Integrated air spring assembly for suspension system and using method of integrated air spring assembly

Abstract

The invention discloses an integrated air spring assembly for a suspension system and a using method of the integrated air spring assembly, and belongs to the technical field of mechanical damping. The integrated air spring assembly comprises an air spring body and a control module which are arranged between a top plate and a bottom plate; the middle of the upper surface of the bottom plate, the interior of the air spring body and the middle of the lower surface of the top plate are communicated, a valve path block and a sensor are fixedly arranged in the middle of the upper surface of the bottom plate, an air path connector is formed in the side wall of the bottom plate, a first air port of the valve path block is communicated with the interior of the air spring body, and a second air port of the valve path block is communicated with the air path connector. The integrated structure that the valve path block and the sensor are integrated on the bottom plate and directly connected with the air spring body is adopted, air path minimization and signal embedding are achieved, and the problems that a traditional split type air spring is bloated in structure, large in response delay and low in reliability are solved.

Description

Technical Field

[0001] This invention belongs to the field of mechanical vibration reduction technology, and in particular relates to an integrated air spring assembly for suspension systems and its usage method. Background Technology

[0002] Air springs are core components in modern vehicle suspensions and industrial equipment vibration isolation systems. By adjusting internal air pressure, they change stiffness and height to achieve load support, attitude adjustment, and vibration isolation functions. As active suspension systems, constant height suspension systems, and constant pressure suspension systems place higher demands on the response speed and control precision of air springs, the limitations of traditional split-type air springs are becoming increasingly apparent.

[0003] Currently, a typical implementation involves treating the air spring as a separate mechanical component, connecting it to a centralized pneumatic control module (including solenoid valves, etc.) via external piping. Additionally, if monitoring is required, sensors (such as height or pressure sensors) are installed near the spring or in other locations. This approach constitutes a split-type air spring.

[0004] This type of split-type air spring has the following disadvantages:

[0005] 1) Bulky Structure: Separate valves, sensors, and springs require additional installation space and complex connections. In practical applications, the need for independent fixing devices and connectors for each component significantly increases the size and weight of the entire system. Especially in space-constrained vehicle chassis or precision equipment, this bloated structural design often fails to meet the requirements of a compact layout and increases the difficulty of system integration.

[0006] 2) Limited Dynamic Performance: Long air passages result in low inflation / deflation efficiency, slow system response, and difficulty in achieving rapid and precise active control. Due to the long connecting pipe between the control valve and the air spring body, pressure loss and response delay occur during gas transmission. This delay is particularly noticeable in active suspension systems requiring rapid adjustments, potentially preventing timely adjustments to suspension parameters when encountering uneven road surfaces, affecting driving stability and comfort. Furthermore, long air passages are prone to pressure fluctuations, reducing control precision.

[0007] 3) Reliability Risks: External gas lines and cables are the main risk points for system failure, prone to leaks and signal interference. During long-term use, connecting pipes and cables are susceptible to vibration, wear, and corrosion, leading to gas leaks or unstable signal transmission. This reliability issue is particularly pronounced in harsh operating environments, such as high temperature, high humidity, or corrosive media. A failure at any connection point can cause the entire system to fail, increasing maintenance costs and downtime.

[0008] 4) Cost and Maintainability: Numerous components, complex assembly, and high maintenance costs. The modular design requires a large number of connectors, seals, and fixing devices, increasing both initial procurement costs and the complexity of assembly and debugging. During maintenance, a large number of components need to be inspected and replaced, increasing workload and time costs. Furthermore, compatibility issues may arise due to components coming from different suppliers, further complicating system integration and maintenance. Summary of the Invention

[0009] Based on the technical problems existing in the prior art, the present invention provides an integrated air spring assembly for a suspension system and a method for using the same.

[0010] According to a first aspect of the technical solution of the present invention, an integrated air spring assembly for a suspension system is provided, comprising an air spring body and a control module disposed between a top plate and a bottom plate. The middle part of the upper surface of the bottom plate, the interior of the air spring body, and the middle part of the lower surface of the top plate are connected. A valve block and a sensor are fixedly disposed in the middle part of the upper surface of the bottom plate. An air passage interface is provided on the side wall of the bottom plate. The first air port of the valve block is connected to the interior of the air spring body, and the second air port of the valve block is connected to the air passage interface. The sensor is used to acquire the real-time physical state of the air spring body. The control module is used to generate control commands based on the real-time physical state. The valve block is used to receive the control commands and control the gas to enter and exit the air spring body according to the control commands.

