Adjustable Spring Coupler for Accessible Shock Preload Tuning
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Solution Overview
Problem
Existing shock absorber adjustment mechanisms are difficult to access and require multiple parts, making it challenging to adjust the pre-load of springs, especially in configurations with multiple springs in series, and do not allow for sufficient variation of relative preloads.
Innovation Solution
Incorporating an adjustable coupler between each pair of adjacent spring ends with a hollow cylindrical shaft having threads on its outer surface, allowing for longitudinal adjustment and minimizing lateral movement, and using stop means like lock rings to prevent unintended movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate adjuster is provided at the top or bottom of the strut, then the spring pre-load can be adjusted, but the adjuster becomes difficult to access and requires wheel removal for adjustment
Solution Approach 1:
The adjustment mechanism is merged with the coupler assembly itself. The coupler incorporates a threaded shaft that directly engages with the spring seat, eliminating the need for a separate adjuster component. This integration allows adjustment to be performed from the wheel arch area without requiring wheel removal, while reducing the total number of parts in the suspension system.
2Adaptability or versatility
If multiple springs are arranged in series with intermediate coupling seats, then the spring constants can be varied to improve performance, but the adjustment mechanism becomes more complex and harder to access
Solution Approach 1:
The suspension system is segmented into multiple spring assemblies arranged in series, with each spring having its own coupler assembly. This segmentation allows each spring constant to be independently selected and adjusted to optimize performance for different driving conditions, while maintaining accessibility to each adjustment point from the wheel arch area.
Solution Approach 2:
The adjustment functionality is merged into each coupler assembly rather than being located at the extreme ends of the strut. This allows intermediate springs to be adjusted just as easily as terminal springs, making the entire multi-spring system accessible without wheel removal.
3Adaptability or versatility
If a threaded mounting is used to adjust spring pre-load, then the responsiveness and ride height can be changed, but the adjustment mechanism requires multiple parts and is difficult to retrofit
Solution Approach 1:
The coupler assembly is designed as a universal component that combines multiple functions: it locates the spring, transmits loads, and provides adjustment capability through its threaded shaft. This multi-functional design allows the same component to be used across different suspension configurations and vehicle types, simplifying retrofitting to existing shock absorbers without requiring vehicle-specific customization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the adjustment process by making it more accessible without removing the wheel, reduces the number of parts, and allows for greater variation in spring preloads, enhancing the shock absorber's performance and ease of retrofitting to existing systems.
Implementation Method 1
a thread 13a formed on its outer surface... each flange having an internal thread by means of which it mounts on the cylindrical member and is longitudinally adjustable therealong
Implementation Method 2
The outer dimension of the shaft is preferably sized to be a close tolerance fit inside the springs in which it engages to minimise lateral movement of the springs on the coupler
Implementation Method 3
The stop means may take the form, for example, of a lock ring or nut which winds up behind the adjustable flange
Data Source
Figure 1
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AI summary
A shock absorber assembly comprises two springs 11, 12 arranged in series so as, in use, to extend between a pair of spaced apart spring seats. A coupling member 13 is arranged between the adjacent ends 11b, 12a of the springs11, 12. The coupling member 13 is adjustable and is formed by a shaft having a pair of flanges 14, 15 provided on the outer surface thereof. The shaft extends axially beyond each flange 14, 15 so as to extend inside the windings of the abutting spring ends 11b, 12a to locate the spring ends 11b, 12a on the coupler 13. Each flange 14, 15 engages an associated adjacent ends 11b, 12a of one of the springs 11, 12. At least one of said flanges 14, 15 is moveable longitudinally along the shaft so as to vary the longitudinal separation between the two flanges 14, 15 and thereby vary the preload on the springs 11, 12.