Composite Multi-Plate Spring Suspension Windup Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional multi-plate spring suspensions using composite materials face challenges with windup phenomena and breakage due to friction, leading to vehicle instability and inability to operate if one composite spring is damaged.
Innovation Solution
A multi-plate spring suspension system with multiple composite springs, where each spring is coupled to a bracket unit and a trunnion base, with reinforcing fibers impregnated with resin, designed to prevent windup and allow vehicle operation even if one spring is broken by distributing load and reducing friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a single composite spring is used to replace a multi-plate leaf spring, then weight is reduced and tensile strength is improved, but reliability deteriorates because the vehicle cannot operate if the spring is damaged
Solution Approach 1:
The single composite spring is divided into multiple independent composite springs (first composite spring, second composite spring, etc.). Each spring can function independently, so if one spring is damaged, the vehicle can still operate with the remaining springs, thereby improving reliability while maintaining the weight reduction benefits of composite materials.
2Ease of manufacture
If the bolting method is used to assemble multi-layer composite springs, then manufacturing is simplified, but reliability deteriorates due to friction-induced damage to the composite spring
Solution Approach 1:
The traditional bolting method is replaced with a welding method to connect the bracket units to the composite springs. This substitution eliminates the friction and stress concentration issues associated with bolting, preventing damage to the composite spring material while still achieving secure assembly. The welding method provides a more reliable connection that maintains the integrity of the composite spring structure.
3Strength
If conventional metal leaf springs are used, then structural strength is sufficient, but harmful factors increase due to windup phenomenon causing vehicle body tilt and potential breakage
Solution Approach 1:
Conventional metal leaf springs are replaced with composite springs made of fiber-reinforced plastic materials. These composite springs maintain sufficient structural strength while eliminating the windup phenomenon that occurs with metal springs. The composite material properties prevent the rotational deformation and associated harmful effects such as vehicle body tilting and load concentration that lead to breakage.
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 system enhances durability and prevents windup, allowing the vehicle to run safely even if one composite spring is damaged, while extending the lifespan of the springs by reducing friction and improving rigidity.
Implementation Method 1
a plurality of composite springs coupled to the first bracket unit and the second bracket unit at opposite ends thereof, respectively, and being vertically spaced apart from each other
Data Source
AI summary
A multi-plate spring suspension of composite material for a vehicle includes: a first bracket unit mounted to a rubber spring; a second bracket unit mounted to a trunnion base; and a plurality of composite springs manufactured by impregnating reinforcing fibers with resin, coupled to the first bracket unit and the second bracket unit at opposite ends thereof, respectively, and being vertically spaced apart from each other.