DAMPING AIR SPRING WITH DYNAMICALLY VARIABLE ORIFICE

Abstract

An air spring for a heavy-duty vehicle includes a bellows chamber, a piston chamber, and at least one opening. The piston chamber is operatively connected to the bellows chamber. The at least one opening is in fluid communication with the bellows chamber and the piston chamber to provide fluid communication between the bellows chamber and the piston chamber. An orifice assembly is disposed adjacent the at least one opening for variably changing the size of the opening. The air spring provides damping to the heavy-duty vehicle.

Claims

1. An air spring for a heavy-duty vehicle, said air spring comprising: a bellows chamber; a piston chamber operatively connected to said bellows chamber; at least one opening in fluid communication with said bellows chamber and said piston chamber for providing fluid communication between the chambers; and an orifice assembly disposed adjacent said at least one opening, said orifice assembly variably changing a size of said at least one opening, wherein said air spring provides damping to said heavy-duty vehicle.

2. The air spring for a heavy-duty vehicle of claim 1, wherein said orifice assembly further comprises a control module for variably changing the size of said at least one opening in response to a selected condition sensed by said control module.

3. The air spring for a heavy-duty vehicle of claim 1, wherein said at least one opening includes a horizontal cross section comprising a shape chosen from the group consisting of a circle, an oval, an ellipse and a polygon.

4. The air spring for a heavy-duty vehicle of claim 2, wherein said selected condition comprises a pressure in said air spring.

5. The air spring for a heavy-duty vehicle of claim 2, wherein said selected condition comprises a pressure in said bellows chamber.

6. The air spring for a heavy-duty vehicle of claim 2, wherein said selected condition comprises a pressure in said piston chamber.

7. The air spring for a heavy-duty vehicle of claim 2, wherein said selected condition comprises an air pressure in an air system of said heavy-duty vehicle.

8. The air spring for a heavy-duty vehicle of claim 2, wherein said selected condition comprises a lateral acceleration of said heavy-duty vehicle.

9. The air spring for a heavy-duty vehicle of claim 2, wherein said selected condition comprises a roll acceleration of said heavy-duty vehicle.

10. The air spring for a heavy-duty vehicle of claim 2, wherein said control module comprises a microprocessor operatively connected to at least one sensor, said sensor being positioned on said heavy-duty vehicle in order to sense a selected condition of the heavy-duty vehicle during operation.

11. The air spring for a heavy-duty vehicle of claim 2, wherein said control module comprises a mechanical device.

12. The air spring for a heavy-duty vehicle of claim 1, wherein said orifice assembly comprises a bladder, said bladder variably changing said size of said at least one opening.

13. The air spring for a heavy-duty vehicle of claim 12, wherein said bladder includes a ring-shape.

14. The air spring for a heavy-duty vehicle of claim 1, wherein said orifice assembly comprises an iris, said iris variably changing said size of said at least one opening.

15. The air spring for a heavy-duty vehicle of claim 1, said orifice assembly being disposed in said at least one opening.

16. The air spring for a heavy-duty vehicle of claim 1, said at least one opening being disposed between said bellows chamber and said piston chamber.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0025] The preferred embodiments of the present invention, illustrative of the best mode in which applicants have contemplated applying the principles, are set forth in the following description and are shown in the drawings, and are particularly and distinctly pointed out and set forth in the appended claims.

[0026] FIG. 1 is a top rear driver side perspective view of an axle/suspension system incorporating a pair of prior art non-damping air springs, and showing a pair of shock absorbers, with each one of the pair of shock absorbers mounted on a respective one of the suspension assemblies of the axle/suspension system;

[0027] FIG. 2 is a perspective view, in section, of a prior art air spring with damping characteristics, showing the bellows chamber connected to the piston chamber via a pair of openings;

[0028] FIG. 3 is a perspective view, in section, of a first exemplary embodiment damping air spring with dynamically variable orifice of the present invention, showing the ring-shaped bladder disposed in the orifice in an inflated state for increased restriction of airflow between the piston chamber and the bellows chamber during operation;

[0029] FIG. 4 is an enlarged top perspective view of the dynamically variable orifice of the first exemplary embodiment damping air spring of the present invention, showing the ring-shaped bladder disposed in the orifice in an inflated state for increased restriction of airflow between the piston chamber and the bellows chamber during operation;

[0030] FIG. 5 is an enlarged perspective view similar to FIG. 3, showing the ring-shaped bladder disposed in the orifice in an inflated state for increased restriction of airflow between the piston chamber and the bellows chamber during operation and showing the conduit in fluid communication with the ring-shaped bladder;

[0031] FIG. 6 is a greatly enlarged view similar to FIG. 5;

[0032] FIG. 7 is a perspective view, in section, of the first exemplary embodiment damping air spring with dynamically variable orifice of the present invention, showing the ring-shaped bladder disposed in the orifice in a reduced inflated state for decreased restriction of airflow between the piston chamber and the bellows chamber during operation;

[0033] FIG. 8 is an enlarged top perspective view of the dynamically variable orifice of the first exemplary embodiment damping air spring of the present invention, showing the ring-shaped bladder disposed in the orifice in a reduced inflated state for decreased restriction of airflow between the piston chamber and the bellows chamber during operation;

[0034] FIG. 9 is an enlarged perspective view similar to FIG. 7, showing the ring-shaped bladder disposed in the orifice in a reduced inflated state for decreased restriction of airflow between the piston chamber and the bellows chamber and showing the conduit in fluid communication with the ring-shaped bladder;

[0035] FIG. 10 is a greatly enlarged view similar to FIG. 9;

[0036] FIG. 11 is a perspective view, in section, of a second exemplary embodiment damping air spring with dynamically variable orifice of the present invention, showing an iris disposed in the orifice in a constricted state for increased restriction of airflow between the piston chamber and the bellows chamber during operation;

