Exhaust brake electromagnetic valve

Abstract

The invention relates to an exhaust brake electromagnetic valve. According to the electromagnetic valve, a main gas circuit unit, a proportional electromagnetic driving structure, a gas circuit switching structure and a gas pressure detection structure are integrated. Continuous and linear accurate adjustment of output air pressure is realized through a proportional electromagnetic driving structure; the gas path switching structure can intelligently switch gas flow between the first gas outlet and the second gas outlet according to an instruction; the pressure sensor integrated in the valve body monitors the actual output air pressure in real time, closed-loop feedback control is formed, and accurate matching of braking force is ensured. The system is compact in structure, remarkably reduces external pipelines and leakage points, has the advantages of being rapid in response, accurate in control, high in reliability and high in adaptability, and remarkably improves the smoothness and safety of vehicle braking.

Description

Technical Field

[0001] This invention relates to the field of solenoid valves, and in particular to an exhaust braking solenoid valve. Background Technology

[0002] Exhaust braking is a key component in the auxiliary braking system of commercial vehicles (such as trucks and buses). It increases engine operating resistance by blocking the engine exhaust passage, thereby effectively reducing the load on the wheel brakes and improving driving safety and brake life. The solenoid valve, as the core control element of the exhaust braking system, directly determines the timeliness, accuracy, and reliability of the braking response.

[0003] While existing exhaust brake solenoid valve technology has been developed for many years, it still has several shortcomings that urgently need improvement. Firstly, many traditional solenoid valves employ a simple "on / off" two-position two-way or two-position three-way structure, offering limited functionality. These valves can only achieve the opening and closing of the air path or basic switching, and cannot perform precise, linear proportional regulation of the output air pressure. This results in insufficient precision in braking force control, failing to meet the high demands of modern vehicles for smooth braking and precise matching of braking force under different operating conditions.

[0004] Secondly, to achieve more complex functions, such as the integration of pressure monitoring and gas path switching, it is usually necessary to connect and combine multiple independent valve bodies (such as proportional valves, on / off valves, and sensors) through external pipelines. This discrete solution has problems such as loose structure, large space occupation, increased leakage risk due to multiple interfaces, complex assembly process, and high cost. At the same time, the large volume of the externally connected gas path cavity will reduce the system's response speed.

[0005] Furthermore, some integrated designs attempt to incorporate pressure monitoring functionality, but the layout is often inefficient. For example, the sensor sampling point may be located at the air inlet or far from the actual working air path, causing the monitoring data to fail to accurately reflect the final air pressure value output to the actuator. This prevents the formation of effective closed-loop control and affects the accuracy and reliability of braking control.

[0006] Therefore, there is an urgent need in the field for a highly integrated, rapidly responsive exhaust brake solenoid valve capable of precise proportional control and closed-loop feedback to overcome the structural and functional deficiencies in the prior art. To address these deficiencies, this invention proposes improvements. Summary of the Invention

[0007] The present invention proposes an exhaust braking solenoid valve that is compact in structure, highly efficient in exhaust, reliable in sealing, and highly adaptable, which solves the above-mentioned problems existing in the use of the prior art.

[0008] The technical solution of this invention is implemented as follows:

[0009] An exhaust braking solenoid valve, characterized in that:

[0010] It includes a main air passage unit, which is equipped with a single air inlet pipe assembly, a first air outlet pipe assembly, and a second air outlet pipe assembly;

[0011] The proportional electromagnetic drive structure includes an electromagnetic valve body and a proportional electromagnetic drive assembly. The proportional electromagnetic drive assembly is installed in the electromagnetic valve body. The electromagnetic valve body has an air inlet pipe that communicates with the air inlet assembly and an air outlet pipe that communicates with the first air outlet assembly.

[0012] The air path switching structure switches the airflow of the intake pipe assembly from the first exhaust pipe assembly to the second exhaust pipe assembly;

[0013] The air pressure monitoring module is integrated at the lower end of the solenoid valve body and includes a pressure sensor and a branch air path. The branch air path is connected to the air inlet pipe of the solenoid valve body and monitors the output air pressure value in real time.

[0014] When the proportional electromagnetic drive component is energized, the air pressure of the intake pipe component is regulated and output to the first exhaust pipe component. At the same time, another air path is sent to the pressure sensor through a branch air path. The pressure sensor monitors the pressure of the first exhaust pipe component in real time.

