Retrofittable Air Suspension Brackets for Fast Chassis Mounting
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Solution Overview
Problem
Retrofitting an air suspension system onto existing vehicle chassis, particularly pickup trucks, is challenging due to the need to access difficult-to-reach areas and applies stress to the chassis material, leading to fatigue and increased installation time.
Innovation Solution
A retrofittable rear aft suspension assembly using U-shaped bolts, quarter turn nuts, C-straps, and adjustable chassis hooks to attach air spring brackets, distributing load across the chassis and avoiding damage through pre-existing holes, allowing for faster and less stressful installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stick nuts are used to affix air spring brackets to box shape chassis, then the air suspension system can be installed, but the installation time increases significantly and the installer must access difficult-to-reach regions
Solution Approach 1:
Instead of reaching inside the chassis to install stick nuts from the interior, the invention inverts the approach by installing U-bolts from the exterior of the chassis. The U-bolts wrap around the chassis members and are secured with nuts on the outside, eliminating the need to access difficult-to-reach interior regions and significantly reducing installation time.
Solution Approach 2:
The invention divides the attachment system into separate components: U-bolts that wrap around the chassis, mounting brackets that attach to the U-bolts, and nuts that secure the assembly. This segmentation allows each component to be installed and positioned independently, making the overall installation process simpler and faster compared to using single-piece stick nuts.
2Reliability
If air spring forces are applied to the outer chassis surface in conventional designs, then the air spring can be mounted, but the chassis material experiences fatigue due to stress concentrations
Solution Approach 1:
The invention transitions from applying force at a single point (conventional stick nut attachment) to distributing force across multiple dimensions. The U-bolts wrap around the chassis members, creating a three-dimensional attachment that distributes the air spring forces across multiple contact points and along the length of the U-bolts, rather than concentrating stress at single attachment holes in the chassis surface.
Solution Approach 2:
The U-bolts and mounting brackets are designed to distribute and cushion the forces from the air springs before they reach the chassis. The gradual load distribution through the U-bolt curvature and multiple attachment points prevents sudden stress concentrations that would cause chassis fatigue, effectively cushioning the chassis against harmful forces.
3Reliability
If conventional attachment methods are used, then air spring brackets can be affixed, but the installation process is complex and difficult to remove or service
Solution Approach 1:
The attachment system is segmented into distinct, easily separable components: U-bolts, mounting brackets, and nuts. Each component can be independently removed and reinstalled, making the system highly serviceable. The air spring can be quickly detached by removing the nuts from the U-bolts, and the system can be reconfigured or repaired by replacing individual components without affecting the entire assembly.
Solution Approach 2:
The invention creates a dynamic, adjustable attachment system where the mounting brackets can be positioned at different locations along the U-bolts, and the U-bolts themselves can be removed and repositioned. This dynamic capability allows the system to be easily adapted for different service requirements, whereas conventional fixed attachment methods lack this flexibility.
Data Source
AI summary
A retrofittable rear aft suspension assembly comprises an air spring retained between an air spring upper mount and an air spring lower mount. The air spring lower mount is attached to the leaf spring or axle, while the air spring upper mount is attached to the vehicle chassis through U-bolts, quarter turn nuts, C-straps or an adjustable chassis hook. This allows an installer to quickly install and remove an air spring to a wide variety of chassis types without having to access the difficult-to-reach regions behind the chassis, or damage the chassis through welding, cutting or drilling additional holes. A cradle extends from the air spring upper mount under the chassis to carry the majority of the vertical load from the air spring to the bottom of the chassis.