Vibration Damper Valve Layout for Overload-Protected Damping
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Solution Overview
Problem
Existing vibration dampers for vehicle wheel suspensions face issues with compact design, risk of damage, and less sensitive damping detection, particularly due to the external location of bypass valves and complex separating pistons, which affect damping behavior and reliability.
Innovation Solution
The introduction of additional valves configured as overload valves, which protect the control valve and modify damper characteristics by influencing the pressure stage, allowing for a more compact design and improved damping behavior without the need for complex separating pistons, and enabling adjustable damping settings for sporty or comfort-oriented driving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the bypass valve is attached to the outside of the container tube, then the valve is easily accessible for maintenance, but the vibration damper has unfavorable external dimensions and the valve is at risk of damage
Solution Approach 1:
The bypass valve is integrated into the piston rod guide structure, nesting the valve within the existing damper components rather than attaching it externally. This eliminates the need for external valve mounting while maintaining functional accessibility through the piston rod guide's internal passages.
2Ease of manufacture
If the bypass valve is attached to the outside of the container tube, then the valve can be installed independently, but the valve protrudes far from the container tube and is at risk of damage
Solution Approach 1:
The bypass valve is merged with the piston rod guide to form an integrated assembly. The valve body becomes part of the piston rod guide structure, eliminating the protruding external valve while maintaining independent installation capability through modular assembly of the piston rod guide unit.
3Adaptability or versatility
If hydraulic valves are arranged on opposite sides of the piston, then each valve can be optimized for its stage, but the valve-piston arrangement requires a relatively large diameter
Solution Approach 1:
The control valve is positioned axially on the piston rod rather than radially on the piston face. This axial arrangement in the longitudinal dimension allows opposite-side valve optimization while maintaining a compact radial diameter, as the valve flow paths extend axially through the piston rod length rather than requiring increased radial width.
4Ease of operation
If a control valve is used to influence overflow in the working chamber, then the damping behavior can be precisely controlled, but the control valve is at risk of overload damage
Solution Approach 1:
The bypass valve is positioned to open before the control valve under overload conditions, providing prior protection by diverting excess flow away from the control valve. This preemptive action prevents overload damage to the precision control valve while maintaining its ability to provide precise damping control during normal operation.
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
This solution enhances the compactness and reliability of vibration dampers by providing overload protection and adjustable damping characteristics, reducing the risk of damage and improving damping detection sensitivity, while allowing for a wide range of damping settings through coordinated valve operation.
Implementation Method 1
a first hydraulic valve for the rebound stage of the vibration damper and a second hydraulic valve for the compression stage of the vibration damper, as well as a control valve connected in series with these for arrangement in the working chamber of the vibration damper in order to influence an overflow of a damping medium between the first and second working chambers
Implementation Method 2
the first and second additional valves are configured as overload valves for protecting the control valve... which have a differential pressure upstream of a differential pressure at which the control valve opens, at which the first and second additional valves open before the control valve in order to protect the control valve
Data Source
Figure 1
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AI summary
A vibration damper comprises a container (2), an inner tube (3) arranged within the container tube (2) and providing a working chamber, a piston rod (4) extending into the inner tube (3), and a piston (5) arranged on the piston rod (4) to divide the working chamber of the vibration damper into a first working chamber (6) and a second working chamber (7). Furthermore, a first hydraulic valve (11) for the rebound stage and a second hydraulic valve (12) for the compression stage, as well as a control valve (13) connected in series with these, are provided in the working chamber to control the flow of a damping medium into the working chambers (6, 7) within the intended operating range of the vibration damper. Additionally, a first auxiliary valve (14) for the rebound stage and a second auxiliary valve (15) for the compression stage are provided on the piston (5) and connected in parallel with the first hydraulic valve, the second hydraulic valve, and the control valve (13).Another valve (10b) is arranged between the inner tube (3) and the container tube (2). The first and second auxiliary valves (14, 15) are configured as overload valves to protect the control valve (13). Furthermore, at least the second auxiliary valve (15) for the pressure stage has a working range upstream of an overload threshold of the control valve (13), which overlaps the working range of the second valve (10b) in order to influence the damping behavior in the pressure stage determined by the second valve (10b) and the control valve (13) within the intended operating range of the vibration damper.