Internal Valve Assembly With Pilot Pressure Relief for Rebound Lag
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Solution Overview
Problem
Internal type electronically controlled dampers face issues with rebound lag due to progressive damping force at high flow rates in hard mode during compression strokes, requiring precise processing and being vulnerable to foreign substances, which increases cost and instability.
Innovation Solution
An internal type electronically controlled valve assembly with a main poppet retainer disposed horizontally between a main poppet and a control disk, allowing working fluid to pass through a hollow hole and reduce pressure in the pilot passage, thereby controlling damping force and preventing rebound lag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the size of the orifice is changed by moving a spool based on current, then the damping force can be varied, but the damping force rapidly increases depending on flow rate causing rebound lag
Solution Approach 1:
A pilot passage is introduced as an intermediary flow path that allows working fluid to flow from the lower chamber to the upper chamber through a controlled route. This pilot flow mechanism mediates the pressure balance between chambers, preventing the rapid damping force increase that causes rebound lag while maintaining electronic control capability through the solenoid valve.
Solution Approach 2:
The spool mechanism is replaced with a poppet valve structure that separates the main flow control from the pilot control. The solenoid valve controls only the pilot passage, extracting the rapid response function from the main damping control, thereby eliminating rebound lag while maintaining adaptability.
2Manufacturing precision
If precision processing is required for smooth movement of a spool, then damping control is achieved, but the cost of the damper increases
Solution Approach 1:
The invention replaces the expensive precision spool with a simpler poppet valve structure made from standard components. The poppet and seat can be manufactured with conventional tolerances using common materials, significantly reducing manufacturing cost while maintaining functional performance through the pilot-controlled mechanism.
Solution Approach 2:
The control function is segmented into two parts: the solenoid valve controls the pilot passage, and the poppet valve controls the main flow based on pilot pressure. This segmentation allows each component to be simpler and less expensive, eliminating the need for a single complex precision spool.
3Adaptability or versatility
If the internal type electronically controlled damper structure is used, then damping force control is achieved, but the structure is vulnerable to foreign substances
Solution Approach 1:
A flexible seal structure is used around the poppet to create an effective barrier against foreign substances. The flexible seal conformally contacts the poppet and seat surfaces, preventing foreign particles from interfering with the valve operation while allowing for manufacturing tolerances and thermal expansion.
4Measurement precision
If a separate process for adjusting the initial position of the spool is required, then control accuracy is improved, but device complexity increases
Solution Approach 1:
The poppet valve structure is designed to automatically return to its initial position through spring force and pressure balance when the solenoid valve is de-energized. This self-resetting mechanism eliminates the need for separate adjustment processes or additional components, achieving control accuracy through the inherent design rather than external intervention.
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 stabilizes vehicle driving by reducing rebound lag and energy loss during compression strokes, enhancing ride comfort and assembly ease.
Implementation Method 1
a solenoid valve at a top of an inner space of the outer housing; a pilot poppet having at least a portion accommodated in an upper part of the main poppet, the pilot poppet being configured to adjust an opening force of the main flow passage based on a control current applied to the solenoid valve
Implementation Method 2
during a compression stroke, a working fluid introduced through the hollow hole of the main sheet passes between the control disk and the main poppet retainer, reducing the pressure, and then flows into a pilot passage formed in the main poppet
Data Source
AI summary
An internal type electronically controlled valve assembly includes a main poppet retainer formed in a disc shape with a rim protruding downward and disposed horizontally between a main poppet and a control disk. The internal type electronically controlled valve assembly is configured such that, during a compression stroke, a working fluid introduced through a hollow hole of a main sheet passes between the control disk and the main poppet retainer, reducing the pressure, and then flows into a pilot passage formed in the main poppet, thereby significantly reducing the pressure of a compression pilot chamber.