24 may emit the ultrasonic pulse toward the upper surface 56 of the damper body 52, the upper surface 56 may reflect the ultrasonic pulse, and the sensor 24 may receive the reflection of the ultrasonic pulse from the upper surface 56. The elapsed time between emission and receipt of the ultrasonic pulse multiplied by the speed of sound is the distance between the sensor 24 and the upper surface 56 of the damper body 52. The distance measured correlates to a weight of the vehicle 12, and the sensor 24 and/or an electronic control unit can determine the weight of the vehicle 12 according to empirical correlations and/or simulation models that use dimensions of components of the vehicle 12 and the distance to output the weight of the vehicle 12. The sensor 24 includes a data port 58. A cable (not shown) can connect to the data port 58 to receive data collected by the sensor 24. Alternatively, the sensor 24 may be a different type of sensor 24, e.g., radar, lidar, vision, subsonic, sonic, etc. [0035] The damper assembly 10 may include an eye mount 60. The eye mount 60 is connectable to the vehicle body 46. The damper assembly 10 may include a second eye mount 62. The second eye mount 62 connects the damper body 52 to the wheel 48. The vehicle body 46 may apply force to the eye mount 60, moving the shield 50 and the piston rod 14. The wheel 48 may apply force to the second eye mount 60, moving the damper body 52.

[0036] The damper assembly 10 includes the mount 18, as shown in Figures 4-5. The mount 18 supports the sensor 24. The mount 18 includes the rod attachment 20 and the sensor attachment 22. Figure 4 illustrates the damper assembly 10 without the shield 50. The rod attachment 20 is attachable to the piston rod 14, as shown in Figure 4. That is, the rod attachment 20 can secure the sensor 24 to the piston rod 14 and can align the sensor 24 to a specified orientation relative to the piston rod 14. The “specified orientation” can be along an axis parallel to the central axis A and directed toward the upper surface 56 of the damper body 52. By aligning the sensor 24 to the specified orientation, the sensor 24 may emit the ultrasonic pulse toward the upper surface 56 of the damper body 52 while reducing interference from the shield 50. Aligning the sensor 24 with the upper surface 56 of the damper body 52 in the specified orientation may thus improve quality of data collected, e.g., the received reflection of the ultrasonic pulse may be reflected off the upper surface 56 of the damper body 52 and reflection off the shield 50 may be reduced.

[0037] The shield 50 defines a sensor cavity 64. The sensor attachment 22 may be disposed in the sensor cavity 64. The sensor cavity 64 allows the data port 58 of the sensor 24 to extend from the shield 50. The sensor cavity 64 may be removed from the shield 50 based on the size of the sensor attachment 22. That is, the shield 50 may be installed to protect the piston rod 14 from debris and the sensor cavity 64 may be shaped such that the sensor attachment 22 may be disposed in the sensor cavity 64.

[0038] The piston rod 14 defines the groove 16. The groove 16 extends around a circumference of the piston rod 14. The rod attachment 20 of the mount 18 can include the tongue 26, as shown in Figure 5. The tongue 26 may be insertable into the groove 16. When the tongue 26 of the rod attachment 20 is disposed in the groove 16 of the piston rod 14, the mount 18 aligns the sensor 24 to a specified orientation relative to the piston rod 14. That is, the groove 16 may extend substantially perpendicular to the central axis A, and when the tongue 26 is inserted into the groove 16, the mount 18 may extend substantially perpendicular to the central axis A, aligning the sensor 24 in the specified orientation.

[0039] Figure 5 is an exploded view of the mount 18 and the sensor 24. The sensor 24 can be placed into the sensor attachment 22 of the mount 18 to secure the sensor 24 relative to the piston rod 14, as shown in Figures 3-4. The sensor attachment 22 defines at least one slot 28. The sensor 24 is mateable with the sensor attachment 22 in the slot 28. That is, the sensor attachment 22 may include extensions 30 that extend into the slot 28. The sensor 24 may form a friction fit or a press fit with the extensions 30, securing the sensor 24 relative to the piston rod 14.

