Hybrid Leaf Spring and Air Suspension for Light Load Ride Quality
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Solution Overview
Problem
Mechanical leaf spring suspension systems, particularly those with sliding subframes, experience poor ride quality when lightly loaded, as they fail to effectively absorb load, leading to a rough ride and potential damage to cargo.
Innovation Solution
A hybrid mechanical and air suspension system that incorporates an air spring to absorb a percentage of the load both when the vehicle is laden and unladen, combining the benefits of mechanical leaf springs for heavy loads and air springs for improved ride quality, eliminating the need for shock absorbers and reducing the weight of the suspension system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical leaf spring suspension systems are used, then the structure is simple and easy to manufacture, but the ride quality is poor when lightly loaded
Solution Approach 1:
The patent combines mechanical leaf springs with an air spring system into a hybrid suspension. The air spring is positioned to work in conjunction with the leaf springs, providing supplemental support when the vehicle is lightly loaded. This merging of two different suspension technologies allows the system to maintain structural simplicity while significantly improving ride quality across varying load conditions.
Solution Approach 2:
The air spring system dynamically adjusts its support characteristics based on load conditions. When the vehicle is lightly loaded, the air spring becomes more active to improve ride quality. When heavily loaded, the mechanical leaf springs bear the primary load. This dynamic adaptation allows the system to optimize performance for current operating conditions without requiring a completely different suspension design.
2Reliability
If air ride suspension systems are used, then the ride characteristics and driver comfort are improved, but the design complexity and service parts increase
Solution Approach 1:
Rather than implementing a complete air ride suspension system on all suspension components, the patent applies the air spring partially - specifically targeting the rear axle suspension where ride quality improvement is most needed. This partial application provides the ride characteristic benefits of air suspension without the full complexity and cost of a complete air ride system, making it a more practical solution for heavy duty vehicles.
3Strength
If mechanical suspension is used with jounce bumper, then the structure is robust, but the slap or slam creates rough ride and potential cargo damage
Solution Approach 1:
The air spring system provides beforehand cushioning by maintaining a constant cushion between the jounce bumper and the vehicle frame even when the vehicle is lightly loaded. This pre-cushioning effect prevents the harsh metal-to-metal impact that occurs in traditional mechanical suspensions, thereby protecting cargo from damage while maintaining the structural robustness of the jounce bumper design.
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 hybrid system enhances ride quality by damping road inputs and maintaining axle alignment, reducing the need for additional support structures and dock lock mechanisms, while allowing the use of lighter leaf springs, resulting in a smoother ride and improved load handling across various loading conditions.
Implementation Method 1
incorporating an air spring to absorb a percentage of the load when unladen as well as laden to improve ride quality
Implementation Method 2
enhances ride quality by damping road inputs and maintaining axle alignment
Data Source
AI summary
A leaf spring suspension is provided with an air spring to absorb a percentage of the load.