Air Spring Support Unit Wear Reduction
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Solution Overview
Problem
Existing support units for air springs in commercial vehicles are heavy due to multiple components and lack flexibility, leading to excessive wear and reduced operational reliability, especially when loaded by crane.
Innovation Solution
A support unit comprising a lightweight base body made of materials like aluminum or plastic, reinforced with a metallic reinforcement element of higher strength and hardness, which absorbs forces and protects against wear, allowing for flexible adaptation and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a support unit with multiple components is used to support the plunger, then the plunger can be held in the correct position and wear resistance is improved, but the weight of the air spring increases
Solution Approach 1:
The support unit is divided into two functional segments: a lightweight base body made of aluminum or plastic that provides structural support, and a metallic reinforcing element that provides wear resistance and force absorption. This segmentation allows each component to be optimized for its specific function, reducing overall weight while maintaining reliability
Solution Approach 2:
The support unit combines different materials with complementary properties: lightweight materials (aluminum, plastic) for the base body and hard metallic materials for the reinforcing element. This composite approach enables the structure to achieve both low weight and high wear resistance simultaneously
2Weight of moving object
If a conventional one-piece plunger is used, then the structure is simple and weight is reduced, but wear resistance and service life are insufficient
Solution Approach 1:
Instead of making the entire support unit from hard wear-resistant material, the metallic reinforcing element is applied only locally at the contact surfaces where wear occurs. This local reinforcement provides the necessary durability while keeping the overall structure lightweight
3Reliability
If multiple components are used in the support unit, then wear resistance is improved, but the device complexity increases
Solution Approach 1:
The metallic reinforcing element is integrated with the base body through various connection methods (casting, bonding, mechanical attachment) to form a unified support unit. This merging approach maintains the benefits of multiple materials while presenting a simple, compact component structure
Data Source
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AI summary
The invention relates to a support unit for use on a pneumatic spring, comprising a base body and a reinforcing element, wherein the basic body has a first contact side for fixing on the chassis of a commercial vehicle, wherein the reinforcing element can be secured to a second contact side of the base body and is designed to support a plunger of a pneumatic spring, the reinforcing element being made of a material of higher strength and/or hardness than the base body.