[0015] When the gas path switching structure is energized, the switching valve core is switched to the first working position to switch the gas path, so that the gas from the first gas outlet assembly is switched to the output of the second gas outlet assembly.

[0016] When the gas path switching module is powered off, the switching valve core resets to the second working position, and the airflow switches back to the first outlet.

[0017] Preferably, the gas path switching module includes a valve core, a movable diaphragm, and a linkage sealing assembly;

[0018] When energized, the valve core pushes down the diaphragm, connecting the air intake pipe assembly to the second air outlet.

[0019] In the power-off state, the sealing assembly resets, connecting the air intake pipe assembly to the first air outlet.

[0020] Preferably, the branch gas path is diverted from the channel of the first gas outlet pipe assembly and extends to the detection end of the pressure sensor.

[0021] Preferably, the air pressure monitoring module and the electromagnetic drive module are interconnected.

[0022] The pressure sensor feeds back the air pressure signal to the control unit in real time. The control unit adjusts the current intensity of the input electromagnetic drive module and dynamically controls the opening of the proportional electromagnetic drive component to achieve precise adjustment of the output air pressure.

[0023] Preferably, the gas path switching structure includes: a switching valve body, a coil valve cover, a coil assembly, a valve-moving core assembly, and an air intake core assembly. The coil valve cover and the valve-moving core assembly are mounted on the coil assembly. The coil assembly is energized to allow the valve core of the valve-moving core assembly to move back and forth. The air intake core assembly is connected to the valve-moving core assembly and is mounted on the valve core. The switching valve body has a first-side air intake channel that connects to the first air outlet pipe assembly and a second-side air intake channel that connects to the second air outlet pipe assembly. The first-side air intake channel serves as a first working position, and the second-side air intake channel serves as a second working position.

[0024] Preferably, the proportional electromagnetic drive structure and / or the gas path switching structure are connected to the backup gas path or the pressure relief channel.

[0025] Preferably, a special-shaped air passage guide seat is installed between the solenoid valve body and the switching valve body. The special-shaped air passage guide seat is divided into a first guide air passage area connecting the first air outlet pipe assembly and the first side air inlet channel and a second guide air passage area connecting the second air outlet pipe assembly and the second side air inlet channel. The switching valve body is machined with an embedded groove that matches the special-shaped air passage guide seat. The special-shaped air passage guide seat extends beyond the end face of the switching valve body.

[0026] Preferably, the irregularly shaped air passage guide seat extends 1-3mm beyond the end face of the switching valve body.

[0027] In summary, the exhaust braking solenoid valve disclosed in this invention has the following advantages:

[0028] This invention highly integrates three major functional modules—proportional control, air path switching, and air pressure monitoring—into a single valve body, achieving modular and integrated functionality. This design completely eliminates the complex external connection pipelines between multiple independent valve bodies, significantly reducing potential leakage points. Not only is the overall structure compact and small in size, facilitating placement within the limited space of a vehicle, but it also greatly improves the system's sealing reliability and overall service life.

[0029] By employing a proportional electromagnetic drive structure and integrating a pressure sensor to monitor the actual output air pressure in real time, this invention can continuously and linearly control the output air pressure with precise proportional control based on the input electrical signal command. The closed-loop feedback circuit formed by the pressure sensor ensures a high degree of consistency between the output air pressure and the target value, allowing the exhaust braking force to be precisely and smoothly adjusted. This effectively avoids the jolt caused by traditional on / off braking, greatly improving the smoothness and handling of the vehicle braking process.

[0030] Thanks to its highly integrated internal flow channel design, the gas flow path is shorter and the cavity is smaller, significantly reducing gas path resistance and charging / discharging time. Simultaneously, the diaphragm or pilot-operated structure design of the gas path switching module ensures sensitive operation, allowing the entire solenoid valve to respond quickly upon receiving a control signal, achieving pressure establishment and switching, and promptly generating the required braking force, resulting in excellent dynamic performance.

[0031] Through an independently controlled air path switching structure, this invention can intelligently switch the proportionally regulated air pressure between the first and second air outlets. This dual-output capability allows a single valve body to control different actuators or meet more complex braking logic requirements (such as different levels of braking intensity), enriching the functionality of the exhaust braking system and making its application more flexible.

