1、空气弹簧Air Spring发展 Development. 空气弹簧结构Air Spring Construction. 空气弹簧开发程序Air Spring Development Process. 空气弹簧应用Air Spring Application. 产品验证及产品生产控制Product validation and production controlResearch Facilities. 研究设施 研究中心 Central Research Meichen. Meichen 先进材料开发 Advanced Material Development. 产品和材料分析 Produc
2、t & Material Analysis. 环境试验能力 Environmental Test Capability. 先进生产技术评 Advanced Manufacturing Evaluations.空气弹簧系列The Air Spring Family.空气弹簧结构Air Spring Construction空气弹簧结构：概述Air Spring Construction: General我公司双层线网气囊的组成部分 ：Our Standard Two ply construction is actually made up of :a. 混练橡胶内衬 An inner liner
3、 of calendared rubber. b. 相互成一定斜角的两层加强线网Two plys of fabric reinforced rubber, with specific bias to one another. c. 混练橡胶外覆盖层 An outer cover of calendared rubber. 空气弹簧零件Air Spring Components.1T 型空气弹簧总成1T Style Assembly1安装螺柱 Mounting Stud2组合螺柱 Combo Stud5缘板 Bead Plate6柔性元件（气囊）Flex Member (Bellows)7缓冲垫
4、 Bumper 8活塞 Piston9活塞螺钉 Piston Bolt空气弹簧零件Air Spring Components.回转曲面型空气弹簧总成Convoluted Assembly1安装螺柱 Mounting Stud2组合螺柱 Combo Stud3暗螺母 Blind Nut4空气入口 Air Inlet5缘板 Bead Plate6柔性元件（气囊）Flex Member (Bellows)10环箍Girdle Hoop空气弹簧配料Air Spring Compounds当前天然橡胶配料Current Natural Rubber Compound 工作温度范围Temperature
5、Range -55 f to 135f. 长期实践证明的有效配料 Time Proven compound. 新型重载天然橡胶(New) Heavy Duty Natural Rubber 工作温度范围Temperature Range -65 f to 135f. 极佳抗臭氧性能 Excellent Ozone Resistance. 空气弹簧低温性能很好Great Low temperature Air Spring Performance. 聚氯丁橡胶 Neoprene Rubber 工作温度范围Temperature Range -40 f to 180f. 整形寿命循环性能极佳 Ex
6、cellent cosmetic life cycle performance. 空气弹簧高温性能很好Great high temperature Air Spring performance.空气弹簧零件Air Spring Components.盖板Bead Plates9 号(.149”厚)碳钢板,镀防锈层,96小时喷盐试验不产生红色锈蚀.永久性地与柔性元件卷成一体以构成密封组件,使其在发运前可在工厂进行气密性试验. 不管缘板直径大小, 悬架或支架都应对其提供不小于80%的支承面积. 9 Gauge (.149”) carbon steel, plated for corrosion r
7、esistance to (96 hrs) with no red rust. Permanently crimped to the flex member to form an airtight assembly which allows for integrity testing before the unit leaves the factory. Regardless of bead plate diameter, 80% of support area should be provide from the suspension frame or bracket. 管接头和拧紧扭矩要求
8、Fittings & Torque Requirements. 盖板和管接头有我公司的控股厂家并按照我公司要求设备制造, 所以选择性很大, 可以冷镦或攻丝, 有英制和公制. 最常用型式为:Bead Plates and fittings are manufactured and managed by our Dyersburg facility, therefore most options area available if they can be cold headed or screw machined, in both imperial & metric. The most commo
9、n types are:(i)单安装螺柱,一般是1/2-13统一标准粗牙螺纹.Single Mounting Stud, usually ”-13 UNC. (ii)组合螺柱, 将3/4”-16统一标准细牙安装螺柱与1/4”锥管内螺纹空气入口组合在一起. Combination Stud, combination ”-16 UNF mounting stud with ” NPT internal air entrance. 拧紧扭矩要求清楚标明在固定于气囊缘板上的标牌上空气弹簧零件Air Spring Components.缓冲垫 Bumpers. 在系统无气压时防止损坏空气弹簧的内部缓冲装
