Suspension Damper Pilot Valve for Low-Power Damping Adjustment
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Solution Overview
Problem
Conventional vehicle suspension systems lack the ability to dynamically adjust damping rates during compression and extension, which is necessary for advanced recreational and sporting vehicles that require varying damping characteristics.
Innovation Solution
A pilot spool valve assembly that uses a latching solenoid to control a pressure-balanced pilot spool, allowing for controllable damping forces with low power consumption and an externally adjustable orifice size, enabling both preload and damping rate adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional dampers are used, then the structure is simple, but the damping rate cannot be dynamically adjusted
Solution Approach 1:
The valve assembly is segmented into distinct functional components: a pilot spool valve for controlling main valve operation, a latching solenoid for pilot spool actuation, and a main valve for damping fluid flow control. This segmentation allows each component to be optimized independently while working together to achieve dynamic damping adjustment capability without excessive overall complexity.
Solution Approach 2:
The pilot spool valve acts as an intermediary component that uses low-pressure control fluid to operate the high-pressure main valve. The latching solenoid serves as an intermediary that uses electrical signals to control the hydraulic pilot spool, which in turn controls the mechanical main valve. This intermediary mechanism enables efficient power transmission and control.
2Use of energy by moving object
If a latching solenoid is used to control the pilot spool, then power consumption is reduced, but the control system becomes more complex
Solution Approach 1:
The latching solenoid operates by applying periodic electrical pulses to transition the pilot spool between latched positions, rather than requiring continuous power application. The solenoid latches the pilot spool in place using spring forces and pressure differential after brief activation, creating a periodic action pattern that significantly reduces average power consumption compared to continuously powered systems.
Solution Approach 2:
The latching mechanism uses the system's own hydraulic pressure and spring forces to maintain the pilot spool position without continuous external power input. Once the solenoid initiates the transition, the pressure differential and spring bias self-maintain the new position, making the system self-sustaining between control pulses and minimizing ongoing energy requirements.
3Adaptability or versatility
If an externally adjustable orifice is provided, then damping characteristics can be customized, but manufacturing complexity increases
Solution Approach 1:
The orifice assembly is designed with dynamic adjustability, allowing the orifice size to be changed during operation or between uses. This dynamic feature enables customization of damping characteristics for different riding conditions, rider preferences, or vehicle configurations, transforming a static component into an adaptable element that responds to varying requirements.
Solution Approach 2:
The externally adjustable orifice mechanism allows changing the flow area parameter of the damping system. By providing an adjustable orifice, the system can modify the flow resistance parameter to achieve different damping rates and characteristics, enabling parameter customization without redesigning the entire damper assembly.
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
Enables reduced power consumption and allows riders to customize damping settings, providing improved control over suspension behavior by generating large damping forces with minimal power input and adjustable damping characteristics.
Implementation Method 1
a latching solenoid to actuate a pressure-balanced pilot spool
Implementation Method 2
pilot spool valve assembly that uses a latching solenoid to control a pressure-balanced pilot spool
Implementation Method 3
allowing for controllable damping forces with low power consumption
Data Source
AI summary
A vehicle suspension damper is described. The vehicle suspension damper includes: a pilot valve assembly; a primary valve; and an adjuster, wherein the pilot valve assembly meters fluid to the primary valve, and the adjuster moves the primary valve.