[0032] Modular design makes the function of each component clear, and in case of failure, it is easy to diagnose and replace specific modules. The integrated structure also reduces assembly steps, which is conducive to large-scale and standardized production and reduces manufacturing costs.

[0033] In summary, this invention, through innovative integrated design, successfully solves many problems in existing technologies, such as limited functionality, complex structure, poor control precision, and slow response, and provides a high-performance, high-reliability exhaust brake solenoid valve solution. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0035] Figure 1 This is a schematic diagram of an exhaust braking solenoid valve according to this embodiment.

[0036] Figure 2 This is a planar schematic diagram of an exhaust braking solenoid valve.

[0037] Figure 3 for Figure 2 A schematic diagram of the cross-sectional structure along the AA direction.

[0038] Figure 4 This is a plan view of the proportional control valve structure of an exhaust braking solenoid valve.

[0039] Figure 5 This is a schematic diagram of the internal cavity of a proportional control valve structure for an exhaust braking solenoid valve.

[0040] Figure 6 This is a schematic diagram of the branch gas path of the air pressure monitoring module.

[0041] Figure 7 for Figure 6 A schematic cross-sectional view of the structure along the BB direction.

[0042] Figure 8 This is a planar schematic diagram of a proportional electromagnetic drive assembly.

[0043] Figure 9 for Figure 8 A schematic diagram of the cross-sectional structure along the CC direction.

[0044] Figure 10 A schematic diagram of a non-standard air passage guide seat installed between the solenoid valve body and the switching valve body.

[0045] Figure 11 This is a schematic diagram of the switching valve body.

[0046] Figure 12 A schematic diagram of the steel ball structure for the pressure relief channel. Detailed Implementation

[0047] The following will refer to the appendices in the embodiments of the present invention. Figure 1-12 The technical solutions in the embodiments of the present invention are clearly and completely described herein. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0048] Example

[0049] like Figures 1 to 12 As shown in the accompanying drawings, the present invention will be further described in detail below. The purpose of this embodiment is to provide a highly integrated exhaust brake solenoid valve that is precisely controllable and has a dual-path switching function.

[0050] Example 1

[0051] See Figure 1 and Figure 12 The exhaust braking solenoid valve of this embodiment includes an integrated main air circuit unit, a valve mounting seat 10, a proportional control valve structure 20, an air circuit switching module 30, and an air pressure monitoring module.

[0052] The main air passage unit constitutes the main airflow channel of the solenoid valve, and includes an intake pipe assembly 60, a first outlet pipe assembly 40, and a second outlet pipe assembly 50. The intake pipe assembly 60 is connected to the vehicle's air source, and the first and second outlet pipe assemblies are respectively connected to different actuators or air passages.

[0053] The intake pipe assembly 60 has a main intake port, the first exhaust pipe assembly has a first exhaust port, and the second exhaust pipe assembly has a second exhaust port.

[0054] The proportional control valve structure 20 is fixedly installed on the upper part of the valve body of the integrated valve mounting base 10. The proportional electromagnetic drive structure includes an electromagnetic valve body 201 and a proportional electromagnetic drive assembly 202. The electromagnetic valve body is preferably made of aluminum alloy integral casting and has complex gas flow channels pre-embedded or machined inside.

[0055] The proportional electromagnetic drive assembly 202 is installed inside the solenoid valve body 201. The solenoid valve body has an air inlet pipe 203 that communicates with the air inlet assembly and an air outlet pipe 204 that communicates with the first air outlet pipe assembly.

[0056] The proportional electromagnetic drive assembly includes a proportional electromagnetic coil 205, a proportional valve core 206, and a pilot valve seat 207. The proportional valve core 206 can generate axial displacement relative to the pilot valve seat 207 under electromagnetic force, and the displacement is proportional to the input current. The main air intake is connected to the inlet of the pilot valve seat 207 through an intake passage within the valve body. When the electrical connector receives a control signal from the vehicle ECU, the proportional electromagnetic coil 205 is energized, generating electromagnetic force to drive the proportional valve core 206 to move, opening the pilot valve port. This allows compressed air from the main air intake to be precisely throttled and output to the solenoid valve outlet 208, which is connected to the pilot valve seat outlet. The solenoid valve outlet 208 is connected to the aforementioned solenoid valve outlet pipe 204. By adjusting the input current, the air pressure output to the solenoid valve outlet 208 can be linearly controlled.