10、置. 该材料有两种:An internal device to prevent damage to the Air Spring during times when no air is in the system. Two materials are available(i)天然橡胶根据变形系数设计可调节其弹性系数(刚度). 目前可提供许多种不同尺寸的缓冲垫. Natural Rubber - Adjustable rate based on shape factor design, currently available in many different sizes.(ii) TPE2/复
11、合材料高刚度小变形, 耐冲击性能极佳, 可作为刚性停挡使用, 即客车跪低头部等情况下使用. 与橡胶缓冲垫比较尺寸很小. TPE2 / Composite - High rate & low deflection, excellent impact resistance, works well as a positive stop, i.e. for knelling bus applications etc. minimal permanent set as compared to Rubber bumpers. Light weight alternative as compared to
12、rubber.密封端板End Closure. 钢材制造, 与柔性元件永久性地模铸在一起(1T19系列和扣紧组装型总成除外). 密封端板作为缓冲垫的安装界面并连接柔性元件与活塞. This is made of steel and is permanently molded to the flex member (except for the 1T19 Series and snap on assemblies). The end closure is used as the interface for holding the bumper and attached the flex memb
13、er to the piston.空气弹簧零件Air Spring Components.活塞材料 Piston Materials. 材料Material特性Feature钢Steel塑料Plastic铝Aluminum重量Weight. 最重Highest最轻Lowest中等ModerateInternal Volume.国内产量全部Full部分Particle部分Particle耐蚀性Corrosion Resistance. 400 Hrs400小时无限Infinite400 Hrs400小时年产量Annual Volume.低/ 中等Low / Moderate最高Highest中等
14、Moderate总成本/ 价格Cost Pcs/Price低/ 中等Low / Moderate最低Lowest中等Moderate模具成本Tooling Cost.最低Lowest最高Highest中等ModerateAir Spring Components.空气弹簧零件Piston Contour 活塞外形 Load Deflection Curve 载荷变形曲线 Comments 说明 Moderate Rate & Natural Frequency 中等刚度和中等自然频率 Constant Load Range Over Usable Stroke 可用行程内载荷不变 Low Ra
15、te & Natural Frequency 低刚度和低自然频率 Decreasing Load Range Over Usable Stroke 可用行程内载荷下降 Lowest Rate & Natural Frequency 最低刚度和最低自然频率 Constant Load Range Over Usable Stroke 可用行程内载荷不变 Highest Rate and Natural Frequency 最高刚度和最高自然频率 Lift Application Preferred 最好用于提升装置 空气弹簧开发程序Air Spring Development Process空气
16、弹簧开发程序Air Spring Development Process空气弹簧开发程序Air Spring Development Process通过EPCRN接收项目(设计输入) Project Received Via EPCRN (Design Input) 审查用户原始要求和当前工程规格(建立项目检查表) Review initial customer requirements and current engineering specification. (Establish Project Check List)通过有限单元分析建立设计理念,包括制造和要求的外部供货商 Establ
17、ish design concept via FEA, involving manufacturing & external suppliers were required.生成审批图纸(设计输出) APQP Via DFMEA & DVP&R. 设计审查阶段 Produce Proposal Drawings. (Design Output) Design Review Stage. 制造样机并进行性能试验Manufacture Prototypes & conduct performance testing. 设计审查(验证) Design Review (Verification). 样
