Magnetorheological Damper Piston Assembly With Compact High-Force Flow Paths
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Solution Overview
Problem
Conventional magnetorheological dampers require multiple axially arranged coils, leading to a large axial size, insufficient installation space, reduced piston rod strength, and increased damper chamber volume.
Innovation Solution
A piston assembly design with a coaxially arranged coil and iron core components that include primary and secondary iron cores, forming radial and axial flow channels to enhance damping force without increasing axial length, allowing for adjustable damping force through current regulation and channel modulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If multiple axially arranged coils are used to generate sufficient magnetic field, then the damping force is improved, but the axial size of the damper increases
Solution Approach 1:
The patent transitions from axial arrangement of multiple coils to a single coil with radial extension of iron core components. The magnetic field generation is shifted from axial stacking to radial expansion, allowing the magnetic field to extend radially outward to generate sufficient damping force without increasing axial length.
Solution Approach 2:
The patent nests the primary iron core inside the coil component, and the secondary iron core inside the mounting chamber at an end of the primary iron core. This nested arrangement maximizes space utilization within the axial constraint, allowing multiple functional components to occupy overlapping spatial volumes.
2Force
If multiple axially arranged coils are used, then the damping force is improved, but the installation space is reduced
Solution Approach 1:
The invention expands the magnetic field generation in the radial dimension rather than the axial dimension. The single coil with radially extending iron cores creates a broader radial magnetic field distribution, increasing the effective working area for damping force generation without consuming additional axial installation space.
3Force
If multiple axially arranged coils are used, then the damping force is improved, but the piston rod strength is reduced
Solution Approach 1:
By shifting from axial to radial magnetic field extension, the patent reduces the axial length requirement, which allows for a shorter axial distance between mounting points on the piston rod. This reduces the bending moment and stress on the piston rod, thereby maintaining or improving piston rod strength while still achieving sufficient damping force through radial field distribution.
4Force
If multiple axially arranged coils are used, then the damping force is improved, but the damper chamber volume increases
Solution Approach 1:
The nested arrangement of iron core components within the coil and mounting chamber maximizes the utilization of the available damper chamber volume. The radial extension of iron cores from the single coil creates an efficient spatial configuration that generates sufficient magnetic field coverage without requiring additional axial space, thereby maintaining compact damper chamber volume.
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 design increases damping force while reducing the axial size of the damper, improving installation space and piston rod strength, and providing adjustable damping force ranges with high and low current settings.
Implementation Method 1
the piston assembly of the magnetorheological damper is equipped with a coil. The magnitude of the current on the coil can be controlled to adjust a damping force of the magnetorheological damper in real time
Implementation Method 2
The cylinder of the magnetorheological damper is filled with magnetorheological fluid, and the piston assembly of the magnetorheological damper is equipped with a coil
Data Source
AI summary
Disclosed are a piston assembly, a magnetorheological damper, and a vehicle. The piston assembly includes a piston casing, a coil component and an iron core component, where a mounting chamber is arranged inside the piston casing, and the iron core component includes a primary and a secondary iron core. A central main flow channel is arranged inside the primary iron core and axially runs through the primary iron core, and a central auxiliary flow channel is arranged inside the secondary iron core and axially runs through the secondary iron core. An outer peripheral wall of the secondary iron core and an inner peripheral wall of the piston casing define an edge axial flow channel, and ends of the secondary iron core and the piston casing define an auxiliary radial flow channel and a main radial flow channel, respectively. At least some of the channels are in communication with each other.