Research on Key Technology for Performance Optimization of Heavy Truck Shock Absorber
DATE : Mar 28th, 2025
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abstract
Aiming at the shock absorption requirements of heavy trucks under complex working conditions, this paper analyzes the performance improvement path of the shock absorber from four dimensions: material selection, structural design, damping characteristic matching and intelligent control. Combined with road test data, a multi-objective collaborative optimization solution is proposed to provide reference for the design of commercial vehicle chassis system.
Special performance requirements for heavy truck shock absorbers
1.1 Extreme load characteristics
Single axle load up to 10-16 tons (ordinary passenger car < 0.5 tons)
The peak dynamic impact load exceeds the static load by 200%.
1.2 Durability challenges
Mine vehicles need to withstand more than 3 million impact cycles (road trucks > 1 million times)
Sealing reliability in corrosive environments (snow melting agents/acid and alkali substances in mining areas)
1.3 Temperature adaptability
-40 ℃ to 120 ℃ operating temperature range
Damping stability problem caused by viscosity attenuation of high temperature oil
Key performance optimization direction
2.1 Material innovation
Components, traditional solutions, improved solutions, improved performance
Piston rod, hard chrome plated 45 #steel, plasma sprayed WC-Co coating, wear resistance ↑ 300%
Oil seal NBR rubber, fluororubber + PTFE composite layer, 2.5 times longer life
2.2 Damping valve system optimization
Multi-stage linear valve system: Adaptive damping force adjustment for empty/full load operation
Frequency-sensitive construction: Provides an additional 30% damping force at 2-8Hz (typical body resonance band)
2.3 Thermal management design
Integrated cooling fins (40% increase in surface area)
Nanofluid heat transfer technology (15% increase in thermal conductivity)
Frontier development of intelligent shock absorption systems
3.1 Semi-active control scheme
Magnetorheological shock absorber response time < 5ms
PID Control Algorithm Based on Pavement Recognition
3.2 Energy recovery system
Hydraulic motor-generator integrated design
Recyclable electricity 0.8-1 kWh per 100 km
Innovation in test verification methods
4.1 Accelerated durability test
Introduction of asymmetric load spectrum (including 30% random shock component)
Bench test equivalent mileage of 500,000 km
4.2 Multi-parameter coupling testing
Test Matrix Example: Load Conditions, Frequency (Hz) Temperature (℃) Evaluation Index -------------------------------------------------- 50% Full Load 2.5 25 Damping Force Decay Rate 120% Overload 5.0 -30 Seal Leakage
Typical case studies
Improvement effect of a 6 × 4 mine dump truck:
After adopting the three-stage damping valve + high-temperature synthetic oil scheme:
Comfort indicator ISO 2631 reduced by 28%
Suspension rubber parts have been extended from 3 months to 9 months
Conclusion and Outlook
In the next 5 years, the penetration rate of smart shock absorbers in the heavy truck market is expected to reach 35%.
Need to establish a more accurate "load-road-speed" three-dimensional performance map
Material-structure-control collaborative optimization is a breakthrough direction
