Shear Spring Variable Rate Suspension
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Solution Overview
Problem
Vehicle suspensions with single spring rates compromise either ride quality or roll stability, as they cannot effectively adjust to varying loads, leading to suboptimal performance in vocational or heavy haul truck applications.
Innovation Solution
A suspension system with shear springs and a load cushion that provides a continuously increasing spring rate, utilizing V-shaped surfaces and elastomeric materials to distribute load evenly and maintain stability across varying loads, eliminating the need for separate spring mounts and simplifying assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single spring rate is used in the suspension, then the suspension structure is simple, but either ride quality or roll stability is compromised
Solution Approach 1:
The patent applies the dynamics principle by transitioning from a fixed single spring rate to a variable spring rate system. The elastomeric spring's effective spring rate changes dynamically based on the applied load, allowing the suspension to adapt its characteristics during operation. This resolves the contradiction by providing both ride quality at low loads and roll stability at high loads without requiring complex adjustable mechanisms.
Solution Approach 2:
The patent utilizes parameter changes by designing an elastomeric spring where the spring rate parameter varies with the load parameter. The non-linear elastic properties of the elastomeric material cause the spring rate to increase as the load increases, thereby changing the suspension's mechanical characteristics dynamically. This allows a single-component system to achieve the performance of multiple spring rates.
2Reliability
If a variable spring rate suspension is implemented using bolster springs and auxiliary springs, then ride quality and roll stability are improved, but the device complexity increases
Solution Approach 1:
The patent applies the merging principle by combining the functions of multiple springs (bolster springs and auxiliary springs) into a single elastomeric spring component. This unified component achieves variable spring rate behavior through its non-linear elastic properties, eliminating the need for separate spring assemblies while maintaining the variable rate characteristic. The consolidation reduces structural complexity while preserving the improved ride quality and roll stability.
Solution Approach 2:
The elastomeric spring serves multiple functions simultaneously: it provides the primary springing function, achieves variable spring rate behavior, and eliminates the need for separate auxiliary components. This multi-functionality resolves the contradiction by delivering the performance benefits of a variable spring rate system without requiring the complex multi-component architecture of traditional designs.
3Reliability
If separate spring mounts are used for bolster springs and auxiliary springs, then the suspension can achieve variable spring rate, but the assembly and maintenance difficulty increases
Solution Approach 1:
The patent merges the separate spring mounts into a single integrated mounting structure for the elastomeric spring. This consolidation eliminates the need for multiple separate mounting locations and simplifies the assembly process. The single elastomeric spring can be installed and secured in one location, significantly reducing assembly time and maintenance complexity while maintaining the variable spring rate performance.
Solution Approach 2:
The patent extracts and eliminates the unnecessary complexity of separate spring mounts by using a single elastomeric spring that requires only one mounting location. This removal of redundant components simplifies the overall suspension structure and makes assembly and maintenance more straightforward while preserving the essential variable spring rate functionality.
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 enhances ride quality and roll stability by adjusting spring rate in response to increased loads, improving the overall performance and longevity of the suspension system while simplifying installation and maintenance processes.
Implementation Method 1
a first shear spring positioned between a first side wall of the first spring mount and a first side wall of the opening of the first spring module
Implementation Method 2
load cushion with a continuously increasing spring rate
Implementation Method 3
V-shaped surfaces and elastomeric materials to distribute load evenly
Data Source
AI summary
A shear spring having a base plate having a flat upper surface, and an upper plate having a V-shaped upper surface opposite the base plate adapted to mate with a corresponding V-shaped surface positioned on a side wall of a spring mount, the upper plate having a flat lower surface parallel to the flat upper surface of the base, and an elastomeric material positioned between the flat upper surface of the base plate and the flat lower surface of the upper plate.