[0037] FIG. 12 is an enlarged top perspective view of the dynamically variable orifice of the second exemplary embodiment damping air spring of the present invention, showing the iris disposed in the orifice in a constricted state for increased restriction of airflow between the piston chamber and the bellows chamber during operation;

[0038] FIG. 13 is an enlarged perspective view similar to FIG. 11, showing the iris disposed in the orifice in a constricted state for increased restriction of airflow between the piston chamber and the bellows chamber during operation;

[0039] FIG. 14 is a greatly enlarged view similar to FIG. 13;

[0040] FIG. 15 is a perspective view, in section, of the second exemplary embodiment damping air spring with dynamically variable orifice of the present invention, showing the iris disposed in the orifice in a reduced constricted state for decreased restriction of airflow between the piston chamber and the bellows chamber during operation;

[0041] FIG. 16 is an enlarged top perspective view of the dynamically variable orifice of the second exemplary embodiment damping air spring of the present invention, showing the iris disposed in the orifice in a reduced constricted state for decreased restriction of airflow between the piston chamber and the bellows chamber during operation;

[0042] FIG. 17 is an enlarged perspective view similar to FIG. 15, showing the iris disposed in the orifice in a reduced restricted state for decreased restriction of airflow between the piston chamber and the bellows chamber during operation; and

[0043] FIG. 18 is a greatly enlarged view similar to FIG. 17.

[0044] Similar numerals refer to similar parts throughout the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0045] In order to better understand the environment in which the air spring with damping characteristics for a heavy-duty vehicle of the present invention is utilized, a trailing arm overslung beam-type air-ride axle/suspension system that incorporates a pair of prior art air springs 24 without damping characteristics, is indicated generally at 10, is shown in FIG. 1, and now will be described in detail below.

[0046] It should be noted that axle/suspension system 10 is typically mounted on a pair of longitudinally-extending spaced-apart main members (not shown) of a heavy-duty vehicle, which is generally representative of various types of frames used for heavy-duty vehicles, including primary frames that do not support a subframe and primary frames and/or floor structures that do support a subframe. For primary frames and/or floor structures that do support a subframe, the subframe can be non-movable or movable, the latter being commonly referred to as a slider box. Because axle/suspension system 10 generally includes an identical pair of suspension assemblies 14, for sake of clarity only one of the suspension assemblies will be described below.

[0047] Suspension assembly 14 is pivotally connected to a hanger 16 via a trailing arm overslung beam 18. More specifically, beam 18 is formed having a generally upside-down integrally formed U-shape with a pair of sidewalls 66 and a top plate 65, with the open portion of the beam facing generally downwardly. A bottom plate (not shown) extends between and is attached to the lowermost ends of sidewalls 66 by any suitable means such as welding to complete the structure of beam 18. Trailing arm overslung beam 18 includes a front end 20 having a bushing assembly 22, which includes a bushing, pivot bolts and washers as are well known in the art, to facilitate pivotal connection of the beam to hanger 16. Beam 18 also includes a rear end 26, which is welded or otherwise rigidly attached to a transversely extending axle 32.

[0048] Suspension assembly 14 also includes air spring 24, mounted on and extending between beam rear end 26 and the main member (not shown). Air spring 24 includes a bellows 41 and a piston 42. The top portion of bellows 41 is sealingly engaged with a bellows top plate 43. With continued reference to FIG. 1, an air spring mounting plate 44 is mounted on top plate 43 by fasteners 45, which are also used to mount the top portion of air spring 24 to the vehicle main member (not shown). Piston 42 is generally cylindrical-shaped and has a generally flat bottom plate and top plate (not shown). The bottom portion of the bellows 41 is sealingly engaged with the piston top plate (not shown). The piston bottom plate rests on beam top plate 65 at beam rear end 26 and is attached thereto in a manner well known to those having skill in the art, such as by fasteners or bolts (not shown). The piston top plate is formed without openings so that there is no fluid communication between piston 42 and bellows 41. As a result, piston 42 does not generally contribute any appreciable volume to air spring 24. The top end of a shock absorber 40 is mounted on an inboardly extending wing 17 of hanger 16 via a mounting bracket 19 and a fastener 15, in a manner well known in the art. The bottom end of shock absorber 40 is mounted to beam 18 (the mount not shown) in a manner well known to those having skill in the art. For the sake of relative completeness, a brake system 28 including a brake chamber 30 is shown mounted on prior art suspension assembly 14.

[0049] As mentioned above, axle/suspension system 10 is designed to absorb forces that act on the vehicle as it is operating. More particularly, it is desirable for axle/suspension system 10 to be rigid or stiff in order to resist roll forces and thus provide roll stability for the vehicle. This is typically accomplished by using beam 18, which is rigid, and is rigidly attached to axle 32. It is also desirable, however, for axle/suspension system 10 to be flexible to assist in cushioning the vehicle (not shown) from vertical impacts and to provide compliance so that the axle/suspension system resists failure. Such flexibility typically is achieved through the pivotal connection of beam 18 to hanger 16 with bushing assembly 22. Air spring 24 cushions the ride for cargo and passengers while shock absorber 40 controls the ride for cargo and passengers.

[0050] Prior art air spring 24 described above, has very limited or no damping capabilities because its structure, as described above, does not provide for the same. Instead, prior art air spring 24 relies on shock absorber 40 to provide damping to axle/suspension system 10. Because shock absorber 40 is relatively heavy, this adds weight to axle/suspension system 10 and therefore reduces the amount of cargo that can be carried by the heavy-duty vehicle. Shock absorbers 40 also add complexity to axle/suspension system 10. Moreover, because shock absorbers 40 are a service item of axle/suspension system 10 that will require maintenance and/or replacement from time to time, they also add additional maintenance and/or replacement costs to the axle/suspension system.