[0011] A further improvement of the present invention is that the sensor is one or any combination of two or more of the following: displacement sensor, accelerometer, temperature sensor, vibration sensor or pressure sensor.

[0012] A further improvement of the present invention is that a support frame is also provided inside the air spring body.

[0013] A further improvement of the present invention is that the air passage interface is a quick-connect fitting or a threaded interface.

[0014] A further improvement of the present invention is that a sealing ring is provided at both the first and second air ports of the valve block.

[0015] A further improvement of the present invention is that the valve block is composed of one or two solenoid valves.

[0016] A further improvement of the present invention is that: the side wall of the base plate is also provided with an electrical interface, the electrical interface being electrically connected to the sensor and the valve block respectively via cables, the cables being disposed inside the base plate.

[0017] A further improvement of the present invention is that the air spring is a spherical structure or a stack of several spherical structures.

[0018] A further improvement of the present invention is that: an air passage is provided inside the base plate, and the air passage is used to connect the air interface and the second air port of the valve block.

[0019] According to a second aspect of the present invention, a method for using an integrated air spring assembly for a suspension system is provided, which is based on the above-described integrated air spring assembly for a suspension system and includes the following steps:

[0020] Step S1: Acquire real-time physical data through the sensor (5) and upload the real-time physical data to the control module;

[0021] Step S2: The control module generates control commands based on the real-time physical data and sends the control commands to the valve block (4);

[0022] Step S3: The valve block (4) opens / closes the air circuit according to the control command, and adjusts the internal air pressure and spring height of the air spring body (1).

[0023] Compared with the prior art, the above-mentioned technical solution of the present invention has the following beneficial technical effects:

[0024] 1. This invention integrates the control valve block and sensor directly onto the base plate of the air spring, and directly connects them to the internal air chamber of the air spring body. This eliminates the lengthy external air connection paths and scattered wiring harnesses of traditional solutions. It achieves a significant simplification of the gas path and embedding of signal transmission from a physical structure perspective. This significantly reduces gas flow resistance and volumetric delay, thereby greatly improving the response speed and control bandwidth of inflation and deflation, meeting the stringent requirements of active suspension systems for high-frequency real-time adjustment.

[0025] 2. This invention utilizes a variety of sensor types, including displacement, pressure, acceleration, temperature, and vibration sensors. This configuration endows the integrated component with powerful multi-dimensional state perception capabilities. The displacement sensor provides direct feedback for constant height control, the pressure sensor is the core for achieving constant pressure control and load estimation, while the acceleration and vibration sensors capture the dynamic motion spectrum of the sprung mass. Multi-sensor fusion enables the control system to obtain more comprehensive and accurate operating condition information, achieving not only higher-precision single-target control but also supporting complex composite control strategies, such as active vibration isolation based on vibration signals. It solves the problems of traditional solutions that typically rely on a single type of sensor (such as only a height sensor), resulting in limited control dimensions, poor environmental adaptability, and susceptibility to control deviations or malfunctions under complex operating conditions due to incomplete information. This significantly improves the overall system's control intelligence and environmental robustness.

[0026] 3. This invention solves the problems of low installation efficiency and easy loosening and leakage of connections under vibration by setting the air circuit interface as a quick-connect or threaded interface to achieve quick connection or high-strength sealing.

[0027] 4. This invention achieves a reliable static seal at the interface by setting a sealing ring at the gas port of the valve block, thus solving the problem of system control inaccuracy and performance degradation caused by gas leakage at the gas connection point.

[0028] 5. This invention uses one or two solenoid valves to form a valve block, thereby achieving independent or combined control of intake and exhaust, which solves the problems of single air path adjustment method and insufficient response flexibility.

[0029] 6. This invention solves the problems of easily damaged, messy, and poorly protected external cables by setting an integrated electrical interface on the side wall of the base plate and laying cables inside.

[0030] 7. By designing the air spring as a spherical structure, this invention achieves better force distribution and deformation characteristics, thus solving the problems of local stress concentration and short fatigue life of non-ideal shaped springs.

