Abstract: A suspension system and associated control methods that reduce temperature related fluctuations in the internal pressures and stiffness of the suspension system. A manifold assembly is connected in fluid communication with a plurality of dampers via hydraulic circuits and a pump assembly via a pump hydraulic line. Onboard sensors generate real-time data regarding the vehicle. A suspension control unit, arranged in electronic communication with the aforementioned components, monitors the real-time data, sets a target stiffness and a target pressure, calculates an effective stiffness based on the real-time data, determines if the effective stiffness is above or below the target stiffness and sets a new target pressure accordingly by making stepwise decreases or increases until the new target pressure is reached.

Abstract: A damper assembly includes a pressure tube forming a chamber, a piston assembly disposed in the chamber and dividing the chamber into two subchambers, and a piston rod fixed to the piston assembly. The piston assembly includes a body having an inner bore extending axially through the body. The piston assembly includes a blowoff disc contacting the body at the inner bore and having a throughhole aligned with the inner bore. The piston rod extends through and concentrically contacts the inner bore and the throughhole. The body has a groove extending axially along a length of the inner bore. The groove and the piston rod form a passageway permitting fluid to travel across the body. The blowoff disc has a notch extending from the throughhole and arranged to permit fluid from the passageway to pass across the blowoff disc.

Abstract: An apparatus for applying torque to a body includes a base defining an inner chamber. The apparatus includes a plurality of pins supported by base and disposed in the inner chamber, the plurality of pins moveable relative to the base between engaged positions and disengaged positions. The apparatus includes a trigger actuatable to move at least one of the plurality of pins to the disengaged position.

Abstract: A damper assembly includes a pressure tube defining a first chamber and a piston movable within the first chamber. The damper assembly includes a reserve tube defining a second chamber. The damper assembly includes a cylinder end attached to the pressure tube, the cylinder end defining a passage in fluid communication with the first chamber and the second chamber. The damper assembly includes an orifice disc attached to the cylinder end and defining an opening in fluid communication with the passage. The damper assembly includes a check disc attached to the cylinder end, the check disc movable from a first position spaced from orifice disc to a second position abutting the orifice disc. Movement of the piston within the first chamber causes fluid flow between the first chamber and the second chamber via the passage of the cylinder end. The check disc and the orifice disc limit a rate of such fluid flow.

Abstract: A shock absorber having a metal damper tube and base assembly is provided. The base assembly, which includes a composite mounting attachment made of a composite material, such as a recyclable thermoplastic, is fixed to an external surface of the metal damper tube, which may be a finished product. A cavity in the composite mounting attachment houses at least a portion of the metal damper tube and thus defines an overlapping region where the composite mounting attachment and the metal damper tube are co-extensive with each other. One or more windows are provided in the overlapping region of the composite mounting attachment where the metal damper tube is left exposed. This helps to promote heat dissipation away from the metal damper tube while reducing weight and heat transmission from the metal damper tube to the composite mounting attachment to reduce overheating of the composite material.

Abstract: A damper assembly includes a cylinder defining a chamber. The damper assembly includes a body supported by the cylinder and having a first surface and a second surface opposite the first surface. The body defines a passage extending from the first surface to the second surface. One of the first surface or the second surface define a slope at the passage. The damper assembly includes a check disc at the slope, the check disc selectively restricting fluid flow through the passage.

Abstract: The present disclosure provides a method of manufacturing a damper for a vehicle. The method includes forming a groove on an outer surface of a first component in a first annular region. The first component is tubular. The method further includes inducing a compressive residual stress in a second annular region. The second annular region is at least partially aligned with the first annular region along a longitudinal axis of the first component. The method further includes coupling a second component to the first component. Surfaces of the first component and the second component directly engage one another at an interface. The second component is axially aligned with and radially surrounding at least a portion of the first annular region. In some configurations, forming the groove and inducing the compressive residual stress are performed concurrently, such as by low plasticity burnishing.

Abstract: A damper including inner and outer tubes and a control valve. A piston is slidably disposed within the inner tube to define first and second working chambers. An intermediate member assembly is disposed annularly about the inner tube. An intermediate channel is positioned radially between the intermediate member assembly and the inner tube and a reservoir channel is positioned radially between the intermediate member assembly and the outer tube. A first unidirectional blocking valve forms a first partition between first and second intermediate channel portions of the intermediate channel. A second unidirectional blocking valve forms a second partition between the second intermediate channel portion and a third intermediate channel portion. An external control valve has a control valve inlet that is arranged in fluid communication with the second intermediate channel portion.

Abstract: A damper assembly includes a damper with a pressure tube and a piston slidably disposed within the pressure tube. A first working chamber is defined on one side of the piston and a second working chamber is defined on an opposite side of the piston such that a volume of the second working chamber decreases during a compression stroke of the piston and the volume of the second working chamber increases during a rebound stroke of the piston. A bellow accumulator assembly is included and in fluid communication with the second working chamber. The bellow accumulator assembly includes a housing, a bellow accumulator disposed within the housing, a pressurized gas chamber defined between the housing and the bellow accumulator and an accumulator chamber defined between the bellow accumulator and the second working chamber.

