Through-Tube Suspension Actuator Assembly for Lower-Cost Manufacturing
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Solution Overview
Problem
Active vehicle suspension systems with hydraulic actuators have higher system costs and complex manufacturing processes due to additional components like pumps, accumulators, and valves, limiting their mass commercial adoption compared to passive or semi-active systems.
Innovation Solution
A method for assembling an active hydraulic cylinder using a manifold and outer tube with different materials of construction, where the outer tube supports tensile and compressive loads and the manifold is lighter with flow channels, allowing for cost-effective mass production by using techniques similar to conventional hydraulic damper manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional components (pumps, accumulators, valves) are added to create active hydraulic cylinders, then active suspension functionality is achieved, but system cost and manufacturing complexity increase
Solution Approach 1:
The patent merges the manifold and outer tube into a single integrated component with flow channels formed directly within the tube wall. This consolidation eliminates the need for separate manifolds and reduces the number of parts, directly addressing the manufacturing complexity issue while maintaining active suspension functionality through the integrated flow control paths.
Solution Approach 2:
The outer tube serves multiple functions simultaneously: it acts as a structural component, a flow conduit with integrated channels, and a mounting structure for the piston assembly. This multi-functionality reduces the overall component count and simplifies manufacturing while achieving the required active suspension performance.
2Adaptability or versatility
If additional components (pumps, accumulators, valves) are added to create active hydraulic cylinders, then active suspension functionality is achieved, but system cost increases
Solution Approach 1:
By combining the manifold and outer tube into one component with flow channels formed during manufacturing, the patent reduces part count and assembly steps. This integration directly lowers manufacturing costs while preserving the active suspension functionality that requires complex fluid flow control.
3Ease of manufacture
If conventional hydraulic damper manufacturing techniques are used, then manufacturing simplicity is maintained, but active suspension functionality with flow control is limited
Solution Approach 1:
The patent incorporates flow channels with varying cross-sectional areas at specific locations within the outer tube wall to provide active flow control capability. This local modification of the tube structure enables active suspension functionality while maintaining compatibility with conventional manufacturing techniques like tube forming and welding.
Solution Approach 2:
The outer tube is designed to perform both structural support and active fluid flow control functions through integrated flow channels. This multi-functionality allows conventional manufacturing processes to produce a component that delivers advanced active suspension 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
This approach reduces system costs and simplifies manufacturing while maintaining structural integrity, enabling the mass production of active hydraulic cylinders with reduced material usage and complexity.
Implementation Method 1
electromagnetic pulse welding may be used to affix the manifold to the outer tube
Data Source
AI summary
Disclosed herein are active hydraulic cylinders for use in active vehicle suspension systems, and methods for assembling active hydraulic cylinders for use in an active vehicle suspension system. In particular, in certain embodiments a manifold may encircle a portion of an outer tube of a twin tube assembly. The manifold may mechanically and fluidly couple a pump assembly to the twin tube assembly. In certain embodiments, the manifold may be welded onto the outer tube.