[0051] A prior art air spring with damping features is shown in FIG. 2 at reference numeral 124. Like prior art air spring 24, prior art air spring 124 is incorporated into an axle/suspension system similar to axle/suspension system 10, or other similar air-ride axle/suspension system, but without shock absorbers. Air spring 124 includes a bellows 141 and a piston 142. The top end of bellows 141 is sealingly engaged with a bellows top plate 143 in a manner well known in the art. An air spring mounting plate (not shown) is mounted on the top surface of top plate 143 by a fastener 147 which is also used to mount the top portion of air spring 124 to a respective one of the main members (not shown) of the vehicle. Alternatively, bellows top plate 143 could also be mounted directly on a respective one of the main members (not show) of the vehicle. Piston 142 is generally cylindrical-shaped and includes a continuous generally stepped sidewall 144 attached to a generally flat bottom plate 150, and includes a top plate 182. Bottom plate 150 is formed with an upwardly extending central hub 152. Central hub 152 includes a bottom plate 154 formed with a central opening 153. A fastener 151 is disposed through opening 153 in order to attach piston 142 to the beam top plate (not shown) at beam rear end (not shown).

[0052] Top plate 182, sidewall 144 and bottom plate 150 of piston 142 define a piston chamber 199 having an interior volume V.sub.1. Top plate 182 of piston 142 is formed with a circular upwardly extending protrusion 183 having a lip 180 around its circumference. Lip 180 cooperates with the lowermost end of bellows 141 to form an airtight seal between the bellows and the lip, as is well known to those of ordinary skill in the art. Bellows 141, top plate 143 and piston top plate 182 define a bellows chamber 198 having an interior volume V.sub.2 at standard static ride height. A bumper 181 is rigidly attached to a bumper mounting plate 186 by means generally well known in the art. Bumper mounting plate 186 is in turn mounted on piston top plate 182 by a fastener 184. Bumper 181 extends upwardly from the top surface of bumper mounting plate 186. Bumper 181 serves as a cushion between piston top plate 182 and bellows top plate 143 in order to keep the plates from contacting one another during operation of the vehicle, which can potentially cause damage to the plates and air spring 124.

[0053] Piston top plate 182 is formed with a pair of openings 185, which allow volume V.sub.1 of piston chamber 199 and volume V.sub.2 of bellows chamber 198 to communicate with one another. More particularly, openings 185 allow fluid or air to pass between piston chamber 199 and bellows chamber 198 during operating of the vehicle. Openings 185 are circular shaped.

[0054] The ratio of the cross-sectional area of openings 185 measured in in..sup.2 to the volume of piston chamber 199 measured in in..sup.3 to the volume of bellows chamber 198 measured in in..sup.3 is in the range of ratios of from about 1:600:1200 to about 1:14100:23500. The range of ratios set forth above is an inclusive range of ratios that could be alternatively expressed as 1:600-14100:1200-23500, including any combination of ratios in between, and, for example, would necessarily include the following ratios: 1:600:23500 and 1:14100:1200.

[0055] By way of example, air spring 124 for axle/suspension system 10 for a heavy-duty trailer having an axle GAWR of about 20,000 lbs., utilizes bellows chamber 198 having volume V.sub.2 equal to about 485 in..sup.3, piston chamber 199 having volume V.sub.1 of about 240 in..sup.3, and openings 185 having a combined cross-sectional area of about 0.06 in..sup.2.

[0056] Having now described the structure of air spring 124, the operation of the damping characteristics of the air spring will be described in detail below. When axle 32 of axle/suspension system 10 experiences a jounce event, such as when the vehicle wheels encounters a curb or a raised bump in the road, the axle moves vertically upwardly toward the vehicle chassis. In such a jounce event, bellows chamber 198 is compressed by axle/suspension system 10 as the wheels of the vehicle travel over the curb or the raised bump in the road. The compression of air spring bellows chamber 198 causes the internal pressure of the bellows chamber to increase. As a result, a pressure differential is created between bellows chamber 198 and piston chamber 199. This pressure differential causes air to flow from bellows chamber 198, through piston top plate openings 185 and into piston chamber 199. The restricted flow of air between bellows chamber 198 into piston chamber 199 through piston top plate openings 185 causes damping to occur. As an additional result of the airflow through openings 185, the pressure differential between bellows chamber 198 and piston chamber 199 is reduced. Air continues to flow through piston top plate openings 185 until the pressures of piston chamber 199 and bellows chamber 198 have equalized.

[0057] Conversely, when axle 32 of axle/suspension system 10 experiences a rebound event, such as when the vehicle wheels encounter a large hole or depression in the road, the axle moves vertically downwardly away from the vehicle chassis. In such a rebound event, bellows chamber 198 is expanded by axle/suspension system 10 as the wheels of the vehicle travel into the hole or depression in the road. The expansion of air spring bellows chamber 198 causes the internal pressure of the bellows chamber to decrease. As a result, a pressure differential is created between bellows chamber 198 and piston chamber 199. This pressure differential causes air to flow from piston chamber 199 through piston top plate openings 185, and into bellows chamber 198. The restricted flow of air between piston chamber 199 into bellows chamber 198 through piston top plate openings 185 causes damping to occur. As an additional result of the airflow through openings 185, the pressure differential between the bellows chamber 198 and piston chamber 199 is reduced. Air will continue to flow through the piston top plate openings 185 until the pressures of piston chamber 199 and bellows chamber 198 have equalized. When little or no suspension movement has occurred over a period of several seconds the pressure of bellows chamber 198 and piston chamber 199 can be considered equal.

[0058] As described above, volume V.sub.1 of piston chamber 199, volume V.sub.2 of bellows chamber 198, along with the cross-sectional area of openings 185, all in relation to one another, provide application-specific damping characteristics, at standard temperature and pressure, to air spring 124 during operation of the vehicle.

