Air Spring Cover Segmentation for Vehicle Suspension
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Solution Overview
Problem
Existing air spring covers for motor vehicle suspension systems are either costly due to complex metal processing or heavy due to plastic reinforcement, lacking a simple and cost-effective manufacturing solution that maintains stability and load capacity.
Innovation Solution
The air spring cover is designed in two parts, with a metal first cover part for force introduction and a plastic second cover part for bellows guidance, allowing for a cost-effective and lightweight construction using stamping and injection molding processes, respectively, and reinforced with glass fibers for enhanced load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If air spring cover is made of metal to absorb forces, then strength and service life are improved, but manufacturing complexity and costs increase
Solution Approach 1:
The air spring cover is divided into two separate parts: a metal first cover part for force introduction and a plastic second cover part for bellows guidance. This segmentation allows each part to be optimized for its specific function, with the metal part handling mechanical loads and the plastic part providing guidance, thereby reducing overall manufacturing complexity while maintaining strength
Solution Approach 2:
Different materials are used in different regions of the air spring cover based on functional requirements. The metal first cover part is used where high strength is needed for force absorption, while the plastic second cover part is used where guidance and positioning functions are required, optimizing both performance and manufacturability
2Weight of moving object
If air spring cover is made of plastic to reduce weight, then weight is reduced, but load capacity decreases
Solution Approach 1:
The cover is segmented into metal and plastic portions, with the metal first cover part retaining the critical load-bearing function for shock absorber forces while the plastic second cover part provides guidance. This allows weight reduction in non-critical areas while maintaining load capacity where needed
Solution Approach 2:
The material selection is localized to match functional demands: metal is used in the first cover part where high strength and load capacity are required, while plastic is used in the second cover part where weight reduction is beneficial and load requirements are lower
3Ease of manufacture
If plastic is used for second cover part, then manufacturing cost and complexity are reduced, but force transmission stability may be affected
Solution Approach 1:
The functional segmentation ensures that force transmission occurs primarily through the metal first cover part, which maintains stability and reliability. The plastic second cover part is designed to guide the bellows rather than bear primary loads, reducing manufacturing complexity while preserving force transmission integrity
Solution Approach 2:
The interface between the metal first cover part and plastic second cover part is designed as a precise fitting connection that ensures stable force transmission. The metal part acts as an intermediary that transfers forces reliably while the plastic part provides guidance, combining the advantages of both materials
Data Source
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AI summary
The invention relates to an air spring strut (1) for a motor vehicle, comprising an air spring (2) with a shock absorber for springing and damping vibrations of a motor vehicle chassis. The air spring (2) comprises an air spring cover (3) and an air spring piston. An air spring bellows (5) which is clamped in an airtight manner and which is made of an elastomer material partly delimits a working chamber (6) filled with compressed air between the air spring cover (3) and the air spring piston and rolls on the air spring cover (3) and/or the air spring piston, thereby forming a rolling fold (7). The air spring cover (3) is designed in two parts, a first cover part (3a) for receiving a damper bearing (15) and a second cover part (3b) for securing the air spring bellows (5). The first cover part (3a) is made of metal, and the second cover part (3b) is made of plastic.