[0031] 8. This invention solves the problems of slow response, easy leakage and complex layout caused by the lengthy external pipeline by opening an air passage inside the base plate to connect the air passage interface and valve block, thus achieving a completely built-in air passage and an extremely short path. Attached Figure Description

[0032] The accompanying drawings are provided to better understand the invention and are not intended to unduly limit the scope of the invention. Wherein:

[0033] Figure 1 This is a schematic diagram of the structure of a single sphere in an integrated air spring assembly for a suspension system according to the present invention;

[0034] Figure 2 This is a schematic diagram of a double-sphere structure in an integrated air spring assembly for a suspension system according to the present invention;

[0035] Figure 3 This is a schematic diagram of the structure of a screw-fixed valve block in an integrated air spring assembly for a suspension system according to the present invention;

[0036] Figure 4 This is a schematic diagram of the joint connecting valve block in an integrated air spring assembly for a suspension system according to the present invention;

[0037] Figure 5 This is a schematic diagram of the sensor potting installation in an integrated air spring assembly for a suspension system according to the present invention;

[0038] Figure 6This is a schematic diagram of the sensor sealing ring installation in an integrated air spring assembly for a suspension system according to the present invention;

[0039] Figure 7 This is a schematic diagram of an independently installed support frame structure in an integrated air spring assembly for a suspension system according to the present invention;

[0040] Figure 8 This is a schematic diagram of a support frame structure installed around a sensor in an integrated air spring assembly for a suspension system according to the present invention;

[0041] Figure 9 This is a pipeline layout diagram of an integrated air spring assembly for a suspension system according to the present invention;

[0042] Figure 10 This is a cable layout diagram of an integrated air spring assembly for a suspension system according to the present invention.

[0043] The attached figures are labeled as follows: 1. Air spring body; 2. Top plate; 3. Bottom plate; 4. Valve block; 5. Sensor; 6. Support frame; 7. Electrical interface; 8. Air interface; 9. Air passage. Detailed Implementation

[0044] The following description, in conjunction with the accompanying drawings, illustrates exemplary embodiments of the present invention, including various details to aid understanding. These details should be considered merely exemplary. Therefore, those skilled in the art will recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the invention. Similarly, for clarity and brevity, descriptions of well-known functions and structures are omitted in the following description.

[0045] Example 1

[0046] like Figure 1-6As shown, this invention provides an integrated air spring assembly for a suspension system, comprising an air spring body 1 disposed between a top plate 2 and a bottom plate 3, and a control module. The air spring body 1 includes several stacked air springs. The middle of the upper surface of the bottom plate 3, the interior of the air spring body 1, and the middle of the lower surface of the top plate 2 are connected. A valve block 4 and a sensor 5 are fixedly disposed in the middle of the upper surface of the bottom plate 3. An air passage interface is provided on the side wall of the bottom plate 3. The first air port of the valve block 4 is connected to the interior of the air spring body 1, and the second air port of the valve block 4 is connected to the air passage interface 8. The sensor is used to acquire the real-time physical state of the air spring body. The control module is used to generate control commands based on the real-time physical state. The valve block 4 is used to receive the control commands and control the gas flow in and out of the air spring body 1 according to the control commands. The air spring body 1 utilizes the compressibility of its internal sealed gas to provide elastic support and vibration isolation, realizing the physical basis for load bearing, attitude adjustment, and vibration isolation. The top plate 2 and the bottom plate 3 together form the rigid sealing structure of the sealed air chamber. The top plate 2 is directly connected to the supported load to transfer the load, while the bottom plate 3 serves as the interface for connection with the foundation structure. The valve block 4, as an actuator, is integrated on the bottom plate 3. Through the rapid action of its internal solenoid valve, it directly controls the gas flow into and out of the spring body 1, which is key to achieving active control of inflation, pressure holding, and deflation. The sensor 5 is also integrated on the bottom plate 3, serving as the system's sensing unit. It is used to monitor the physical state of the spring body 1 in real time, such as pressure, height, or vibration, providing accurate feedback for closed-loop control. The integrated layout of the valve block 4 and sensor 5 built into the bottom plate 3 completely eliminates the lengthy external air paths and complex wiring harnesses of traditional solutions, significantly saving installation space and reducing the overall weight and structural complexity of the system. The built-in air path between the air interface 8 on the side wall of the base plate 3 and the valve block 4 minimizes the inflation and deflation path, significantly reducing gas flow resistance and delay. This results in a response speed and control precision far superior to that of a split structure, meeting the stringent requirements of active suspension systems for high-frequency real-time adjustment. Based on the intelligent sensing capabilities built into the sensor 5, combined with the rapid execution capabilities of the integrated valve block 4, this component is endowed with active sensing and real-time adjustment functions, making it a plug-and-play standardized intelligent module that greatly simplifies system installation, configuration, and subsequent maintenance.

