Air Spring Plunger Ventilation for Vacuum Prevention
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Solution Overview
Problem
In commercial vehicles, air springs face issues when the vehicle is raised, leading to a drop in pressure within the air bellows, potential vacuum formation, and uneven rolling of the air sleeve upon landing, which can cause damage.
Innovation Solution
An air spring with a plunger that includes ventilation openings and a non-return valve, ensuring the air bellows' pressure remains above ambient pressure by connecting the bellows' interior with the plunger's interior, preventing collapse and ensuring smooth operation without external pressurization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the vehicle is raised for loading, then the axle is lifted off the ground, but the air bellows is stretched and pressure drops causing vacuum formation
Solution Approach 1:
The ventilation opening is pre-positioned in the plunger casing body at a location that becomes exposed when the air spring is extended. This preliminary positioning ensures that as soon as the air bellows stretches during vehicle lifting, the ventilation opening automatically exposes and allows air intake, preventing vacuum formation before it can cause damage.
Solution Approach 2:
The plunger casing body acts as an intermediary element that houses the ventilation opening. When the air spring extends, the plunger moves relative to the air bellows, causing the ventilation opening to expose and mediate the connection between the air bellows interior and the external environment, allowing pressure equalization.
2Reliability
If the air bellows is vented to prevent vacuum, then negative pressure is prevented, but the air bellows may collapse without proper support
Solution Approach 1:
The air spring system is self-regulating through the strategically positioned ventilation opening. When the air bellows collapses or extends excessively, the opening automatically exposes to allow air intake, and when the air spring returns to its normal position, the opening becomes covered again. This self-service mechanism maintains pressure without requiring external control systems.
Solution Approach 2:
The ventilation opening is positioned at a specific location on the plunger casing body where it only exposes under extreme extension conditions. This local positioning ensures that ventilation occurs only where and when needed, preventing vacuum formation during normal operation while maintaining structural integrity during collapse.
3Ease of operation
If the vehicle is lowered after loading, then the axle touches the ground, but uneven rolling of the air sleeve can damage the air bellows
Solution Approach 1:
The ventilation opening is pre-positioned to expose before the air spring fully extends during the lowering process. This preliminary exposure ensures that air can enter the bellows in advance, maintaining positive pressure that supports the bellows structure and prevents collapse or uneven rolling when the vehicle touches the ground.
Solution Approach 2:
The ventilation opening provides preliminary anti-action by allowing air intake before the harmful collapse or uneven rolling can occur. This preemptive pressure equalization counteracts the tendency of the air bellows to collapse under its own weight when the vehicle is lowered, preventing damage before it happens.
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 solution provides reliable ventilation and prevents damage to the air bellows by maintaining pressure, ensuring even rolling and operational reliability when the vehicle is raised and lowered.
Implementation Method 1
a non-return valve, through which the interior of the bellows can be connected, in particular fluidically connected or brought into fluid communication, with the interior of the plunger
Implementation Method 2
ensuring the air bellows' pressure remains above ambient pressure by connecting the bellows' interior with the plunger's interior
Implementation Method 3
the plunger has at least one ventilation opening, which is arranged in the jacket body of the plunger and via which the interior of the plunger can be fluidically connected or brought into fluid communication with the environment
Implementation Method 4
the air bellows is fastened to an upper connection area of the plunger and can roll over a lateral surface of the plunger during a compression movement
Data Source
Figure 1
Figure 2a~2g
Figure 3~4
AI summary
An air spring for a vehicle, in particular for a commercial vehicle, comprising an air bellows (20) with a bellows interior (23) that can be filled with compressed air, and a plunger (40) which is coupled to the air bellows (20) and has a jacket body (46) that forms a rolling surface for the air bellows (20). The plunger (40) is designed as a hollow body and has a piston interior (43). A valve (70) is provided for venting the bellows interior (23), through which the bellows interior (23) can be fluidically connected to the piston interior (43). The plunger (40) has at least one vent opening (80) which is arranged in the jacket body (46) of the plunger (40) and through which the piston interior (43) can be fluidically connected to the environment.