Integrated Air-Supply Unit for Vehicle Air Suspension
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Solution Overview
Problem
Current air supply units for air spring systems in motor vehicles are complex, costly, and space-intensive due to separate housing of components connected via numerous pneumatic and electrical lines, leading to high application effort and costs.
Innovation Solution
Integration of an air compressor with an electric motor, air dryer, pneumatic valves, and electronic control unit into a compact pneumatic block, eliminating the need for external pneumatic connections and using a three-cylinder radial or two-piston compressor design for reduced torque fluctuations and improved heat dissipation, along with semiconductor motor control and plug-in connections for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components (air compressor, valves, control unit) are housed separately and connected via pneumatic and electrical lines, then vibration decoupling is achieved, but application effort and costs increase significantly
Solution Approach 1:
The patent integrates the air compressor, pneumatic valves, control unit, and electronic components into a single housing unit. This merging eliminates the need for separate pneumatic and electrical lines connecting distributed components, thereby reducing application effort and costs while maintaining functional separation through internal mounting structures that provide vibration decoupling.
2Reliability
If components are housed separately and connected via independent lines, then vibration decoupling is achieved, but space consumption increases
Solution Approach 1:
By combining all necessary components (air compressor, valves, control unit, electronics) into one integrated housing, the patent eliminates the space required for separate component mounting locations and the routing paths for pneumatic and electrical lines. The compact integrated design reduces overall space consumption in the vehicle.
3Ease of manufacture
If integrated air supply units are used in simple rear axle level control systems, then production costs are reduced, but application is limited to niche markets
Solution Approach 1:
The integrated air supply unit is designed with universal adaptability to serve multiple application scenarios. By incorporating all necessary components (compressor, valves, control unit, electronics) in a single versatile housing, the unit can be applied not only to simple rear axle level control systems but also to more complex air spring systems, thereby expanding its market applicability beyond niche markets.
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 design results in a compact, cost-effective, and space-efficient air supply unit with improved performance, longer running times, and enhanced diagnostic capabilities, reducing installation effort and interference while enabling efficient air supply to air spring systems.
Implementation Method 1
an air compressor with an electric motor
Implementation Method 2
an air dryer
Implementation Method 3
pneumatic solenoid valves, in particular consisting of a core, sleeve, armature, spring and sealing seat
Data Source
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AI summary
The invention relates to an integrated air-supply unit (1), in particular for air-suspension systems for motor vehicles, said unit comprising an air compressor (2) having an electric motor (3) and an air dryer (4). The air compressor (2) together with the electric motor (3), air dryer (4) and a number of pneumatic connections (8) form a functional unit.