[0059] Prior art air spring 124 with damping characteristics, although satisfactorily performing its intended damping function, has certain constraints due to its structural make-up. First, because prior art air spring 124 includes openings having a fixed size located directly between the bellows chamber and the piston chamber, the damping range of the air spring is typically limited to a particular load or wheel motion. Such constraints on the damping range of prior art air spring 124 limit the ability to “tune” the damping for a given application. Second, prior art air spring 124 with damping characteristics typically provides maximum damping that is frequency dependent. This means that the maximum damping provided by air spring 124 at a frequency of 1 Hz is greatly reduced at a frequency of 10 Hz. Third, prior art air spring 124 with damping features typically requires a relatively large air volume. This large air volume requirement in turn increases the amount of space required by the axle/suspension system, which typically is not desirable in the heavy-duty vehicle industry, because increasing the amount of space required by the axle/suspension system increases weight and reduces the room allowed for payload, with the result being that less payload can be carried by the vehicle.

[0060] The damping air spring with dynamically variable orifice of the present invention overcomes the deficiencies of prior art non-damping and damping air springs 24,124 described above, and will now be described in detail below.

[0061] A first exemplary embodiment damping air spring with dynamically variable orifice of the present invention is shown in FIGS. 3-10 at reference numeral 224 and will now be described in detail below.

[0062] Like prior art air springs 24 and 124, air spring 224 of the present invention is incorporated into an axle/suspension system having a structure similar to axle/suspension system 10, or other air-ride axle/suspension system, but typically without shock absorbers. With particular reference to FIGS. 3 and 7, air spring 224 includes a bellows 241, a bellows top plate 243, and a piston 242. Top plate 243 includes a pair of fasteners 245 (only one shown), each formed with an opening 246. Fasteners 245 are utilized to mount air spring 224 to an air spring plate (not shown), that in turn is mounted to the main member of the vehicle (not shown). Piston 242 is generally cylindrical-shaped and includes a sidewall 244, a flared portion 247, and a top plate 282.

[0063] With continuing reference to FIGS. 3 and 7, a bumper (not shown) is disposed on a top surface of a retaining plate 286. The bumper (not shown) is formed from rubber, plastic or other compliant material and extends generally upwardly from retaining plate 286 mounted on piston top plate 282. Retaining plate 286 and piston top plate 282 are each formed with an aligned opening 260, 264, respectively. A fastener (not shown), such as a bolt, is disposed through an opening formed in the bumper (not shown), retaining plate opening 260, and piston top plate opening 264. The bumper (not shown) and retaining plate 286 are mounted on the top surface of piston top plate 282 by the fastener (not shown). The bumper (not shown) serves as a cushion between piston top plate 282 and the underside of bellows top plate 243 in order to prevent the plates from damaging one another during operation of the vehicle. Retaining plate 286 includes a flared end 280 that is molded into the lower end of bellows 241, which holds the bellows in place on piston 242 and forms an airtight seal between the bellows and the piston. It should be understood that flared end 280 of retaining plate 286 could also be separate from the lower end of bellows 241. In such an arrangement, separate flared end 280 captures and holds the lower end of bellows 241 in place on piston 242 to form an airtight seal between the bellows and the piston, without changing the overall concept or operation of the present invention. Bellows 241, retaining plate 286, and bellows top plate 243 generally define a bellows chamber 298 having an interior volume V.sub.2 at standard ride height. Bellows chamber 298 preferably has a volume of from about 305 in..sup.3 to about 915 in..sup.3.

[0064] A generally circular disc 270 is attached or mated to the bottom of piston 242 of first exemplary embodiment damping air spring 224 of the present invention. Circular disc 270 is formed with an opening (not shown) for fastening piston 242 to beam rear end top plate 65 (FIG. 1) directly or utilizing a beam mounting pedestal (not shown) in order to attach piston 242 of air spring 224 to beam 18 (FIG. 1). Once attached, a top surface 289 of circular disc 270 is mated to a lower surface 287 of piston sidewall 244 to provide an airtight seal between the circular disc and piston 242. Circular disc 270 is formed with a continuous raised lip 278 on its top surface along the periphery of the circular disc, with the continuous raised lip being disposed generally between flared portion 247 and sidewall 244 of piston 242 when the circular disc is mated to the piston. The attachment of circular disc 270 to piston 242 may be accomplished via fastening means such as a threaded fastener, other types of fasteners or the like. Optionally, the attachment of circular disc 270 to piston 242 may be supplemented by additional attachment means such as welding, soldering, crimping, friction welding, an O-ring, a gasket, adhesive or the like. Circular disc 270 may be composed of metal, plastic, and/or composite material, or other materials known to those skilled in the art, without changing the overall concept or operation of the present invention. Circular disc 270 may optionally include a groove (not shown) formed in top surface 289 disposed circumferentially around the circular disc, and configured to mate with a downwardly extending hub (not shown) of piston 242 in order to reinforce the connection of the disc to the bottom of the piston. An O-ring or gasket material could optionally be disposed in the groove to ensure an airtight fit of circular disc 270 to piston 242. Once circular disc 270 is attached to piston 242, top plate 282, sidewall 244, and the circular disc define a piston chamber 299 having an interior volume V.sub.1. Piston chamber 299 is generally able to withstand the required burst pressure of axle/suspension system 10 (FIG. 1) during vehicle operation. Piston chamber 299 preferably has a volume of from about 150 in..sup.3 to about 550 in..sup.3.

[0065] Turning now to FIGS. 4-6 and 8-10 and in accordance with one of the primary features of the present invention, an opening 274 is formed in retaining plate 286 and a generally aligned opening 275 is formed in top plate 282 of piston 242. A dynamically variable orifice assembly 230 is disposed generally in retaining plate opening 274. More specifically, dynamically variable orifice assembly 230 includes a ring-shaped mounting plate 232 that is formed with a plurality of openings 234, spaced circumferentially around the top surface of the mounting plate. An inflatable bladder 236 including an outwardly extending bracket 238 is disposed within retaining plate opening 274. It should be understood that bladder 236 has a horizontal cross section with a generally circular or ring-shape but may have other shapes without changing the overall concept or operation of the present invention. Mounting plate 232 is mounted over retaining plate opening 274 and outwardly extending bracket 238 and fixed to retaining plate 286 by disposing each of a plurality of fasteners (not shown) into respective ones of openings 234. In this manner, mounting plate 232 securely fastens inflatable bladder 236 within retaining plate opening 274. A conduit 231 formed in inflatable bladder bracket 238 provides fluid communication between inflatable bladder 236 and an air supply (not shown).

