Internal Damper Pilot Poppet Control for Linear Damping Force
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Solution Overview
Problem
Conventional electronically controlled internal dampers face issues with high product costs due to precision requirements, vulnerability to foreign substances, and complex assembly processes, as well as rapid damping force increases with flow rate, which complicates the adjustment of damping forces.
Innovation Solution
The design includes an outer housing with an inner housing and movable poppets that adjust the main flow path's opening force through control currents, utilizing pilot chambers and springs to control damping forces, simplifying assembly and reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed orifice size is changed according to a current to vary damping force, then damping force control is achieved, but damping force increases rapidly according to flow rate
Solution Approach 1:
A pilot chamber is introduced as an intermediary between the control current and the main flow path. The control current adjusts the pilot poppet position, which in turn modulates the pilot flow path to control the main poppet position. This two-stage control mechanism prevents direct coupling between current changes and main orifice area changes, thereby eliminating rapid damping force increases.
2Ease of operation
If precision processing is performed to enable smooth spool movement, then spool movement smoothness is improved, but product cost increases
Solution Approach 1:
The patent replaces the traditional mechanical spool-valve system with a poppet-valve system controlled by pilot pressure. Instead of relying on precision-machined spool surfaces for smooth movement, the system uses a pilot chamber to control poppet position through pressure differential. This substitution reduces mechanical tolerance requirements and simplifies manufacturing while maintaining smooth operation.
3Ease of operation
If a separate process is added to adjust the initial position of the spool, then initial position adjustment capability is improved, but device complexity increases
Solution Approach 1:
The pilot chamber system provides self-adjusting initial position capability. The pilot poppet and main poppet are designed with inherent pressure balance features that automatically establish the correct initial positions during assembly without requiring separate adjustment procedures. The system self-regulates through the interaction of spring forces and pilot pressure.
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 ensures linearity of damping forces, reduces power consumption, and lowers costs by simplifying assembly and control, while maintaining stability and adjustability of damping forces.
Implementation Method 1
a main spring elastically supporting the main poppet downwards
Implementation Method 2
a pilot spring disposed between the valve and the pilot poppet to elastically support the pilot poppet downwards
Implementation Method 3
main flow path which makes the upper chamber and the lower chamber of the cylinder communicate with each other, and may be opened or closed depending on pressure at which the working fluid pushes the main poppet upwards
Data Source
AI summary
An electronically controlled internal damper includes an outer housing reciprocated in a cylinder and partitioning the cylinder into an upper chamber and a lower chamber, an inner housing disposed inside the outer housing and forming a main flow path which makes the upper chamber and the lower chamber of the cylinder communicate with each other, a main poppet disposed in the inner housing to be movable up and down, thus opening or closing the main flow path, a pilot poppet configured such that at least a portion thereof is accommodated in an upper portion of the main poppet and adjusting an opening force of the main flow path according to a control current applied to a valve, and a soft valve coupled to a lower portion of the outer housing.