ABS Brake Modulator Cover Segmentation for Alignment and Sealing
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Solution Overview
Problem
Existing brake modulators for anti-lock braking systems (ABS) face challenges in ensuring proper alignment and sealing of multiple components, leading to potential leakage and increased manufacturing costs.
Innovation Solution
The brake modulator incorporates separately formed cover portions for the supply and exhaust valve cavities, along with a relay valve cover plate, which are either integrally formed with the main cover or formed separately, to facilitate easy alignment and sealing during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single integrated main cover is used to close all valve cavities and the relay valve cylinder, then the structural integrity is maintained, but the alignment precision and sealing quality deteriorate due to the long tolerance chain
Solution Approach 1:
The main cover is segmented into multiple separate cover portions: a first cover portion for the first supply valve cavity, a second cover portion for the second supply valve cavity, a third cover portion for the first exhaust valve cavity, and a fourth cover portion for the second exhaust valve cavity. Each cover portion is manufactured and assembled independently, eliminating the long tolerance chain problem while maintaining structural integrity through individual sealing surfaces.
Solution Approach 2:
A relay valve cover plate is introduced as an intermediary component to close the relay valve cylinder. This separate cover plate is positioned between the relay valve and the main cover portions, providing an additional sealing interface and simplifying the assembly process by allowing the relay valve to be pre-assembled and tested independently.
2Reliability
If high-tolerance manufacturing processes are used to ensure proper alignment and sealing, then the sealing quality improves, but the manufacturing cost increases
Solution Approach 1:
By dividing the main cover into multiple separate cover portions, each with its own sealing surface, the patent enables the use of standard-tolerance manufacturing processes for each individual portion. This segmentation eliminates the need for expensive high-tolerance machining while ensuring reliable sealing at each interface between cover portions and the main body.
Solution Approach 2:
The patent employs multiple separate cover portions that can be manufactured using cost-effective methods such as casting or standard machining. These individual cover portions replace the need for a single expensive, precision-machined integrated cover, reducing overall manufacturing cost while maintaining sealing reliability.
3Manufacturing precision
If multiple separate cover portions are used for each valve cavity, then the alignment and sealing improve, but the number of components and assembly complexity increases
Solution Approach 1:
The main cover is divided into four separate cover portions, each corresponding to a specific valve cavity. This segmentation allows each portion to be independently manufactured and assembled, improving alignment precision at each interface while the modular nature simplifies the overall assembly process by allowing sequential installation.
Solution Approach 2:
Each cover portion serves multiple functions: it closes its respective valve cavity, provides a sealing surface, and contributes to the overall structural integrity of the brake modulator. The relay valve cover plate similarly serves both as a closure and as a mounting surface for the relay valve, reducing the need for additional separate components.
4Ease of manufacture
If a simple flat cover plate is used, then the manufacturing cost is reduced, but the alignment and sealing of multiple components deteriorate
Solution Approach 1:
Instead of using a single simple flat cover plate, the patent employs multiple separate cover portions, each shaped and sized to fit its specific valve cavity. This segmentation maintains the cost-effectiveness of simpler manufacturing processes while ensuring proper alignment and sealing for each individual cavity through customized geometry.
Solution Approach 2:
Each cover portion is designed with specific local features tailored to its function: sealing surfaces matching the contours of their respective valve cavities, mounting interfaces for specific valves, and structural reinforcement where needed. This local customization ensures reliable sealing and alignment without requiring the entire cover structure to be manufactured at high tolerance.
Data Source
AI summary
A brake modulator (1) for providing an ABS brake function to a vehicle (200) includes a main body (17), a first ABS valve unit (47) configured to provide a first brake pressure (pB1) and a second ABS valve unit (53) configured to provide a second brake pressure (pB2), and a main cover (19) for closing of an assembly side (27) of the main body (17). The cover portions (127, 131, 133, 135) for covering corresponding valve cavities (33, 35, 37, 39) are formed separately from a main cover plate (20) of the main cover (19). A relay valve cover plate (137) is formed integrally with or separately from the main cover plate (20). The present disclosure further relates to a commercial vehicle (202) and to an assembly method (300) for a brake modulator (1).