Bellows Accumulator Pre-Charging to Prevent Pressure Deformation
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Solution Overview
Problem
Bellows accumulators in vehicle suspension systems are prone to damage during pre-charging and fluid filling due to differential pressure conditions, leading to deformation and reduced fatigue life, and existing methods result in contamination and inefficient assembly processes.
Innovation Solution
A method involving an outer shell with an accumulator port and a gas charging port, where a bellows assembly with an annular bellows wall is inserted, and the accumulation chamber is evacuated to create a vacuum before filling the gas chamber with pressurized gas, ensuring the bellows remains undamaged and properly shaped.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the accumulation chamber is filled with fluid before assembling the bellows assembly, then the accumulator is ready for operation, but the bellows may be damaged due to differential pressure conditions
Solution Approach 1:
The method performs the evacuation of the accumulation chamber before assembling the bellows assembly into the outer shell. This preliminary action ensures that when the bellows is subsequently charged with pressurized gas, the pressure differential is controlled and prevents bellows damage during the charging operation.
Solution Approach 2:
The conventional sequence is inverted: instead of filling the accumulation chamber with fluid first and then assembling the bellows, the method evacuates the accumulation chamber first, assembles the bellows, and then charges the gas chamber. This reversal of the conventional sequence prevents differential pressure damage to the bellows.
2Ease of operation
If pressurized gas is supplied to the gas chamber while the accumulation chamber contains fluid at atmospheric pressure, then the bellows expands to provide working fluid, but the bellows may be undesirably deformed
Solution Approach 1:
The method applies a preliminary anti-action by evacuating the accumulation chamber to create a vacuum or reduced pressure condition before charging the gas chamber. This counteracts the potential harmful effect of uncontrolled pressure differential that would otherwise cause bellows deformation during the charging operation.
Solution Approach 2:
The method changes the pressure parameter in the accumulation chamber from atmospheric pressure to vacuum or reduced pressure before gas charging. This parameter change controls the pressure differential across the bellows, preventing unwanted deformation while allowing the bellows to expand properly when charged.
3Productivity
If the accumulator is preassembled and charged with pressurized gas before installation, then the accumulator is ready for immediate use, but residual fluid may leak during installation causing contamination
Solution Approach 1:
The method performs evacuation of the accumulation chamber as a preliminary action before assembling the bellows and charging the gas chamber. This ensures that when the accumulator is installed and connected to the suspension system, residual fluid can be drawn into the accumulation chamber by the vacuum, preventing leakage and contamination during installation.
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
This method prevents bellows deformation during charging, maintains its shape under varying pressures, and minimizes fluid leakage, ensuring robust operation and efficient assembly of the bellows accumulator in vehicle suspension systems.
Implementation Method 1
evacuating the accumulation chamber when the bellows assembly is not at the fully extended position to obtain a pressure within the accumulation chamber less than atmospheric pressure
Implementation Method 2
supplying pressurized gas to the gas charging port
Data Source
AI summary
A method of charging a bellows accumulator for a vehicle suspension system comprises providing an outer shell with an accumulator port and a gas charging port, and inserting a bellows assembly within the outer shell. The bellows assembly includes an annular bellows wall at least partially defining a gas chamber of variable volume. The bellows assembly is axially extendable between a retracted position and a fully extended position. The gas chamber is arranged in fluid communication with the gas charging port. An accumulation chamber is provided between the outer shell and the bellows assembly and is in fluid communication with the accumulator port. The method further includes evacuating the accumulation chamber when the bellows assembly is not at the fully extended position to obtain a pressure within the accumulation chamber less than atmospheric pressure and supplying pressurized gas to the gas charging port.