Vehicle Suspension Strut Torsion Element Design
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Solution Overview
Problem
Existing vehicle suspension struts with torsion elements experience reduced resilience and unreliable repositioning due to breakdown or tearing under vertical loads, leading to air leaks and compressor overheating.
Innovation Solution
A robust torsion element with a specific geometry that surrounds the damper unit tube and complements the rolling tube, featuring a compressed spring and tapered components for improved sealing and torque transmission, including a coil spring for additional damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional torsion element is used to reposition the assembly around the longitudinal axis, then the initial rotational resistance is adequate, but the element becomes less resilient over time due to breakdown or tearing under vertical loads
Solution Approach 1:
The torsion element is divided into multiple segments or sections along its length, with each segment capable of independent deformation. This segmentation distributes the stress and prevents catastrophic failure, as tearing in one segment does not compromise the entire element. The segmented structure maintains rotational resistance while improving durability under vertical loads.
Solution Approach 2:
The torsion element employs composite material construction, combining materials with different properties to achieve both flexibility for rotation and strength against vertical loads. The composite structure prevents breakdown by utilizing materials that resist tearing while maintaining the necessary torsional resilience over extended service life.
2Reliability
If the torsion element breaks down or tears, then air leaks occur requiring continuous compressor operation, but continuous compressor operation causes overheating
Solution Approach 1:
The improved torsion element incorporates redundant sealing features and stress-distribution design that prevent breakdown before it occurs. By distributing vertical loads across multiple contact points and reinforcing vulnerable areas, the element resists tearing and maintains sealing integrity, avoiding air leaks that would trigger continuous compressor operation and subsequent overheating.
3Strength
If the torsion element geometry is increased to surround the damper unit tube, then structural support and sealing are improved, but the device complexity increases
Solution Approach 1:
The enlarged torsion element geometry serves multiple functions simultaneously: it provides structural support for the assembly, creates sealing surfaces against the damper unit tube, and maintains rotational flexibility. This multi-functional design improves strength and sealing without requiring additional separate components, thereby managing device complexity while achieving enhanced performance.
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
Enhances durability, reduces wear on the compressor motor, and improves torque transmission and vehicle road handling by providing a sealed environment and increased strut life.
Implementation Method 1
The present torsion element preferably includes a spring which is compressed between the geometries of the damper unit tube and the rolling tube
Data Source
AI summary
A suspension strut including an air spring unit and a damper unit that are aligned on a common axis is disclosed. The air spring unit includes a rolling tube having a flared terminal end that extends over a damper tube associated with the damper unit. The damper tube has a circumferential groove formed in an outer diameter of the damper tube. A retaining ring has a greater outer diameter than the outer diameter of the damper tube and is positioned in the circumferential groove. A base has an inner diameter less than the outer diameter of the retaining ring, and an outer diameter smaller than the predetermined diameter of the flared free end, and is supported on the retaining ring. A torsion element fits around the damper tube and within the flared free end.