[0057] The air path switching structure switches the airflow of the intake pipe assembly from the first exhaust pipe assembly to the second exhaust pipe assembly;

[0058] The gas path switching structure includes: a switching valve body 301, a coil valve cover 30, a coil assembly 304, a valve-operated core assembly 303, and an air inlet core assembly 305. The coil valve cover 302 is installed on the switching valve body 301, and the valve-operated core assembly 303 is installed on the coil assembly 304. The coil assembly is energized to move the valve core of the valve-operated core assembly back and forth. The air inlet core assembly 305 is connected to the valve-operated core assembly and is installed on the valve-operated core assembly 303. The switching valve body 301 has a first-side air inlet channel 306 that connects to the first air outlet pipe assembly. Specifically, the first-side air inlet channel 306 connects to the solenoid valve air outlet pipe 204 and a second-side air inlet channel 309 that connects to the second air outlet pipe assembly 50. The first-side air inlet channel serves as a first working position, and the second-side air inlet channel serves as a second working position. The switching valve body 301 has a switching valve body outlet 307 that connects to the first air outlet pipe assembly.

[0059] The first air outlet pipe assembly: A complete circuit is the air inlet pipe assembly 60 → solenoid valve air outlet pipe 204 → first side air inlet channel 306 → switching valve body air outlet 307.

[0060] Second exhaust pipe assembly: A complete circuit is intake pipe assembly 60 → solenoid valve exhaust pipe 204 → first side intake channel 306 → second side intake channel 309.

[0061] It should be noted that the structures of proportional valves and switching valves are existing technologies and will not be described in detail in this solution.

[0062] In the default power-off state, the switching chamber is in the upper position, and at this time, it remains connected to the first air outlet pipe assembly through its internal flow channel. When the switch solenoid coil is energized, it pushes the air inlet core assembly 305, thereby changing the air path connection within the switching chamber, disconnecting it from the first air outlet pipe assembly, and instead connecting it to the second air outlet pipe assembly (second side air inlet channel 309). This achieves the switching of the air path from the first air outlet pipe assembly to the second air outlet pipe assembly.

[0063] The air pressure monitoring module is integrated into the bottom of the integrated solenoid valve body 201, and includes a pressure sensor 41. The detection end of the pressure sensor 41 is connected to the main air passage leading to the solenoid valve outlet pipe 204 via a fine branch air passage 17. The design of this branch air passage 17 ensures that the pressure sensor 41 can monitor the actual air pressure value at the solenoid valve outlet pipe 204 in real time and accurately. The pressure sensor 41 converts the air pressure signal into an electrical signal and feeds it back to the ECU. The ECU compares this feedback value with the target value and dynamically adjusts the current of the input proportional solenoid coil 21, thereby forming a precise closed-loop pressure control system.

[0064] The proportional electromagnetic drive structure and / or air circuit switching structure are connected to a pressure relief channel, which mainly includes a solenoid valve body pressure relief channel 70 and a switching valve pressure relief channel 302 connected to the solenoid valve body pressure relief channel 70. The channel has an outlet, and a steel ball 701 is installed on the outlet.

[0065] A non-standard air path guide seat 308 is installed between the solenoid valve body and the switching valve body. The non-standard air path guide seat is divided into a first guide air path area connecting the first outlet pipe assembly and the first side inlet channel, and a second guide air path area connecting the second outlet pipe assembly and the second side inlet channel. The switching valve body has an embedded groove that matches the non-standard air path guide seat, which extends beyond the end face of the switching valve body. This design ensures orderly and sealed guidance of the air path within the complex valve body. Preferably, the non-standard air path guide seat extends approximately 1-3 mm beyond the end face of the switching valve body; this interference fit ensures a better sealing effect during assembly with the solenoid valve body.

[0066] Work process:

[0067] 1. Proportional Pressure Establishment and Monitoring: Based on braking requirements, the vehicle ECU outputs a specific current signal to the electrical connector of the proportional control valve structure. The proportional valve core opens accordingly to a certain degree, and the compressed air from the main intake port is regulated and output to the solenoid valve outlet 208. At the same time, the pressure at the solenoid valve outlet 208 is monitored and fed back in real time by the pressure sensor 41 through the branch air passage 17.

