Trailer Suspension With Torsion Axle and Air Spring Load Adaptation
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Solution Overview
Problem
Current trailer suspension systems, particularly torsion suspension systems for heavy freight vehicles, face limitations in load capacity, vertical stability, and compliance with regulatory deflection requirements, with air suspension systems experiencing inexact leveling and stiff spring material issues, making it difficult to achieve optimal performance and safety.
Innovation Solution
A suspension system combining a torsion axle with an air spring, eliminating the need for additional shock absorbers, and utilizing a rocker system to adjust spring rate, providing a simplified configuration that adapts to varying loads and ensures smooth ride stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional torsion suspension systems are used, then the system provides independent shock absorption for each wheel, but the load capacity is limited and the rebound and jounce travel distance is restricted
Solution Approach 1:
The patent combines the air spring and shock absorber into a single integrated assembly, where the air spring provides the primary suspension force and the shock absorber provides damping control. This merging allows the system to achieve greater load capacity through the air spring's adjustable pressure while providing extended rebound and jounce travel distance through the coordinated action of both components in one assembly.
2Force
If overloaded suspension components are used, then the load capacity increases, but the components are likely to fail
Solution Approach 1:
The air spring's pressure can be dynamically adjusted based on the actual load conditions. The system transitions from a static, fixed-capacity suspension to a dynamic system that can adapt its spring rate and load capacity in real-time, allowing the suspension to handle varying loads optimally without overloading components during normal operation.
3Weight of moving object
If underloaded or unloaded suspension components are used, then the system is lighter, but excessive vertical instability occurs
Solution Approach 1:
The air spring allows dynamic adjustment of the suspension characteristics. When the trailer is underloaded or unloaded, the air pressure can be reduced to soften the suspension and maintain vertical stability. When fully loaded, the pressure is increased to provide adequate support, optimizing both weight efficiency and stability across all operating conditions.
4Ease of operation
If air suspension systems with struts and dampers are used, then the ride height can be adjusted, but forces on the struts or dampers cause the leveling to be inexact due to undershoot or overshoot
Solution Approach 1:
By integrating the shock absorber and air spring into a single assembly with shared mounting points and coordinated action, the system reduces the independent forces that cause undershoot or overshoot in separate-component systems. The merged design allows the damping and spring forces to work together more harmoniously, improving leveling precision while maintaining ride height adjustability.
5Force
If spring material is made extremely stiff to handle heavy loads, then the load capacity increases, but the spring can be easily damaged and may not provide adequate suspension under no-load condition
Solution Approach 1:
The air spring replaces extremely stiff mechanical spring material with an adjustable pneumatic system. The spring rate is not fixed by material properties but can be dynamically changed by adjusting air pressure, allowing the system to provide high load capacity when needed while remaining durable and adaptable to no-load conditions without the risk of material failure.
6Adaptability or versatility
If a modified suspension system is assembled using parts from various manufacturers, then customization is possible, but it is difficult to achieve optimum performance
Solution Approach 1:
The integrated air spring and shock absorber assembly provides a pre-coordinated system where the damping and spring characteristics are designed to work together optimally. This merged design eliminates the compatibility and performance optimization issues that arise when assembling mismatched components from different manufacturers, while still allowing customization through air pressure adjustment and assembly configuration.
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 system achieves improved load capacity, stability, and compliance with regulations by using a combination of air spring and torsion axle, offering adjustable spring rate and reduced costs without compromising safety, while maintaining smooth ride quality across different load conditions.
Implementation Method 1
an air spring, one end of which is hingedly connected to the first bracket assembly
Implementation Method 2
a torsion axle extending between a set of trailer wheels
Implementation Method 3
The combination of rubber/elastic member and air in series provided by the torsion axle and air spring, respectively
Data Source
AI summary
The suspension system for a trailer is disclosed. The suspension system includes a torsion axle and an air spring operating to accommodate a wide range of a load weight applied to the trailer without any change in ride comfort. The air spring can be adjusted for its pressure inside to cover a heavy load weight, while the torsion axle can have relatively softer spring materials therein to cover a light (and zero) load weight. The air spring and the torsion axle are arranged in series to provide adequate suspension based on the load weight.