Lightweight composite air suspension matching electric drive axle

Abstract

The application discloses a lightweight composite air suspension matched with an electric drive bridge, breaks the conventional composite air suspension structure based on the requirements of all aspects, and improves the whole guide arm structure of the traditional composite air suspension into a separated front guide arm system and a rear air spring system.The guide arm of the front guide arm system is assembled on the upper side of the electric drive bridge in a short straight arm mode, the length of the guide arm is shortened, and the Z-direction structure of the guide arm support is shortened.The air spring of the rear air spring system is not assembled on the guide arm, the air spring is assembled on the lower side of the electric drive bridge in a cast air bag bracket mode, and the rear air spring system is integrated with a lower support of a shock absorber, so that the problems of the heavy weight of the composite air suspension, the poor stress, and the lack of space for arranging the shock absorber when the composite air suspension is matched with the new energy electric drive bridge can be solved.The cantilever of the guide arm support is short, the stress of the frame and the support is small, and the safety and reliability are high.

Description

Technical Field

[0001] This invention relates to the field of suspension technology for new energy commercial vehicles, and in particular to a lightweight composite air suspension matched with an electric drive axle. Background Technology

[0002] Currently, the air suspension systems matched with new energy heavy trucks are mainly full air suspension and composite air suspension. Although full air and composite air suspension structures each have their own advantages and disadvantages, neither has a weight advantage over leaf springs. Lightweighting has always been the development trend of suspension and a demand of vehicles.

[0003] The full air suspension has many components and a complex structure. Some of its layouts conflict with the layout of the electric drive axle. The electric drive axle occupies a large space inside the vehicle frame, leaving no space for shock absorbers, stabilizer bars, etc.

[0004] Traditional composite air suspensions consist of guide arms, guide arm brackets, air springs, lateral thrust rods, and shock absorbers. The guide arms primarily handle guidance and some load-bearing, while the air springs, located at the rear of the guide arms, provide auxiliary load-bearing and adjust height. Existing composite air suspension guide arms come in two structures: L-shaped and Z-shaped. The L-shaped guide arm is L-shaped and fixed to the underside of the axle with U-bolts, while the Z-shaped guide arm is Z-shaped and fixed to the top of the axle with U-bolts. Air springs are mounted on the guide arms in both cases. However, when matched with new energy electric drive axles, the following disadvantages exist: L-shaped guide arm composite air suspensions have long and heavy guide arm brackets, resulting in poor stress distribution between the guide arm bracket and the vehicle frame; Z-shaped guide arm composite air suspensions have large and heavy guide arms, leading to a large space occupied by the electric drive axle and no space for shock absorber placement within the vehicle frame. Summary of the Invention

[0005] To address the problems existing in the background technology, this invention provides a lightweight composite air suspension for matching electric drive axles. The traditional integral guide arm structure of composite air suspension is improved into a separate front guide arm system and rear air spring system. The guide arm of the front guide arm system is a short straight arm mounted above the electric drive axle, with a short cantilever for the guide arm bracket. The air spring of the rear air spring system is not mounted on the guide arm; instead, a cast air spring bracket is used to mount the air spring below the electric drive axle. Furthermore, the rear air spring system integrates a shock absorber lower bracket. This solves the problems of heavy weight, poor stress distribution, and lack of space for shock absorber placement when matching new energy electric drive axles in composite air suspension systems.

[0006] The technical solution adopted in this invention is: A lightweight composite air suspension for matching an electric drive axle includes a front guide arm system, a rear air spring system, and a lateral thrust rod system; the front guide arm system includes a guide arm bracket, a guide arm assembly, a U-bolt, a pressure plate, and a fixing plate; the guide arm assembly is a single-piece composite material short straight arm structure, with its front end connected to the vehicle frame via the guide arm bracket, and its rear end fixed to the electric drive axle via the U-bolt, pressure plate, and fixing plate.

[0007] Preferably, the fixing plate includes U-bolt fixing holes corresponding to two sets of U-bolts, and the rear side of the fixing plate is provided with shock absorber lower bracket mounting holes and airbag bracket.

[0008] Preferably, the rear air spring system includes an airbag bracket, an air spring, an upper air spring bracket, a shock absorber, an upper shock absorber bracket, and a lower shock absorber bracket; Preferably, the upper end of the shock absorber is connected to the outside of the vehicle frame via the upper shock absorber bracket, and the lower end is mounted on the fixing plate via the lower shock absorber bracket mounting hole, connecting the shock absorber to the electric drive axle and arranging it between the electric drive axle and the air spring; the lower end of the air spring is mounted on the airbag bracket, and the upper end is connected to the vehicle frame via the upper air spring bracket.

[0009] The lateral thrust rod system includes a lateral thrust rod and a thrust rod support. One end of the lateral thrust rod is connected to the vehicle frame via the thrust rod support, and the other end is connected to the electric drive axle via bolts.

[0010] Preferably, the guide arm assembly is a single-piece composite material short straight arm structure, with the ends fixed by metal, the front end connected to the guide arm bracket, and the rear end fixed to the electric drive bridge by U-bolts, pressure plates, and fixing plates.

