Vehicle Axle Air Spring Plunger Deformable Projection
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Solution Overview
Problem
Existing air-sprung vehicle axle assembly methods require precise initial alignment of components to prevent twisting during assembly and service life impairment, increasing installation effort and potential for misalignment.
Innovation Solution
The air-sprung vehicle axle features a deformable projection or group of projections around the central screw connection that deforms upon tightening, providing early positive locking and preventing plunger rotation relative to the trailing arm, ensuring precise form fit independent of rotational position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the central screw connection is tightened to secure the plunger to the trailing arm, then the mechanical fastening is improved, but the plunger may rotate during tightening causing twisting of the air spring components
Solution Approach 1:
The deformable projection is designed to deform automatically during the screw tightening process, creating a positive locking effect before the screw is fully tightened. This preliminary locking action prevents plunger rotation during the tightening process, eliminating the need for pre-alignment of the air spring components.
Solution Approach 2:
The projection is designed with specific material properties and geometric parameters (height h between 0.1-2mm, diameter D between 5-20mm) that allow it to deform under the tightening torque of the screw. This parameter optimization enables the projection to provide sufficient locking force while being deformable enough to accommodate the tightening process without causing damage.
2Reliability
If precise initial alignment of the air spring components is performed before assembly, then the service life of the rolling bellows is improved, but the installation effort and time are increased
Solution Approach 1:
The deformable projection automatically performs the alignment function during the screw tightening process itself. As the screw is tightened, the projection deforms and creates a positive locking effect that self-aligns the plunger with the trailing arm, eliminating the need for separate pre-alignment operations by the installer.
Solution Approach 2:
The projection is pre-designed with specific geometric parameters and material properties that enable it to perform the alignment function automatically during assembly. The projection's dimensions (height h between 0.1-2mm, diameter D between 5-20mm) are optimized to provide sufficient locking force while being deformable enough to accommodate the self-alignment process.
3Manufacturing precision
If additional alignment structures are added to the plunger, then the alignment precision is improved, but the device complexity is increased
Solution Approach 1:
Instead of adding complex alignment structures throughout the plunger, the invention introduces a simple deformable projection at the specific location where alignment is needed (at the bottom surface of the plunger). This localized solution provides the necessary alignment function without complicating the overall plunger structure.
Solution Approach 2:
The projection is designed with optimized parameters (height h between 0.1-2mm, diameter D between 5-20mm) that allow it to provide sufficient alignment precision through simple deformation during tightening, eliminating the need for complex mechanical alignment structures.
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
Simplifies the assembly process by preventing twisting during assembly and enhancing the mechanical stability of the plunger, thereby maintaining precise alignment and extending the service life of the rolling bellows.
Implementation Method 1
The deformable projection or group of projections (35) is at least partially deformed by crushing when the central screw (19) is tightened.
Implementation Method 2
This deformation results in an early positive locking in the circumferential direction
Data Source
Figure 1~2
Figure 3~5
Figure 6a~6c
AI summary
The spring has a plunger (8) connected with rolling bellows and functioning as a contact surface (8a) for the bellows during compression. A lower surface of the plunger is supported on top side of a chassis part i.e. semi-trailing arm, that is provided with a floor space (26) formed around a central fastening opening. A structure of the plunger downwardly projects in relation to a level of the floor space for rotation lock of the plunger. The structure is designed as a projection or a group of projections that are distributedly arranged around the central fastening opening.