[0040] The mount 18 may include a mount shield 66, as shown in Figures 3-5. The mount shield 66 may extend over the sensor cavity 64, as shown in Figure 3. The mount shield 66 prevents debris from entering the sensor cavity 64. That is, the sensor cavity 64 may allow debris to enter the shield 50, and the debris may disrupt operation of the piston rod 14. The mount shield 66 may cover the sensor cavity 64, preventing debris from entering the shield 50. The mount shield 66 may be curved, as shown in Figure 5, to cover the sensor cavity 64. The mount shield 66 may extend over the shield 50, overlapping a portion of the shield 50 around the sensor cavity 64. The mount shield 66 may secure the sensor 24 relative to the sensor attachment 22, aligning the data port 58 out from the mount shield 66.

[0041] Figures 6-7B illustrate of another embodiment of the damper assembly 10a. The damper assembly 10a includes the piston rod 14a and the eye mount 60. As described above, the eye mount 60 secures the piston rod 14a to the vehicle body 46. The piston rod 14a extends into the damper body 52, as shown in Figure 7B. The piston rod 14a defines the central axis A. [0042] The damper assembly 10a includes the sensor mount 32. The sensor mount 32 includes the tube 36 and the sensor housing 40. The tube 36 prevents debris from disrupting operation of the piston rod 14a. The sensor mount 32 supports the sensor 24. The data port 58 of the sensor 24 may extend from the sensor mount 32. The sensor housing 40 may be formed separately from the tube 36, as shown in Figures 6-7B. That is, the tube 36 may be a conventional shock absorber tube, and the tube 36 may define a cavity 68 removed from the tube 36. The sensor housing 40 may be disposed in the cavity 68 and fixed to the tube 36. The sensor housing 40 may be a lighter material than the tube 36, e.g., the sensor housing 40 may be plastic.

[0043] The sensor housing 40 may support the sensor 24, as shown in Figures 7A-7B. As shown in Figure 7A, the sensor 24 may be disposed at a first end 70 of the sensor housing 40. Alternatively, not shown in the Figures, the sensor 24 may be disposed at a second end 76 of the sensor housing 40 opposite the reflector 44. The sensor housing 40 may define a housing cavity 72. The sensor 24 is disposed in the housing cavity 72. The sensor housing 40 may define a slot 74, and the sensor 24 may be disposed with the slot 74. The data port 58 of the sensor 24 may extend away from the piston rod 14a and out from the sensor housing 40. [0044] As shown in Figure 7B, the reflector 44 may be disposed at the second end 76 of the sensor housing 40. The reflector 44 may be supported by the damper body 52. For example, the reflector 44 may be fastened with a suitable fastener, e.g., an adhesive, a bolt, a screw, a weld, etc. Alternatively, the reflector 44 may form a friction fit with the damper body 52, securing the reflector 44 relative to the damper body 52. The reflector 44 defines a reflection surface 78. The reflection surface 78 may reflect an ultrasonic pulse emitted by the sensor 24 and transmitted through the sensor housing 40. Based on an elapsed time between emission of the ultrasonic pulse and receipt of the reflected pulse and the speed of sound, the sensor 24 can determine a distance between the sensor 24 and the reflector 44. Based on the distance, the sensor 24 can determine a weight of the vehicle 12, as described above. The reflection surface 78 may be substantially planar, i.e., flat. The reflector 44 may be designed to present the substantially planar surface toward the sensor 24, e.g., the reflector 44 may be a tab, a ledge, a bar, etc. The reflection surface 78 may face the sensor 24.

[0045] The sensor 24 and the reflector 44 are aligned along the axis B parallel to the central axis A of the piston rod 14a. The axis B is radially offset from the central axis A of the piston rod 14a. That is, to identify the height of the damper assembly 10a, the sensor 24 emits an ultrasonic pulse toward the reflector 44 and receives a reflected pulse from the reflector 44, as described above. To reduce interference from the sensor housing 40, the sensor 24 and the reflector 44 are aligned along the axis B, and the sensor 24 emits the ultrasonic pulse along the axis B. Thus, the ultrasonic pulse may travel to the reflector 44 with less interference from the sensor housing 40, reducing noise in the collected data.

