Vehicle Vibration Damper With Integrated Compression Stop Assembly
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Solution Overview
Problem
Existing vibration dampers with hydraulic compression stops face challenges in high production costs and limited installation space, particularly for external damping valves, due to the need for precise production tolerances and additional components.
Innovation Solution
A vibration damper design that incorporates an auxiliary piston movably positioned within the damper tube, utilizing a compression stop assembly with a spring element and a bypass channel, where the adapter serves as a fluid-tight seal and axial end stop, allowing for independent movement of the auxiliary piston and piston rod, and adjustable damping through a solenoid control valve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic compression stop with auxiliary piston is used to provide additional damping, then compression stage damping performance is improved, but production cost increases due to precise production tolerances required for components
Solution Approach 1:
The adapter serves dual functions as both a fluid-tight seal and an axial end stop for the auxiliary piston, eliminating the need for separate axial stop components. This merging of functions reduces the number of parts and simplifies manufacturing while maintaining the compression damping performance provided by the auxiliary piston and spring element assembly.
Solution Approach 2:
The adapter is designed as a multi-functional component that simultaneously provides fluid sealing and mechanical stopping functions. This universal component approach reduces manufacturing complexity and cost while maintaining the reliability of the compression stop assembly, as the adapter handles multiple tasks that would otherwise require separate specialized components.
2Reliability
If a compression stop assembly with auxiliary piston is added to the vibration damper, then compression damping is improved, but installation space is reduced particularly for external damping valves
Solution Approach 1:
The auxiliary piston and spring element assembly is nested within the existing damper tube internal volume, utilizing the available space between the piston rod and the closed end of the damper tube. This nested arrangement allows the compression stop functionality to be integrated without requiring additional external space, preserving installation space for external damping valves and other components.
Solution Approach 2:
The compression stop assembly is integrated into the existing damper structure by using the adapter as both a sealing element and an axial stop. This merging of functions eliminates the need for separate dedicated stop components that would occupy additional space, allowing the compression damping functionality to be added while minimizing impact on installation space for external components.
3Manufacturing precision
If separate axial stops and guides are used for the auxiliary piston, then positioning precision is improved, but device complexity and production cost increase
Solution Approach 1:
The adapter combines the functions of fluid sealing and axial positioning into a single component. By serving as both the fluid-tight seal and the axial end stop, the adapter eliminates the need for separate axial stop components and guides, reducing device complexity while maintaining sufficient positioning precision for the auxiliary piston through the adapter's geometric constraints.
Solution Approach 2:
The adapter is designed as a universal component that performs multiple functions simultaneously: providing fluid sealing between chambers and serving as the axial end stop for the auxiliary piston. This multi-functionality reduces the total number of components needed, simplifying the device while maintaining the precision required for auxiliary piston positioning through the integrated design.
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 design reduces production costs and simplifies installation by eliminating the need for additional axial stops and guides, while providing effective compression stage damping with adjustable flow cross-sections, enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
a spring element (52), which is arranged between the auxiliary piston (50) and the end of the damper tube (14) away from the piston rod (20)
Implementation Method 2
a damper tube (14) filled with hydraulic fluid
Data Source
AI summary
The present disclosure relates to a vibration damper for a vehicle, comprising a damper tube filled with hydraulic fluid, a working piston, which is connected to a piston rod and is arranged movably back and forth within the damper tube. An interior of the damper tube is divided by the working piston into a first working chamber and a second working chamber, a closure package, which closes off the damper tube fluid-tightly on the piston rod side, an adapter, which is fitted inside the damper tube and is intended for attaching a damping valve device, and a compression stop assembly with an auxiliary piston, which is arranged axially movably within the damper tube. The auxiliary piston is arranged between the adapter and the end of the damper tube away from the piston rod.