Motorcycle Damper Diaphragm Unit for Coil-to-Air Spring Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motorcycle suspensions with coil springs require complex structural changes and replacement processes to convert to air spring structures, and coil springs have higher inertia and bending loads compared to air springs, affecting actuation performance.
Innovation Solution
A detachable diaphragm unit is integrated into the damper body, comprising a cylinder, piston rod, rod guide, end member, rod side member, diaphragm, and bump rubber, allowing easy conversion from coil spring to air spring structure by attaching and detaching the diaphragm unit, which includes an air chamber for adjustable reaction force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a coil spring structure is used in the suspension, then the structure is simple and easy to manufacture, but the inertia force and bending load are higher, worsening actuation performance
Solution Approach 1:
The patent replaces the coil spring with an air spring structure that uses compressed air stored in an air chamber to provide suspension force. The air chamber is sealed within the cylinder, and the air pressure generates the elastic force needed for suspension, eliminating the mechanical coil spring while maintaining the necessary force generation function.
Solution Approach 2:
The air spring utilizes a flexible diaphragm or membrane to contain the compressed air and transmit the elastic force. This flexible element replaces the rigid coil spring structure, allowing for lighter weight and reduced inertia while maintaining the suspension function through air pressure rather than mechanical spring coils.
2Reliability
If the suspension is converted from coil spring to air spring structure, then the inertia force and bending load are reduced, improving actuation performance, but the structure becomes more complex and requires significant changes
Solution Approach 1:
The cylinder structure serves multiple functions: it contains the air chamber for the air spring, houses the piston and piston rod for damping functions, and provides mounting points for the suspension system. This multi-functionality reduces the need for separate components that would otherwise be required, thereby simplifying the overall structure despite the transition to an air spring system.
Solution Approach 2:
The patent combines the air spring chamber and the damping mechanism within a single integrated cylinder assembly. The air chamber, piston, and damping components are merged into one unified structure, eliminating the need for separate spring housings and reducing structural complexity compared to traditional coil spring suspensions that require distinct spring mounts and damping units.
3Object-affected harmful factors
If a dust seal and oil seal are provided in the cylinder opening, then protection against dust and oil leakage is achieved, but the conversion to air spring structure requires replacing these seals with sealing members for both oil and air
Solution Approach 1:
The sealing system is designed to handle both air and oil by using sealing members that are compatible with pneumatic and hydraulic applications. The seals are positioned to prevent both air leakage from the air chamber and oil leakage from the damping mechanism, providing dual-function sealing without requiring separate sealing systems for each fluid.
Solution Approach 2:
The sealing members are designed to perform multiple sealing functions simultaneously: sealing the air chamber to prevent air leakage, sealing the oil passages to prevent oil leakage, and protecting against dust intrusion. This multi-functional sealing approach reduces the number of separate seal components needed compared to having distinct seals for each function.
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 enables easy conversion to an air spring structure with reduced inertia and bending loads, improving actuation performance and allowing adjustable reaction force through air chamber pressure adjustment, while minimizing temperature effects on air chamber characteristics.
Implementation Method 1
a tubular diaphragm fixed to the end member at one end of the diaphragm and fixed to the rod side member at other end of the diaphragm
Implementation Method 2
An oil seal 213 is provided at an inner peripheral portion of the rod guide 212, which allows the piston rod 220 to slide freely in a liquid tight manner
Implementation Method 3
A dust seal 215 is provided at an inner peripheral portion of the end plate 214, which prevents intrusion of dust
Implementation Method 4
an annular bump rubber fixed to an inner bottom portion of the rod side member and having a through hole into which the piston rod is inserted
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A diaphragm unit detachably attached to a damper body, includes: a cylinder in which a liquid is sealed; a piston rod having a piston sliding inside the cylinder on one end side of the piston rod, in which other end side of the piston rod is extended to an outside of the cylinder; and a rod guide having a bottomed cylindrical shape wherein an insertion opening into which the piston rod is inserted is provided at a bottom portion of the rod guide, the rod guide being fixed to a side of an opening of the cylinder into which the piston is inserted to thereby make the piston rod be slidably inserted in a liquid tight manner, the diaphragm unit further comprising: an end member; an air seal; a rod side member; an annular bump rubber; and a tubular diaphragm, as defined herein.