[0066] A control module 235 is operatively connected to inflatable bladder 236 and/or conduit 231, such that inflatable bladder 236 is either inflated to reduce the size of a bladder opening 233 or deflated to increase the size of the bladder opening during operation. Bladder opening 233 has a horizontal cross section with a generally circular shape but may have other shapes including oval, elliptical, polygonal or other shapes without changing the overall concept or operation of the present invention. Control module 235 could be an electronic type device such as a microprocessor that is operatively connected to one or more sensors that are positioned on the vehicle in order to monitor certain conditions of the vehicle during operation, such that in response to a selected condition, inflatable bladder 236 inflates or deflates in order to reduce or increase the size of bladder opening 233. In addition, control module 235 could be a mechanical type device, such as a valve with an arm or other mechanical feature that responds to a selected condition of the vehicle during operation, so that in response to a condition, inflatable bladder 236 inflates or deflates in order to reduce or increase the size of bladder opening 233 during operation. For example, control module 235 could monitor air spring pressure within the air spring itself, air pressure within the entire air system of the vehicle, or the like. Control module 235 could also monitor the vehicle's lateral acceleration or roll acceleration. The inflation or deflation of bladder 236 to increase or reduce the size of opening 233 promotes optimized damping in air spring 224 (FIGS. 3 and 7).

[0067] Having now described the overall structure of first exemplary embodiment damping air spring with dynamically variable orifice 224 of the present invention, the operation of the damping air spring will now be described in detail below.

[0068] More specifically, when axle 32 (FIG. 1) of axle/suspension system 10 (FIG. 1), having been alternatively configured with air spring 224 of the present invention, experiences a jounce event, such as when the vehicle wheels encounter a curb or a raised bump in the road, the axle moves vertically upwardly toward the vehicle chassis. In such a jounce event, bellows chamber 298 is compressed by axle/suspension system 10 as the wheels of the vehicle travel over the curb or the raised bump in the road. The compression of air spring bellows chamber 298 causes the internal pressure of the bellows chamber to increase. As a result, a pressure differential is created between bellows chamber 298 and piston chamber 299. This pressure differential causes air to flow from bellows chamber 298, through bladder opening 233 into piston chamber 299. The restricted flow of air, between bellows chamber 298 and piston chamber 299 through bladder opening 233, causes damping to occur. As an additional result of the airflow through bladder opening 233, the pressure differential between bellows chamber 298 and piston chamber 299 is reduced. Air will continue to flow back and forth between piston chamber 299 and bellows chamber 298 through bladder opening 233 until the pressures in the piston chamber and the bellows chamber have equalized or pressure equilibrium has been reached between the piston and bellows chambers.

[0069] Conversely, when axle 32 (FIG. 1) of axle/suspension system 10 (FIG. 1), having been alternatively configured with air spring 224 of the present invention, experiences a rebound event, such as when the vehicle wheels encounter a large hole or depression in the road, the axle moves vertically downwardly away from the vehicle chassis. In such a rebound event, bellows chamber 298 is expanded by axle/suspension system 10 as the wheels of the vehicle travel into the hole or depression in the road. The expansion of air spring bellows chamber 298 causes the internal pressure of the bellows chamber to decrease. As a result, a pressure differential is created between bellows chamber 298 and piston chamber 299. This pressure differential causes air to flow from piston chamber 299, through bladder opening 233 into bellows chamber 298. The restricted flow of air, between piston chamber 299 and bellows chamber 298 through bladder opening 233, causes damping to occur. As an additional result of the airflow through bladder opening 233, the pressure differential between bellows chamber 298 and piston chamber 299 is reduced. Air will continue to flow back and forth between bellows chamber 298 and piston chamber 299 through bladder opening 233 until the pressures in the piston chamber and the bellows chamber have equalized or pressure equilibrium has been reached between the piston and bellows chambers.

[0070] In addition, when a selected condition is sensed by control module 235, such as a decreased system air pressure, indicating that the load of the vehicle is relatively small, the control module can inflate bladder 236 by supplying air to conduit 231. Inflated bladder 236 reduces the size of bladder opening 233 and in turn provides reduced airflow between piston chamber 299 and bellows chamber 298 during operation of the vehicle in order to promote optimized damping of air spring 224.

[0071] Conversely, when a different condition is sensed by control module 235, such as an increased system air pressure, indicating that the load of the vehicle is relatively large, the control module can deflate bladder 236 by exhausting air from conduit 231. The deflation of bladder 236 increases the size of bladder opening 233 and in turn provides increased airflow between piston chamber 299 and bellows chamber 298 during operation of the vehicle in order to promote optimized damping of air spring 224.

[0072] The dynamically variable orifice of first exemplary embodiment damping air spring 224 of the present invention promotes optimized damping of the air spring in response to a sensed condition of the vehicle. The sensed condition, as set forth above, can be the pressure in the air spring, the pressure in a particular chamber of the air spring, or even the overall pressure of the air system outside of the air spring, or other such condition or the like. In addition, the condition could also be one that corresponds to increased weight of the vehicle such as the vertical height of a component mounted on the vehicle in relation to a component mounted on the axle/suspension system of the vehicle, for example, a height control valve. The condition could also be one that corresponds to increased lateral acceleration or roll acceleration.

[0073] First exemplary embodiment damping air spring 224 with dynamically variable orifice of the present invention overcomes the problems associated with prior art air spring 24 by eliminating the need for shock absorbers or allowing for the utilization of reduced size shock absorbers, thereby reducing complexity, saving weight and cost, and allowing the heavy-duty vehicle to haul more cargo. Moreover, elimination of the shock absorbers potentially eliminates costly repairs and/or maintenance costs associated with these systems.