[0047] Specifically, the valve block 4 and the base plate 3 are fixedly connected by screws, such as... Figure 3 As shown. The valve block 4 and the base plate 3 can also be connected by a connector, such as... Figure 4 As shown, the valve block 4 and the base plate 3 can also be fixed in other rigid ways.

[0048] Specifically, the air spring body is a sphere, a stack of several spheres, a cylinder, or other conventional or unconventional shapes, and the air spring body is filled with compressed air, nitrogen, or other inert gases.

[0049] Specifically, the air spring body 1 utilizes the compressibility of compressed gas to bear loads and generate elastic deformation, thereby achieving the core functions of support, vibration isolation, and attitude adjustment. Its deformable bladder or cavity is the physical basis for realizing the "spring" effect. The top plate 2 and bottom plate 3 are both made of metal. The lower edge of the top plate 2 and the upper edge of the bottom plate 3 are fixedly connected to the air spring body 1 by mechanical clamping and sealing (e.g., using metal rings and screws). The top plate 2 is directly connected to the supported equipment structure to transmit loads. It also serves as the upper cover of the sealed air chamber. The bottom plate 3 is the lower cover of the air chamber and the connection interface with the foundation, and is directly connected to the foundation. The top plate 2 and bottom plate 3, together with the air spring body 1, constitute a sealed air chamber. The bottom plate 3 integrates a valve block 4, a sensor 5, and an air interface 8. The valve block 4 consists of one or two solenoid valves. With one solenoid valve, it is mainly used for air intake; with two solenoid valves, air intake and exhaust can be controlled separately. The base plate has internally machined air passages that directly connect the solenoid valve to the spring air chamber. The base plate 3, valve block 4, and sensor 5 are fixed to the base plate 3 using screws or clips, and are connected to the air passage 9 and cables within the base plate. The support frame 6 is fixed to the base plate 3 using screws or welding. The air passage interface 8 is used to connect to an external air source and is the only external channel for gas to enter and exit the component. It is typically a standard quick-connect or threaded interface, fixed to the base plate 3, and directly connected to the air passage 9 inside the base plate.

[0050] Specifically, the sensor 5 is one or a combination of two or more of the following: displacement sensor, accelerometer, temperature sensor, vibration sensor, or pressure sensor. The integrated multi-sensor configuration enables multi-dimensional, high-precision real-time sensing of the working state of the air spring body 1. Specifically, the displacement sensor directly monitors changes in spring height, providing crucial feedback for constant height control; the pressure sensor accurately measures internal air pressure, serving as the core basis for constant pressure control and load judgment; the accelerometer and vibration sensor capture the motion and vibration spectrum of the spring mass, providing dynamic information for active vibration isolation and condition monitoring; and the temperature sensor can be used to monitor the working environment and component temperature rise, assisting in thermal compensation and overheat protection. The beneficial effects of this multi-sensor fusion configuration are significant and multifaceted: Firstly, it improves control accuracy and robustness. Through multi-parameter cross-validation and composite judgment, the system can more accurately identify load changes, road surface excitation, or its own state, thereby making more reasonable control decisions and avoiding erroneous adjustments caused by single signal distortion. Secondly, it enhances functional adaptability, allowing users to flexibly select sensor combinations based on specific application scenarios (such as active suspension for vehicles and vibration isolation platforms for precision equipment) to achieve single or combined control objectives such as height, pressure, and vibration suppression. Thirdly, it empowers predictive maintenance and condition monitoring, with abundant sensor data enabling the analysis of spring health status, prediction of lifespan, and fault warnings, thus improving the system's intelligence and maintainability.

[0051] Specifically, sensor 5 can come in different forms, in different quantities, and in different installation methods. For example... Figure 5 As shown, this is a base-mounted installation. The cable exits through electrical interface 7, and the interface channel is sealed with glue. Figure 6 As shown, the base of sensor 5 is sealed to the base plate 3 with an O-ring, and the cable exits through the electrical interface 8. No potting sealant is required inside the interface channel. In addition to these two types, other types can also be used.

