Modular Air-Brake Valve Unit with Integrated Solenoid Housing
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Solution Overview
Problem
Existing valve units for compressed air braking systems are complex and costly to produce due to their multi-piece design and intricate machining requirements, particularly in arranging diaphragm valves with parallel actuation axes in a common diaphragm plane, which complicates installation and increases production costs.
Innovation Solution
The precontrol valves of the inlet and outlet valves are arranged in the housing cover with actuation axes parallel to the division plane, integrated within a magnet module and air guide modules, connected via a single element to the base housing, allowing for a compact and modular design that simplifies installation and reduces production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the valve unit uses a multi-piece design with intricate machining to arrange diaphragm valves with parallel actuation axes in a common diaphragm plane, then the valves can be precisely positioned and function correctly, but the production complexity and cost increase significantly
Solution Approach 1:
The patent merges the previously separate housing pieces into a single-piece valve housing. The diaphragm valves with parallel actuation axes are integrated into this unified housing structure, eliminating the need for multiple housing components and complex assembly operations while maintaining precise positioning of the valves.
Solution Approach 2:
The single-piece valve housing is designed with integrated seating surfaces and mounting features that segment the functional zones within the unified structure. This allows precise positioning of diaphragm valves and precontrol valves without requiring separate housing pieces, achieving functional segmentation within a monolithic structure.
2Manufacturing precision
If the valve unit uses a complex multi-piece design, then the valves can be arranged in a common diaphragm plane, but the installation and assembly become more difficult and time-consuming
Solution Approach 1:
By combining multiple housing pieces into a single-piece valve housing, the patent eliminates complex assembly operations. The diaphragm valves are pre-positioned on integrated seating surfaces during manufacturing, ensuring alignment of the common diaphragm plane while simplifying installation to a single unit rather than multiple components.
Solution Approach 2:
The single-piece housing is manufactured with pre-formed seating surfaces and mounting features that automatically position the diaphragm valves in the correct alignment. This preliminary positioning during manufacturing eliminates the need for complex field assembly and alignment operations, making installation easier and more reliable.
3Manufacturing precision
If the valve unit uses intricate machining and multi-piece construction, then the valves can be precisely positioned, but the production cost increases
Solution Approach 1:
The patent consolidates multiple machined housing pieces into a single-piece valve housing manufactured using injection molding or similar cost-effective processes. This merging eliminates expensive multi-step machining operations and assembly costs while maintaining precise valve positioning through integrated design features.
Solution Approach 2:
The patent replaces traditional mechanical machining and assembly of multiple metal housing pieces with a single-piece construction method such as injection molding. This substitution maintains the necessary positioning precision through molded-in features while dramatically reducing production complexity and cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration results in a compact valve unit with short switching times and easy assembly, as the housing cover is low in height and the modules can be produced simply, reducing production costs and improving installation accessibility.
Implementation Method 1
respective precontrol valves which are each configured as a 3/2-way solenoid valve
Implementation Method 2
A diaphragm valve has a largely circular, disc-like flexible membrane which is clamped at its edge in a valve housing. A central, round valve seat of a cylindrical inner flow channel, with an annular outer flow channel arranged concentrically thereto, is arranged on the axial inside of the diaphragm on which the flow channels are arranged which are connected to the compressed air input and compressed air outputs.
Data Source
AI summary
A valve unit (1.1, 1.2, 1.3) for modulating pressure in a compressed air braking system has an inlet valve (6) configured as a diaphragm valve, an outlet valve (7) configured as a diaphragm valve, and respective precontrol valves (8, 9), which are each configured as a 3/2-way solenoid valve and are arranged in an elongate valve housing (2), which is divided by a division plane (10) that is largely horizontal in the installation position into a base housing (11) and a housing cover (12). The precontrol valves (8, 9) are arranged in the housing cover (12) in the longitudinal direction (13), and the housing cover (12) has a centrally arranged magnet module (20) and two air guide modules (23, 24) adjacent to the magnet module (20) in the longitudinal direction (13) and connected via a single connecting element (45) both to each other and to the base housing (11).