[0011] More preferably, the composite material is glass fiber.

[0012] Preferably, the mounting holes for the fixing plate, airbag bracket, and shock absorber lower bracket are integrally formed from high-grade ductile iron. Preferably, the high-grade ductile iron includes QT800, QT900, QTD900, QT1000, GJS-800, GJS-900, or GJS-1000.

[0013] The advantages of this invention compared to existing technologies are as follows: 1) The guide arm bracket of the present invention has a short cantilever, is lightweight, and has low stress on the bracket and frame, resulting in higher safety and reliability; 2) The shock absorber is located between the electric drive axle and the air spring, providing more space for the electric drive axle on the inner side of the frame; 3) The guide arm of the present invention adopts a segmented structure. The front section is assembled on the electric drive axle and adopts a short straight arm. The rear section adopts an airbag bracket structure and is assembled under the electric drive axle. It also integrates the lower support of the shock absorber, making it lighter in weight. Attached Figure Description

[0014] Figure 1 This is an axonometric view of the composite air suspension of the present invention.

[0015] Figure 2 This is an installation effect diagram of the composite air suspension of the present invention (electric drive axle omitted).

[0016] Figure 3 This is a schematic diagram of the guide arm assembly of the present invention.

[0017] Figure 4 This is a schematic diagram of the structure of the fixing plate of the present invention.

[0018] Figure 5 This is a structural schematic diagram of the bottom surface angle of the fixing plate of the present invention. Figure 1 .

[0019] Figure 6 This is a structural schematic diagram of the bottom surface angle of the fixing plate of the present invention. Figure 2 .

[0020] In the diagram: 1-Guide arm bracket, 2-Guide arm assembly, 3-U-bolt, 4-Pressure plate, 5-Fixing plate, 51-U-bolt fixing hole, 52-Shock absorber lower bracket mounting hole, 53-Airbag bracket, 6-Shock absorber, 7-Shock absorber upper bracket, 8-Air spring, 9-Air spring upper bracket, 10-Transverse thrust rod bracket, 11-Transverse thrust rod, 12-Electric drive axle, 13-Chassis, 14-Shock absorber lower bracket. Detailed Implementation

[0021] The invention will be further described in detail with reference to the accompanying drawings.

[0022] like Figure 1-4 As shown, this invention provides a lightweight composite air suspension for matching an electric drive axle, including a front guide arm system, a rear air spring system, and a lateral thrust rod system. The lightweight composite air suspension structure of this invention breaks through the traditional composite air suspension structure, dividing into two separate parts: the front part is supported by a short guide arm, and the rear part is supported by an airbag bracket and air springs. The airbag bracket integrates a shock absorber lower bracket, and the shock absorber is arranged between the electric drive axle and the air springs. This invention is applicable to vehicles equipped with an electric drive axle and composite air suspension.

[0023] like Figure 1-2As shown, the front guide arm system includes a guide arm bracket 1, a guide arm assembly 2, a U-bolt 3, a pressure plate 4, and a fixing plate 5. The guide arm assembly 2 is a single-piece composite material short straight arm structure. Its front end is connected to the vehicle frame 13 via the guide arm bracket 1, and its rear end is fixed to the electric drive axle 12 via the U-bolt 3, pressure plate 4, and fixing plate 5. The guide arm assembly 2 bears part of the load between the vehicle frame 13 and the electric drive axle 12, and also plays a role in resisting vehicle roll and guiding the vehicle.

[0024] like Figure 4-6 As shown, the fixing plate 5 includes four U-bolt fixing holes 51 corresponding to two sets of U-bolts 3. The rear side of the fixing plate 5 is provided with shock absorber lower bracket mounting holes 52 and airbag brackets 53. The fixing plate 5 also includes multiple weight reduction holes located in the middle.

[0025] The rear air spring system includes an airbag bracket 53, an air spring 8, an upper air spring bracket 9, a shock absorber 6, an upper shock absorber bracket 7, and a lower shock absorber bracket 14. The upper end of the shock absorber 6 is connected to the outside of the vehicle frame 13 through the upper shock absorber bracket 7, and the lower end is assembled to the fixing plate 5 through the lower shock absorber bracket mounting hole 52. The shock absorber 6 is connected to the electric drive axle 12 and arranged between the electric drive axle 12 and the air spring 8. The shock absorber 6 mainly serves to reduce vehicle vibration and limit the lower limit of the suspension.

[0026] The lower end of the air spring 8 is mounted on the airbag bracket 53, and the upper end is connected to the vehicle frame 13 via the air spring upper bracket 9. The air spring 8 serves to transmit another part of the load between the vehicle frame and the electric drive axle 12, and also plays a role in adjusting the vehicle body position during driving.

[0027] The lateral thrust rod system includes a lateral thrust rod 11 and a thrust rod support 10. One end of the lateral thrust rod 11 is connected to the frame 13 via the thrust rod support 10, and the other end is connected to the electric drive axle 12 via bolts. The lateral thrust rod system not only transmits the lateral forces between the frame and the electric drive axle 12, but also plays a guiding role in the movement of the electric drive axle 12.

