Hydraulic Damper Insert With Variable Wall Thickness
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Solution Overview
Problem
Existing hydraulic damper assemblies with hydraulic compression stops (HCS) face issues with leakproofness and fluid flow restrictions due to high interference in press-fitting connections, which can damage components and impede fluid flow.
Innovation Solution
A hydraulic damper assembly design that incorporates a hydraulic compression stop with an insert and fixing member, featuring a terminal section with a smaller external diameter and internal flange for press-fit engagement, minimizing fluid flow restrictions while maintaining leakproofness with reduced interference, allowing for a smoother compression stroke and enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simple tubular end section of the insert with constant wall thickness is pressed onto the fixing member head portion, then the press fit connection can be implemented, but the required leakproofness cannot be achieved without implementing a relatively high degree of interference which can damage the head portion
Solution Approach 1:
The insert is designed with different wall thicknesses at different locations: a first wall thickness in the main body section and a second, greater wall thickness at the end section. This local variation in geometry allows the end section to provide sufficient interference fit for leakproof connection while the main body maintains appropriate clearance for fluid flow, thus achieving both sealing and flow requirements without damaging the head portion
Solution Approach 2:
The insert geometry is modified by changing the wall thickness parameter along its length. By increasing the wall thickness at the end section specifically, the design achieves the necessary interference fit pressure for reliable sealing while maintaining optimal fluid flow characteristics in the main body section, resolving the contradiction between sealing effectiveness and component integrity
2Force
If an insert is placed inside the compression chamber to provide additional damping force, then the damping performance is improved, but the flow of working liquid through the compression chamber is restricted
Solution Approach 1:
The insert features a main body section with a first wall thickness designed to minimize fluid flow restriction, and an end section with a greater wall thickness designed to provide the additional damping force. This spatial differentiation allows the insert to simultaneously achieve its damping function while maintaining optimal fluid flow characteristics through the compression chamber
Solution Approach 2:
The solution addresses the flow restriction problem by varying the insert's cross-sectional dimensions along its length. The main body section has smaller dimensions to reduce flow resistance, while the end section has larger dimensions to provide the necessary damping force, effectively using dimensional variation to resolve the contradiction between force generation and fluid flow
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 design minimizes fluid flow restrictions and reduces the risk of component damage during press-fitting, ensuring efficient damping performance and improved sealing with lower interference, thereby enhancing the overall functionality of the hydraulic damper assembly.
Implementation Method 1
The internal flange defines a mounting opening for receiving the head portion to establish a press-fit engagement
Implementation Method 2
A hydraulic compression stop is located in the compression chamber for providing an additional damping force during the compression stroke
Implementation Method 3
A base valve is located in the compression chamber and coupled to the main tube for controlling working fluid flow between the compression chamber and the compensation chamber
Implementation Method 4
A main piston is located in the main tube dividing the fluid chamber into a compression chamber and a rebound chamber
Implementation Method 5
A piston rod extends into the main tube and coupled to the main piston for moving the main piston between a compression stroke and a rebound stroke
Data Source
AI summary
A hydraulic damper assembly comprises a main tube defining a fluid chamber. An external tube extends about the main tube defining a compensation chamber between the main and external tubes. A main piston, located in the main tube, divides the fluid chamber into a compression chamber and a rebound chamber. A piston rod couples to the main piston. A base valve, located in the compression chamber, couples to the main tube. A hydraulic compression stop, located in the compression chamber, includes an additional piston, an insert, and a fixing member. The additional piston couples to the main piston. The insert, located in the compression chamber, couples to the base valve. The insert has a main section and a terminal section. The terminal section having an external diameter that is less than an external diameter of the main section.