[0074] First exemplary embodiment damping air spring 224 with dynamically variable orifice of the present invention also overcomes the problems associated with prior art air spring 124 with damping features. By providing a dynamically variable orifice between the bellows chamber and the piston chamber, air spring 224 provides better airflow control, resulting in optimization of the damping characteristics of the air spring. First exemplary embodiment damping air spring 224 with dynamically variable orifice of the present invention provides damping features to the axle/suspension system over a broader damping range to accommodate a broader range of loads and wheel motions, thereby expanding the operating range of the damping air spring. In addition, first exemplary embodiment damping air spring 224 of the present invention reduces or eliminates frequency dependence. Moreover, first exemplary embodiment damping air spring 224 of the present invention reduces the need for larger air volumes to increase damping characteristics, which in turn reduces the amount of space required by the axle/suspension system and allows more room and weight for payload or cargo. In addition, first exemplary embodiment damping air spring 224 of the present invention increases the ability to tune the damping provided by the air spring for different applications over a broader range of frequencies, for example, by varying the opening size between piston chamber 299 and bellows chamber 298 based upon conditions of the vehicle that provides optimized damping over a broad range of frequencies.

[0075] A second exemplary embodiment damping air spring with dynamically variable orifice of the present invention is shown in FIGS. 11-18 at reference numeral 324 and will now be described in detail below.

[0076] Like prior art air springs 24 and 124, second exemplary embodiment air spring 324 of the present invention is incorporated into an axle/suspension system having a structure similar to axle/suspension system 10, or other air-ride axle/suspension system, but typically without shock absorbers. With particular reference to FIGS. 11 and 15, air spring 324 includes a bellows 341, a bellows top plate 343, and a piston 342. Top plate 343 includes a pair of fasteners 345 (only one shown), each formed with an opening 346. Fasteners 345 are utilized to mount air spring 324 to an air spring plate (not shown), that in turn is mounted to the main member of the vehicle (not shown). Piston 342 is generally cylindrical-shaped and includes a sidewall 344, a flared portion 347, and a top plate 382.

[0077] With continuing reference to FIGS. 11 and 15, a bumper (not shown) is disposed on a top surface of a retaining plate 386. The bumper (not shown) is formed from rubber, plastic or other compliant material and extends generally upwardly from retaining plate 386 mounted on piston top plate 382. Retaining plate 386 and piston top plate 382 are each formed with an aligned opening 360,364, respectively. A fastener (not shown), such as a bolt, is disposed through an opening formed in the bumper (not shown), retaining plate opening 360, and piston top plate opening 364. The bumper (not shown) and retaining plate 386 are mounted on the top surface of piston top plate 382 by the fastener (not shown). The bumper (not shown) serves as a cushion between piston top plate 382 and the underside of bellows top plate 343 in order to prevent the plates from damaging one another during operation of the vehicle. Retaining plate 386 includes a flared end 380 that is molded into the lower end of bellows 341, which holds the bellows in place on piston 342 and forms an airtight seal between the bellows and the piston. It should be understood that flared end 380 of retaining plate 386 could also be separate from the lower end of bellows 341. In such an arrangement, separate flared end 380 captures and holds the lower end of bellows 341 in place on piston 342 to form an airtight seal between the bellows and the piston, without changing the overall concept or operation of the present invention. Bellows 341, retaining plate 386, and bellows top plate 343 generally define a bellows chamber 398 having an interior volume V.sub.2 at standard ride height. Bellows chamber 398 preferably has a volume of from about 305 in..sup.3 to about 915 in..sup.3.

[0078] A generally circular disc 370 is attached or mated to the bottom of piston 342 of second exemplary embodiment damping air spring 324 of the present invention. Circular disc 370 is formed with an opening (not shown) for fastening piston 342 to beam rear end top plate 65 (FIG. 1) directly or utilizing a beam mounting pedestal (not shown) in order to attach piston 342 of air spring 324 to beam 18 (FIG. 1). Once attached, a top surface 389 of circular disc 370 is mated to a lower surface 387 of piston sidewall 344 to provide an airtight seal between the circular disc and piston 342. Circular disc 370 is formed with a continuous raised lip 378 on its top surface along the periphery of the circular disc, with the lip being disposed generally between flared portion 347 and sidewall 344 of piston 342 when the circular disc is mated to the piston. The attachment of circular disc 370 to piston 342 may be accomplished via fastening means such as a threaded fastener, other types of fasteners or the like. Optionally, the attachment of circular disc 370 to piston 342 may be supplemented by additional attachment means such as welding, soldering, crimping, friction welding, an O-ring, a gasket, adhesive or the like. Circular disc 370 may be composed of metal, plastic, and/or composite material, or other materials known to those skilled in the art, without changing the overall concept or operation of the present invention. Circular disc 370 may optionally include a groove (not shown) formed in top surface 389 disposed circumferentially around the circular disc, and configured to mate with a downwardly extending hub (not shown) of piston 342 in order to reinforce the connection of the circular disc to the bottom of the piston. An O-ring or gasket material could optionally be disposed in the groove to ensure an airtight fit of circular disc 370 to piston 342. Once circular disc 370 is attached to piston 342, top plate 382, sidewall 344, and the circular disc, define a piston chamber 399 having an interior volume V.sub.1. Piston chamber 399 is generally able to withstand the required burst pressure of axle/suspension system 10 (FIG. 1) during vehicle operation. Piston chamber 399 preferably has a volume of from about 150 in..sup.3 to about 550 in..sup.3.

