Integrated Crossover Valve for Air Suspension Stiffness Control
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Solution Overview
Problem
The operational performance of off-road vehicles with air suspensions is limited by roll stiffness, leading to uneven ground contact due to limited articulation, and existing crossover valve solutions are costly and challenging to integrate, especially in terms of packaging and material usage.
Innovation Solution
An integrated crossover valve within a suspension valve block that separates left and right portions, allowing fluid communication only between springs on the same axle when closed, enabling stiffness attenuation while maintaining four-wheel contact, and controlled by an electronic control unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple crossover valves are used on front and rear axles, then stiffness attenuation is achieved to maintain four-wheel contact, but cost and material usage increase
Solution Approach 1:
The patent combines multiple crossover valve functions into a single integrated valve assembly located at the rear axle. This single valve performs the stiffness attenuation function for both front and rear springs by allowing air communication between laterally opposite springs, thereby reducing the total number of valves from two to one while maintaining the ability to maintain four-wheel contact.
Solution Approach 2:
The integrated crossover valve is designed to serve multiple functions: it controls air flow between front right and front left springs, and between rear right and rear left springs, through a single valve mechanism. This multi-functional design eliminates the need for separate crossover valves on each axle, reducing component quantity while preserving the reliability of four-wheel contact maintenance.
2Reliability
If multiple crossover valves are installed, then desired stiffness attenuation is provided, but packaging space and installation complexity increase
Solution Approach 1:
By merging the crossover valve functions into a single integrated assembly, the patent simplifies the routing and installation process. Instead of needing to route and install two separate crossover valves on different axles, the system requires only one valve assembly, thereby reducing packaging space requirements and installation complexity while maintaining the stiffness attenuation capability.
3Reliability
If traditional separate crossover valves are used, then stiffness control is achieved, but manufacturing and installation costs increase
Solution Approach 1:
The patent merges multiple valve functions into a single manufacturable assembly, reducing the total number of components that need to be manufactured, inventoried, and installed. This integration reduces manufacturing costs through economies of scale and simplifies installation procedures, while the integrated valve maintains full stiffness control capability for the air suspension system.
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 configuration provides cost-effective stiffness adjustment, ensuring all wheels maintain ground contact and reduces material and labor costs by eliminating the need for multiple crossover valves, enhancing off-road vehicle performance.
Implementation Method 1
The crossover valve attenuates stiffness by allowing air from one spring on one side of the vehicle to be communicated to a laterally opposite spring on the other side of the vehicle
Data Source
AI summary
An air suspension includes a crossover valve in fluid communication with a manifold, a first set of springs in fluid communication with the manifold through a first set of valves, and a second set of springs in fluid communication with the manifold through a second set of valves. The crossover valve is movable between an open position to allow fluid communication to each of the first and the second sets of springs and a closed position that separates the first set of springs from the second set of springs.