[0052] Specifically, the air spring body 1 also has a support frame 6 inside. For example... Figure 7 As shown, the support frame is independent of the air spring body 1. Alternatively, it can be as follows: Figure 8 As shown, the support frame 6 is fixed to the mounting base of the sensor 5. The fixing method of the support frame 6 is not limited. The support frame 6 serves as a safety feature for the component. When the air spring completely loses pressure due to a malfunction (such as cracking or leakage), its height will drop sharply. At this time, the support frame 6 will contact and support the top plate 2, preventing the internally integrated valve block 4 and sensor 5 from being crushed, and also preventing the supported structure from suddenly collapsing, thus ensuring safety. The support frame 6 is typically fixed to the spring base plate 3 or to the sensor mounting base by screws or welding. During normal operation, a certain safety gap is maintained between the support frame 6 and the top plate 2.

[0053] Specifically, the air circuit interface 8 is either a quick-connect fitting or a threaded interface. The quick-connect fitting allows for rapid connection and disconnection of the external air supply line, significantly improving installation and replacement efficiency and facilitating quick on-site operation. Simultaneously, the self-sealing function typically found in the air circuit interface 8 effectively prevents gas leakage during insertion and removal, enhancing ease of use and safety. The threaded interface provides a robust and reliable mechanical and airtight connection, offering high connection strength and stable sealing performance. It is particularly suitable for harsh operating conditions involving continuous vibration or requiring high tensile forces, ensuring long-term reliable operation of the air circuit. By equipping the air circuit interface 8 with either a quick-connect fitting or a threaded interface, the integrated air spring assembly can flexibly adapt to different on-site piping connection standards and habits, improving the assembly's versatility and engineering applicability.

[0054] Specifically, sealing rings are provided at both the first and second air ports of the valve block 4. The sealing rings at the air ports of the valve block 4 ensure the airtightness of the interfaces between the valve block 4 and the internal air passage 9 of the base plate 3, and between the valve block 4 and external pipelines (where applicable). The sealing rings effectively prevent high-pressure gas leakage at the connection interface by elastically deforming and filling the microscopic gaps between the mating parts. By eliminating gas leakage at the interface through the sealing rings, the accuracy and stability of the internal pressure control of the air spring body 1 are ensured, which is the foundation for achieving high-precision control functions such as constant pressure and constant height. Good static sealing significantly reduces the risk of system performance degradation or failure due to leakage, improving the operational reliability of the integrated air spring assembly under long-term vibration and pressure alternation conditions. The standardized sealing ring connection method reduces the stringent requirements for assembly precision, facilitating the installation, replacement, and maintenance of the valve block 4.

[0055] Specifically, the valve block 4 can be replaced by other types of electro-pneumatic valves such as proportional valves and high-speed switching valves.

[0056] Specifically, the side wall of the base plate 3 is also provided with an electrical interface 7. This interface 7 is electrically connected to the sensor 5 and the valve block 4 via cables, which are located inside the base plate 3. The electrical interface 7 provides a centralized, standardized electrical connection point for the integrated air spring assembly. It enables power transmission and signal communication between the internal control unit (sensor 5 and valve block 4) and the external controller. By embedding the cables connecting the sensor 5 and valve block 4 inside the base plate 3, all internal electrical connections are encapsulated within the base plate 3, eliminating messy external wiring and resulting in a clean appearance and highly integrated structure, conforming to the design trends of modern mechatronics products. The built-in wiring method protects the cables from the structure of the base plate 3 itself, effectively preventing damage, short circuits, or signal interference caused by mechanical pulling, wear, oil corrosion, or accidental impacts. In vibration environments, this design significantly improves the long-term stability and reliability of the electrical connections. By using electrical interface 7 as the sole external electrical outlet and combining it with a sealing design (such as potting and the use of waterproof connectors), a high level of dust and water resistance (IP protection rating) can be more easily achieved for the entire electrical component, enhancing its suitability for harsh environments. During field installation, only the external control cables need to be connected to the unified electrical interface 7, simplifying wiring operations, reducing wiring error rates, and facilitating subsequent modular replacement and maintenance.

