Vehicle Vibration Damper Rebound Stop for Progressive Damping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vibration dampers with hydraulic rebound stops are expensive to manufacture due to the need for precise manufacturing tolerances to compensate for transverse forces on the piston rod, and they lack a cost-effective and efficient rebound stop arrangement for reliable damping.
Innovation Solution
A vibration damper with a rebound stop arrangement that includes an auxiliary piston concentrically surrounding the piston rod, a sleeve-like rebound stop receptacle, and a spring element positioned mechanically in series with the auxiliary piston, allowing for mechanical decoupling and progressive damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic rebound stop components are designed to compensate for transverse forces on the piston rod, then reliable damping is achieved, but manufacturing cost increases due to very precise manufacturing tolerances
Solution Approach 1:
The invention extracts the transverse force compensation function from the hydraulic rebound stop components and transfers it to a separate transverse force compensation arrangement. This allows the rebound stop components to focus solely on providing rebound damping without needing to simultaneously compensate for transverse forces, thereby reducing their manufacturing precision requirements and cost while maintaining reliable damping performance.
Solution Approach 2:
The vibration damper is segmented into functionally independent components: a rebound stop arrangement for providing rebound damping and a separate transverse force compensation arrangement for compensating transverse forces. This functional segmentation allows each component to be optimized independently, reducing the manufacturing precision requirements for the rebound stop components.
2Reliability
If hydraulic rebound stop components are designed to compensate for transverse forces on the piston rod, then reliable damping is achieved, but device complexity increases
Solution Approach 1:
The invention extracts the transverse force compensation function from the rebound stop components and places it in a separate transverse force compensation arrangement. This functional separation simplifies the design of each individual component, as the rebound stop components no longer need to simultaneously handle both damping and transverse force compensation, thereby reducing overall device complexity while maintaining reliable damping.
3Ease of manufacture
If auxiliary piston is mounted axially movably on piston rod with spring element in series, then manufacturing cost is reduced and assembly is simplified, but progressive damping response is achieved
Solution Approach 1:
The invention uses the hydraulic fluid and hydraulic chambers to provide progressive damping through pressure build-up as the auxiliary piston moves into the rebound stop receptacle. This hydraulic damping mechanism achieves precise progressive damping response without requiring very precise manufacturing tolerances, as the hydraulic system naturally provides smooth, progressive resistance to piston movement.
Solution Approach 2:
The spring element positioned in series with the axially movable auxiliary piston creates progressive damping by changing the mechanical resistance parameter as compression increases. This mechanical progressive damping, combined with the hydraulic damping, achieves reliable progressive damping response with reduced manufacturing precision requirements compared to purely hydraulic designs.
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 proposed solution achieves reliable damping while reducing manufacturing costs and simplifying the assembly process, with progressive damping that increases damping force with increasing piston speed, resulting in a smoother response behavior.
Implementation Method 1
The rebound stop arrangement has a spring element, which is fastened to the auxiliary piston
Implementation Method 2
a damper tube (14) filled with hydraulic fluid
Data Source
AI summary
A vibration damper for a vehicle comprises a damper tube filled with hydraulic fluid, a working piston which is connected to a piston rod and which is arranged within the damper tube so as to be movable back and forth, wherein an interior of the damper tube is divided by the working piston into a first working chamber and a second working chamber, a rebound stop arrangement having an auxiliary piston, which concentrically surrounds the piston rod, and a sleeve-like rebound stop receptacle, which is mounted on the damper tube, for receiving the auxiliary piston in the rebound stage, wherein the auxiliary piston is mounted on the piston rod so as to be axially movable relative thereto, and the rebound stop arrangement has a spring element that is fastened to the auxiliary piston.