Air Spring Module Layout for Automated Valve Installation
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Solution Overview
Problem
The existing air spring modules for vehicle suspension face challenges in simplified production and automated valve installation due to the offset arrangement of valves, which complicates assembly and increases production costs.
Innovation Solution
The air spring module features adjacent working spaces in the rolling piston, allowing all valves to be arranged in a single component, facilitating automated installation and reducing positional tolerances, with the option to adjust the spring rate by connecting additional volumes through valves, and utilizing a one-piece piston upper part for simplified production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the working spaces are arranged one above the other in the axial direction, then the spring rate can be adjusted by controlling valves, but the device complexity increases and automated installation becomes difficult
Solution Approach 1:
The patent transitions from a vertical axial arrangement of working spaces to a radial arrangement where working spaces are positioned around the circumference of the rolling piston. This dimensional change allows all valves to be positioned in approximately the same axial plane, enabling automated installation while maintaining the adjustable spring rate functionality through radial positioning of the working spaces.
2Adaptability or versatility
If the working spaces are arranged one above the other, then the spring rate can be adjusted, but the manufacturing precision requirements increase due to multiple joining zones
Solution Approach 1:
By arranging working spaces radially around the circumference rather than vertically stacking them, the patent eliminates the need for multiple axial joining zones. The radial configuration allows the rolling piston to be manufactured as a single piece or with fewer joints, significantly reducing the cumulative tolerance requirements while preserving the ability to adjust spring rate through valve control.
3Adaptability or versatility
If valves are positioned offset in the axial direction, then multiple working spaces can be provided, but the ease of manufacture decreases due to difficult automated installation
Solution Approach 1:
The patent positions all valves in approximately the same axial plane by arranging working spaces radially around the circumference of the rolling piston. This configuration allows a single automated installation device to access and install all valves without complex positioning mechanisms, dramatically improving ease of manufacture while maintaining the multi-chamber functionality for spring rate adjustment.
Data Source
AI summary
The invention relates to an air spring module having an air spring and a shock absorber for the suspension and damping of vibrations of a motor vehicle chassis. The air spring has a rolling bellows which is fastened to an air spring cover and a rolling piston. The rolling bellows at least partially delimits a first working space filled with compressed air. At least two working spaces are provided in the rolling piston, which are separated from one another by a partition and connectable to the first working space via switchable valves arranged in the rolling piston. In order to achieve simple production and installation as well as a low overall height, the rolling piston has at least two working spaces which are arranged adjacent to one another.