Air Pressure Regulator with Integrated Leak Detection Sensor
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Solution Overview
Problem
Existing air pressure regulators in vehicle tire suspension systems lack an integrated sensor that accurately detects leaks without false signals and are difficult to assemble and adjust for various pressure ranges.
Innovation Solution
A combination air regulator and sensor assembly featuring a head with a first chamber, a regulator dome with a valve assembly and diaphragm, and a sensor dome with a conductive contact ring and non-conductive cup washer, which uses differential pressure to engage electrical contacts and activate an electrical switch for leak detection, allowing for adjustable pressure regulation and accurate leak indication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate flow sensor is used to detect tire leaks, then leak detection capability is provided, but device complexity increases and assembly becomes more difficult
Solution Approach 1:
The patent combines the flow sensor and pressure regulator into a single integrated assembly. The sensor dome with diaphragm and electrical contacts is merged with the regulator body, allowing both leak detection and pressure regulation functions to be performed by one component unit, thereby reducing assembly complexity while maintaining detection accuracy
2Stress or pressure
If a manually adjustable regulator is used to set pressure, then pressure regulation capability is provided, but ease of operation decreases and adjustment for various pressure ranges becomes difficult
Solution Approach 1:
The patent incorporates an adjustable mechanism within the regulator dome that allows the pressure set point to be dynamically changed. The regulator can be adjusted to provide for various pressure actuation ranges, transforming a static pressure regulation device into a dynamic one that adapts to different operational requirements
3Device complexity
If an integrated sensor and regulator assembly is used, then device complexity is reduced and assembly is easier, but measurement precision may be compromised
Solution Approach 1:
The patent applies local quality by providing separate optimized zones within the integrated assembly. The sensor dome contains specifically positioned electrical contacts and diaphragm components for accurate leak detection, while the regulator section contains the valve and spring mechanisms for pressure control. Each zone is designed with its own specific geometric and material properties to optimize its function, ensuring measurement precision is maintained despite integration
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
The solution provides an integrated, accurate, and adjustable air pressure regulator with a built-in sensor that effectively detects leaks and prevents false signals, enhancing the reliability and ease of assembly in tire inflation systems.
Implementation Method 1
The valve assembly moves in response to a pressure applied to the first diaphragm
Implementation Method 2
A spring contacts the first diaphragm and applies a biasing force to the first diaphragm
Implementation Method 3
The electrical contacts selectively engage a component of the second diaphragm responsive to a differential pressure of the second diaphragm to define an electrical switch
Data Source
AI summary
A combination air regulator and sensor assembly includes a head including a first chamber having an inlet and an outlet. A regulator dome including a second chamber is linked with the first chamber through a bore. The second chamber includes at least one outlet. A valve assembly is housed within the bore and moveable between closed and open positions sealing and allowing flow in the bore. A first diaphragm is positioned in the second chamber and linked with the valve assembly. The valve assembly moves in response to a pressure applied to the first diaphragm. A spring contacts the first diaphragm and applies a biasing force to the first diaphragm. A sensor dome including a third chamber is linked with the outlet of the second chamber. The sensor chamber includes a discharge outlet. A second diaphragm is positioned in the sensor chamber. The second diaphragm includes a rubber disk having a conductive contact ring attached on one side of the rubber disk and a non-conductive cup washer attached on the same side of the disk. The cup washer includes a hole formed there through allowing passage of air between opposing sides of the second diaphragm. A sensor spring contacts the second diaphragm and applies a biasing force to the second diaphragm. Electrical contacts are attached to the sensor chamber. The electrical contacts selectively engage the contact ring and are responsive to a differential pressure of the second diaphragm to define an electrical switch.