Abstract: A continuously variable damper is disclosed. The damper includes an elongate outer tube and inner tube with a piston in the inner tube. The piston defines a rebound working chamber and compression working chamber. An active rebound valve is in fluid communication with the rebound working chamber through a rebound down tube, and an active compression valve is in fluid communication with the compression working chamber through a compression down tube. An intake compression valve is in fluid communication with the rebound working chamber through the rebound down tube, and an intake rebound valve is in fluid communication with the compression working chamber through the compression down tube. The opposite position of the intake valves balance the active rebound and compression valves to avoid asymmetric/bending loads on the inner tube in the damper.

Abstract: A damper assembly includes a cylinder defining a chamber. The damper assembly includes a body supported by the cylinder and having a first surface and a second surface opposite the first surface. The body defines a passage extending from the first surface to the second surface. One of the first surface or the second surface define a slope at the passage. The damper assembly includes a check disc at the slope, the check disc selectively restricting fluid flow through the passage.

Abstract: A suspension system including four dampers is disclosed where each damper includes a compression chamber and a rebound chamber. A first hydraulic circuit includes a front hydraulic line, a rear hydraulic line, and a first longitudinal hydraulic line that extends between and fluidly connects the front and rear hydraulic lines of the first hydraulic circuit. A second hydraulic circuit includes a front hydraulic line, a rear hydraulic line, and a second longitudinal hydraulic line that extends between and fluidly connects the front and rear hydraulic lines of the second hydraulic circuit. First and second longitudinal comfort valves are positioned in the first and second longitudinal hydraulic lines, respectively, between the front and rear hydraulic lines. Both of the first and second longitudinal comfort valves are electromechanical valves and can be actuated to couple and decouple front axle roll control from rear axle roll control.

Abstract: A damper assembly includes a pressure tube defining a chamber. The damper assembly includes a body supported by the pressure tube. The body has a first surface and a second surface opposite and spaced from the first surface along an axis. The body defines a passage extending from the first surface to the second surface. The damper assembly includes an orifice disc movable from an unflexed position to a first flexed position and movable from the first flexed position to a second flexed position. The orifice disc in the unflexed position is spaced from the first surface radially outward and radially inward of the passage. The orifice disc in the first flexed position is spaced from the first surface radially outward of the passage and abuts the first surface radially inward of the passage. The orifice disc in the second flexed position abuts the first surface radially outward and radially inward of the passage.

Abstract: A system for filling a tank of a suspension system with hydraulic fluid includes: a module configured to turn on an external pump and pump hydraulic fluid into the suspension system, where the external pump is separate from the suspension system and is configured to pump hydraulic fluid into the suspension system via a port fluidly connected to a hydraulic line of the suspension system; and a fill module configured to, after operating the external pump, operate a pump of the suspension system and pump hydraulic fluid from the hydraulic line into the tank of the suspension system thereby filling the tank.

Abstract: A control system includes: a target volume module configured to determine a target volume of hydraulic fluid within a suspension system of a vehicle based on a target pressure of the hydraulic fluid within the suspension system; a volume command module configured to generate a volume command based on the target volume and a present volume of the hydraulic fluid within first and second circuits; a command module configured to, based on the volume command, generate: a pump command for an electric hydraulic fluid pump; and first and second valve commands for first and second seat valves that regulate hydraulic fluid flow to and from the first and second circuits, respectively; a valve control module that actuates the first and second seat valves based on the first and second valve commands, respectively; and a pump control module that controls operation of the pump based on the pump command.

Abstract: A shock for a vehicle includes a tube elongated along an axis. A piston is disposed in the tube and is moveable relative to the tube along the axis. A rod is connected to the piston. A floating piston is spaced from the piston along the axis and is moveable relative to the tube along the axis. The tube defines a working chamber between the piston and the floating piston. The tube defines a gas chamber. The floating piston separates the gas chamber from the working chamber. The floating piston has a housing slideably engaged with the tube and a membrane fluidly separating the working chamber from the gas chamber. The membrane is flexible relative to the housing.

Abstract: A valve body for a damper includes a plurality of pressure tubes of the damper having different diameters. The valve body includes a plurality of fluid passages. The valve body further includes a plurality of stepped regions having different diameters relative to a valve axis of the valve body. Each stepped region is configured to be selectively coupled to one of the plurality of pressure tubes having a corresponding diameter.

Abstract: A shock absorber includes a first end fitting connected to a first telescoping member, a second end fitting connected to a second telescoping member, the first and second telescoping members being telescopically mounted relative to each other. An elastomeric spring/damper is disposed between the first telescoping member and the second telescoping member.

Abstract: A method for assembling a damper assembly includes securing a damper interface to an external surface of a pressure tube. The method includes securing an accumulator interface to an external surface of an accumulator tube. The method includes, after the damper interface is secured to the pressure tube and the accumulator interface is secured to the accumulator tube, securing the pressure tube to the accumulator tube by press fitting the damper interface to the accumulator interface.

Abstract: An apparatus for applying torque to a body includes a base defining an inner chamber. The apparatus includes a plurality of pins supported by base and disposed in the inner chamber, the plurality of pins moveable relative to the base between engaged positions and disengaged positions. The apparatus includes a trigger actuatable to move at least one of the plurality of pins to the disengaged position.