Accelerometer leveling in an actively controlled vehicle suspension

1. A method for compensating for a misalignment characteristic of one or more acceleration sensors fixed to a sprung mass of a vehicle, each acceleration sensor having a location on the vehicle and a desired orientation relative to the vehicle, the method comprising:

for each acceleration sensor of the one or more acceleration sensors,

receiving by a controller data characterizing misalignment of the acceleration sensor from the desired orientation of the acceleration sensor;

receiving by the controller a signal from the acceleration sensor representing an acceleration acting on the acceleration sensor, the signal including components representing acceleration in a direction other than the desired orientation of the acceleration sensor related to a misalignment of the acceleration sensor;

receiving by the controller signals representing inertial measurements from one or more inertial sensors in the vehicle; and

combining the signals from the inertial sensors and the signal from the acceleration sensor based on the data characterizing misalignment of the acceleration sensor to form a corrected acceleration signal substantially representing the acceleration in the desired orientation at the location of the acceleration sensor,

forming a control signal based on the corrected acceleration signal; and

providing the control signal to an active suspension element associated with the acceleration sensor.

2. The method of claim 1 further comprising, for each acceleration sensor of the one or more acceleration sensors, determining the data characterizing misalignment of the acceleration sensor based on a signal received from the acceleration sensor and signals received from the one or more inertial sensors.

3. The method of claim 2 wherein determining the data characterizing misalignment of the acceleration sensor includes adaptively determine the data characterizing misalignment of the acceleration sensor during operation of the vehicle.

4. The method of claim 2 wherein determining the data characterizing misalignment of the acceleration sensor includes determining the data characterizing misalignment of the acceleration sensor at a calibration time and subsequently updating the data characterizing misalignment of the acceleration sensor during operation of the vehicle.

5. The method of claim 1 wherein the data characterizing misalignment of the acceleration sensor is at least in part based on information determined by performing a tilt test of the vehicle.

6. The method of claim 5 wherein the tilt test includes determining misalignment information including

receiving the signal from the acceleration sensor as the vehicle chassis is rotated through a number of known orientations; and

determining the misalignment information including determining an orientation of the vehicle chassis where the signal from the acceleration sensor is at an extreme value.

7. The method of claim 1 further comprising determining the data characterizing misalignment of the acceleration sensor including

determining an estimate of a reference acceleration acting on the acceleration sensor based on one of the signals representing inertial measurements and a distance between a location of the inertial sensor and the location of the acceleration sensor; and

determining the data characterizing misalignment based on the estimate of the true linear acceleration and the signal from the acceleration sensor;

wherein the signal representing the inertial measurement includes second linear acceleration signal, a rotational acceleration signal, and a rotational velocity signal.

8. The method of claim 1 wherein receiving inertial measurements from one or more inertial sensors includes receiving inertial measurements from a first inertial sensor during a calibration time and receiving inertial measurements from a second inertial sensor during a time that the vehicle is operated.

9. The method of claim 8 wherein the first inertial sensor is a removable inertial sensor and the second inertial sensor is a fixed inertial sensor associated with a vehicle stability control system.

10. The method of claim 1 wherein the vehicle includes four corners, each corner including

a suspension actuator coupled to the sprung mass,

a wheel coupled to the suspension actuator, and

an acceleration sensor of the one or more acceleration sensors coupled to the sprung mass in the vicinity of the location where the suspension actuator is coupled to the sprung mass.

11. A computer-readable medium having encoded thereon instructions for causing a data processing system to compensate for a misalignment characteristic of one or more acceleration sensors fixed to a sprung mass of a vehicle, each acceleration sensor having a location on the vehicle and a desired orientation relative to the vehicle, the compensating comprising:

for each acceleration sensor of the one or more acceleration sensors,

receiving by a controller data characterizing misalignment of the acceleration sensor from the desired orientation of the acceleration sensor;

receiving by the controller a signal from the acceleration sensor representing an acceleration acting on the acceleration sensor, the signal including components representing acceleration in a direction other than the desired orientation of the acceleration sensor related to a misalignment of the acceleration sensor;

receiving by the controller signals representing inertial measurements from one or more inertial sensors in the vehicle; and

combining the signals from the inertial sensors and the signal from the acceleration sensor based on the data characterizing misalignment of the acceleration sensor to form a corrected acceleration signal substantially representing the acceleration in the desired orientation at the location of the acceleration sensor, forming a control signal based on the corrected acceleration signal; and

providing the control signal to an active suspension element associated with the acceleration sensor.

