Integrated Air Supply Unit for High-Pressure Air Suspension Control
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Solution Overview
Problem
The existing motor vehicle air suspension systems rely on single-stage compression methods, resulting in low output gas pressure and reduced adjustment sensitivity, necessitating a more efficient compressed air control device with higher pressure air output.
Innovation Solution
A compressed air control device comprising a housing with an electric motor, air dryer, and a two-piston compressor, along with a valve assembly and electronic control device, which includes a method for designing a more efficient reciprocating piston compressor with multiple stages to increase output air pressure, and a solenoid valve for regulating air delivery to the air spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single-stage compression method is used, then the output gas volume is large, but the output gas pressure is low
Solution Approach 1:
The compression process is divided into multiple stages (first compression stage and second compression stage), each with its own piston and cylinder. The first stage compresses air to intermediate pressure, and the second stage further compresses it to high pressure, resolving the contradiction between maintaining gas volume and achieving high pressure output.
Solution Approach 2:
A pressurized container serves as an intermediary storage device between the two compression stages. The first stage pumps air into this container, which then supplies pressurized air to the second stage, enabling efficient multi-stage compression and resolving the pressure-volume contradiction.
2Device complexity
If a single-stage compression method is used, then the compressor structure is simple, but the adjustment sensitivity of the air suspension system is low
Solution Approach 1:
The compressor is segmented into two functional units: a first functional unit (electric motor and air dryer) and a second functional unit (valve assembly and electronic control device). This segmentation allows independent optimization of each unit, improving overall system sensitivity while managing complexity through modular design.
Solution Approach 2:
The system incorporates electronically controllable pneumatic valves that can dynamically adjust air flow and pressure delivery. This dynamic control capability enables real-time adjustment of air suspension characteristics, significantly improving adjustment sensitivity compared to static single-stage systems.
3Stress or pressure
If a two-piston compressor with multiple stages is implemented, then the output air pressure is high, but the device complexity increases
Solution Approach 1:
Multiple functional components (electric motor, air dryer, valve assembly, electronic control device, and pressurized container) are merged into a single integrated air supply unit. This consolidation achieves high output pressure through two-piston compression while managing complexity by combining components into one cohesive system rather than separate units.
Solution Approach 2:
The integrated air supply unit serves multiple functions: compression (two pistons), drying (air dryer), storage (pressurized container), and control (electronic control device with pneumatic valves). This multi-functionality reduces the need for separate systems, managing overall complexity while achieving high pressure output.
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
The solution enhances the air suspension system's adjustment sensitivity and comfort by achieving higher air pressure output, improving the stiffness and damping control, and reducing the complexity and cost of the air supply unit.
Implementation Method 1
The housing may comprise an electric motor
Implementation Method 2
a two-piston compressor, along with a valve assembly and electronic control device, which includes a method for designing a more efficient reciprocating piston compressor with multiple stages to increase output air pressure
Implementation Method 3
The housing may comprise an electric motor and an air dryer
Data Source
AI summary
The patent application discloses a method of compressing air. The method for designing a more efficient reciprocating piston compressor comprising the steps of: providing an air compressor having a first compression stage adapted for compressing gas from a low pressure to an intermediate pressure and including a first piston connected to reciprocate in a first cylinder, a second compression stage adapted for compressing gas from the intermediate pressure to a higher pressure and including a second piston connected to reciprocate in a second cylinder, and a motor connected to reciprocate said first piston in said first cylinder over a stroke and said second piston in said second cylinder over a stroke; and establishing a sufficiently fewer number of strokes over which the gas to be pressured starting from the atmosphere pressure.