Multi-Stage Damping Valve Using Discrete Pilot Flow Control
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Solution Overview
Problem
Current damping-adjustable shock absorbers are costly, difficult to manufacture, and maintain, with high requirements for machining and control accuracy, and often experience drift in damping force over time, making them unsuitable for widespread use beyond high-end vehicles.
Innovation Solution
A multi-stage adjusting damping valve system comprising a throttle valve, overflow valve, and multi-stage pilot valve with mechanical regulating and high-speed switch electromagnetic valves, which allows for adjustable damping characteristics and compensates for assembly errors, reducing costs and improving reliability by using a small number of electromagnetic valves to achieve multiple damping stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous damping adjustment technology is used with high-precision spool position control, then suspension performance is improved, but manufacturing cost and machining accuracy requirements increase significantly
Solution Approach 1:
The continuous damping adjustment system is segmented into multiple discrete damping stages (first damping stage, second damping stage, third damping stage, fourth damping stage). Each stage corresponds to a specific throttle hole diameter (first, second, third, fourth throttle hole diameters), transforming the continuous control problem into discrete stage selection, which reduces machining precision requirements while maintaining suspension performance.
Solution Approach 2:
The system changes the throttle hole diameter parameter to achieve different damping characteristics. By providing multiple throttle holes with different diameters and selectively opening them based on road conditions, the system achieves variable damping without requiring high-precision continuous position control, thus reducing manufacturing complexity.
2Volume of moving object
If built-in damping valve structure is adopted to reduce space occupation, then structure compactness is improved, but maintenance convenience deteriorates
Solution Approach 1:
The damping valve assembly is extracted from the built-in structure and made as a removable component. The piston rod can be pulled out from the shock absorber body, allowing the damping valve to be accessed and replaced independently, which significantly improves maintenance convenience while maintaining a relatively compact overall structure.
3Volume of moving object
If built-in damping valve structure is used, then structure compactness is improved, but component mating accuracy requirements increase
Solution Approach 1:
The damping valve is segmented into modular components including the piston rod, valve body, and throttle holes. This segmentation allows each component to be manufactured and assembled separately with standardized interfaces, reducing the overall mating accuracy requirements compared to a fully integrated built-in structure.
4Adaptability or versatility
If damping-adjustable shock absorbers are used to adapt to different road conditions, then handling stability and riding comfort are improved, but product cost increases
Solution Approach 1:
The system provides dynamic damping adjustment by selectively opening different throttle holes based on road conditions, vehicle speeds, loads and movement modes. This dynamic adaptability is achieved through a cost-effective mechanism using multiple discrete throttle holes rather than expensive continuous adjustment systems, making damping-adjustable shock absorbers more affordable for widespread use.
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 system provides a cost-effective, reliable, and long-lasting solution for damping regulation, capable of adapting to different vehicle models, with enhanced handling stability and riding comfort by selectively controlling high-speed switch electromagnetic valves, reducing the risk of damping force drift and improving manufacturing efficiency.
Implementation Method 1
a plurality of high-speed switch electromagnetic valves which are provided in parallel
Implementation Method 2
a calibration value of a 'differential pressure-flow' characteristic of the multi-stage pilot valve is adjusted in a manner that at least part of the oil flows through the mechanical regulating valve
Implementation Method 3
a calibration value of a 'differential pressure-flow' characteristic of the multi-stage pilot valve is adjusted in a manner that at least part of the oil flows through the mechanical regulating valve to compensate for assembly errors
Implementation Method 4
In a case that the multi-stage pilot valve receives the oil which flows in after sequentially flowing through the throttle valve and the overflow valve
Implementation Method 5
the multi-stage pilot valve can provide multi-stage damping characteristics under displacement excitation
Data Source
AI summary
A multi-stage adjusting damping valve as well as a shock absorber and suspension system using the damping valve are provided. The multi-stage adjusting damping valve comprises a throttle valve, an overflow valve and a multi-stage pilot valve. The multi-stage pilot valve comprises a mechanical regulating valve and a plurality of high-speed switch electromagnetic valves having different throttle hole diameters. The damping valve is connected between a rod cavity and an oil storage cavity of the shock absorber by means of a middle cavity, and the multi-stage damping rapid regulation of the shock absorber is achieved through high-frequency opening and closing of a high-speed switching electromagnetic valve, and in comparison, the machining precision, the manufacturing cost and the control and calibration difficulty of the present disclosure are greatly reduced.