[0057] Specifically, the base plate 3 has an internal air passage 9, which connects the air interface 8 and the second air port of the valve block 4. The air passage 9 directly connects the air interface 8 and the second air port of the valve block 4, and further connects to the first air port and the air spring body 1 through an internal passage in the valve block, forming a complete internal gas passage. By creating the air passage 9 inside the base plate 3, the external connecting pipes essential in traditional split structures are eliminated, and the gas transmission path from the external air source to the internal chamber of the air spring is completely integrated into the base plate structure. This significantly shortens the air path and improves dynamic response: the extremely short and regular internal passage greatly reduces the resistance and volumetric delay of gas flow, making the inflation and deflation processes more rapid, thereby significantly improving the response speed and control bandwidth of the integrated air spring assembly, meeting the stringent requirements of active suspension and other systems for high-frequency real-time adjustment. By eliminating external hoses or rigid pipes prone to leakage, loosening, or damage, the system's most significant leakage risk point is eliminated. The integrated internal channel structure ensures stability and significantly reduces the sealing surface area, fundamentally enhancing the reliability and durability of the entire pneumatic system under long-term vibration and pressure alternation conditions. This allows the space occupied by the air circuit to be integrated into the interior of the base plate 3, eliminating the need for pre-reserved space for external piping. This greatly optimizes the overall structure of the components, making them more compact and easier to install in space-constrained environments. It also eliminates the steps of installing, fixing, and sealing external piping, simplifying the overall assembly process and reducing the complexity and cost of later maintenance due to piping issues.

[0058] Specifically, the air spring assembly pipeline arrangement in this embodiment is as follows: Figure 9 As shown, this example uses four groups of springs, with four springs in each group. The diagram above illustrates a split-type valve spring structure. The springs require an external air distributor and an external valve block (which in turn requires a valve block bracket, protective housing, and all other accessories). Each spring needs to be connected to the air path of the valve block. The overall layout is very complex, and it becomes increasingly complex as the number of springs increases.

[0059] Specifically, the cable arrangement of the air spring assembly in this embodiment is as follows: Figure 10 As shown, taking four springs as a group as an example. The diagram above shows a separate structure for the valve spring, where the sensor cable inside the spring extends out and is connected to the control cabinet along with the cable for the valve block solenoid valve, requiring a large number of cables. In contrast, with an integrated valve spring assembly, the sensor and solenoid valve are both located inside the spring and output via a bus interface. Therefore, only one busbar is needed to connect all the springs to the control cabinet, reducing the number of cables and simplifying field wiring.

[0060] Example 2

[0061] This invention provides a method of using an integrated air spring assembly for a suspension system, which uses the integrated air spring assembly for a suspension system described in Embodiment 1 above, and includes the following steps:

[0062] Step S1: Acquire real-time physical data through the sensor (5) and upload the real-time physical data to the control module;

[0063] Step S2: The control module generates control commands based on the real-time physical data and sends the control commands to the valve block (4);

[0064] Step S3: The valve block (4) opens / closes the air circuit according to the control command and adjusts the internal air pressure of the air spring body (1).

[0065] Specifically, the physical data includes height data, pressure data, or vibration data, etc. When generating control commands based on the height data, the spring height is monitored in real time. When a change in load causes the height to decrease, the controller commands the intake solenoid valve to open and inflate, restoring the height; when the height increases, the exhaust solenoid valve opens and vents, reducing the height.

[0066] When generating control commands based on the pressure data, the internal pressure of the spring is monitored in real time. When the load increases, causing the pressure to rise, the controller commands the exhaust solenoid valve to open to release air and reduce the pressure; when the load decreases, causing the pressure to drop, the intake solenoid valve opens to fill air and increase the pressure.

[0067] When generating control commands based on the vibration data, the system monitors the spring vibration data in real time. When the sensor detects that the supported object has shifted due to vibration, the system quickly adjusts the internal pressure of the spring to generate a force opposite to the direction of the vibration displacement, thus actively counteracting the vibration energy.

[0068] Specifically, in step S1, the physical data of the working state of the air spring body 1 is monitored and acquired in real time by the sensor 5 integrated on the base plate 3. The physical data may include, but is not limited to, internal air pressure, height displacement relative to the base plate, and vibration acceleration of the spring mass. The sensor 5, as an intelligent sensing terminal, converts the collected multi-dimensional physical signals into electrical signals and uploads them in real time to the external or built-in control module through the circuit and electrical interface 7 inside the base plate 3. By incorporating multiple types of sensors, direct, in-situ, and high-precision sensing of the spring's working state pressure, height, and vibration is achieved, avoiding the installation errors, signal attenuation, and transmission delay problems of traditional external sensors, and providing a reliable, real-time, and multi-dimensional data foundation for subsequent precise closed-loop control.

