Air Suspension Valve Reduction for Cost and Reliability
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Solution Overview
Problem
Conventional air suspension systems face challenges in balancing ride comfort and control stability due to the high number of valves, which complicates diagnostics and increases manufacturing costs, and the two-way three-port valve has high power consumption and manufacturing costs.
Innovation Solution
The air suspension system is designed with a reduced number of valves, featuring a transfer pipe with a filter, compressor, dryer, and check valves, along with a control unit and storage unit connected via transfer pipes, allowing for air pressure control and bypass, and includes a pressure sensor and injector to manage air flow efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional air suspension system uses multiple valves (intake valve, switching valve, opening/closing valve, check valve, throttle valve) to control air flow, then the system can achieve basic suspension functions, but the number of valves becomes large, making diagnosis difficult and manufacturing costs high
Solution Approach 1:
The patent combines multiple valve functions into a single three-way solenoid valve. This single valve integrates the functions of the intake valve, switching valve, and opening/closing valve from conventional systems, thereby reducing the total number of valves while maintaining suspension control capabilities. The merging principle directly addresses the contradiction by consolidating components to reduce complexity while preserving reliability.
Solution Approach 2:
The three-way solenoid valve serves multiple functions simultaneously: it controls air intake, regulates air flow direction, and manages air discharge to the atmosphere. This multi-functional valve replaces several specialized valves, reducing system complexity while maintaining comprehensive suspension control. The universality principle enables one component to perform the roles previously requiring multiple separate valves.
2Device complexity
If a two-way three-port valve is used to control air flow direction, then the number of valves is reduced, but the power consumption increases and manufacturing costs become great
Solution Approach 1:
The patent employs a three-way solenoid valve with optimized local characteristics, where only specific portions of the valve mechanism are actuated electrically. This localized actuation reduces power consumption compared to two-way three-port valves while maintaining effective air flow control. The local quality principle allows the system to achieve valve control with minimized energy input by focusing electrical actuation only where necessary.
3Reliability
If the compressor is used frequently to maintain air pressure, then the air pressure is maintained, but the compressor lifespan is reduced and energy consumption increases
Solution Approach 1:
The system pre-charges the air storage tank to a high pressure level before operation begins. This preliminary action ensures that sufficient compressed air is available in the storage tank to handle initial suspension adjustments without immediately engaging the compressor. By preparing the system in advance with pre-stored compressed air, the compressor is protected from excessive cycling and extended in service life.
Solution Approach 2:
The air storage tank serves as a self-contained reservoir that can independently supply compressed air for suspension adjustments without continuous compressor operation. This self-service capability allows the system to maintain air pressure and perform suspension control functions using stored air, thereby reducing compressor run time and extending its lifespan while maintaining reliable air pressure.
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 design simplifies the air suspension system circuit, reduces manufacturing costs, and minimizes compressor usage, enhancing ride comfort and control stability while extending compressor lifespan.
Implementation Method 1
a filter (31) mounted on the first transfer pipe (21) for filtering out foreign matter from the air
Implementation Method 2
a compressor (32) mounted on the first transfer pipe (21) for compressing the air
Implementation Method 3
a dryer (33) mounted on the first transfer pipe (21) for drying the air
Data Source
AI summary
An air suspension system includes a first transfer pipe having one end communicating with the outside, the first transfer pipe being constructed such that air flows through the first transfer pipe; a filter mounted adjacent to the one end of the first transfer pipe to filter out foreign matter from the air; a compressor mounted on the first transfer pipe, such that the compressor is located adjacent to the filter, to compress the air; a dryer mounted on the first transfer pipe, such that the dryer is located adjacent to the compressor, to dry the air; an exhaust pipe extending from the first transfer pipe between the compressor and the dryer; an exhaust valve mounted on the exhaust pipe to control the flow of the air; a second transfer pipe communicating with the other end of the first transfer pipe; a control unit connected to the second transfer pipe, the control unit being constructed such that the high and low of the control unit are controlled by the pressure of the air; and a storage unit connected to the second transfer pipe to store the compressed air.