Characteristics of air spring

Application of air spring
1. Application of air spring in automobile
In 1947, the United States first used air springs on Pullman buses. By 1964, 38 of the 55 large and medium-sized buses produced in Germany used air springs. At present, the utilization rate of air springs in foreign high-speed buses and luxury city buses has reached 100%, and in medium and heavy trucks and trailers has also exceeded 80%, such as Ford in the United States and Man in Germany. Some premium cars are also equipped with air springs, such as Lincoln in the United States and Benz 600 in Germany. Air springs are more widely used in some special vehicles, such as instrument vehicles, ambulances, and container transport vehicles requiring height adjustment. In recent years, the use of air springs in commercial vehicles has developed rapidly. The commonly used air springs include cylinder air springs, variable load piston cylinder air springs, straight cylinder piston edge compression cylinder air springs, and double ring air springs.
China has studied air springs since the 1950s. In 1957, Changchun Automobile Research Institute and the Rubber Industry Research Institute of the Ministry of Chemical Industry jointly manufactured the first truck equipped with air springs in China, and successively designed and manufactured air springs for buses. In recent years, with the development of automobile technology and the introduction of foreign air suspension, a small number of domestic advanced tourist vehicles have begun to use imported air springs, such as passenger cars produced by Shenyang Aircraft Factory, North Automobile Factory, Xiamen Jinlong United Automobile Co., Ltd., Yaxing Bus Group Co., Ltd., Dandong Automobile Factory, etc.
In recent years, with the popularization of the application of air spring, the research and development of air spring has been paid more and more attention. Sifang Institute has developed SYS330 air spring for luxury passenger cars. The air spring is a free membrane air spring, which is sealed by the pressure self-sealing method by the upper cover plate, capsule, emergency rubber stop and base (also used as an additional air chamber).
Guizhou Qianjin Rubber Co., Ltd. has carried out research on rubber air springs of passenger cars in Sanos, Yugoslavia, Volvo and Kesbauer in Germany. The D52603260 diaphragm air spring developed by the Chongqing Highway Research Institute of the Ministry of Communications has good performance in practical use, with a service life of more than 100000 kilometers, and has been widely installed in imported and domestic vehicles.
The air spring developed by Weishi County Rubber Factory in Henan Province was used on the IKARUS 256 luxury passenger car in Hungary, and it ran for 100000 kilometers without quality problems. Zhuzhou Times New Material Co., Ltd. has developed EQ6111 automobile air spring, which has passed the 10000-kilometer loading operation test, and also developed 29S35000 automobile air spring for Xiamen Jinlong Bus, which has passed 5 million fatigue tests.
2. Application of air spring in rail transit
Air springs are widely used in rail vehicles such as high-speed trains, subways, light rail and maglev trains. Application on fast trains In the early 1970s, the secondary suspension on the Y225 bogie of TGV001, a French experimental high-speed train, adopted the restraint diaphragm air spring produced by Sumitomo in Japan. At the beginning of the 1980s, the 684N4.10B air spring with high flexibility produced by ContiTech was adopted on the TGVPSE, which ensured that the TGV still had excellent running stability at the world record speed of 515km/h in 1990. Due to the successful application of this large curved bag air spring on TGVPSE, all other TGV series, such as TGVA, TGV2N, E UROSTAR, T HALYS, AVE in Spain, TGV in South Korea, have adopted this air spring. The high flexible 7050N. 10 air spring produced by ContiTech was used for the German test high-speed train ICE, which set the world record of 406 km/h in 1987. On the Swedish X2000 tilting train, the secondary suspension of the trailer bogie is composed of air springs, upper and lower bolsters and rubber piles. The air spring is placed between the car body and the upper bolster. The secondary suspension of the power car bogie is a bolsterless structure, and the air spring is directly located on the frame. Air springs are used on 300 series, 400 series, 500 series, 500 series and 700 series passenger cars in Japan. 300 series passenger car bogies are equipped with large lateral displacement and small lateral stiffness free film air springs. The standard working height of the air spring is 201 mm, the working pressure is 0.37 Mpa, the effective diameter is 500 mm, and the minimum lateral displacement can reach 100 mm. The 400 series passenger cars adopt the form of bolsterless bogies, and also use the free membrane air spring as the secondary suspension. The standard working height of the air spring is 190 mm, the working pressure is 0.46 Mpa, the small radius of the air bag is 60 mm, and the plate type variable throttle valve is installed, and the maximum lateral displacement can reach 100 mm. The air spring of the 500 series test vehicle adopts a free membrane structure. The space between the two air springs is 2600 mm, the effective diameter is 500 mm, the standard working height of the air spring is 200 mm, the working pressure is 0.39 Mpa, and the volume of the additional air chamber is 70 L. The 700 series mainly adopts nonlinear air spring, which makes the air spring soft when driving in straight line and hard when driving in curve, improving the ride comfort on the whole.
As early as 1958, the bogie of double-deck passenger cars trial-produced in China began to use air springs. During this period, the air springs used are basically bladder air springs. Air spring suspension is also used on KZ2 passenger car bogies developed in the 1960s, and the restraint membrane air spring is used. Through continuous development and application, new air springs have been increasingly applied to bogies of quasi-high speed and high-speed trains in China in recent years. The air spring used on CW2 bogies of quasi-high speed vehicles in China is installed between the bolster and the bracket, with a transverse spacing of 1956 mm. The inner chamber of the bolster is used as the additional air chamber, and the adjustable flow valve is set between the air spring and the additional air chamber. The representative is the SYS600A air spring. The secondary suspension of 209HS bogie adopts membrane air spring, and its bolster is also used as additional air chamber. The 206KP bogie adopts a bolsterless moving platform structure, adopts a rubber pile elastic support air spring system, and is also equipped with a variable orifice. The representative is the SYS550C air spring. In addition, the SW200 and SW160 bogies use the SYS550D and SYS600A air springs, whose structural characteristics are basically the same as those of the SYS550C and SYS600A bogies. On this basis, the Zhengzhou-Wuhan line above 200km/h in China is under test, and the newly developed air spring with large flexibility and longitudinal traction rod are used on the PW200 bogie developed by Pu Factory, which improves the stability of the vehicle.
