Integrated Air Spring Damping and Level Control
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Solution Overview
Problem
Conventional air springs for damping and level control of motor vehicles and driver's cabs require external components and complex constructions, leading to increased space requirements and manufacturing costs, while offering limited damping capabilities.
Innovation Solution
An air spring design integrating two damping devices in parallel, with a compact level control system that includes a compressed-air inlet and outlet device, allowing for efficient damping and level regulation through the use of variable and constant volume chambers and adjustable damping channels, eliminating the need for external guides and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional air springs use external control valves and damping devices, then the damping and level control functions are achieved, but the construction space increases and manufacturing costs rise
Solution Approach 1:
The patent integrates the damping device directly into the air spring body, merging previously separate external components (damping device and air spring) into a single integrated unit. This eliminates the need for external mounting space and reduces overall construction volume while maintaining independent damping functionality.
Solution Approach 2:
The air spring body is designed to serve multiple functions: it provides suspension support, houses the damping mechanism, and integrates the level control system. The lid structure simultaneously serves as a closure, a mounting surface for control valves, and part of the damping channel system, reducing the need for separate components.
2Reliability
If conventional air springs use external control valves, then level position control is achieved, but device complexity and manufacturing costs increase
Solution Approach 1:
The level control system is integrated directly into the air spring body, with control valves mounted on the lid and connected to the working chamber. This merging of control functions into the main body eliminates external piping and mounting structures, simplifying the overall device while maintaining level control capability.
Solution Approach 2:
The air spring system uses its own internal structures (lid, bellows, working chamber) to house and operate the level control system, eliminating the need for external control devices. The system regulates its own level position using integrated valves and chambers.
3Reliability
If air spring bellows roll on external guides, then the bellows are supported during movement, but assembly complexity and manufacturing costs increase
Solution Approach 1:
The guide structure is integrated into the air spring body itself, with the bellows rolling on the outer surface of the rolling piston which is part of the main assembly. This eliminates separate external guide components and simplifies assembly to a single integrated unit.
4Reliability
If damping channel cross section is constricted, then damping effect is improved, but fluid flow resistance increases
Solution Approach 1:
The damping channel is designed with locally constricted cross-sections at specific locations where damping is most effective, rather than uniformly constricting the entire channel. This allows targeted energy dissipation at critical points while maintaining adequate flow capacity in other sections.
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 integrated damping devices enhance damping action, reduce construction space, and lower manufacturing costs, while the level control system maintains or adjusts the vehicle's level position effectively across varying loads, providing improved vibration control and cost-effectiveness.
Implementation Method 1
Damping most frequently takes place by the working medium flowing back and forth between the working space and another chamber via a damping channel. Due to the constricted cross section of the damping channel and the accompanying friction, the introduced vibrations are damped.
Implementation Method 2
During spring contraction and extension, the air spring bellows rolls on the outer surface of the rolling piston and thus cushions in vibrations that are introduced.
Data Source
AI summary
An air spring for damping and controlling a level position of a driver's cab or of a motor vehicle includes a lid, a rolling piston and at least one air spring bellows. At least one damping device is integrated into the air spring. A level control system is integrated into the air spring and is configured to at least one of supply and discharge compressed air, gas or a compressible medium so as to control the level position of the driver's cab or of the motor vehicle.