When it comes to achieving the perfect balance between durability, flexibility, and performance in automotive suspension systems, bespoke air bellows design plays a critical role. In our experience at Tevema, designing custom air bellows is not merely about meeting the functional requirements of a vehicle—it’s about ensuring longevity, improving ride comfort, and optimizing the entire suspension system to provide a superior driving experience. Below, we dive into key considerations for designing tailor-made air bellows for automotive applications.
Material Selection for Optimal Performance
The choice of materials is fundamental in defining the durability and functional capacity of air bellows. Typically, air bellows consist of an elastomeric rubber core reinforced with fabric plies, all enclosed with high-quality metal components at the ends. For custom designs, factors such as operating pressure, exposure to environmental conditions, and load-bearing capacity determine the choice of rubber and other components.
At Tevema, we use a variety of elastomer compounds, including natural rubber (NR/SBR), chlorobutyl rubber (CIIR), nitrile rubber (NBR), and ethylene propylene diene monomer (EPDM), each with specific properties to enhance performance based on operational needs:
- Natural rubber (NR/SBR) offers exceptional dynamic capabilities, making it ideal for vehicle suspensions with varying loads.
- Chlorobutyl rubber (CIIR) is chosen for its resistance to acids, which is particularly beneficial in corrosive environments.
- Nitrile rubber (NBR) has excellent resistance to oil, ozone, and fuel, which is advantageous in automotive applications where such exposures are unavoidable.
The correct pairing of elastomer with appropriate reinforcing materials ensures maximum durability and efficiency in different conditions.
Engineering Custom Air Bellows: Key Parameters
When engineering custom air bellows, several key parameters must be considered:
1. Load Capacity and Stroke
Air bellows are designed to withstand substantial loads while maintaining a specific stroke, which is crucial for automotive suspensions that need a combination of compressibility and strength. In our custom designs, we carefully calculate the stroke range, taking into account the maximum and minimum ride height, as well as the static load when the vehicle is stationary.
2. Pressure Handling
Operating pressure significantly impacts the performance of air bellows. In custom applications, understanding the required dynamic pressure and the maximum pressure the bellow will endure during high-demand scenarios helps ensure the system’s reliability and safety. For high-performance designs, we opt for four-ply construction that withstands pressures of up to 12 bar, offering enhanced load-bearing capacity.
3. Temperature Resistance
Different vehicle applications require bellows capable of withstanding extreme temperatures. We design air bellows with elastomers like EPDM, which can handle temperatures up to 115°C, making them suitable for automotive environments that experience high engine heat or cold climates.
4. Height Control and Vibration Isolation
A well-designed air bellow not only offers height adjustment for maintaining consistent ride quality but also contributes significantly to vibration isolation. Tevema’s air bellows are crafted to absorb more than 99% of unwanted vibrations, thanks to the uniform isolation properties. The addition of auxiliary reservoirs can also enhance isolation efficiency, especially in situations requiring reduced natural frequency.
Applications in Automotive Suspension Systems
Our bespoke air bellows are designed for a range of automotive applications, such as:
- Passenger Comfort Systems: By providing controlled adjustments to ride height, air bellows improve ride comfort. They absorb shocks from uneven roads, providing an exceptionally smooth driving experience.
- Load Leveling: In utility vehicles, trailers, and trucks, air bellows help maintain a consistent ride height regardless of the load. Our custom designs ensure that air bellows can accommodate uneven distribution of load without compromising comfort.
- Multi-Axle Systems: The flexibility of air bellows makes them particularly well-suited for multi-axle setups. The ability to evenly distribute forces across multiple points enhances both stability and control, particularly for large vehicles like trucks and buses.
Design Process: Balancing Efficiency and Performance
We begin the design process with a comprehensive understanding of the vehicle’s specific needs. The selection of bellows type (single, double, or triple convoluted) depends on the application:
- Single convoluted bellows offer lower stroke and higher force capabilities, ideal for applications where height change is minimal.
- Double or triple convoluted bellows are used when a greater range of motion is necessary, providing more flexibility in ride height and vibration isolation.
Dynamic Testing and Iterative Prototyping
Our engineering team engages in iterative prototyping, simulating the vehicle’s suspension dynamics to determine the effectiveness of the bellow design. Dynamic tests include endurance testing under varying pressures and temperatures to guarantee long-term reliability. This iterative approach ensures that our bespoke air bellows meet all required safety and performance metrics.
Albert Einstein once said, “Strive not to be a success, but rather to be of value.” At Tevema, we believe in providing air bellows that bring significant value to our clients through efficient performance and unmatched durability.
Advantages of Custom Air Bellows
Choosing custom air bellows over standard units offers numerous benefits for automotive applications, including:
- Enhanced Vehicle Stability: Custom designs help maintain stability during lateral acceleration by adapting to dynamic load changes.
- Reduced Maintenance Requirements: Air bellows designed with high-quality materials and optimized load handling capabilities minimize the need for frequent maintenance.
- Perfect Fit for Specific Requirements: Unlike off-the-shelf products, bespoke bellows are manufactured to precisely meet the requirements of each application, ensuring seamless integration.
No Maintenance Requirements
With no internal rods or pistons, air bellows avoid many maintenance issues common to traditional hydraulic actuators. The absence of sliding seals eliminates the risk of seal failure due to grit or dirt, which is a significant advantage in automotive suspensions exposed to road debris.
Custom Air Bellows for a Superior Driving Experience
At Tevema, we understand that designing bespoke air bellows is an intricate balance of material science, engineering, and practical application. Every vehicle has unique suspension needs, and a custom air bellow system designed to cater to those specific needs offers unparalleled advantages—from improved ride comfort and stability to extended product lifespan.
Our goal is to provide not just a product but a comprehensive solution that enhances automotive performance while reducing maintenance costs and improving efficiency. By leveraging the latest in material science, engineering know-how, and rigorous testing, Tevema is redefining the role of air bellows in the automotive industry.
“The measure of intelligence is the ability to change.” – Albert Einstein
With our bespoke air bellows, we are ready to help you change the way your vehicles ride, handle, and perform—for the better.