Pneumatic Spring Interface Unit for Sensor Integration
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Solution Overview
Problem
Existing air spring designs face challenges in efficiently integrating compressed air and electrical connections while maintaining pressure tightness and minimizing manufacturing costs and installation space, especially when retrofitting existing systems with sensor systems.
Innovation Solution
An air spring with a screw-in interface unit that penetrates the end plate in a pressure-tight manner, featuring means for connecting compressed air, electrical, and optical lines, and housing sensors, which can be easily assembled and disassembled, and is designed to minimize the influence of compressed air on the sensor system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate connections are provided for compressed air and electrical lines, then reliable connections are achieved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines multiple separate connection functions (compressed air connection and electrical line connection) into a single integrated interface unit. This interface unit contains both a compressed air line connection and electrical cable connections, reducing the number of separate components and simplifying the overall structure while maintaining reliable connections for all utilities.
Solution Approach 2:
The interface unit is designed as a multi-functional component that simultaneously handles compressed air supply and electrical power/data connections. This universal interface can be used across different air spring designs, providing adaptability and reducing the need for multiple specialized connection components.
2Reliability
If multiple separate connections are provided for compressed air and electrical lines, then reliable connections are achieved, but installation space increases
Solution Approach 1:
The interface unit consolidates multiple connection points into a single compact component mounted on the end plate. By integrating the compressed air connection and electrical connections into one unit, the space required for installations is significantly reduced compared to having separate distributed connections.
Solution Approach 2:
The interface unit contains nested sub-components including the compressed air line connection and electrical cable entries within a single housing structure. This nesting arrangement allows multiple functions to be packed into a minimal space on the end plate.
3Adaptability or versatility
If existing air springs are retrofitted with sensor systems, then measurement capabilities are added, but manufacturing costs and complexity increase
Solution Approach 1:
The interface unit is designed as a universal component that can be applied to existing air springs regardless of their specific design. This standardized interface simplifies retrofitting operations and reduces manufacturing costs by using the same interface unit across different air spring models rather than creating custom integration solutions for each.
Solution Approach 2:
The sensor system is integrated through a modular interface unit that can be independently manufactured and installed. This segmentation allows the sensor integration to be handled as a separate module, simplifying both the retrofitting process and manufacturing by allowing independent production of the interface unit and the air spring itself.
4Ease of operation
If a threaded bushing is used for the interface unit, then ease of assembly and disassembly is improved, but pressure tightness may be compromised
Solution Approach 1:
A sealing element is introduced as an intermediary component between the threaded bushing and the compressed air line connection. This sealing element mediates between the mechanical connection provided by the threaded bushing and the requirement for pressure tightness, allowing the threaded connection to remain easy to assemble while the sealing element ensures no air leakage.
Data Source
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AI summary
The invention relates to an air spring (40), for example for a motor vehicle, with a largely tubular air spring bellows (42) which is made of a fiber-reinforced elastomeric plastic and is designed as a single-fold, multi-fold or unfolded air spring, wherein a first axial end (46) of the air spring bellows (42) is attached to a first end plate (48) and a second axial end (50) of the air spring bellows (42) is attached to a second end plate (52), wherein the air spring bellows (42) and the two end plates (48, 52) are designed rotationally symmetrical about a longitudinal center axis (30) and define an interior space (54) in a pressure-tight manner, and with electronic sensors integrated on the air spring.In this air spring, it is provided that an end plate (48) is connected to an interface unit (60) which penetrates it in a pressure-tight manner, that the interface unit (60) has means for connecting a compressed air line (62) for conveying compressed air into and/or out of the interior (54), and that the interface unit (60) has means for receiving at least one electrical and/or optical line (64) and means for connecting at least one sensor (70) which is in a physical operative connection with the interior (54) of the air spring.