Air Spring Bellows Integrity Detection Using Reinforcement Threads
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Solution Overview
Problem
Existing air spring arrangements lack a simple and effective method for detecting the onset of material weakness or destruction of their bellows, and there is a need to forward sensor signals from the lower chassis-side area to the upper body-side area.
Innovation Solution
The air spring arrangement uses at least one thread-like reinforcement as a signaling conductor connected to a diagnostic device, which monitors mechanical integrity and forwards signals from a separate sensor, eliminating the need for separate signaling conductors and simplifying the structure by integrating the reinforcement into the bellows fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate signaling conductors are installed to detect bellows destruction and forward sensor signals, then detection reliability is improved, but device complexity increases
Solution Approach 1:
The reinforcement threads in the bellows are designed to serve dual functions: providing structural reinforcement and acting as signaling conductors for both destruction detection and sensor signal transmission. This multi-functionality eliminates the need for separate signaling conductors, reducing device complexity while maintaining detection reliability
Solution Approach 2:
The patent combines the reinforcement structure with the signaling conductor function by integrating conductive threads into the bellows fabric. This merging of structural and sensing functions simplifies the overall device architecture while ensuring reliable detection of bellows integrity
2Measurement precision
If multiple separate components are used for sensing and signaling, then measurement precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The sensor unit and signaling conductors are integrated into a single composite structure where strain gauge elements are incorporated directly into the reinforcement threads of the bellows. This merging simplifies manufacturing by eliminating separate assembly steps for installing individual sensors and conductors, while maintaining precise deformation measurement capabilities
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 approach allows for reliable detection of impending bellows destruction and forwarding of sensor signals, enhancing the monitoring of mechanical integrity and vehicle level control while simplifying the production and structure of the air spring.
Implementation Method 1
at least one signaling conductor being arranged in the elastomeric material of the bellows and running without interruption from the clamping bead to the supporting bead... due to a reduction or interruption of the signal conductivity of the signaling conductor
Data Source
Figure 1
AI summary
The invention relates to an air spring arrangement (2) with a bellows (4) made of an elastomeric material (20) and reinforcing elements (26, 28) arranged therein, which has a torus-like central section (9) and adjoining an upper bellows end (5) and a lower bellows end (7), and in which an annular clamping bead (6) is formed at the upper bellows end (5) and an annular support bead (8) is formed at the lower bellows end (7), wherein at least one signal conductor (22) is arranged in the elastomeric material (20) of the bellows (4), which runs continuously from the clamping bead (6) to the support bead (8), wherein the two ends of the signal conductor (22) are connected to a diagnostic device (30) for signaling purposes, and wherein the diagnostic device (30) is configured to generate a warning signal.if, due to a reduction or interruption in the signal conductivity of the signal conductor (22), it detects its imminent or actual destruction. To simplify the construction of the bellows (4) with its sensor, the invention provides that at least one of the thread-like reinforcing elements in the bellows (4) is used as the signal conductor (22) connected to the diagnostic device (30).