[0046] With reference to Figures 8-10, various unitary embodiments of tubes 36a, 36b, 36c and sensor housings 40a, 40b, 40c are shown. Unitary means a single, uniform piece of material with no seams, joints, fasteners, or adhesives holding the tubes 36a, 36b, 36c and the sensor housings 40a, 40b, 40c together, i.e., the tubes 36a, 36b, 36c and the sensor housings 40a, 40b, 40c are formed together simultaneously as a single continuous unit, e.g., by machining from a common blank, molding, forging, casting, 3-D printing, etc. Non-unitary components, in contrast, are formed separately and subsequently assembled, e.g., by threaded engagement, welding, etc. The tubes 36a, 36b, 36c and the sensor housings 40a, 40b, 40c may be included in the of the damper assembly 10a as an alternative to the tube 36 and housing 40 shown in Figures 6-7B, e.g., to prevent debris from disrupting operation of the piston rod 14a and support the sensor 24.

[0047] With reference to Figure 8, the tube 36a and the housing 40a may each define a respective opening 37, 41. The opening 37 of the tube 36a may be centered on the axis A. The opening 41 of the sensor housing 40amay be centered on the axis B. When included in the damper assembly 10a, the piston rod 14a may extend through the opening 37 of the tube 36a and the sensor 24 may be supported at the opening 41 of the sensor housing 40a (not shown). [0048] With reference to Figure 9, the tube 36b and the housing 40b may collectively define an opening 37a. The opening 37a of the tube 36b and the sensor housing 40b may include a first perimeter portion 39a centered on the axis A and a second perimeter portion 39b centered on the axis B. The first perimeter portion 39a and the second perimeter portion 39b may be at a common location along the axes A, B, e.g., the first perimeter portion 39a and the second perimeter portion 39b may be on a common plane and the axes A, B may extend normal from such plane. When included in the damper assembly 10a, the piston rod 14a may extend through the first perimeter portion 39a and the sensor 24 may be supported at the second perimeter portion 39b (not shown).

[0049] With reference to Figure 10, the tube 36c and the housing 40c may collectively define an opening 37b. The opening 37b of the tube 36c and the sensor housing 40c may include a first perimeter portion 39a’ centered on the axis A and a second perimeter portion 39b’ centered on the axis B. The first perimeter portion 39a’ may be spaced from the second perimeter portion 39b’ along the axes A, B, e.g., a step extending along the axes A, B may separate the first perimeter portion 39a’ from the second perimeter portion 39b’. When included in the damper assembly 10a, the piston rod 14a may extend through the first perimeter portion 39a’ and the sensor 24 may be supported at the second perimeter portion 39b’ (not shown).

[0050] Figures 11-13B illustrate another embodiment of the damper assembly 10b. The damper assembly 10b includes the sensor mount 34. As shown in Figure 11, the sensor mount 34 may include a first axial piece 80 and a second axial piece 82. The first axial piece 80 includes a first portion of the tube 38 and a first portion of the sensor housing 42. The second axial piece 82 includes a second portion of the tube 38 and a second portion of the sensor housing 42. That is, the first axial piece 80 can be integrally formed, and the first portion of the tube 38 can be integral with the first portion of the sensor housing 42. The second axial piece 82 can be integrally formed, and the second portion of the tube 38 can be integral with the second portion of the sensor housing 42. The first and second axial pieces 80, 82 extend along the central axis A of the piston rod 14b. The first axial piece 80 includes a first edge 84. The second axial piece 82 includes a second edge 86. The first edge 84 is joinable to the second edge 86. That is, the first edge 84 may be fastened to the second edge 86, securing the first axial piece 80 to the second axial piece 82. The first edge 84 may be fastened to the second edge 86 in a suitable manner, e.g., an adhesive, a bolt, a screw, a friction fit, a snap fastener, etc. When the first axial piece 80 is joined to the second axial piece 82, the tube 38 and the sensor housing 42 of the sensor mount 34 support the sensor 24 and enclose the piston rod 14b. [0051] The first axial piece 80 may include a first loop 88. The second axial piece 82 may include a second loop 90. The first and second loops 88, 90 may be connectable to the eye mount 60. Connecting the first and second loops 88, 90 to the eye mount 60 secures the sensor mount 34 to the eye mount 60, reducing motion of the sensor mount 34 during operation of the damper assembly 10b. Reducing motion of the sensor mount 34 may reduce interference of the ultrasonic pulse emitted by the sensor 24, reducing noise and improving accuracy of the data collected by the sensor 24.

