Air Spring Control Element Isolation via Flexible Bumper
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Solution Overview
Problem
Traditional air suspension units face challenges in integrating an internally mounted valve actuator that must move linearly with the upper assembly while resisting tilting and torsional movements, which causes bending and twisting, making it difficult to sense vertical movement without being affected by these forces.
Innovation Solution
The air spring apparatus includes a flexible bumper element secured to the piston rod, allowing it to flex and absorb torsional and tilting forces, thereby isolating these forces from the control element, ensuring linear movement and proper valve operation despite cabin movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the actuating member is directly attached to the upper assembly to sense vertical movement, then the valve control is directly linked to cabin height, but the actuating member is subjected to tilting and torsional movements causing bending and twisting
Solution Approach 1:
The patent introduces a spherical interface as an intermediary between the upper assembly and the actuating member. This spherical connection allows the actuating member to move vertically to control the valve while accommodating tilting and torsional movements of the upper assembly through rotational freedom at the spherical joint, thereby isolating the actuating member from harmful lateral forces
Solution Approach 2:
The patent applies different structural qualities to different parts of the connection system. The upper assembly connection point uses a spherical interface that permits rotational movement, while the actuating member maintains a rigid linear structure for accurate valve control. This localized differentiation of structural properties allows each component to perform its specific function while mitigating the effects of tilting and torsion
2Device complexity
If the valve is integrated into the internal construction of the air spring unit, then the system complexity is reduced, but the mechanism to physically actuate the valve becomes difficult to integrate
Solution Approach 1:
The patent merges the actuating member and control element into a single integrated component that moves linearly within the air spring unit. This combined structure is housed within the bladder assembly, consolidating multiple functions (actuation, control, and valve operation) into one compact mechanism that is easier to manufacture and integrate than separate components
Solution Approach 2:
The control element is nested within the actuating member structure, with the control element sliding within the actuating member's linear path. This nested arrangement allows both components to occupy the same space efficiently, reducing overall complexity while maintaining the necessary functional separation between the actuating mechanism and the valve control interface
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
The flexible bumper element effectively limits torsional and tilting forces, allowing the control element to maintain linear movement and proper valve operation, ensuring consistent cabin height adjustment without adding significant cost, weight, or complexity to the air spring unit.
Implementation Method 1
The flexible bumper element is able to flex in response to at least one of torsional and tilting forces experienced by the one of the upper and lower assemblies adjacent to the flexible element, to thus limit the at least one of torsional and tilting forces experienced by the at least one of the upper and lower assemblies
Data Source
AI summary
The present disclosure relates to an air spring apparatus for use with a cabin of a vehicle. The apparatus has an upper assembly, a lower assembly, a shock absorber, a bladder, a flexible bumper element and a control element. The shock absorber has a piston rod protruding therefrom and extending through the other one of the upper and lower assemblies. The bladder is attached to the upper and lower assemblies. The flexible bumper element is secured to the piston rod adjacent one of the upper and lower assemblies, and secured to the other one of the upper and lower assemblies. The control element is secured to the flexible bumper element at a first end, and to a valve at a second end, and controls operation of the valve. The flexible bumper element can flex in response to torsional or tilting forces experienced by the one of the upper and lower assemblies, to thus help to limit these forces from being imparted to the control element.