[0079] Turning now to FIGS. 12-14 and 16-18 and in accordance with one of the primary features of the present invention, an opening 374 is formed in retaining plate 386 and a generally aligned opening 375 is formed in top plate 382 of piston 342. A dynamically variable orifice assembly 330 is disposed generally in retaining plate opening 374. More specifically, dynamically variable orifice assembly 330 includes a ring-shaped mounting plate 332 that is formed with a plurality of openings 334, spaced circumferentially around the top surface of the mounting plate. A mechanical iris 336 including an outwardly extending actuator 338 is disposed within retaining plate opening 374. Mounting plate 332 is mounted over retaining plate opening 374 and outwardly extending actuator 338 and fixed to retaining plate 386 by disposing each of a plurality of fasteners (not shown) into respective ones of openings 334. In this manner, mounting plate 332 securely fastens mechanical iris 336 within retaining plate opening 374.

[0080] A control module 335 is operatively connected to actuator 338, such that mechanical iris 336 is either closed to reduce the size of an iris opening 333, or opened to increase the size of the iris opening during operation. Control module 335 could be an electronic type device such as a microprocessor that is operatively connected to one or more sensors that are positioned on the vehicle in order to monitor certain selected conditions of the vehicle during operation, such that in response to a condition, mechanical iris 336 opens or closes in order to reduce or increase the size of opening 333. In addition, control module 335 could be a mechanical type device, such as a valve with an arm or other mechanical feature that responds to a selected condition of the vehicle during operation, so that in response to a given condition, mechanical iris 336 opens or closes in order to increase or reduce the size of opening 333 during operation. For example, control module 335 could monitor air spring pressure within the air spring itself, air pressure within the entire air system of the vehicle, or the like. Control module 335 could also monitor the vehicle's lateral acceleration or roll acceleration and then open or close mechanical iris 336 based on that condition. The closing or opening of mechanical iris 336 to reduce or increase the size of opening 333 promotes optimized damping in air spring 324 (FIGS. 11 and 15).

[0081] Having now described the overall structure of second exemplary embodiment damping air spring 324 with dynamically variable orifice of the present invention, the operation of the damping air spring will now be described in detail below.

[0082] More specifically, when axle 32 (FIG. 1) of axle/suspension system 10 (FIG. 1), having been alternatively configured with second exemplary embodiment air spring 324 of the present invention, experiences a jounce event, such as when the vehicle wheels encounter a curb or a raised bump in the road, the axle moves vertically upwardly toward the vehicle chassis. In such a jounce event, bellows chamber 398 is compressed by axle/suspension system 10 as the wheels of the vehicle travel over the curb or the raised bump in the road. The compression of air spring bellows chamber 398 causes the internal pressure of the bellows chamber to increase. As a result, a pressure differential is created between bellows chamber 398 and piston chamber 399. This pressure differential causes air to flow from bellows chamber 398, through iris opening 333 into piston chamber 399. The restricted flow of air, between bellows chamber 398 and piston chamber 399 through iris opening 333, causes damping to occur. As an additional result of the airflow through iris opening 333, the pressure differential between bellows chamber 398 and piston chamber 399 is reduced. Air will continue to flow back and forth between piston chamber 399 and bellows chamber 398 through iris opening 333 until the pressures in the piston chamber and the bellows chamber have equalized or pressure equilibrium has been reached between the piston and bellows chambers.

[0083] Conversely, when axle 32 (FIG. 1) of axle/suspension system 10 (FIG. 1), having been alternatively configured with second exemplary embodiment air spring 324 of the present invention, experiences a rebound event, such as when the vehicle wheels encounter a large hole or depression in the road, the axle moves vertically downwardly away from the vehicle chassis. In such a rebound event, bellows chamber 398 is expanded by axle/suspension system 10 as the wheels of the vehicle travel into the hole or depression in the road. The expansion of air spring bellows chamber 398 causes the internal pressure of the bellows chamber to decrease. As a result, a pressure differential is created between bellows chamber 398 and piston chamber 399. This pressure differential causes air to flow from piston chamber 399, through iris opening 333 into bellows chamber 398. The restricted flow of air, between piston chamber 399 and bellows chamber 398 through iris opening 333, causes damping to occur. As an additional result of the airflow through iris opening 333, the pressure differential between bellows chamber 398 and piston chamber 399 is reduced. Air will continue to flow back and forth between bellows chamber 398 and piston chamber 399 through iris opening 333 until the pressures in the piston chamber and the bellows chamber have equalized or pressure equilibrium has been reached between the piston and bellows chambers.

[0084] In addition, when a particular condition is sensed by control module 335, such as a decreased system air pressure, indicating that the load of the vehicle is relatively small, the control module can move actuator 338 of iris 336 in order to close the iris. Closed iris 336 reduces the size of iris opening 333 and in turn provides reduced airflow between piston chamber 399 and bellows chamber 398 during operation of the vehicle in order to promote optimized damping of air spring 324.

[0085] Conversely, when a particular condition is sensed by control module 335, such as an increased system air pressure, indicating that the load of the vehicle is relatively large, the control module can move actuator 338 of iris 336 in order to further open the iris. This increases the size of iris opening 333 and in turn provides increased airflow between piston chamber 399 and bellows chamber 398 during operation of the vehicle in order to promote optimized damping of air spring 324.

[0086] The dynamically variable orifice of second exemplary embodiment damping air spring 324 of the present invention promotes optimized damping of the air spring in response to a sensed condition of the vehicle. The sensed condition, as set forth above, can be the pressure in the air spring, the pressure in a particular chamber of the air spring, or even the overall pressure of the air system outside of the air spring, or other such condition. In addition, the condition could also be one that corresponds to increased weight of the vehicle such as the vertical height of a component mounted on the vehicle in relation to a component mounted on the axle/suspension system of the vehicle, for example, a height control valve. The condition could also be one that corresponds to increased lateral acceleration or roll acceleration.

[0087] Second exemplary embodiment damping air spring 324 with dynamically variable orifice of the present invention overcomes the problems associated with prior art air spring 24 by eliminating the need for shock absorbers or allowing for the utilization of reduced size shock absorbers, thereby reducing complexity, saving weight and cost, and allowing the heavy-duty vehicle to haul more cargo. Moreover, elimination of the shock absorbers potentially eliminates costly repair's and/or maintenance costs associated with these systems.

