Suspension Damper Relief Valve Layout for Internal Pressure Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing damper designs face issues with internal pressures exceeding design requirements due to the use of externally mounted electromechanical valves, which can lead to inefficiencies and potential damage.
Innovation Solution
The damper incorporates internally mounted rebound and compression chamber pressure relief valves, featuring plunger mechanisms and springs to manage fluid flow beyond a threshold pressure without increasing the damper's length or reducing its travel capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If externally mounted electromechanical valves are used to control damping, then damping control capability is improved, but internal pressure management deteriorates causing pressures to exceed design requirements
Solution Approach 1:
The pressure relief valves are nested within the piston structure itself, with the rebound chamber pressure relief valve positioned in the rod end of the piston and the compression chamber pressure relief valve positioned in the head end of the piston. This nesting approach allows the pressure relief functionality to be integrated into the existing piston without adding external components, thereby maintaining compact design while improving pressure management reliability
Solution Approach 2:
The pressure relief valves act as intermediary components that provide an alternative fluid path when primary damping control valves fail or when pressure exceeds design limits. The rebound chamber pressure relief valve provides fluid communication between the rebound chamber and compression chamber, while the compression chamber pressure relief valve provides fluid communication between the compression chamber and accumulation chamber, serving as a safety mechanism that operates independently of the electromechanical control system
2Reliability
If pressure relief valves are added to manage internal pressures, then safety and durability are improved, but device complexity increases
Solution Approach 1:
The pressure relief valve assemblies are merged with the existing piston and valve structure. The rebound chamber pressure relief valve is integrated into the rod end of the piston, and the compression chamber pressure relief valve is integrated into the head end of the piston. This merging approach allows multiple functions (damping control and pressure relief) to be combined in single components, reducing overall device complexity while maintaining safety and durability improvements
Solution Approach 2:
The piston structure serves multiple functions: it acts as both the damping control element and the housing for the pressure relief valves. The rod end and head end of the piston are designed to accommodate both the primary damping valves and the pressure relief valves, allowing a single component to perform multiple critical functions and thereby avoiding the need for separate dedicated pressure relief assemblies that would increase complexity
3Volume of moving object
If internally mounted pressure relief valves are used, then space utilization is improved without increasing length, but manufacturing precision requirements increase
Solution Approach 1:
The piston structure is designed with localized features specifically optimized for pressure relief valve mounting. The rod end and head end of the piston incorporate specific geometric features (such as recesses, sealing surfaces, and fluid passages) that are tailored to the pressure relief valve requirements. This local quality approach allows precise valve positioning and sealing without requiring the entire piston to be manufactured to higher tolerances, thereby managing manufacturing precision requirements while achieving effective space utilization
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 internal pressure relief valves effectively manage high pressures within the damper chambers, enhancing performance without altering the damper's travel or length, thus improving operational efficiency and durability.
Implementation Method 1
a spring positioned in the plunger bore that biases the plunger towards the first piston rod end such that the plunger pulls the valve head against the second piston end to obstruct fluid flow
Implementation Method 2
configured to permit fluid flow through the rebound chamber pressure relief passageway(s) in one direction from the rebound chamber to the compression chamber when fluid pressure in the rebound chamber exceeds a blow-off pressure threshold
Implementation Method 3
The piston may limit the flow of damping fluid between rebound and compression chambers that are defined within the damper body in order to produce a damping force that counteracts the vibrations
Data Source
AI summary
A damper with inner and outer tubes, a piston rod extending between first and second piston rod ends, and a piston mounted to the second piston rod end. The piston is disposed within the pressure tube to define rebound and compression chambers. A fluid transport chamber is positioned between the inner and outer tubes and an intake valve assembly, abutting one end of the pressure tube inside the outer tube, and defines at least one intermediate chamber that is arranged in fluid communication with at least one externally mounted, electro-mechanical control valve. A rebound chamber pressure relief valve, mounted inside the piston and piston rod end, releases excess fluid pressure in the rebound chamber. A compression chamber pressure relief valve, mounted inside the intake valve assembly, releases excess fluid pressure in the compression chamber.