Application in metro
The bolsterless bogie of Shanghai Metro adopts a high flexible free film air spring, and its sealing mode is the combination of screw sealing and pressure self-sealing. The air spring has the following characteristics: ⑴ small transverse stiffness and can adapt to large transverse deformation; ⑵ When the curve passes, the air spring itself has good lateral resilience characteristics; ⑶ It has good torsion characteristics and torsion durability.
Application on light rail train
Urban light rail vehicles running on urban ground, underground or elevated lines require low noise, good damping performance, and the ability to adapt to large changes in vehicle load. Therefore, air springs have been widely used. Sifang Factory has developed the SYS450 air spring for trams. The air spring adopts full pressure air self-sealing sealing mode, which simplifies the air spring structure; The use of rubber pile support improves the lateral vibration performance of the vehicle; With adjustable damping throttle valve, the vehicle has good vibration performance under various line conditions and operating speeds.
Application in magnetic levitation train
The maglev train is a new type of non-ground contact mode of transportation, which has the advantages of ultra-high speed, low noise, energy saving, and so on. More and more attention has been paid to it. Of course, the application of air spring is a very key technology. In the 1980s, the maglev train technology in Japan, Germany and other countries has reached the practical level. In China, the technology started in the 1980s, and the development of a practical test maglev train was carried out in the 1990s. Sifang Institute has developed two types of air springs (membrane type and capsule type) for the bogie of SYS130A and SYS130B maglev trains (Figure 15). The adoption of the air spring central suspension improves the riding comfort of the maglev train and plays a positive role in promoting the practical application research of the maglev train in China. The air spring produced by NEWAY Company of the United States is selected for the maglev train of the Badaling tourism demonstration line in China. The product uses liquid shock absorber without additional air chamber, which reduces the volume and weight. The application of air spring improves the secondary suspension quality of the vehicle and improves the comfort and stability.
3. Application of air spring in industrial machinery
Air spring is widely used in equipment vibration isolation in industrial machinery, such as precision mechanical equipment and precision test equipment such as press, air compressor, centrifuge, vibration conveyor, control hammer, casting machinery and textile machinery, optical and laser instruments, integrated circuits, ultra-precision machine tools, etc., and has been applied abroad. With the development of society, people's requirements for life (including the interference of reducing vibration and noise) are becoming higher and higher, so air spring vibration isolation technology will become more and more, and its prospects are very broad. In mechanical vibration isolation, the air spring generally adopts the constrained membrane structure and the free membrane structure. Air spring can be used in various mechanical devices to buffer and absorb vibration, control movement or boost pressure. Compared with the cylinder or other elastic elements with the same function, the air spring has simple structure, reliable operation, no complex parameter calculation and structural design, no seal leakage, convenient use and maintenance, and long service life. In the stamping process, such as stamping car covers, doors, etc., necessary buffer devices shall be used. The buffer shall bear large and periodic impact load during processing. Its performance directly affects the processing accuracy of products. If the air spring is used as the buffer, the processing cost can be reduced and the processing accuracy can be guaranteed. During material transfer, the material box is driven by a vibrator to make the material mix evenly, or to make the material flow into the material box. Vibration can cause fatigue and even damage to the supporting parts of the material box, so vibration isolation devices must be used. If air spring is used, it can provide greater flexibility. Adjusting the inflation volume of the spring can adapt to different working loads and height requirements without affecting the vibration isolation effect. In paper making, textile and other industries, the paper or cloth needs to bypass many transfer rollers at a high speed during the winding process, so a constant tension is required during the transmission process to prevent the paper or cloth from loosening, twisting or cracking. In this case, the combined structure of hollow roll and air spring can provide constant tension. Moreover, it has a strong ability to withstand impact load and protect the transmission device and transmission parts from damage. Air spring is very suitable for high pressure and small stroke conditions. In the bonding process, the use of air springs can provide uniform pressure and ensure the bonding quality. The performance of the air spring is superior to that of the general vibration isolator. Since its inception, its application in the field of anti-micro-vibration has developed rapidly and has been widely used in developed countries, with a series of products available. The development of air-spring vibration isolation technology in China started early but developed slowly. By the early 1980s, there was no mature air-spring vibration isolation device for micro-vibration prevention.
Since 1982, China Electronics Engineering Design Institute has cooperated with Liaoning Shock Absorber Factory to develop air spring vibration isolation device for micro vibration isolation. By 1995, 8 models of JYKT series have been developed, with a bearing capacity of 6-200kN. They are widely used for vibration isolation of precision equipment, instruments and meters in metallurgy, machinery, electronics, optics, aerospace and other fields, and have achieved good results. At the same time, the air spring vibration isolation system of ultra-precision machining machine tool developed by Harbin Institute of Technology has also achieved good vibration isolation effect. Qingdao Rubber Industry Research Institute φ 113 Air springs are widely used in the field of vibration isolation of precision instruments.