[0068] 2. Air Circuit Switching: When it is necessary to switch the braking power to another circuit, the ECU sends an energizing command to the switching solenoid coil of the air circuit switching structure. This switches the air circuit output from the first outlet pipe assembly to the second outlet pipe assembly. After the switch, the air pressure value output by the second outlet pipe assembly is still precisely controlled by the proportional control valve structure.

[0069] 3. Reset: When the switch solenoid coil is de-energized, the valve core resets under the action of the reset spring, and the air circuit switches back to the output of the first air outlet assembly.

[0070] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An exhaust braking solenoid valve, characterized in that: It includes a main air circuit unit, which is provided with a single air inlet pipe assembly, a first air outlet pipe assembly and a second air outlet pipe assembly; a proportional electromagnetic drive structure, which includes an electromagnetic valve body and a proportional electromagnetic drive assembly, the proportional electromagnetic drive assembly being installed in the electromagnetic valve body, the electromagnetic valve body having an air inlet pipe communicating with the air inlet assembly and an air outlet pipe communicating with the first air outlet pipe assembly. The air path switching structure switches the airflow of the intake pipe assembly from the first outlet pipe assembly to the second outlet pipe assembly; the air pressure monitoring module is integrated at the lower end of the solenoid valve body and includes a pressure sensor and a branch air path. The branch air path is connected to the air inlet pipe of the solenoid valve body and monitors the output air pressure value in real time. When the proportional electromagnetic drive component is energized, the air pressure of the intake pipe component is regulated and output to the first exhaust pipe component. At the same time, another air path is sent to the pressure sensor through a branch air path. The pressure sensor monitors the pressure of the first exhaust pipe component in real time. When the gas path switching structure is energized, the switching valve core is switched to the first working position to switch the gas path, so that the gas from the first gas outlet assembly is switched to the output of the second gas outlet assembly. When the gas path switching module is powered off, the switching valve core resets to the second working position, and the airflow switches back to the first outlet.

2. The exhaust brake solenoid valve according to claim 1, characterized in that: The gas path switching module includes a valve core, a movable diaphragm, and a linkage sealing assembly. When energized, the valve core pushes down the diaphragm, connecting the air intake pipe assembly to the second air outlet. In the power-off state, the sealing assembly resets, connecting the air intake pipe assembly to the first air outlet.

3. The exhaust braking solenoid valve according to claim 2, characterized in that: The branch gas path is diverted from the channel of the first gas outlet pipe assembly and extends to the detection end of the pressure sensor.

4. An exhaust braking solenoid valve according to claim 1, 2, or 3, characterized in that: The air pressure monitoring module is interconnected with the electromagnetic drive module; The pressure sensor feeds back the air pressure signal to the control unit in real time. The control unit adjusts the current intensity of the input electromagnetic drive module and dynamically controls the opening of the proportional electromagnetic drive component to achieve precise adjustment of the output air pressure.

5. The exhaust brake solenoid valve according to claim 1, characterized in that: The gas path switching structure includes: a switching valve body, a coil valve cover, a coil assembly, a valve-moving core assembly, and an air intake core assembly. The coil valve cover and the valve-moving core assembly are mounted on the coil assembly. The coil assembly is energized to move the valve core of the valve-moving core assembly back and forth. The air intake core assembly is connected to the valve-moving core assembly and is mounted on the valve core. The switching valve body has a first-side air intake channel that connects to the first air outlet pipe assembly and a second-side air intake channel that connects to the second air outlet pipe assembly. The first-side air intake channel serves as the first working position, and the second-side air intake channel serves as the second working position.

6. The exhaust brake solenoid valve according to claim 1, characterized in that: The proportional electromagnetic drive structure and / or gas path switching structure are connected to the backup gas path or pressure relief channel.

7. The exhaust brake solenoid valve according to claim 5, characterized in that: A special-shaped air passage guide seat is installed between the solenoid valve body and the switching valve body. The special-shaped air passage guide seat is divided into a first guide air passage area connecting the first air outlet pipe assembly and the first side air inlet channel, and a second guide air passage area connecting the second air outlet pipe assembly and the second side air inlet channel. The switching valve body is machined with an embedded groove that matches the special-shaped air passage guide seat. The special-shaped air passage guide seat extends beyond the end face of the switching valve body.

8. The exhaust brake solenoid valve according to claim 7, characterized in that: The irregularly shaped air passage guide seat extends 1-3mm beyond the end face of the switching valve body.

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