Rigid Axle Air-Suspension Module With Tool-Free Bellows Locking
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Solution Overview
Problem
Conventional air spring assemblies for rigid axles in commercial vehicles face challenges during loading and unloading, where the air bellows can buckle and lose spring effect, leading to operational failure and potential damage, due to the lack of secure locking mechanisms between the support body and the air bellows holder.
Innovation Solution
A locking mechanism is introduced that uses a coupling projection and recess with a preloaded engagement section, allowing for secure alignment and locking of the support body to the air bellows holder without tools, utilizing a bow spring for preload and friction to prevent unintentional loosening, ensuring the air bellows remains in place during operation and loading/unloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking mechanism is introduced to prevent air bellows buckling, then reliability is improved, but device complexity increases
Solution Approach 1:
The coupling projection and locking element are integrated into a single support body component, eliminating the need for separate locking mechanisms. The mounting device combines coupling and locking functions in one element, reducing overall device complexity while maintaining reliability.
Solution Approach 2:
The coupling projection automatically engages with the coupling recess through self-alignment during assembly, requiring no additional tools or complex locking procedures. The design enables automatic positioning and securing of the air bellows holder to the support body.
2Reliability
If a secure locking mechanism is implemented, then air bellows positioning is improved, but ease of operation deteriorates
Solution Approach 1:
The coupling projection and recess are designed to self-align and automatically engage during assembly, eliminating the need for tools or complex manual operations. The support body and air bellows holder secure themselves through the geometric configuration of the coupling elements.
Solution Approach 2:
The locking function is extracted as an inherent geometric feature of the coupling projection and recess, rather than requiring separate locking mechanisms or tools. The securing action is built into the basic coupling structure itself.
3Reliability
If the air bellows holder is firmly connected to the support body, then air bellows stability is improved, but ease of repair deteriorates
Solution Approach 1:
The coupling projection and recess create a dynamic connection that is firm during operation but can be easily released when needed. The geometric coupling allows for controlled disassembly by applying force to overcome the engagement, enabling repair while maintaining operational stability.
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 solution provides a secure and tool-free locking engagement that maintains the air bellows in its operational position, preventing buckling and ensuring the spring effect is maintained, even under the weight of the axle body, thus enhancing the load capacity and reliability of the air spring assembly.
Implementation Method 1
utilizing a bow spring for preload
Implementation Method 2
friction to prevent unintentional loosening
Data Source
Figure 1
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Figure 3
AI summary
The present invention relates to an air spring assembly (34) for a rigid axle (10), comprising an air bellows holder (22) and an air bellows assembly (24) supported on the air bellows holder (22) in the operational state of the air spring assembly (34), wherein the air bellows assembly (24) has a shape-changing air spring bellows (28) and a support body (26) connected to the air spring bellows (28), wherein a component consisting of the air bellows holder (22) and the support body (26) has a coupling projection (38) extending along a virtual projection path (V), which engages in a coupling recess (40) formed on the respective other component along the projection path (V), wherein a translational relative movement of the support body (26) relative to the air bellows holder (22) is physically limited orthogonally to the projection path (V) and in a direction along the projection path (V). is.According to the invention, it is provided that one component consisting of air bellows holder (22) and support body (26) has a locking element (60) and the other component consisting of air bellows holder (22) and support body (26) has a locking recess (64) such that the locking element (60) is in positive locking engagement with the locking recess (64), so that a translational relative movement of the support body (26) relative to the air bellows holder (22) in both opposite directions along the projection track (V) is physically limited.