Vehicle Suspension Rebound Control Spring Bracket
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Solution Overview
Problem
Modern vehicles, especially electric vehicles, experience excessive front end rise and reduced tractive capability during rapid acceleration due to the limitations of existing suspension systems, which fail to effectively control rebound forces and maintain a clear driver view and proper tire loading.
Innovation Solution
A vehicle suspension system incorporating a first and second suspension component with a spring element mounted between them, utilizing materials like microcellular urethane or thermoplastic polyurethane to create a rebound control mechanism that limits upward travel and enhances steering, handling, and roll control by engaging when acceleration forces exceed a threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional suspension components (shock absorbers, springs) are used, then basic suspension function is provided, but rebound forces are not adequately controlled during rapid acceleration
Solution Approach 1:
The rebound control spring element is integrated into the existing suspension component structure, combining rebound control function with the suspension arm or control link. This merging approach provides adequate rebound control during rapid acceleration without significantly increasing overall suspension system complexity.
Solution Approach 2:
The suspension component is designed to perform multiple functions: traditional suspension support, shock absorption, and rebound control during acceleration. The spring element mounted on the suspension component serves both as a structural element and as an active rebound control mechanism, making the system more versatile without adding separate dedicated components.
2Stability of the object's composition
If high-rate spring elements are used to control rebound forces, then front end rise is limited and driver view remains clear, but the system becomes more complex
Solution Approach 1:
The high-rate spring element is applied locally at specific points on the suspension component where rebound control is most needed. This localized application provides effective front end rise control during acceleration without requiring the entire suspension system to be redesigned with high-complexity components throughout.
Solution Approach 2:
The spring element provides dynamic rebound control that activates when needed during acceleration events. The system transitions from a static suspension design to a dynamic one where the spring element engages to control body rise during rapid acceleration, maintaining stability without constant complexity.
3Productivity
If existing suspension components are used, then basic ride comfort is provided, but tractive capability is reduced during rapid acceleration
Solution Approach 1:
The spring element is positioned and configured to provide preliminary counter-action to rebound forces before they can significantly reduce tire loading during acceleration. By anticipating and opposing the upward body movement that would unload the front tires, the system maintains consistent tractive capability throughout the acceleration event.
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 suspension system effectively controls rebound forces, maintaining a clear driver view and proper tire loading, improving steering, handling, and structural feel by using high-rate spring elements that respond faster and generate more force than traditional coil springs or MacPherson strut arrangements.
Implementation Method 1
a spring element mounted to one of the bracket and the surface portion of the second suspension component. Interaction between the spring element and the another of the bracket and the surface portion limits upward travel of the body of the vehicle
Data Source
AI summary
A vehicle suspension system for a vehicle having a body supported on a frame includes a first suspension component having a surface and a bracket cantilevered from the surface, a second suspension component including a surface portion, and a spring element mounted to one of the bracket and the surface portion of the second suspension component. Interaction between the spring element and the another of the bracket and the surface portion of the second suspension component limits upward travel of the body of the vehicle.