Shock Absorber PCB Carrier Housing Design
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Solution Overview
Problem
Existing vehicle suspension systems with hydraulic dampers lack efficient integration of electronic control systems, leading to complexity and potential environmental exposure of electronic components, which can affect performance and reliability.
Innovation Solution
An electrically adjustable hydraulic shock absorber system with an integrated electronic control system, featuring a carrier housing that protects and seals electronic components, including a circuit board and solenoids, and a bumper cap assembly that transfers compressive loads while minimizing deflection and ensuring easy installation and protection from the environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electronic control components are integrated within the shock absorber, then the system complexity is reduced and reliability is improved, but the manufacturing and assembly complexity increases
Solution Approach 1:
The patent integrates the electronic control components (circuit board, solenoids) directly within the shock absorber assembly by mounting the circuit board on the rod guide and positioning solenoids within the shock absorber body. This merging of electronic and mechanical systems into a single integrated unit reduces overall system complexity and improves reliability by eliminating separate mounting structures and connections, while the modular integration approach maintains manufacturing feasibility.
2Ease of operation
If electronic components are exposed to the environment, then the installation is simpler, but the performance and reliability deteriorate due to environmental exposure
Solution Approach 1:
The circuit board is mounted on the rod guide which is nested within the shock absorber body, and the solenoids are positioned within the shock absorber body. This nested arrangement provides inherent protection for electronic components from environmental factors such as moisture, dust, and contaminants, while maintaining easy installation through the integrated mounting structure that requires no additional external housing or complex sealing arrangements.
Data Source
AI summary
An electrically adjustable hydraulic shock absorber includes a tube defining a fluid chamber and a piston assembly positioned within the tube. The piston assembly divides the fluid chamber into a first working chamber and a second working chamber. A piston rod is attached to the piston assembly and projects out of the tube. Further, a rod guide guides the piston rod and an electronically-controlled valve is positioned within the rod guide for controlling a damping state of the shock absorber. A circuit board is positioned around the piston rod for actuating the electronically-controlled valve. A carrier housing receives the circuit board and engages with the rod guide. The carrier housing includes an inner column and an outer column. A bumper cap is mounted on the carrier housing and is engaged with the inner and outer columns.