Double Rolling Lobe Air Spring Reducing Harshness Stiffness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Air spring units in vehicles face a 'harshness' issue due to high-frequency vibrations and low-amplitude roughness, caused by design dependencies, materials, and working pressure, which compromises comfort and load capacity.
Innovation Solution
The design features cylindrical rolling contours on the air spring cover and piston, allowing for a double roll fold with identical rolling diameters, enabling almost force-free axial movement of the air spring bellows relative to the fittings, reducing harshness stiffness by half through the series connection of rolling resistance forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high working pressure is applied to the rolling bellows to increase load capacity, then the load bearing capability is improved, but the material hardens and internal springing/damping changes causing increased harshness
Solution Approach 1:
The bellows is divided into multiple rolling lobes (at least two) arranged in parallel, each lobe bearing a portion of the total load. This segmentation allows the load to be distributed across multiple rolling contacts, reducing the pressure concentration on individual lobes and minimizing material hardening effects while maintaining overall load capacity.
Solution Approach 2:
The rolling contours of the lobes are designed with specific geometric characteristics (cylindrical or conical shapes with defined radii) to optimize the distribution of contact pressure. By controlling the local geometry of rolling surfaces, the patent achieves more uniform pressure distribution that reduces harshness while supporting the required load.
2Object-affected harmful factors
If the rolling contours are designed to reduce harshness through optimized geometry, then the comfort is improved, but the manufacturing precision requirements increase
Solution Approach 1:
By dividing the rolling structure into multiple lobes, the patent reduces the manufacturing precision requirement for each individual lobe. The overall harshness reduction effect is achieved through the combined action of multiple lobes, each with simpler geometric requirements, making the system more tolerant to manufacturing variations.
3Force
If multiple rolling lobes are used to distribute load and reduce harshness, then the load capacity and comfort are improved, but the device complexity increases
Solution Approach 1:
Multiple rolling lobes are merged into a single integrated bellows structure, forming a unified component that performs both load bearing and harshness reduction functions. The lobes are arranged in parallel and work together as a cohesive system, avoiding the need for separate components and simplifying the overall device architecture.
Solution Approach 2:
The multi-lobe bellows structure simultaneously achieves multiple functions: it distributes the load across multiple rolling contacts to increase load capacity, reduces harshness through optimized pressure distribution, and maintains a compact integrated form factor. This universal design eliminates the need for additional separate components.
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 design significantly reduces harshness by approximately 50% compared to conventional air springs, maintaining high load capacity and comfort, and allows for centering of the air spring bellows, enhancing overall performance and service life.
Implementation Method 1
The rolling air spring bellows (2) is fastened to the air spring cover (3) and to the rolling piston (4) with the formation of a rolling fold (6; 7) each in such a way that it rolls on both rolling contours (8; 9) when the air spring unit (1) compresses and extends
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The spring unit (1) has pneumatic spring rolling bellows (2) secured at a pneumatic spring lid (3) and a rolling piston (4), where the bellows, lid and the piston enclose a workspace (5) filled with pressurized air. The lid and the piston have rolling contours (8, 9), and the bellows are secured at the lid and the piston by forming rolling pleats (6, 7) such that the bellows are unwound at the contours during compressing and releasing of the spring unit. The contours are cylindrically formed in a working area (10), and rolling diameters (11, 12) of the lid and the piston are equal.