Air Suspension Bumper Stop Integration
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Solution Overview
Problem
Existing air suspension arrangements for vehicles, such as trucks, have a high number of components which increase costs and complexity, and there is a need to simplify the manufacturing process while maintaining structural integrity and vibration absorption efficiency.
Innovation Solution
Incorporating a polymer member between the bumper stop and the flexible bellows to form a connected, integral part, reducing the number of components and allowing for a two-step manufacturing process, and enhancing stiffness and connection strength, with a polymer ring or other structural features like taper-shaped surfaces and rib-like structures on the piston.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a connection bolt and connection apparatus are used to connect the bumper stop to the piston, then the connection strength is sufficient, but the number of components increases and manufacturing complexity increases
Solution Approach 1:
The patent integrates the bumper stop directly with the piston by forming the bumper stop as an integral part of the piston structure. This eliminates the need for separate connection bolts and connection apparatus, reducing the number of components while maintaining structural integrity and connection strength through the unified design.
2Reliability
If multiple separate components are used in the air suspension arrangement, then each component can be optimized for its specific function, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The bumper stop is designed as an integral part of the piston, combining two previously separate components into one unified structure. This reduces manufacturing complexity and cost while maintaining the functional optimization of both the bumper stop and piston through their integrated design.
Solution Approach 2:
The piston structure is designed to serve multiple functions: it provides the primary suspension function while also incorporating the bumper stop function as an integral part. This multi-functionality reduces the need for separate components and simplifies the overall manufacturing process.
3Ease of operation
If the flexible bellows is allowed to have large movement range, then the vibration absorption capability is improved, but the risk of piston buckling increases
Solution Approach 1:
The bumper stop is positioned to provide preliminary support and cushioning before the piston can buckle. When the flexible bellows moves downward to absorb vibrations, the bumper stop engages first to prevent excessive movement that would cause piston buckling, thus protecting the piston while maintaining vibration absorption capability.
Data Source
AI summary
An air suspension arrangement arranged to be connected between a vehicle axle and a vehicle chassis of a vehicle includes a flexible bellows having an upper portion connectable to the vehicle chassis of the vehicle, and a bumper stop, wherein the air suspension arrangement further includes a polymer member arranged between the bumper stop and the flexible bellows for connecting the bumper stop to the flexible bellows. A method for manufacturing the air suspension arrangement and a vehicle including such an air suspension arrangement are also provided.