12. A system comprising:

one or more acceleration sensors, each fixed to a location on a sprung mass of a vehicle and having a desired orientation relative to the vehicle;

one or more inertial sensors for generating signals representing inertial measurements;

a controller configured to receive data characterizing misalignment of the acceleration sensor from the desired orientation of the acceleration sensor, to receive signals from the one or more inertial sensors, and to receive signals from the one or more acceleration sensors representing accelerations acting on the one or more acceleration sensors, the acceleration signals including components representing acceleration in a direction other than the desired orientation of the one or more acceleration sensors related to a misalignment of the one or more acceleration sensor,

wherein the controller is further configured to combine the signals from the inertial sensors and the signals from the acceleration sensors based on the data characterizing misalignment of the one or more acceleration sensors to form corrected acceleration signals substantially representing the accelerations in the desired orientation at the locations of the one or more acceleration sensors, form a control signal based on the corrected acceleration signal, and provide the control signal to an active suspension element associated with the acceleration sensor.

13. A system for compensating for a misalignment characteristic of one or more acceleration sensors fixed to a sprung mass of a vehicle, each acceleration sensor having a location on the vehicle and a desired orientation relative to the vehicle, the system comprising:

a controller, wherein for each acceleration sensor of the one or more acceleration sensors the controller comprises:

a first input for receiving data characterizing misalignment of the acceleration sensor from the desired orientation of the acceleration sensor;

a second input for receiving a signal from the acceleration sensor representing an acceleration acting on the acceleration sensor, the signal including components representing acceleration in a direction other than the desired orientation of the acceleration sensor related to a misalignment of the acceleration sensor;

a third input for receiving signals representing inertial measurements from one or more inertial sensors in the vehicle; and

wherein the controller combines the signals from the inertial sensors and the signal from the acceleration sensor based on the data characterizing misalignment of the acceleration sensor to form a corrected acceleration signal substantially representing the acceleration in the desired orientation at the location of the acceleration sensor.

14. The system of claim 13 wherein the controller is further configured to, for each acceleration sensor of the one or more acceleration sensors,

form a control signal based on the corrected acceleration signal; and

provide the control signal to an active suspension element associated with the acceleration sensor.

15. The system of claim 13 wherein the controller is configured to, for each acceleration sensor of the one or more acceleration sensors, determine the data characterizing misalignment of the acceleration sensor based on a signal received from the acceleration sensor and signals received from the one or more inertial sensors.

16. The system of claim 15 wherein the controller is further configured to determine the data characterizing misalignment of the acceleration sensor including adaptively determining the data characterizing misalignment of the acceleration sensor during operation of the vehicle.

17. The system of claim 15 wherein the controller is further configured to determine the data characterizing misalignment of the acceleration sensor including determining the data characterizing misalignment of the acceleration sensor at a calibration time and subsequently updating the data characterizing misalignment of the acceleration sensor during operation of the vehicle.

18. The system of claim 13 wherein the data characterizing misalignment of the acceleration sensor received at the first input is at least in part based on information determined by performing a tilt test of the vehicle.

19. The system of claim 13 wherein the controller is further configured to determine the data characterizing misalignment of the acceleration sensor, the controller configured to:

determine an estimate of a reference acceleration acting on the acceleration sensor based on one of the signals representing inertial measurements and a distance between a location of the inertial sensor and the location of the acceleration sensor; and

determine the data characterizing misalignment based on the estimate of the true linear acceleration and the signal from the acceleration sensor;

wherein the signal representing the inertial measurement includes second linear acceleration signal, a rotational acceleration signal, and a rotational velocity signal.

20. The system of claim 13 further configured to receive inertial measurements from one or more inertial sensors including receiving inertial measurements from a first inertial sensor during a calibration time and receiving inertial measurements from a second inertial sensor during a time that the vehicle is operated.

21. The system of claim 20 wherein the first inertial sensor is a removable inertial sensor and the second inertial sensor is a fixed inertial sensor associated with a vehicle stability control system.

22. The system of claim 13 wherein the vehicle includes four corners, each corner including

a suspension actuator coupled to the sprung mass,

a wheel coupled to the suspension actuator, and

an acceleration sensor of the one or more acceleration sensors coupled to the sprung mass in the vicinity of the location where the suspension actuator is coupled to the sprung mass.