Laser-Machined Nozzle Piston for Precise Damper Flow Resistance
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Solution Overview
Problem
Existing damper manufacturing methods face challenges with dirt sensitivity, clogging, and precision issues due to axial nozzle pistons, while radial sintered pistons offer flexibility but suffer from porosity and material control problems, leading to inconsistent damping forces and reliability concerns.
Innovation Solution
A method using ultrashort pulse lasering to create nozzle recesses in a piston blank, allowing for adjustable flow resistance and precise manufacturing of nozzle pistons, which can be produced from solid materials with controlled surface properties, reducing tool wear and thermal deformations, and enabling flexible production with high reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If axial nozzle pistons are used, then the damping force can be adjusted, but the nozzles are dirt-sensitive and prone to clogging
Solution Approach 1:
The patent inverts the conventional axial nozzle design by using radial nozzles instead. This inversion changes the flow direction from axial to radial, which prevents dirt particles from entering the nozzle orifice and causing clogging, while still allowing effective damping force adjustment through the radial flow path.
Solution Approach 2:
The patent applies different local qualities to different parts of the piston. The nozzle region has a specific radial geometry optimized for dirt resistance, while other parts of the piston maintain different properties. This localized optimization allows the nozzle area to be specifically designed for contamination resistance without compromising overall piston function.
2Area of moving object
If radial nozzle pistons are produced using sintering process, then smaller cross-sections are possible, but porosity reduces flow resistance control precision
Solution Approach 1:
The patent replaces the sintering process with a machining process (turning or milling) to create the radial nozzles. This substitution eliminates the porosity inherent in sintered materials, providing a solid, non-porous piston body with precisely controlled nozzle geometry, thereby improving flow resistance control precision while still achieving small cross-sections.
Solution Approach 2:
The patent changes the manufacturing parameter from sintering to machining, which fundamentally alters the material structure from porous to solid. This parameter change enables precise control of the nozzle cross-sectional area and flow resistance without the variability introduced by sintering process fluctuations and porosity.
3Ease of manufacture
If sintered materials are used, then production flexibility is improved, but surface quality control becomes difficult and damping force precision decreases
Solution Approach 1:
The patent replaces the sintering process with conventional machining processes (turning or milling) for producing the piston body and radial nozzles. This substitution provides superior surface quality control and dimensional precision while maintaining production flexibility through standard machining operations, eliminating the need for additional post-treatment steps.
4Adaptability or versatility
If laser burning is used to adjust throttle effect, then adjustment flexibility is improved, but residual stresses and material deformations occur
Solution Approach 1:
The patent incorporates the throttle adjustment feature directly into the initial piston manufacturing process through machining. By pre-forming the radial nozzles with the desired flow resistance characteristics during piston production, rather than applying subsequent laser burning, the design achieves throttle adjustment flexibility without introducing residual stresses or material deformations.
Solution Approach 2:
The patent replaces the laser burning process with a machining approach for creating and adjusting the nozzle geometry. This substitution allows for precise control of the throttle effect through mechanical removal of material, avoiding the thermal effects and residual stresses associated with laser processing, while still providing flexibility in adjusting the flow resistance.
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 approach results in a cost-effective, reliable, and precise damper manufacturing process with consistent damping behavior, achieving high precision and reproducibility in damping force adjustment, and reducing production costs and material porosity issues.
Implementation Method 1
introducing at least one recess in the piston blank by ultrashort pulse lasering
Data Source
AI summary
Provided is a method for the production of a nozzle piston for arrangement in a damping space of a damper, which contains a damping fluid, wherein the piston divides the damping space into a first fluid chamber and a second fluid chamber. Also provided is a production method with the method according to the invention for a damper. Also provided is a nozzle piston for arrangement in a damping space of a damper, which contains a damping fluid, wherein the nozzle piston can be obtained by means of ultra-short pulse lasering of the recess from a piston blank. Also provided is a damper having a nozzle piston according to the invention. Also provided is a production plant for the production of a damper having at least one ultra-short pulse laser station for machining a piston blank for the damper by ultra-short pulse lasering.