[0069] Specifically, in step S2, a corresponding precise control command is generated based on the deviation value and the control algorithm (such as PID control, adaptive control, or feedforward control). For example, in constant height control mode, if the real-time height is lower than the target value, an "inflate" command is generated; in active vibration isolation mode, a rapid pressure adjustment command in the opposite direction is generated based on the phase and amplitude of the vibration signal. Based on highly integrated sensor information, the control module can achieve intelligent decision-making in multiple modes (constant height, constant pressure, active vibration isolation). Its control logic is closer to the actuator, and the decision path is extremely short, thereby significantly improving the computational efficiency and real-time decision-making of the entire control loop, making it possible to implement complex active control strategies.

[0070] Specifically, in step S3, the valve block 4, according to the instruction, drives one or two high-speed solenoid valves inside it to precisely control their opening and closing state or degree. This allows for rapid inflation of the air spring body 1 through the air passage 9 inside the base plate 3 to increase air pressure and height, or rapid deflation to decrease air pressure and height. Because the valve block 4 is directly installed inside the spring and directly connected via an extremely short built-in air passage 9, the volume and flow resistance of the gas passage are minimized. This results in exceptionally rapid pressure build-up and release, improving the system's dynamic response speed and fundamentally overcoming the bottleneck of lag in traditional long-pipeline systems. This meets the stringent requirements of high-order active suspension for instantaneous and precise action.

[0071] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is merely an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units and modules are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the units and modules in the above system can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0072] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can occur depending on design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. An integrated air spring assembly for a suspension system, comprising: The application relates to an air spring body (1) and a control module arranged between a top plate (2) and a bottom plate (3), wherein the middle part of the upper surface of the bottom plate (3), the inside of the air spring body (1) and the middle part of the lower surface of the top plate (2) are connected, the middle part of the upper surface of the bottom plate (3) is fixedly provided with a valve path block (4) and a sensor (5), the sidewall of the bottom plate (3) is provided with a gas path interface, the first gas port of the valve path block (4) is connected with the inside of the air spring body (1), the second gas port of the valve path block (4) is connected with the gas path interface (8), the sensor is used for acquiring the real-time physical state of the air spring body, the control module is used for generating a control instruction according to the real-time physical state, and the valve path block (4) is used for receiving the control instruction and controlling the gas to enter or exit the air spring body (1) according to the control instruction.

2. An integrated air spring assembly for a suspension system as defined in claim 1, wherein, The sensor (5) is one of a displacement sensor, an accelerometer, a temperature sensor, a vibration sensor or a pressure sensor or any two or more combinations thereof.

3. An integrated air spring assembly for a suspension system as defined in claim 1, wherein, The inside of the air spring body (1) is further provided with a support frame (6).

4. An integrated air spring assembly for a suspension system as defined in claim 1, wherein, The gas path interface (8) is a quick plug connector or a threaded interface.

5. An integrated air spring assembly for a suspension system as defined in claim 1, wherein, The first gas port and the second gas port of the valve path block (4) are both provided with sealing rings.

6. An integrated air spring assembly for a suspension system as defined in claim 1, wherein, The valve path block (4) is composed of one or two electromagnetic valves.

7. An integrated air spring assembly for a suspension system as defined in claim 1, wherein, The sidewall of the bottom plate (3) is further provided with an electrical interface (7), the electrical interface (7) is electrically connected with the sensor (5) and the valve path block (4) through cables, and the cables are arranged in the inside of the bottom plate (3).

8. An integrated air spring assembly for a suspension system as defined in claim 1, wherein, The air spring is a spherical structure or a plurality of stacked spherical structures.

9. An integrated air spring assembly for a suspension system as defined in claim 1, wherein, The inside of the bottom plate (3) is provided with a gas path channel (9) for connecting the gas path interface (8) and the second gas port of the valve path block (4).

10. A method of using an integrated air spring assembly for a suspension system, according to any one of claims 1-9, wherein, The application further discloses a control method of the air spring. Step S1: acquiring real-time physical data through the sensor (5) and uploading the real-time physical data to the control module; Step S2: the control module generates a control instruction according to the real-time physical data and sends the control instruction to the valve path block (4); Step S3: the valve path block (4) opens / closes the gas path, adjusts the internal gas pressure of the air spring body (1) and the spring height according to the control instruction.

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