Compressor Piston with Check Valves for Air Spring Torque Reduction
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Solution Overview
Problem
Existing air management systems for automotive vehicles are costly, bulky, and complex, requiring high torque loads on motors and necessitating frequent drying and recharging in open systems.
Innovation Solution
A closed air management system with a compressor and reservoir, utilizing a piston with check valves to reduce torque load on the motor, allowing efficient inflation and deflation of air springs, and eliminating the need for continuous drying and recharging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional air management system is used, then air springs can be inflated and deflated, but the motor experiences high torque load and the system becomes bulky and expensive
Solution Approach 1:
A piston assembly is introduced as an intermediary mechanical element between the motor and the air springs. The piston converts rotational motor motion into reciprocating linear motion, creating compression and extension chambers that efficiently compress and release air. This mechanical intermediary reduces the direct torque requirements on the motor while maintaining system compactness.
Solution Approach 2:
The system utilizes pneumatic principles by creating compression and extension chambers within the piston assembly. Air is compressed in the compression chamber during the outward stroke and expanded in the extension chamber during the return stroke, leveraging gas compression and expansion to reduce motor torque load and improve system efficiency.
2Reliability
If an open air management system is used, then air can be continuously supplied, but frequent drying and recharging is required
Solution Approach 1:
The system recovers and stores compressed air in a reservoir during the compression stroke, then reuses this stored air during the extension stroke and for inflating air springs. This recovery and reuse of compressed air eliminates the need for continuous atmospheric air intake, removing the requirement for drying and recharging operations.
Solution Approach 2:
The system changes the operational mode from continuous atmospheric air intake (open system) to cyclic compression and storage (closed system). By maintaining air at controlled pressure parameters in a reservoir and recycling it through the piston assembly, the system achieves operational continuity without moisture accumulation issues that plague open systems.
3Productivity
If a piston assembly with check valves is used, then air pressure builds up efficiently and torque load reduces, but device complexity increases
Solution Approach 1:
Multiple functions are merged into a single piston assembly: compression, expansion, air storage, and directional control. The piston simultaneously creates compression and extension chambers, incorporates check valves for directional flow control, and acts as a mechanical converter between rotational and reciprocating motion. This consolidation improves efficiency while managing complexity through functional integration.
Solution Approach 2:
The piston assembly serves multiple purposes: it compresses air during the outward stroke, stores compressed air in the compression chamber, releases air during the return stroke, and controls air flow direction through integrated check valves. This multi-functionality achieves high productivity without proportionally increasing device complexity, as one component performs several critical functions.
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 reduces motor torque load, operates quietly, and allows for the use of small compressors and high-volume valve components, resulting in a cost-effective and efficient air management solution.
Implementation Method 1
air pressure from the reservoir or the air springs to reduce a torque load on the motor
Implementation Method 2
The check valve allows air to flow from the inlet to the outlet while preventing air from flowing from the outlet to the inlet
Data Source
AI summary
An air management system including at least one air spring and a compressor. The compressor defines a compartment having an inlet and an outlet. A reservoir is fluidly connected to the air spring and the compressor. A piston is moveable in the compartment and is reciprocally moveable in a compression stroke and an extension stroke in response to actuation of the motor in order to build-up air pressure at the outlet. The piston defines at least one passage extending between the extension chamber and the compression chamber, and at least one check valve positioned in the at least one passage such that air pressure in the compression chamber biases the piston toward the extension chamber to reduce a torque load on the motor during movement of the piston.