Modular Piston Assembly for Air Spring Design Flexibility
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Solution Overview
Problem
Existing air spring assemblies with one-piece piston construction lack design flexibility and optimal performance in accommodating varying vehicle heights and diameters, as well as efficient mounting options, leading to suboptimal bellows interaction with the piston profile.
Innovation Solution
A modular piston assembly comprising separate first and second piston portions with interlocking means, intermediate piston portions, and discrete air reservoirs, allowing for customizable profiles and increased air volume, while reducing component costs and enhancing fastener flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If one-piece piston construction is used, then manufacturing simplicity is maintained, but design flexibility and adaptability are reduced
Solution Approach 1:
The piston is divided into multiple separate portions (first piston portion, second piston portion, and intermediate piston portions) that can be assembled together. This segmentation allows each portion to be optimized independently for specific functions while maintaining overall piston performance, directly addressing the need for design flexibility without excessive complexity.
Solution Approach 2:
The modular piston portions are designed with standardized interlocking features and mounting options that can be used across different air spring configurations. The first piston portion can fasten to various bellows types, and intermediate portions can be selectively added to achieve different height requirements, making the system universally applicable to multiple vehicle platforms.
2Adaptability or versatility
If fixed piston height is used, then manufacturing precision is simplified, but adaptability to different vehicle heights is reduced
Solution Approach 1:
The piston height is segmented into modular portions that can be selectively combined. The first piston portion has a standard height, and intermediate piston portions can be added in various combinations to achieve different total heights. This allows precise height adjustment for different vehicle applications while each individual portion can be manufactured with standard precision tolerances.
Solution Approach 2:
The piston configuration is made dynamic and adjustable rather than fixed. By allowing selective assembly of different numbers and types of intermediate piston portions, the same basic piston design can be adapted to various height requirements, effectively creating a customizable height system from standardized components.
3Productivity
If standard air spring volume is used, then manufacturing simplicity is maintained, but performance optimization is limited
Solution Approach 1:
The air spring system is segmented to include discrete air reservoirs that can be integrated with the modular piston structure. These reservoirs can be selectively added to increase air volume and adjust spring rate characteristics. The reservoirs connect to the bellows through standardized interfaces, allowing performance optimization without creating a completely new air spring design.
Solution Approach 2:
The air spring performance parameters (volume, spring rate) can be changed by selectively adding or removing discrete air reservoirs and adjusting piston height. This allows continuous tuning of the air spring characteristics to match specific vehicle performance requirements while using the same basic bellows and piston assembly.
4Adaptability or versatility
If limited mounting options are used, then device complexity is reduced, but fastener flexibility and component sharing are reduced
Solution Approach 1:
The piston portions incorporate universal mounting features including standardized fastener holes and attachment points that can accommodate different fastener types and mounting configurations. The first piston portion can be mounted to various bellows types, and the second piston portion can be mounted to different suspension components, providing flexibility across multiple mounting scenarios without requiring custom designs for each application.
Data Source
AI summary
A modular piston assembly is associated with an air spring assembly that has a bellows rolling over a surface of the piston assembly. The modular piston assembly includes a first piston portion adapted to fasten to an associated air spring bellows. A second piston portion separate from the first portion, is adapted to fasten to an associated mounting component. Interlocking members are provided to secure the first and second piston portions together, and/or any desired intermediate piston portions. Discrete air reservoirs may also be included in the modular piston assembly to increase the volume of the air spring.