[0028] like Figure 3As shown, the guide arm assembly 2 is a single-piece composite material short straight arm structure, with the ends fixed by metal. The front end is connected to the guide arm bracket 1, and the rear end is fixed to the electric drive axle 12 by U-bolts 3, pressure plates 4, and fixing plates 5. The composite material is glass fiber. The front end of the guide arm assembly 2 is fixedly connected to the metal head through positioning holes. The metal head is hinged to the guide arm bracket 1, fixing the guide arm assembly 2 to the side of the frame 13. The rear end of the guide arm assembly 2 is fixed to the composite material by adhesive for upper and lower clamps. The clamps have cylinders for assembly positioning and guidance. The sides of the upper and lower clamps have staggered protective wings, with gaps between the upper and lower protective wings to avoid vertical interference.

[0029] like Figure 4-6 As shown, the fixing plate 5, the damper lower bracket mounting hole 52, and the airbag bracket 53 are integrally formed from high-grade ductile iron. Reinforcing ribs are provided between the U-shaped bolt fixing holes 51 at the bottom of the fixing plate 5. The airbag bracket 53 includes an upper support plate and a lower support plate, with connecting ribs between them. Using high-grade ductile iron can reduce the thickness of the component body surface and the ribs, achieving weight reduction. The high-grade ductile iron includes, but is not limited to, QT800, QT900, QTD900, QT1000, GJS-800, GJS-900, or GJS-1000.

[0030] The air suspension of this invention performs excellently in various transportation scenarios, improving driving comfort, cargo safety, and transportation efficiency. It has been widely used in long-distance, cold chain, dangerous goods, and heavy-duty transportation. Based on various needs, it breaks away from the conventional composite air suspension structure, dividing the guide arm into front and rear parts. The guide arm is mounted on the electric drive axle. Compared with the traditional air suspension, the guide arm of this invention is shorter, the Z-axis structure of the guide arm bracket is shortened, and the rear section adopts a cast airbag bracket structure, integrating the shock absorber lower bracket, etc. to achieve lightweighting and weight reduction. The shock absorber is mounted on the outer side of the frame between the electric drive axle and the air spring, solving the problem of no space for shock absorber mounting on the inner side of the frame when matching the electric drive axle. In addition, the guide arm bracket cantilever is short, the frame and bracket are subjected to less stress, and the safety and reliability are high.

Claims

1. A lightweight composite air suspension for matching an electric drive axle, characterized in that, It includes a front guide arm system, a rear air spring system, and a lateral thrust rod system; the front guide arm system includes a guide arm bracket (1), a guide arm assembly (2), a U-bolt (3), a pressure plate (4), and a fixing plate (5); the guide arm assembly (2) is a single-piece composite material short straight arm structure, the front end of which is connected to the vehicle frame (13) through the guide arm bracket (1), and the rear end is fixed to the electric drive axle (12) through the U-bolt (3), the pressure plate (4), and the fixing plate (5).

2. The lightweight composite air suspension according to claim 1, characterized in that: The fixing plate (5) includes U-bolt fixing holes (51) corresponding to two sets of U-bolts (3), and the rear side of the fixing plate (5) is provided with shock absorber lower bracket mounting holes (52) and airbag bracket (53).

3. The lightweight composite air suspension according to claim 2, characterized in that: The rear air spring system includes an airbag bracket (53), an air spring (8), an upper air spring bracket (9), a shock absorber (6), an upper shock absorber bracket (7), and a lower shock absorber bracket (14). The upper end of the shock absorber (6) is connected to the outside of the frame (13) through the upper shock absorber bracket (7), and the lower end is mounted on the fixing plate (5) through the lower shock absorber bracket mounting hole (52). The shock absorber (6) is connected to the electric drive axle (12) and arranged between the electric drive axle (12) and the air spring (8). The lower end of the air spring (8) is mounted on the airbag bracket (53), and the upper end is connected to the frame (13) through the upper air spring bracket (9).

4. The lightweight composite air suspension according to claim 1, characterized in that: The lateral thrust rod system includes a lateral thrust rod (11) and a thrust rod support (10). One end of the lateral thrust rod (11) is connected to the vehicle frame through the thrust rod support (10), and the other end is connected to the electric drive axle (12) by bolts.

5. The lightweight composite air suspension according to claim 1, characterized in that, The guide arm assembly (2) is a single-piece composite material short straight arm structure, with the end fixed with metal, the front end connected to the guide arm bracket (1), and the rear end fixed to the electric drive bridge (12) by U-bolts (3), pressure plate (4) and fixing plate (5).

6. The lightweight composite air suspension according to claim 5, characterized in that, The composite material is glass fiber.

7. The lightweight composite air suspension according to claim 2, characterized in that, The fixing plate (5), airbag bracket (53) and shock absorber lower bracket mounting hole (52) are integrally formed from high-grade ductile iron material.

8. The lightweight composite air suspension according to claim 7, characterized in that, The high-grade ductile irons include QT800, QT900, QTD900, QT1000, GJS-800, GJS-900, or GJS-1000.

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