18、机布置和发出 Prototype Layout & Release. 1、承载载荷；2、安装空间；3、空气弹簧行程。设计和研发能力设计所需主要参数：产品的结构设计有效面积计算公式：Ae=Ae=r1000wp2相关参数计算欧曼驾驶室悬置驾驶室悬置总成构成1、减振系统：空气弹簧、减振器；2、高度控制系统：高度阀；3、抗侧倾系统：稳定杆；4、锁止机构：正常工作时保证驾驶室与车架的连接；5、翻转机构：翻转驾驶室，便于发动机等部件的维修；6、限位机构，限制异常振动以及保证驾驶室的正常翻转；7、其他联结构件。空气弹簧的开发案例结构空气弹簧的开发案例结构长春一汽的J5车型的底盘空气弹簧底盘空气弹簧的透视图空
19、气弹簧应用Air Spring Application空气弹簧应用 载荷变形曲线Air Spring Application Load Deflection Curves空气弹簧应用 术语Air Spring Application TerminologyA 建议设计位置,静压力Recommended Design Position Static PressureB载荷, 高度和容积座标轴Load, Height & Volume AxesC缓冲垫接触Bumper ContactD最小高度Minimum HeightE最大回弹Maximum ReboundF设计位置Design Positio
20、nG等压曲线Constant Pressure CurveH内部容积曲线Internal Volume CurveI阴影区Shaded AreaJ试验请求号Test Request Number. 空气弹簧应用 计算Air Spring Application Calculationsn22n11V P VP: LawGas Polytropic=气体多变方程多变常数总体积绝对压力其中Constant c Polytropi n Volume Total V PressureAbsolute P:Where=()ec38.1e1e38.1c1ca1A-A14.7 - VVA- VVA PK R
21、ateSpringAir Dynamic=空气弹簧动刚度处有效面积处有效面积处容积处容积平衡位置容积平衡位置绝对压力其中Leat LArea Effective A Lcat LArea Effective A Leat L Volume V Lcat L Volume V Positionriumat Equilib Volume V Positionriumat Equilib PressureAbsolute P:Whereeecce ecc1a1=分周自然频率/ cpm d188LK188 fFrequencyNaturalesss=有效变形弹簧处刚度弹簧处载荷弹簧处频率其中n Def
22、lectio Effective d Springat Rate KSpringat Load LSpringat Frequency f :Whereesss=Air Spring Application Performance空气弹簧应用 性能载荷Load 31.8 kN.刚度Rate 202 N/mm自然频率NF. 1.3 Hz.载荷Load 34.5 kN.刚度Rate 257 N/mm自然频率NF. 1.4 Hz.载荷Load 31.8 kN.刚度Rate 155 N/mm自然频率NF. 1.1 Hz.活塞的选择和分析空气弹簧应用 最小弹起(压缩)高度Air Spring Appli
23、cation Jounce (Minimum) Height1.空气弹簧最小高度,也叫缓冲垫接触高度Air Spring minimum height, also known as bumper contact height.2.缓冲垫接触高度时的倾斜角度不应大于5 度Angle at bumper contact height should be no greater than 5 degrees.3. 空气弹簧偏心从活塞中心线量至缘板中心线Air Spring offset measured from the centerline of the piston to the centerli
24、ne of the bead plate Air Spring Application Maximum Rebound Height空气弹簧应用 最大回弹(拉伸)高度1. Air Spring maximum rebound height measured at the largest extremity. The condition at which the damper locks out or rebound strap engages.空气弹簧最大回弹高度在最大伸长时测量. 即减震器处于最大锁定位置或回弹限位钢带处于拉紧状态情况下.2. Air Spring rebound offse
25、t, measured from the centerline of the piston to the centerline of the bead空气弹簧回弹偏心从活塞中心线量至缘板中心线.=25mm空气弹簧应用 缘板和活塞支承Air Spring Application Bead Plate & Piston Support 活塞Pistons如图示通过活塞中心的100 mm 梁支承, 或者全部支承 100 mm beam which passes through the center of the piston as shown, or fully supported.缘板Bead P
26、lates如图示位置要求最少支承80% 面积 We require at least 80 % support coverage as shown.缘板支架Bead Plate Brackets美晨生产和提供将气囊安装到汽车车架上的支架, 请美晨空气弹簧代表讨论您的应用要求 meicheng manufactures and supplies brackets to mount to vehicle frame rails, please discuss your application needs with meicheng representative . Support for pistons or Bead plates活塞或缘板支承祝：蒸蒸日上！
