Split Air Spring Upper Support for Bushing Replacement
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Solution Overview
Problem
The high cost of after-market replacement due to the difficulty in detaching and replacing bushings in conventional air spring upper supports, which often results in damage to the O-shaped seal ring and increased costs, and the inability to reduce abnormal noise caused by bushing vibration.
Innovation Solution
A split structure air spring upper support with a detachable bushing configuration, comprising an upper and lower housing connected by threaded fasteners, allowing for independent replacement of the bushing without dismounting the entire assembly, and featuring various fitting types between the bushing components to minimize noise and prevent seal ring damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If press fit is adopted for bushing installation, then the bushing is firmly fixed in the upper support housing, but the bushing becomes non-detachable and difficult to replace
Solution Approach 1:
The invention divides the upper support housing into two separable parts: an upper support housing body and an upper support housing cover. The bushing is installed in the housing body, while the cover is connected to the housing body via threaded fasteners. This segmentation allows the bushing to remain firmly fixed during operation while enabling easy removal and replacement by simply detaching the cover, without requiring pressing forces that could damage the bushing or seal ring.
2Reliability
If press fit is used to install the bushing, then the bushing is securely fixed, but the O-shaped seal ring is likely to be damaged during installation
Solution Approach 1:
By segmenting the housing into a body and a cover connected by threaded fasteners, the installation process no longer requires pressing the bushing through the entire housing. The bushing can be installed in the housing body without excessive pressing force, and the seal ring installed on the bushing outer tube is protected from damage since the cover is simply screwed on rather than pressed together.
3Ease of repair
If the bushing is pressed out for replacement, then the bushing can be removed, but great pressing force is required which inevitably results in damage to the bushing or housing
Solution Approach 1:
The segmentation of the housing into removable cover and body eliminates the need to press the bushing out entirely. The cover can be unscrewed from the housing body, providing direct access to the bushing for replacement without applying any pressing force to the housing or bushing, thus preserving their structural integrity.
4Reliability
If the entire air spring assembly needs to be replaced when the bushing fails, then the bushing fixation is secure, but the after-market replacement cost greatly increases
Solution Approach 1:
By dividing the housing into a removable cover and body, the invention enables independent replacement of the bushing without replacing the entire air spring assembly. The cover can be detached, the bushing replaced, and the cover reattached, significantly reducing after-market replacement costs while maintaining secure bushing fixation during operation.
5Device complexity
If conventional press fit structure is used, then the structure is simple, but abnormal noise caused by bushing vibration cannot be minimized
Solution Approach 1:
The segmented housing structure with removable cover allows for better bushing positioning and fixation within the housing body. The cover can be designed with features that minimize bushing vibration, such as vibration-damping materials or precise positioning structures, while keeping the overall structure relatively simple and not significantly increasing device complexity.
Data Source
AI summary
Provided are an air spring upper support, a vehicle air spring assembly, and a vehicle. The air spring upper support is used for a vehicle air spring. The air spring upper support is configured to be of a split structure having an upper housing and a lower housing, the upper housing and the lower housing are connected to each other and form a receiving space, the air spring upper support further has a bushing, and the bushing is arranged in the receiving space.