Air Spring Plunger Recess for Axle Positioning
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Solution Overview
Problem
Existing air springs for vehicle axles face challenges in securing the rotational position due to loose central screw connections, which can lead to misalignment under stress and flexing movements, especially when the central screw connection loosens.
Innovation Solution
The air spring design incorporates a recess at the lower edge of the plunger skirt with a downwardly open free space, limited by internal webs, allowing for a form-fitting attachment to the axle and trailing arm, ensuring secure positioning without requiring special adaptation of chassis parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a central screw connection is used to secure the plunger position, then the air spring can be assembled with simple means, but the rotational position alignment is lost when the screw connection loosens under stress
Solution Approach 1:
The connection system is divided into multiple independent elements: a form-fitting connection element on the plunger and a corresponding reception element on the chassis part. This segmentation allows each element to perform its specific function - the form-fitting element provides precise rotational positioning while the reception element provides structural support, eliminating the need for a central screw connection that compromises reliability.
Solution Approach 2:
The traditional mechanical screw connection system is replaced with a form-fitting geometric connection system. Instead of relying on friction and clamping force from screws, the invention uses precisely shaped complementary surfaces that provide both positioning and support through geometric interlocking, eliminating the reliability issue of screw loosening under vibration and stress.
2Reliability
If multiple screw elements are used to secure rotational position and longitudinal alignment, then position stability is improved, but device complexity increases
Solution Approach 1:
Multiple positioning functions (rotational alignment and longitudinal positioning) are merged into a single integrated form-fitting connection element on the plunger and its corresponding reception element on the chassis part. This single geometric interface simultaneously provides both rotational and longitudinal positioning, eliminating the need for multiple separate screw elements and reducing assembly complexity while maintaining position stability.
Solution Approach 2:
The form-fitting connection element serves multiple functions simultaneously: it provides rotational position alignment, longitudinal alignment, and structural support all through a single geometric interface. This multi-functionality eliminates the need for separate dedicated elements for each positioning task, reducing the overall number of components and simplifying the assembly process.
3Length of moving object
If the plunger is made with low overall height, then the air spring achieves lower overall height, but the support surface area is reduced
Solution Approach 1:
The support function is transitioned from a broad surface area approach to a precisely shaped geometric interface approach. Instead of increasing the plunger height to provide larger support surfaces, the invention creates a three-dimensional form-fitting connection where the reception element on the chassis part provides distributed support through its geometric shape, maintaining short plunger height while ensuring adequate support area through vertical and lateral geometric features.
Data Source
Figure 1~2
Figure 3~4
AI summary
The spring (10) has a plunger piston (15) connected with a rolled bellow (12) at a side of an air-suspended vehicle axle. A plunger piston casing (16) of the plunger piston serves as a contact surface for the rolled bellow during compression. A lower edge (17) i.e. supporting edge, of the plunger piston casing is provided with an opening (29) over a circumference (U), and a downwardly opened free space (28) emanating from the opening extends into the plunger piston. The free space is confined to the side through edges (31, 32) by a base (24).