[0088] Second exemplary embodiment damping air spring 324 with dynamically variable orifice of the present invention also overcomes the problems associated with prior art air spring 124 with damping features. By providing a dynamically variable orifice between the bellows chamber and the piston chamber, air spring 324 provides better airflow control, resulting in optimization of the damping characteristics of the air spring. Second exemplary embodiment damping air spring 324 with dynamically variable orifice of the present invention provides damping features to the axle/suspension system over a broader damping range to accommodate a broader range of loads and wheel motions, thereby expanding the operating range of the damping air spring. In addition, second exemplary embodiment damping air spring 324 of the present invention reduces or eliminates frequency dependence. Moreover, second exemplary embodiment damping air spring 324 of the present invention reduces the need for larger air volumes to increase damping characteristics, which in turn reduces the amount of space required by the axle/suspension system and allows more room and weight for payload or cargo. In addition, second exemplary embodiment damping air spring 324 of the present invention increases the ability to tune the damping provided by the air spring for different applications over a broader range of frequencies, for example, by varying the opening size between piston chamber 399 and bellows chamber 398 based upon conditions of the vehicle that provides optimized damping over a broader range of frequencies.

[0089] It is contemplated that exemplary embodiment air springs 224,324 of the present invention could be utilized on tractor-trailers or heavy-duty vehicles, such as buses, trucks, trailers and the like, having one or more than one axle without changing the overall concept or operation of the present invention. It is further contemplated that exemplary embodiment air springs 224,324 of the present invention could be utilized on vehicles having frames or subframes which are moveable or non-movable without changing the overall concept or operation of the present invention. It is yet even further contemplated that exemplary embodiment air springs 224,324 of the present invention could be utilized on all types of air-ride leading and/or trailing arm beam-type axle/suspension system designs known to those skilled in the art without changing the overall concept or operation of the present invention. It is also contemplated that exemplary embodiment air springs 224,324 of the present invention could be utilized on axle/suspension systems having an overslung/top-mount configuration or an underslung/bottom-mount configuration, without changing the overall concept or operation of the present invention. It is also contemplated that exemplary embodiment air springs 224,324 of the present invention could be utilized in conjunction with other types of air-ride rigid beam-type axle/suspension systems such as those using U-bolts, U-bolt brackets/axle seats and the like, without changing the overall concept or operation of the present invention. It is further contemplated that exemplary embodiment air springs 224,324 of the present invention could be formed from various materials, including composites, metal and the like, without changing the overall concept or operation of the present invention. It is even contemplated that exemplary embodiment air springs 224,324 could be utilized in combination with prior art shock absorbers and other similar devices and the like, without changing the overall concept or operation of the present invention.

[0090] It is contemplated that discs 270,370 may be attached to pistons 242,342, respectively, utilizing other attachments such as soldering, coating, crimping, welding, snapping, screwing, O-ring, sonic, glue, press, melting, expandable sealant, press-fit, bolt, latch, spring, bond, laminate, tape, tack, adhesive, shrink fit, and/or any combination listed without changing the overall concept or operation of the present invention. It is even contemplated that discs 270,370 may be composed of materials known by those in the art other than metal, plastic, and/or composite material without changing the overall concept or operation of the present invention.

[0091] It is contemplated that orifice assembly 230,330 could be disposed within bellows retaining plate 286,386, respectively, as described and shown above, or they could be located within piston top plate 282,382, respectively, or outside of the air spring and connected to the bellows chamber and the piston chamber via conduits, without changing the overall concept or operation of the present invention. It is contemplated that an inflatable bladder 236 or a mechanical iris 336 could be generally ring-shaped, as described and shown above, or they could be any suitable shape without changing the overall concept or operation of the present invention.

[0092] It is contemplated that generally aligned openings 274,275 of first exemplary embodiment 224, and generally aligned openings 374, 375 of second exemplary embodiment 324, respectively, could be formed in a different location within retaining plates 286,386 and top plates 282,382 of pistons 242,342, respectively, and relative to openings 260,360, respectively, without changing the overall concept or operation of the present invention. It is further contemplated that any number of openings may be formed in retaining plates 286,386 and top plates 282,382, of pistons 242,342, respectively, such as multiple small openings which would include multiple orifice assemblies 230,330, without changing the overall concept or operation of the present invention.

[0093] It is contemplated that the concepts shown in exemplary embodiment air springs 224,324 of the present invention could be utilized in any type of air spring utilized in conjunction with heavy-duty vehicles, without changing the overall concept or operation of the present invention. It is also contemplated that exemplary embodiment air spring 224,324 of the present invention could incorporate any type of piston that forms a closed chamber, without changing the overall concept or operation of the present invention. It is even further contemplated that exemplary embodiment air springs 224,324 of the present invention could incorporate a remote air tank in place of piston chambers 299,399, without changing the overall concept or operation of the present invention.

[0094] In the foregoing description, certain terms have been used for brevity, clearness, and understanding, but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and intended to be broadly construed.

[0095] The present invention has been described with reference to specific embodiments. It is to be understood that this illustration is by way of example and not by way of limitation. Potential modifications and alterations will occur to others upon a reading and understanding of this disclosure, and it is understood that the invention includes all such modifications, alterations, and equivalents thereof.

[0096] Accordingly, the damping air spring with dynamically variable orifice of the present invention is simplified, provides an effective, safe, inexpensive and efficient structure and method which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior art air springs with or without damping characteristics, and solves problems and obtains new results in the art.

[0097] Having now described the features, discoveries and principles of the invention, the manner in which the damping air spring with dynamically variable orifice is used and installed, the characteristics of the construction, arrangement and method steps, and the advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, process, parts and combinations are set forth in the appended claims.