Damper Assembly Housing for Faster Variable Damping Response
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Solution Overview
Problem
Conventional electrically controlled hydraulic dampers for vehicular suspension systems are limited by slow response times and inability to provide continuously variable damping due to high friction and small electric actuators, leading to inefficiencies in real-time suspension movement adjustments.
Innovation Solution
A damper assembly design featuring a main tube with a cylindrical shape and a concentric arrangement of a sleeve and external tube, including an actuator that regulates fluid flow through orifices and compartments to minimize flow restrictions and prevent air entrapment, allowing for improved fluid communication and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional electric actuators are used in hydraulic dampers, then the damper can provide discrete damping settings, but the response time is slow and continuously variable damping cannot be achieved
Solution Approach 1:
The patent replaces the conventional electric actuator mechanism with a purely hydraulic control system using a pilot valve and pressure differential. The main valve is controlled by hydraulic pressure from the pilot valve rather than mechanical electric actuation, enabling faster response times and continuously variable damping control without the friction and speed limitations of electric motors.
Solution Approach 2:
The patent utilizes hydraulic pressure differentials and fluid dynamics to control the damping force. The pilot valve modulates hydraulic pressure to the main valve, creating a pressure differential that opens or closes the main valve orifices. This hydraulic control mechanism enables rapid, continuously variable damping adjustment without mechanical friction.
2Stability of the object's composition
If high friction in movable members is present, then discrete damping settings can be maintained, but response time is limited and real-time control is not suitable
Solution Approach 1:
The patent eliminates mechanical friction by replacing electric actuators with a hydraulic pressure-based control system. The pilot valve uses hydraulic pressure differential to actuate the main valve, removing the need for mechanical screws, motors, or friction-based mechanisms. This allows rapid response times while maintaining stable damping settings through precise hydraulic pressure control.
3Ease of manufacture
If limited discrete settings are provided, then manufacturing complexity is reduced, but continuously variable damping control is not achieved
Solution Approach 1:
The patent transforms the static, discrete valve settings into a dynamic, continuously variable system. The main valve contains multiple orifices that can be selectively opened or closed by the pilot valve through hydraulic pressure modulation. This dynamic control mechanism provides continuously variable damping while maintaining a relatively simple valve body structure with fixed orifices.
Solution Approach 2:
The patent uses hydraulic pressure modulation to achieve continuously variable damping control. The pilot valve controls the pressure differential across the main valve, which selectively opens or closes different orifices in the main valve body. This hydraulic mechanism provides infinite damping variability without requiring multiple discrete valve components.
4Shape
If the intermediate portion flares at a large angle, then connection between sections is achieved, but fluid flow restrictions and air entrapment increase
Solution Approach 1:
The patent applies a curved, tapered transition in the intermediate portion of the main tube rather than a sharp angular flare. The gradual curvature allows smooth fluid flow from the first section to the second section, minimizing turbulence and air entrapment while maintaining structural connection. The curved geometry reduces flow restrictions compared to abrupt angular transitions.
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 design enhances operational life by preventing piston damage and reducing fluid flow distance, enabling quicker fluid pressure release and more efficient damping control, thus improving the responsiveness and durability of the damper assembly.
Implementation Method 1
an actuator located in the channel and coupled to the protrusion for regulating fluid flow from the compartment to the compensation chamber
Implementation Method 2
Electrically Controlled hydraulic dampers (shock absorbers and struts) for vehicular suspension systems
Implementation Method 3
A main piston is slidably disposed in the fluid chamber and movable along the center axis dividing the fluid chamber into a rebound chamber and a compression chamber
Data Source
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AI summary
A damper assembly comprises a main tube defining a fluid chamber. The main tube includes a first section, a second section, and an intermediate portion. A sleeve is disposed about the main tube. An external tube is disposed about the main tube and the sleeve. The external tube defines a compensation chamber between the sleeve and the external tube. A main piston divides the fluid chamber into a rebound chamber and a compression chamber. A piston rod couples to the main piston for moving the main piston between a compression stroke and a rebound stroke. The sleeve is in an abutment relationship with the second section of the main tube, radially spaced apart from the first section of the main tube, defining a compartment extending between the sleeve and the first section of the main tube. A housing for the damper assembly is also disclosed herein.