Air Spring Swage Assembly Segmentation
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Solution Overview
Problem
Existing air spring systems, particularly double rolling lobe designs, face challenges due to limited spacing requirements and susceptibility to foreign bodies causing loss of resilience and potential failure, making them infeasible for certain applications.
Innovation Solution
A gas spring system with a swage assembly comprising an end plate, a piston, and two flexible sleeves with a swage assembly that seals and connects the sleeves at a desired bias angle, eliminating the need for a double rolling lobe design and allowing for operation in constrained spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a double rolling lobe design is used to achieve desired jounce and rebound characteristics, then the spring rate characteristics are improved, but the device requires more spacing and is susceptible to foreign bodies causing failure
Solution Approach 1:
The air spring is divided into two separate flexible sleeves (first and second sleeves) connected by a swage assembly, rather than using a single double rolling lobe structure. This segmentation allows each sleeve to function independently with smaller individual dimensions, reducing the overall spacing requirement while maintaining the desired spring characteristics through the combined system.
Solution Approach 2:
A swage assembly is introduced as an intermediary component to connect the first and second flexible sleeves. This swage assembly serves as a mediator that transmits force between the sleeves while allowing the system to achieve the desired jounce and rebound characteristics without requiring the extensive spacing needed for a double rolling lobe design.
2Reliability
If a double rolling lobe design is used to achieve desired jounce and rebound characteristics, then the spring rate characteristics are improved, but the system becomes susceptible to foreign bodies causing loss of resilience and failure
Solution Approach 1:
By segmenting the air spring into two separate flexible sleeves connected by a swage assembly, the system reduces the risk of foreign body interference. Foreign bodies that might become lodged in a double rolling lobe design have limited access to the segmented structure, and the swage assembly provides a protected connection point that maintains resilience even in the presence of foreign bodies.
Solution Approach 2:
The problematic upwardly facing lobe that is susceptible to foreign body intrusion is extracted from the design. Instead of incorporating a second rolling lobe that faces upward and can trap foreign bodies, the invention uses a swage assembly to connect the sleeves, eliminating the source of foreign body susceptibility while maintaining the desired spring characteristics.
3Reliability
If traditional crimped design or sleeve type design with external crimp rings is used to seal the flexible member, then the sealing is achieved, but the device complexity increases
Solution Approach 1:
The swage assembly merges the sealing and connection functions into a single integrated component. Rather than using separate crimp rings or complex crimping mechanisms to seal the flexible sleeves, the swage assembly performs both the sealing and structural connection in one element, reducing overall device complexity while maintaining reliable sealing.
Solution Approach 2:
The swage assembly serves multiple functions simultaneously: it seals the second ends of both flexible sleeves, connects the first and second sleeves together, and provides structural support for the air spring system. This multi-functionality eliminates the need for separate sealing components and simplifies the overall assembly.
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
This configuration provides a reliable air spring system that can function effectively in limited spaces, maintains resilience, and allows for connection of structures at different angles without the need for long bellows, enhancing operational flexibility and durability.
Implementation Method 1
a swage assembly sealingly engaging the respective second ends of said first and second flexible sleeves
Data Source
AI summary
A gas spring system (10), comprising: an end plate (12); a piston (14) laterally spaced from said end plate (12); a first flexible sleeve (16) having a first end (13) and a second end (15), said first end (13) of the first flexible sleeve (16) sealingly connected to the end plate (12); a second flexible sleeve (18) having a first end (17) and a second end (19), said first end (17) of the second flexible sleeve (18) sealingly connected to the piston (14); and a swage assembly (20) sealingly engaging the respective second ends (15, 19) of said first and second flexible sleeves (16, 18).