Modular Air Suspension Valve Layout for Multi-Axle Vehicles
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Solution Overview
Problem
Existing air suspension systems for vehicles are inflexible and require complex adaptation to different vehicle types, making them uneconomical for vehicles with varying numbers of axles, as they are typically designed for specific configurations and cannot be easily integrated into vehicles with different axle counts.
Innovation Solution
A modular air suspension system with a sensor interface, electropneumatic valve, and data interface that allows for easy integration and adaptation to different vehicle types by consolidating valves and sensors into a single housing, reducing installation complexity and enabling vehicle-specific configuration through preprogramming of control devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an integrated air suspension system with all valves and control devices arranged within one housing is used, then the system can be integrated into a vehicle rapidly, but the system is adapted specifically to a vehicle type and cannot be easily adapted to vehicles with different numbers of axles
Solution Approach 1:
The air suspension system is divided into modular valve units, where each valve unit contains a specific number of valves (e.g., two or three valves per unit). These modular valve units can be selectively combined and connected to accommodate different vehicle configurations, allowing rapid integration while maintaining adaptability to various vehicle types with different axle counts.
Solution Approach 2:
The valve units are designed with universal mounting interfaces and standardized connections that allow the same modular components to be used across different vehicle types. By selecting appropriate combinations of valve units and configuring the control device accordingly, the system can serve multiple vehicle configurations without requiring completely different integrated housings for each vehicle type.
2Ease of manufacture
If a system configured for three axles is used for a vehicle with two axles, then the system is over-dimensioned with unused valves, but using a system configured for two axles would not have sufficient valves for a vehicle with three axles
Solution Approach 1:
Instead of providing a complete set of valves for the maximum possible configuration in every system, the valve system is segmented into separate modular valve units. For a two-axle vehicle, only the necessary valve units are installed and connected, while for a three-axle vehicle, additional valve units are added. This eliminates over-dimensioning while ensuring sufficient valves are available for each specific configuration.
Solution Approach 2:
The system configuration is made dynamic rather than fixed. The number and arrangement of valve units can be adjusted during installation to match the specific vehicle configuration. This allows the same base system to be adapted to different axle counts without being over-dimensioned for any single configuration.
3Ease of operation
If individual wheels are equipped with separate valves, then each wheel can be controlled independently, but the system becomes more complicated and requires more components
Solution Approach 1:
Multiple individual wheel valves are merged into consolidated valve units that can control multiple wheels. Each valve unit contains multiple valves that can independently control different wheels, reducing the total number of separate valve components and simplifying the overall system while maintaining wheel-specific control capability through the modular architecture.
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 modular system allows for rapid installation and adaptation to various vehicle types without the need for additional cabling or pressure sensors, reducing complexity and enabling efficient operation across different axle configurations, thus enhancing flexibility and economic viability.
Implementation Method 1
the module has a valve, the valve being, in particular, an electropneumatic valve
Data Source
AI summary
A module is provided for an air suspension system of a vehicle, the module having a sensor interface for connecting to a sensor, in particular a displacement sensor, a valve, in particular an electropneumatic valve, and a data interface. This sensor interface is configured to receive sensor values from the sensor. The data interface is configured to output sensor values received via the sensor interface to a control device, and to receive control commands for controlling the valve from the control device. Furthermore, the disclosure relates to a control device, an air suspension system, a vehicle, a vehicle trailer, a method for operating an air suspension system, and a computer program product.