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inflation unit

inflation unit

The Top Drive System solution for light commercial vehicles consists of air springs applied to the rear axle, interposed between the axle and the chassis with the aim of minimising vibrations due to the impact of the end buffer, a phenomenon that is inevitable when the vehicle is close to the load limit.

inflation unit

The Top Drive System range includes inflation solutions for every needfrom basic systems without a compressor, to kits with a compressor and advanced features such as pressure memories, to fully electronic systems managed by control units designed in Italy.

High production flexibility and in-house testing allow us to offer both standard configurations and customised solutions, adapted to the most specific applications.

BY STRUCTURAL TYPE

Inflation units are the indispensable complement of supplementary suspension systems, particularly on commercial vehicles that do not have an on-board compressed air source.

Top Drive System offers a complete range of solutions for the production, management and control of the air required for the proper functioning of air springs.

Each inflation unit consists of three main elements:

  • compressorresponsible for generating compressed air;
  • air management systemconsisting of mechanical or electromechanical valves and dedicated fittings;
  • control devicemanual, semi-automatic or fully automated, which allows adjustment according to operational requirements.

Our offer ranges from basic manual kits to more advanced solutions with ECAS automatic control, covering all major inflator configurations. The systems are available in different compressor sizes, from compact 6 cc models up to heavy duty 40 cc versions for more demanding applications.

Completing the range are numerous variants available designed for specific application needs. Our technical team is available to evaluate dedicated solutions and customised configurations.

BY TYPE OF INFLATION

Standard

standard

The inflation system for this type includes an “inflation and control unit” equipped with traditional type inflation valves (Schrader connection), combined with a pair of pressure gauges and inlet pressure limiting valves. This system makes it possible to decouple the pressures between the right and left sides and limit the inflation pressure on the individual air springs, allowing differentiated calibration between the two sections of the system. This robust and reliable scheme has always been the TOP DRIVE SYSTEM standard for light commercial vehicles.

Electromechanical automatic control
(AC)

ELECTROMECHANICAL AUTOMATIC CONTROL (AC)

Initially designed for emergency vehicles, it has been transferred to the entire light commercial vehicle product range. It features an air supply system based on a compressor, a small air tank and an integrated valve unit. The presence of a three-position switch in the cabin makes operation extremely simple: AUTOMATIC: the system regulates the pressure up to a set maximum, which can be set by the installer as required, NEUTRAL: the neutral position of the switch inhibits the system by placing it in a “stand by” state, without activating any type of utility, and therefore without consuming energy, DEFLATION (partial or total): the air is partially or totally vented to the outside. If you want to work in intermediate pressure conditions, simply activate the system automatically, wait for it to reach the set pressure level, partially deflate the air springs by actuating the switch and set it back to neutral, thus obtaining a wide adjustment range suitable for all vehicle load conditions.

INFLATION
DIRECT

DIRECT INFLATION

The direct inflation version is a simplification of the standard configuration. It is a technically basic solution, lacking the pressure-limiting valves found in the more complete versions. Because of these characteristics, direct inflation is only offered in special applications, agreed with the customer and referring to very specific regulation requirements. This configuration is not available in the catalogue and must be specifically requested.

SIMPLE DIRECT

SIMPLE DIRECT

A minimalist and functional inflation solution developed for applications with special technical constraints. The absence of restrictor valves and control instruments makes this version suitable only under well-defined operating conditions and subject to dedicated technical evaluation.

basic system with compressor and dashboard panel

basic system with compressor and dashboard panel

Scheme with basic compressor: comprises an air compressor, a dashboard panel with an on/off switch and specific deflation caps. The system allows simultaneous inflation of the suspensions, and deflation is achieved by simply acting on the deflation caps. It is an essential but robust, reliable and effective solution for applications requiring operational simplicity and ease of installation.

Inflating and deflating
independent (diagram j)

Independent inflation and deflation (diagram J)

Kit complete with compressor, dashboard panel with independent switches. The system allows independent inflation and deflation of the two sides of the pneumatic circuit even at different pressures for balancing asymmetric loads. The panel is equipped with emergency inflation valves.

Inflating and deflating
independent (scheme H)

Independent inflation and deflation (Diagram H)

Kit complete with compressor, dashboard panel with independent switches. The system allows independent inflation and deflation of the two sides of the pneumatic circuit even at different pressures for balancing asymmetric loads. A plug-and-play installation, the valve unit is mounted directly on the compressor, allowing only the control buttons to be in the cab. The panel is equipped with emergency inflation valves.

Dashboard panel (Diagram D)

Dashboard panel (Diagram D)

A basic and scalable inflation system, it offers a dashboard panel for easy reading of air spring pressure. It can be integrated with a wide range of air compressors from basic to semi-automatic versions.

Base inflation for Full Air

Base inflation for Full Air

Specific basic scheme for full air suspension dedicated to vehicles with independent wheels. It provides for inflation via a manually operated compressor and incorporates an acoustic warning device that alerts in the event of low pressure. During installation, the system is calibrated to define maximum and minimum pressure values, ensuring simple and safe operation.

Semi-automatic inflation
outdoor (diagram 6)

Semi-automatic outdoor inflation (Diagram 6)

Initially designed for emergency vehicles, it was transferred to the entire light commercial vehicle product range. It features an air supply system based on a compressor, a small air tank and an integrated valve unit. The presence of a three-position switch in the cabin makes operation extremely simple: AUTOMATIC: the system regulates the pressure up to a set maximum, which can be set by the installer as required, NEUTRAL: the neutral position of the switch inhibits the system by placing it in a “stand by” state, without activating any type of utility, and therefore without consuming energy, DEFLATION (partial or total): the air is partially or totally vented to the outside. If you want to work in intermediate pressure conditions, simply activate the system automatically, wait for it to reach the set pressure level, partially deflate the air springs by actuating the switch and set it back to neutral, thus obtaining a wide adjustment range suitable for all vehicle load conditions. Compared to the classic semi-automatic scheme, it combines convenience and the advantage of an external installation of the components with a splash-proof box.

Electronic self-levelling
(diagram 5)

Electronic self-levelling (diagram 5)

A fully electronically controlled system designed to ensure that the optimum ride height is maintained under all load conditions or usage phases. The system uses height sensors and an electronic control unit that continuously detects the position of the chassis in relation to the axle and activates the valves to automatically correct the stance, keeping the vehicle in perfect stability at all times. Various configurations are available, including: - Fully automatic total inflation and deflation; - Step mode (progressive steps) to adjust the height in intermediate steps, depending on vehicle or application specifications; The system ensures high performance in terms of comfort, stability, road holding and adaptability to varying loads, making it ideal for professional applications, heavy transport, special projects or special trim requirements.

Independent inflation and deflation with digital pressure gauges (K diagram)

Independent inflation and deflation with digital pressure gauges (K diagram)

Kit complete with compressor, dashboard panel with digital pressure gauges with independent switches. The system allows independent inflation and deflation of the two sides of the pneumatic circuit even at different pressures for balancing asymmetric loads. The panel is equipped with emergency inflation valves.

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