Vehicle Suspension Travel Control via Mechanical Stop Post
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Solution Overview
Problem
Existing suspension systems for heavy-duty vehicles rely heavily on shock absorbers for rebound control, which shortens their lifespan and increases cost and weight, while existing technologies fail to fully realize the benefits of reducing unsprung weight and cost through improved suspension travel control.
Innovation Solution
A suspension travel control system that includes a stop post secured to the vehicle frame and a suspension travel control formation with a body and base, allowing the axle and suspension linkage to move vertically and limiting travel through engagement of contact surfaces, reducing the need for additional components and enhancing redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shock absorbers are used for rebound control, then suspension travel is controlled, but component lifespan is reduced and cost and weight increase
Solution Approach 1:
The patent extracts the rebound control function from the shock absorber by introducing a separate rebound control mechanism consisting of a rebound control arm and rebound control surface. This separates the travel limitation function from the damping function, allowing the shock absorber to focus solely on damping while the new mechanism handles rebound control, thereby extending component lifespan and reducing overall system complexity.
Solution Approach 2:
The rebound control arm acts as an intermediary mechanism between the suspension linkage and the control surface. It provides a mechanical interface that limits rebound travel through geometric constraints rather than hydraulic damping, reducing reliance on the shock absorber and extending its operational life.
2Device complexity
If traditional rebound stop technologies are used, then suspension travel is limited, but cost and weight approach that of hydraulic shock absorbers
Solution Approach 1:
The rebound control mechanism uses simple, lightweight mechanical components (control arm and control surface) that are less expensive and lighter than hydraulic shock absorbers. While the control arm may experience wear, it is a simple component that can be easily replaced, whereas the shock absorber is a more complex, expensive component whose lifespan is extended by reducing its workload.
Solution Approach 2:
The suspension system is segmented into distinct functional components: the shock absorber handles damping, while the rebound control arm and surface handle travel limitation. This segmentation allows each component to be optimized for its specific function, resulting in a lighter overall system compared to relying solely on heavy-duty shock absorbers for both functions.
3Reliability
If shock absorbers provide positive rebound stop, then suspension travel is controlled, but shock absorber lifespan is significantly shortened
Solution Approach 1:
The patent extracts the positive stop function from the shock absorber and assigns it to a dedicated rebound control mechanism. The shock absorber is relieved of the high-impact rebound stopping duty, allowing it to operate within its optimal damping range and significantly extending its lifespan.
Solution Approach 2:
The rebound control surface is positioned to provide a predetermined mechanical stop before the shock absorber is fully compressed. This pre-positioned geometric constraint cushions the rebound event mechanically, preventing excessive compression forces that would otherwise shorten shock absorber life.
Data Source
AI summary
A suspension travel control system (1046) for a vehicle suspension is disclosed. The suspension travel control system includes a stop post (834) secured to the vehicle frame and a suspension travel control formation that includes a base (1042) and a body (1048). The stop post (834) is positioned in a space defined by the body (1048). The suspension travel control formation may be secured to the axle, the main support member or incorporated into the axle coupling assembly to provide a rebound and jounce stop as well as longitudinal redundancy in the event of the failure or loss of a longitudinal linkage.