Electropneumatic Brake Control Module Redundancy Valve

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Solution Overview

Problem

Existing electropneumatic brake control modules for utility vehicles lack redundancy to ensure safe braking in case of electronic component failures, and they require complex relay valves that increase installation space and cost.

Innovation Solution

Incorporating a redundancy pressure port and valve unit that allows manual override via the brake pedal, eliminating the need for relay valves by using pneumatically switchable 2/2-way valves and a shuttle valve to vent and introduce redundancy pressure, thereby ensuring safe braking even in fault conditions while reducing module size and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If relay valves are used to control braking pressure, then the braking control function is achieved, but the installation space and manufacturing cost increase

Engineering Contradiction:

Improvebraking control functionVSAvoidinstallation space and manufacturing cost

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the essential function of pressure control from complex relay valves and implements it using simpler pneumatic 2/2-way valves combined with electronic control. The relay valve is replaced by a combination of simpler components that achieve the same braking pressure control function with reduced complexity and space requirements.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the purely mechanical relay valve system with a hybrid system combining electronic control signals and pneumatic 2/2-way valves. The electronic control unit receives braking demand signals and actuates the pneumatic valves, substituting complex mechanical pressure control with a more compact electronically-controlled pneumatic system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Extent of automation

If electronic control components are used for braking demand signal processing, then automated braking control is achieved, but system reliability decreases due to potential electronic failures

Engineering Contradiction:

Improveautomated braking controlVSAvoidsystem reliability

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

The patent incorporates a redundancy pressure port that can be pre-charged with compressed air, serving as a backup pressure source. In case of electronic control failure, this pre-stored redundancy pressure can be automatically or manually activated to maintain braking functionality, cushioning against the reliability risks of electronic components.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent introduces a redundancy pressure port as an intermediary backup system between the electronic control unit and the braking system. This intermediary pressure source acts as a mediator that can take over pressure supply functions when the electronic control system fails, ensuring continued operational reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enhances the reliability of the brake control module by enabling safe braking during electronic failures and reduces installation space and manufacturing costs by eliminating the need for complex relay valves.

Implementation Method 1

pneumatically switchable 2/2-way valves and a shuttle valve to vent and introduce redundancy pressure

Methodology Applied

Scientific EffectPneumatic pressure: Pressure Increase

Implementation Method 2

allows manual override via the brake pedal

Methodology Applied

Scientific EffectManual compression: Compression

Data Source

PatentUS11440521B2Electropneumatic brake control module for utility vehicles with redundancy pressure connector

Publication Date: 2022.09.13 ZF CV SYST EURO BV

AI summary

An electropneumatic brake control module (1) for utility vehicles (100) includes a supply port (2) for connecting a compressed air supply (3); a first axle channel port (4); a pneumatically controlled inlet/outlet valve unit (10) for outputting a first braking pressure (PB1) at the first axle channel port (4); and an electropneumatic pilot control unit (8) for outputting at least one first control pressure (P1) at the inlet/outlet valve unit (10). The brake control module (1) further includes a redundancy pressure port (6) for receiving a redundancy pressure (PR) and a redundancy valve unit (12) connected to the redundancy pressure port (6) for outputting a redundancy braking pressure (PBR) at the first axle channel port (4) in the event that the electropneumatic pilot control unit (8) has a fault.