Ball Valve Safety Device for Trailer Brake Leakage
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Solution Overview
Problem
Existing safety devices for trailers with hydraulically actuable brake systems face operational safety issues due to leakage in slide valves, leading to a loss of braking effect over time, posing a risk of unsecured trailers.
Innovation Solution
The use of mechanically coupled ball valves with a check valve and non-return valve in the control unit ensures leak-free operation and continuous brake pressure availability, supported by a compact design with spiral springs and a detent mechanism for secure braking and reactivation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If slide valves are used in the control unit, then the device complexity is reduced, but leakage occurs leading to loss of braking effect
Solution Approach 1:
The patent replaces slide valves with ball valves in the control unit. Ball valves provide a spherical sealing surface that contacts the valve seat at a point or small line, creating a leak-free seal compared to the sliding motion of slide valves. This substitution eliminates the leakage problem while maintaining the mechanical actuation system.
Solution Approach 2:
The patent changes the valve geometry from a sliding interface to a spherical interface. The ball valve's spherical shape allows for a point contact seal that is inherently more reliable than the sliding seal of traditional valves. This geometric parameter change transforms the sealing mechanism from friction-based to pressure-based sealing.
2Reliability
If ball valves are used instead of slide valves, then leakage is eliminated, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions into the ball valve assembly. The ball valves serve both as switching elements and as non-return valves through their integrated design. The mechanically coupled arrangement of two ball valves creates a coordinated system that manages both supply and accumulator connections with a single actuation mechanism, reducing overall system complexity despite using ball valves.
Solution Approach 2:
The ball valves are designed to perform multiple functions: they act as on/off switching valves and simultaneously function as non-return valves. The integrated check valve feature within the ball valve assembly eliminates the need for separate check valves, reducing the total component count and system complexity.
3Reliability
If the trailer is secured in braked state after emergency braking, then operational safety is improved, but the loss of time for reactivation occurs
Solution Approach 1:
The patent pre-charges the hydraulic accumulator with brake fluid pressure before emergency braking is needed. The accumulator is continuously charged from the towing vehicle's brake system through the non-return valve during normal operation. When emergency braking occurs, the pre-stored pressure is immediately available, eliminating any time delay for brake actuation.
Solution Approach 2:
The hydraulic accumulator serves as a cushioning element that stores brake pressure in advance. This pre-stored energy acts as a buffer that can be immediately deployed during emergency situations, ensuring the trailer is secured without time loss. The accumulator compensates for any potential delays in the braking system response.
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 enhanced operational safety by maintaining the trailer in a braked state without pressure reduction, allowing for repeated secure braking and reactivation without connection to the towing vehicle, leveraging the stored braking energy from the hydraulic accumulator.
Implementation Method 1
a hydraulically actuable brake system, with a control unit which has a supply inlet for pressurized fluid to be supplied by the towing vehicle with brake pressure, a brake outlet in connection with at least one brake cylinder of the trailer, a hydraulic accumulator
Implementation Method 2
a switchable valve arrangement which can be brought from a first switching state, in which it connects the supply input to the brake output, into a second switching state, in which it connects the connection from the brake output to the supply input and connects the hydraulic accumulator to the brake outlet
Data Source
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AI summary
The device has a valve arrangement including mechanically-coupled ball valves (5, 7) that are actuated by clamping a traction member (21) from one switching position into another switching position. The switching positions correspond to a switching condition. One of the valves controls a connection between a supply input (P) and a brake output (V), and the other valve controls the connection between the brake output and a hydro pneumatic accumulator (4). The latter valve is provided with a return valve (25) that is pressure operatable for fluid flow from the brake output to the accumulator.