Brake Controller Solenoid Valve Merging for Railcar Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing railcar brake controllers are large and complex due to the numerous solenoid valves required for regular and emergency braking, leading to a high failure rate and inability to utilize the booster solenoid valve in regular braking.
Innovation Solution
A brake controller utilizing a boost-switching solenoid valve to switch pressure output between regular and emergency braking modes, eliminating the need for separate emergency and switching solenoid valves, and incorporating a variable load valve to supply pressure to the brake cylinder in both modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple solenoid valves (emergency solenoid valve, switching solenoid valve, booster solenoid valve) are used to achieve both regular and emergency braking functions, then the braking functionality is complete, but the device size becomes large and the configuration becomes complex
Solution Approach 1:
The patent applies the universality principle by enabling the booster solenoid valve to perform multiple functions: it serves as the booster solenoid valve during regular braking to amplify brake cylinder pressure, and as the emergency solenoid valve during emergency braking to rapidly release pressure. This eliminates the need for separate emergency and switching solenoid valves, reducing the total number of components from three to one while maintaining complete braking functionality across both operating modes
Solution Approach 2:
The patent merges the functions of the emergency solenoid valve and switching solenoid valve into the existing booster solenoid valve. By controlling the opening and closing states of the booster solenoid valve's first and second solenoids in different combinations, the system achieves both regular braking (pressure amplification) and emergency braking (pressure release) functions, thereby combining multiple valve functions into a single integrated component
2Adaptability or versatility
If many solenoid valves are used to achieve complete braking control, then the braking control capability is comprehensive, but the number of parts increases leading to high failure rate
Solution Approach 1:
The booster solenoid valve is designed with multi-functionality to serve as both the booster valve for regular braking and the emergency valve for emergency braking. This reduces the total number of solenoid valves from three to one, directly lowering the probability of component failure while maintaining comprehensive braking control capability through intelligent control of the single valve's multiple states
3Adaptability or versatility
If separate emergency solenoid valve and switching solenoid valve are used, then the emergency braking function is independent, but the device exterior becomes large
Solution Approach 1:
The booster solenoid valve is designed to independently perform emergency braking function while also serving regular braking functions. By integrating the emergency valve function into the booster valve's capability set, the patent eliminates the need for separate emergency and switching valves, significantly reducing the controller's exterior size while maintaining independent emergency braking capability
Solution Approach 2:
The patent merges the emergency valve and switching valve functions into the booster solenoid valve's control logic. The valve can operate in different states (first solenoid on/off, second solenoid on/off) to achieve both regular and emergency braking, combining previously separate functions into a single integrated component that reduces overall device footprint
4Productivity
If booster solenoid valve is only used in regular braking, then the regular braking performance is optimized, but the valve cannot be utilized in emergency braking reducing system efficiency
Solution Approach 1:
The booster solenoid valve is designed with universal applicability to function in both regular braking (pressure amplification) and emergency braking (pressure release) modes. This dual-mode operation maximizes the valve's utilization efficiency, allowing the same component to optimize brake response in normal operations while also providing rapid pressure release capability in emergency situations, thereby improving overall system efficiency
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 results in a smaller, simpler configuration with fewer parts, enabling proper utilization of the boost-switching solenoid valve in both braking modes, improving brake response and reducing the risk of failure.
Implementation Method 1
a first solenoid valve outputting a first pressure; a second solenoid valve outputting a second pressure; a third solenoid valve switching between the first pressure and the second pressure
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The output pressure of a variable load valve (121) is controlled by a boost-switching solenoid valve (111). In the regular braking of the brake, the output pressure of the variable load valve (121) is boosted by the boost-switching solenoid valve (111), adjusted to a target pressure by a brake control valve (131, 132), and supplied to a brake cylinder (21, 24) via a relay valve (141, 142). In the emergency braking of the brake, the boost-switching solenoid valve (111) is turned off and the output pressure is supplied to the brake cylinder (21, 24) via the brake control valve (131, 132) and relay valve (141, 142). In case of possible increase in the braking distance, the boost-switching solenoid valve (111) is turned on to boost the braking force.