[0052] The sensor housing 42 may include a first housing 92 in the first axial piece 80 and a second housing 94 in the second axial piece 82. As shown in Figure 13A, the first housing 92 may be a void in which the sensor 24 is disposed. The first housing 92 may allow the data port 58 to extend out from the first axial piece 80. The first housing 92 may support a portion of the sensor 24, and the second housing 94 may support a portion of the sensor 24 not supported by the first housing 92. Thus, when the first axial piece 80 is joined to the second axial piece 82, the sensor 24 is supported by the first and second housings 92, 94.

[0053] As shown in Figure 12, the first axial piece 80 may be attached to the second axial piece 82 at a hinge 81. The hinge 81 permits the first axial piece 80 to pivot relative the second axial piece 82, e.g., such that the first axial piece 80 and the second axial piece 82 may fold towards each other to join and support the sensor 24. The hinge 81 may be a living hinge or any suitable structure that fixes first axial piece 80 to the second axial piece 82 and permits relative pivot therebetween.

[0054] As shown in Figures 13A-13B, the first and second axial pieces 80, 82 support the sensor 24 and the reflector 44. As shown in Figure 13B, the reflector 44 extends into the first axial piece 80. The sensor 24 may emit an ultrasonic pulse toward the reflector 44, and the reflection surface 78 of the reflector 44 may reflect the ultrasonic pulse to the sensor 24. Based on the elapsed time between emission of the ultrasonic pulse and receipt of the reflected pulse, the sensor 24 can determine the height of the damper assembly 10b, as described above. [0055] Figures 14-14A illustrate another embodiment of the damper assembly 10c. The damper assembly 10c functions as described for the other damper assemblies 10a, 10b. Instead of the of tubes 36, 36a, 36b, 36c, 38 and sensor housings 40a, 40b, 40c, 42 of the damper assemblies 10a, 10b, the damper assembly 10c includes a sensor support 83 fixed relative to an end of the piston rod 14b. The sensor 24 is supported by the sensor support 83 at the axis B. The damper assembly 10c also includes a tube 85 surrounding the damper body 52 that is centered on the axis A. The tube 85 has a larger diameter than a diameter of the damper body to provide spaced for detection by the sensors 24 between an outer surface of the damper body 52 and an inner surface of the tube 85. For example, the axes A, B may be surrounded by the tube 85. A center axis C of the tube 85 may be offset and between the axis A and the axis B. The sensor 24 is supported at a top 91 of the tube 85, e.g., via the sensor support 83, such that the sensor 24 moves away from the reflector 44 when a length of the damper assembly 10c is increased.

[0056] Figures 15-16 illustrate another embodiment of the damper assembly lOd. The damper assembly lOd is generally similar to the damper assembly 10a. The sensor 24 of the damper assembly lOd is supported at a bottom 93 of the tube 85. The reflector 44 is supported at a top of the damper body 52. For example, the reflector 44 may be fixed to the outer surface of the damper body 52. The sensor 24 moves toward the reflector 44 when a length of the damper assembly lOd is increased.

[0057] Figure 17 illustrates another embodiment of the damper assembly lOe. The damper assembly lOe includes a bottom bracket 101 and fixed to the damper tube 52. The bottom bracket 101 may support the sensor 24. The reflector 44 may be fixed to the piston rod 14b, e.g., with a top bracket 103 or other suitable structure. A flexible shield 105 may surround the piston rod 14b, damper body 52, the sensor 24, and the reflector 44. The flexible shield 105 may be rubber or any suitable material. The flexible shield 105 may include folds, e.g., an accordion-type series of folds, that fold and unfold depending on whether the damper assembly lOe is increasing or decreasing in length. The damper assembly lOe may include a coil-spring 107. The coil spring 107 may be compressed between the bottom bracket 101 and the top bracket 103, urging the brackets 101, 103 away from each other and the damper assembly lOe toward an extended position. The flexible shield 105 may be sandwiched between the coil spring 107 and the bottom bracket 101, and between the coil spring 105 and the top bracket 103, e.g., securing the ends of the flexible shield 105 and the coil-spring 107 relative to each other.

