Integrated Air Supply Unit With Two-Stage Compression
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Solution Overview
Problem
The existing single-stage compression method in motor vehicle air suspension systems results in low adjustment sensitivity due to low output gas pressure, necessitating a more efficient compressed air control device with high pressure air output.
Innovation Solution
A compressed air control device comprising a housing with an electric motor, air dryer, and a two-piston compressor mounted centrally on a crankpin, along with a valve assembly and electronic control device, which includes a method for designing a multi-stage reciprocating piston compressor to achieve higher pressure output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single-stage compression method is used, then the output gas volume is large, but the output gas pressure is low resulting in low adjustment sensitivity
Solution Approach 1:
The compression process is divided into multiple stages (first compression stage and second compression stage), where each stage compresses the gas to an intermediate pressure before passing it to the next stage. This segmentation allows the system to achieve high output pressure while maintaining adequate gas volume by distributing the compression work across separate stages rather than attempting single-stage high-pressure compression.
2Device complexity
If a single-stage compression method is used, then the compressor structure is simple, but the adjustment sensitivity of the air suspension system is low
Solution Approach 1:
The air supply unit is segmented into functional modules including the compression module, drying module, and storage module. This modular segmentation allows for optimized performance in each module while maintaining overall system manageability, thereby achieving high adjustment sensitivity without excessive complexity.
Solution Approach 2:
The air drying function is performed in advance before the compressed air is stored and used in the air suspension system. By removing moisture and contaminants beforehand, the system ensures high adjustment sensitivity and reliable operation without needing complex control mechanisms during actual suspension adjustment.
3Area of stationary object
If conventional separate component layout is used, then installation space is sufficient, but installation costs and space requirements increase
Solution Approach 1:
The compression module, drying module, and storage module are merged into a single integrated air supply unit with a unified housing. This consolidation reduces the total installation space required compared to separate components while also reducing installation costs by minimizing the number of connection points, sealing requirements, and mounting operations needed.
Solution Approach 2:
The drying module and storage module are nested within or adjacent to the compression module in a compact arrangement. The housing structure allows these functional modules to occupy overlapping or adjacent spatial volumes, achieving space-efficient packaging that reduces both installation area and associated costs.
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 solution enhances the air suspension system's adjustment sensitivity and comfort by providing higher pressure air output, improving the performance and longevity of the air supply unit while reducing installation costs and space requirements.
Implementation Method 1
a two-piston compressor mounted centrally on a crankpin
Implementation Method 2
a two-piston compressor mounted centrally on a crankpin
Implementation Method 3
The housing may have an electric motor and a gas dryer
Implementation Method 4
The housing may have an electric motor and a gas dryer
Implementation Method 5
a method for designing a multi-stage reciprocating piston compressor
Data Source
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AI summary
The patent application discloses a compressed air control device. The compressed air control device for a source of compressed air on motor vehicles may comprise a housing. The housing may include an air inlet opening located at an outside surface of the housing. The housing comprises an electric motor and an air dryer. The air dryer together with the electric motor forms a first functional unit.