Electromagnetic Damper with Air Spring for Ride Comfort
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Solution Overview
Problem
Conventional passive shock absorbers provide uniform damping regardless of input frequency, leading to harshness and decreased ride quality during high-frequency motions and handling events, while active electro-magnetic shock absorbers are expensive, heavy, and bulky due to the need for re-designing the shock absorber to accommodate electro-magnetic actuators.
Innovation Solution
A damper system comprising a pressurized gas damper, an electromagnetic actuator, and a pressurized gas spring, where the electromagnetic actuator includes a magnetic rotor and stator assembly with permanent magnets and coils, and a pressurized gas spring, which reduces the load and size requirements of the electro-magnetic actuator, allowing for active damping and energy harvesting without a piston and piston rod, thus minimizing cost, size, and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional passive shock absorbers are used, then the structure is simple and cost-effective, but the damping force remains constant regardless of input frequency leading to harshness and decreased ride quality
Solution Approach 1:
The shock absorber transitions from a passive constant-damping design to an active variable-damping system. The electromagnetic actuator dynamically adjusts the damping force based on real-time detection of piston rod velocity and input frequency, allowing the damper to adapt its characteristics to match actual operating conditions and eliminate harshness while maintaining ride quality
Solution Approach 2:
The control system continuously monitors the velocity of the piston rod and the frequency of input through sensors, processes this information through a controller, and adjusts the electromagnetic actuator accordingly. This closed-loop feedback mechanism enables the shock absorber to respond dynamically to changing suspension inputs, optimizing ride quality while maintaining manufacturing feasibility
2Ease of operation
If active electro-magnetic shock absorbers are used, then ride quality and body motion control are improved, but the system becomes heavy and bulky due to the need for permanent magnets and coils
Solution Approach 1:
The electromagnetic actuator serves multiple functions simultaneously: it provides active damping control to improve ride quality, generates electrical energy through energy harvesting during piston rod motion, and integrates with the existing shock absorber structure. This multi-functionality reduces the need for separate heavy components while achieving the desired performance improvements
Solution Approach 2:
The patent replaces traditional mechanical damping adjustment mechanisms with an electromagnetic actuator that uses electromagnetic fields to control damping force. This substitution eliminates the need for complex mechanical linkages, springs, and adjusters, significantly reducing the overall weight and bulk of the active shock absorber system while maintaining effective ride quality control
3Ease of operation
If electro-magnetic actuators with permanent magnets and coils are used, then active damping control is achieved, but the cost increases significantly
Solution Approach 1:
The electromagnetic actuator is designed to harvest energy from the piston rod's motion during normal shock absorber operation. This self-powered energy harvesting capability eliminates or reduces the need for external power sources and complex wiring systems, significantly lowering manufacturing costs while maintaining active damping control functionality
Solution Approach 2:
The patent merges the electromagnetic actuator components (permanent magnets and coils) directly into the existing shock absorber structure, utilizing available space and integrating control functions. This consolidation eliminates the need for separate housings, mounting structures, and additional components, reducing overall manufacturing complexity and cost while achieving effective active damping control
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 system provides improved ride comfort and body motion control over high-frequency motions while maintaining a fail-safe feature and ride height adjustment, reducing the cost and complexity of active dampers compared to traditional active shock absorbers.
Implementation Method 1
When electricity is supplied to the plurality of coils, the plurality of coils create an electro-magnetic field that interacts with the magnetic field of the permanent magnets and applies a magnetic force to the piston rod
Implementation Method 2
The first and second working chambers are each filed with a pressurized gas
Implementation Method 3
a pressurized gas spring, which reduces the load and size requirements of the electro-magnetic actuator
Data Source
AI summary
A damper system for a vehicle is provided that includes a pressurized gas damper, electromagnetic actuator, and pressurized gas spring. The pressurized gas damper includes first and second working chambers that are fluidly connected by a flow control orifice. The electromagnetic actuator includes a stator assembly with a stator cavity and a magnetic rotor that is slidingly received in the stator cavity. The magnetic rotor is fixed to a damper tube that houses the second working chamber. The stator cavity and an end of the damper tube cooperate to define the first working chamber. The pressurized gas spring includes a bellows chamber that extends annularly about the damper tube. The damper tube includes an opening between the second working chamber and the bellows chamber.