Bayonet-Mounted Pilot Valve for Tolerance-Stable Air Brake Assembly
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Solution Overview
Problem
Existing compressed air system pilot valves for commercial vehicles face challenges in modular design, assembly simplicity, avoidance of unintentional disassembly, and consideration of manufacturing tolerances, leading to increased manufacturing effort and storage costs.
Innovation Solution
A compressed air system pilot valve design utilizing a bayonet connection for easy assembly and disassembly, with a control module attached to the valve module housing part, allowing for precise alignment and tolerance compensation, and the use of identical control modules across different valve designs to reduce production and storage efforts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bayonet connection is used to connect the control module to the valve module housing, then assembly and disassembly are simplified and manufacturing tolerances are compensated, but the connection requires sufficient mechanical strength to prevent unintentional disassembly
Solution Approach 1:
The bayonet connection incorporates a rotational locking mechanism that transitions from an insertion motion to a rotated locked position, providing both ease of assembly and secure connection. The dynamic movement allows for tolerance compensation during insertion while the final rotated position ensures reliable locking.
Solution Approach 2:
The bayonet connection features asymmetric flange segments and circumferential recess segments that engage at specific rotational positions. This asymmetry prevents unintentional disassembly by requiring a specific rotational motion to engage or disengage the connection, while still allowing simple assembly through the defined engagement path.
2Ease of manufacture
If identical control modules are used across different valve designs, then manufacturing and storage efforts are reduced, but the control module must be adaptable to various valve module configurations
Solution Approach 1:
The control module is designed as a universal component that can be adapted to different valve module configurations through the standardized bayonet connection interface. The modular design allows the same control module to serve multiple functions across different valve designs, reducing manufacturing complexity while maintaining adaptability.
Solution Approach 2:
The system is divided into separate modular components: a standardized control module and various valve module configurations. This segmentation allows the control module to be manufactured once and reused across different applications, while the valve modules can be customized for specific functions without affecting the control module design.
3Manufacturing precision
If the control module is inserted into a recess of the valve module housing, then precise alignment is achieved, but the connection must prevent unintentional disassembly
Solution Approach 1:
The control module is inserted into a recess of the valve module housing, creating a nested arrangement where one component fits within another. This nesting provides precise alignment through the recess geometry while the bayonet locking mechanism ensures the nested components remain securely connected.
Solution Approach 2:
The recess in the valve module housing is pre-formed to guide and align the control module during insertion. This preliminary structural preparation ensures precise alignment before the bayonet locking mechanism engages, preventing misalignment while maintaining connection security.
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 bayonet connection simplifies assembly and disassembly, ensures secure and rigid connections, and allows for tolerance compensation, resulting in a more efficient and cost-effective modular design with reduced manufacturing and storage requirements.
Implementation Method 1
The control module comprises a control module housing, an electromagnetic actuator, a control valve body actuated by the electromagnetic actuator
Data Source
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AI summary
The invention relates to a compressed air system pilot valve (4) intended for use in a compressed air system, in particular a pneumatic braking system or an air suspension system, of a commercial vehicle. The compressed air system pilot valve (4) has a control module (8) which provides a control pressure for the electropneumatic pilot control of a valve module (11). According to the invention, the valve elements of the compressed air system pilot valve (4) are mounted by means of at least one bayonet connection (50; 51). The compressed air system pilot valve (4) can, for example, be a lift-lower valve, a lift axle valve, or a trailer control valve.