Integral accumulator/reservoir system

1. An integral accumulator/reservoir system, the system comprising:

a low pressure vessel having a low-pressure vessel wall defining a low-pressure vessel cavity;

a high-pressure accumulator having a high-pressure accumulator wall defining a high-pressure accumulator cavity, the high-pressure accumulator being disposed in the low-pressure vessel cavity, the high-pressure accumulator wall including an aluminum layer;

a flexible bladder, the flexible bladder being disposed in the high-pressure accumulator cavity; and

a sensor module operably connected to the aluminum layer.

2. The system of claim 1 wherein the sensor module includes a strain gauge operable to detect strain in the aluminum layer.

3. The system of claim 2 further comprising a central processing unit operably connected to the strain gauge, the central processing unit being operable to use the detected strain to calculate a parameter selected from the group consisting of number of pressure cycles, maximum pressure, and pressure history.

4. The system of claim 1 wherein the sensor module includes a temperature sensor operable to detect temperature of the aluminum layer.

5. The system of claim 4 further comprising a central processing unit operably connected to the temperature sensor, the central processing unit being operable to use the detected temperature to calculate a parameter selected from the group consisting of tank fluid pressure and tank fluid volume.

6. The system of claim 1 wherein the sensor module comprises:

a sensor selected from the group consisting of a strain gauge and a temperature sensor;

an analog-to-digital converter operably connected to the sensor;

a central processing unit operably connected to the analog-to-digital converter; and

a communication interface operably connected to the central processing unit.

7. The system of claim 6 wherein the communication interface is selected from the group consisting of a wireless transceiver and a CAN/BUS communication chip.

8. The system of claim 1 wherein the sensor module further comprises a GPS/GSM interface.

9. The system of claim 1 further comprising a carbon/epoxy layer exterior to the aluminum layer, and a plastic layer interior to the aluminum layer and adjacent to the flexible bladder.

10. The system of claim 9 is further comprising a nonstructural fiberglass layer exterior to the carbon epoxy layer.

11. A braking energy regeneration system for use with a vehicle prime mover, the system comprising:

a power transfer module operably connected to the vehicle prime mover;

a hydraulic pump system operably connected to the power transfer module, the hydraulic pump system having an axial piston pump in fluid communication with a fixed displacement pump;

an integral accumulator/reservoir system operably connected to the hydraulic pump system, the integral accumulator/reservoir system having a high-pressure accumulator, a low-pressure vessel, and a flexible bladder; and

a control system operably connected to the vehicle prime mover, the power transfer module, the hydraulic pump system, and the integral accumulator/reservoir system;

wherein the fixed displacement pump is in fluid communication with the low-pressure vessel, the fixed displacement pump is in fluid communication with the axial piston pump, and the axial piston pump is in fluid communication with the high-pressure accumulator; and

wherein the integral accumulator/reservoir system comprises;

the low pressure vessel having a low-pressure vessel wall defining a low-pressure vessel cavity;

the high-pressure accumulator having a high-pressure accumulator wall defining a high-pressure accumulator cavity, the high-pressure accumulator being disposed in the low-pressure vessel cavity, the high-pressure accumulator wall including an aluminum layer;

the flexible bladder being disposed in the high-pressure accumulator cavity; and

a sensor module operably connected to the aluminum layer.

12. The system of claim 11 wherein the sensor module includes a strain gauge operable to detect strain in the aluminum layer.

13. The system of claim 12 further comprising a central processing unit operably connected to the strain gauge, the central processing unit being operable to use the detected strain to calculate a parameter selected from the group consisting of number of pressure cycles, maximum pressure, and pressure history.

14. The system of claim 11 wherein the sensor module includes a temperature sensor operable to detect temperature of the aluminum layer.

15. The system of claim 14 further comprising a central processing unit operably connected to the temperature sensor, the central processing unit being operable to use the detected temperature to calculate a parameter selected from the group consisting of tank fluid pressure and tank fluid volume.

16. The system of claim 11 wherein the sensor module comprises:

a sensor selected from the group consisting of a strain gauge and a temperature sensor;

an analog-to-digital converter operably connected to the sensor;

a central processing unit operably connected to the analog-to-digital converter; and

a communication interface operably connected to the central processing unit.

17. The system of claim 16 wherein the communication interface is selected from the group consisting of a wireless transceiver and a CAN/BUS communication chip.

18. The system of claim 11 wherein the sensor module further comprises a GPS/GSM interface.

19. The system of claim 11 further comprising a carbon/epoxy layer exterior to the aluminum layer, and a plastic layer interior to the aluminum layer and adjacent to the flexible bladder.

20. The system of claim 19 further comprising a nonstructural fiberglass layer exterior to the carbon epoxy layer.