Combined Air Spring Structure for Low Heavy-Load Vertical Rigidity
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Solution Overview
Problem
Existing hourglass type secondary springs in air spring assemblies exhibit high vertical rigidity at high loads, compromising comfort and failing to meet the requirements of heavy haul trains, particularly double-deck multiple unit trains, which demand low vertical rigidity at high loads.
Innovation Solution
A combined air spring system featuring a low-position hourglass elastomer and a high-position elastomer in a serial structure, with a pressing plate and limiting table, that increases the elevation and transverse displacement of the elastomers, reducing heavy-load vertical rigidity and enhancing comfort and stability, while maintaining structural simplicity and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an hourglass type secondary spring is used, then comfort at low loads is improved, but vertical rigidity at high loads increases excessively
Solution Approach 1:
The secondary spring is segmented into two separate elastomers (first and second elastomers) arranged in parallel, each with different geometric characteristics. The first elastomer has a larger top diameter and smaller bottom diameter, while the second elastomer has a smaller top diameter and larger bottom diameter. This segmentation allows each elastomer to contribute differently to the overall spring characteristics, enabling the system to maintain low vertical rigidity at high loads while preserving comfort at low loads.
Solution Approach 2:
Different regions of the spring system are given different local qualities through the two elastomers with contrasting geometries. The first elastomer (larger top, smaller bottom) provides better comfort at low loads, while the second elastomer (smaller top, larger bottom) helps control vertical rigidity at high loads. This local differentiation of geometric properties allows the system to optimize performance across different load conditions.
2Strength
If the elevation of the elastomer is increased to reduce heavy-load vertical rigidity, then comfort is improved, but transverse displacement stability deteriorates
Solution Approach 1:
Two elastomers with different geometric characteristics are merged in a parallel arrangement to create a combined spring system. The first elastomer (with larger top diameter) and the second elastomer (with smaller top diameter) work together synergistically. This merging allows the system to achieve both low heavy-load vertical rigidity (improving comfort) and maintained transverse displacement stability, as the two elastomers complement each other's strengths.
Solution Approach 2:
The spring system uses a composite structure consisting of two elastomeric elements with different geometric compositions. Rather than using a single homogeneous elastomer, the system combines two elastomers with contrasting dimensional characteristics (different top and bottom diameter ratios), creating a composite spring system that achieves superior overall performance in both vertical and transverse directions.
3Strength
If a split type structure with multiple elastomers is used, then heavy-load vertical rigidity is reduced, but device complexity increases
Solution Approach 1:
The parallel arrangement of two elastomers serves multiple functions simultaneously: it reduces heavy-load vertical rigidity to improve comfort, maintains transverse displacement stability, and provides a relatively simple installation structure. This multi-functional design allows a single spring assembly to achieve several performance objectives without requiring complex additional mechanisms.
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 combined air spring system significantly reduces heavy-load vertical rigidity, improves comfort, and maintains stability by isolating elastomers and restricting transverse displacement, effectively addressing the comfort and stability issues at high loads and meeting the specific requirements of heavy haul trains.
Implementation Method 1
an outer periphery of the upper cover plate is connected with an outer periphery of the upper end plate through the air bag
Implementation Method 2
The elastomer is made of rubber, and compressed by loads acted on the spring assembly
Implementation Method 3
A low-position hourglass elastomer is connected between the upper end plate and the lower end plate
Data Source
AI summary
A combined air spring system includes an upper cover plate, an air bag, an upper end plate and a lower end plate. An outer periphery of the upper cover plate is connected with an outer periphery of the upper end plate through the air bag. A low-position sand clock elastomer is connected between the upper end plate and the lower end plate. A pressing plate is installed at a bottom portion of the upper cover plate, and a high-position elastomer is connected between the upper cover plate and the pressing plate. A limiting table is arranged at a bottom portion of the pressing plate. A limiting groove is formed in a top face of the upper end plate. The limiting table is located in the limiting groove in a deflated state.