[0058] Figure 18 illustrates a illustrates another embodiment of the damper assembly lOf. The damper assembly lOf may include a bottom bracket 109 fixed to the damper body 52. The damper assembly lOf may include a top bracket assembly 111 fixed to the piston rod 14b The damper assembly lOf may include a coil spring 107a surrounding the damper body 52 and the piston rod 14b. The coil spring 107a may be compressed between the bottom bracket 109 and the top bracket assembly 111, urging the brackets 109, 111 away from each other and the damper assembly lOf toward an extended position. The damper assembly lOf includes a tube 36a and a sensor housing 40a, e.g., as described for the embodiment of Figures 8-10. The tube 36a and the sensor housing 40a may be a flexible material and include features, such as an accordion fold, to enable the tube 36a and the sensor housing 40a to vary in length. The unitary tube 36a and sensor housing 40a surround the coil spring 107a. The bottom bracket 109 may reflect pulses or detection by the sensor 24.

[0059] Figures 19-20 illustrate a bumper cap 113 that supports the sensor 24. The bumper cap 113 may be fixed to the end of the damper body 52, and the piston rod 14b may slide through the bumper cap 113. The sensor 24 may point away from the damper body 52 to reflect pulses off the reflector 44 supported by the top bracket 103. Alternately, the bumper cap 113 may be fixed to the piston rod 14b. For example, the bumper cap 113 may replace the end cap 103 of the damper assembly lOe of Figure 17 and a reflector 44 may be fixed to the damper body 52 to reflect pulses to the sensor 24 supported at the bumper cap 113. The coil spring 107 may urge the bumper cap 113 away from the damper body 52. The flexible shield 105 may be compressed between the coil spring 107 and the bumper cap 113, e.g., as described for the top bracket 103.

[0060] The disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described.

[0061] Some components of the various embodiments described herein may be interchangeably used. In other words, some components one or more of the embodiments may be used with the other embodiments.

[0062] The adjectives “first” and “second” are used throughout this document as identifiers and are not intended to signify importance or order.

Claims

CLAIMS What is claimed is:

1. A damper assembly, comprising: a piston rod defining a central axis; a sensor mount including a tube and a sensor housing, the tube extending along the central axis of the piston rod and the sensor housing disposed radially offset from the central axis; a sensor supported by the sensor housing; and a reflector; wherein the sensor and the reflector are aligned along an axis parallel to the central axis of the piston rod.

2. The assembly of claim 1 , wherein the sensor mount includes a first axial piece having a first edge and a second axial piece having a second edge, the first edge being joinable to the second edge.

3. The assembly of claim 2, wherein the piston rod is connected to an eye mount, the first axial piece includes a first loop connectable to the eye mount, and the second axial piece includes a second loop connectable to the eye mount.

4. The assembly of claim 2, wherein the sensor housing includes a first housing in the first axial piece and a second housing in the second axial piece, wherein when the first axial piece is joined to the second axial piece, the sensor is supported by the first and second housings.

5. The assembly of any of claims 1-4, wherein the sensor housing is separately formed from the tube and fixed to the tube.

6. The assembly of claim 5, wherein the tube defines a cavity and the sensor housing is disposed in the cavity.

7. The assembly of claim 5, wherein the sensor is disposed at a first end of the sensor housing and the reflector is disposed at a second end of the sensor housing.

8. The assembly of any of claims 1-4, wherein the sensor is programmed to emit an ultrasonic pulse and to receive a reflection of the ultrasonic pulse from the reflector.

9. The assembly of any of claims 1 -4, wherein the reflector defines a planar surface facing the sensor.

10. The assembly of any of claims 1-4, wherein the axis is radially offset from the central axis of the piston rod.