Brake Modulator Cover Plate Assembly for Leak-Tight Valve Alignment
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Solution Overview
Problem
Existing brake modulators face challenges with leakage, proper alignment, and high manufacturing costs due to the use of conventional flat steel covers that require precise tolerances and complex assembly processes.
Innovation Solution
The brake modulator incorporates a main cover with separate or integrally formed cover portions for supply and exhaust valve cavities, along with a relay valve cover plate, using plastic materials and self-centering mechanisms to ensure alignment and sealing, reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flat steel covers are used to close the main body, then sealing and structural strength are improved, but manufacturing cost and assembly complexity increase due to precise tolerance requirements
Solution Approach 1:
The patent replaces expensive steel covers with cost-effective plastic cover portions that can be manufactured through injection molding. The plastic material allows for easier manufacturing while maintaining adequate sealing performance through integrated sealing elements, thereby reducing manufacturing costs without significantly compromising reliability
Solution Approach 2:
The invention changes the material parameter from steel to plastic, which fundamentally alters the manufacturing approach and cost structure. Plastic materials enable mass production through injection molding, eliminating the need for expensive machining operations and tight tolerance controls required for steel components
2Reliability
If conventional flat steel covers are used to close the main body, then sealing and structural strength are improved, but assembly complexity increases due to complex assembly processes
Solution Approach 1:
The cover is segmented into multiple cover portions (first cover portion for first cavity, second cover portion for second cavity) that can be manufactured and assembled independently. This segmentation simplifies the overall assembly process by allowing modular assembly and reducing the complexity of assembling a single large complex cover
Solution Approach 2:
The patent merges the sealing function directly into the cover portions by integrating sealing elements (such as sealing beads or gaskets) as part of the plastic cover structure. This merging eliminates separate sealing components and simplifies assembly by reducing the number of parts that need to be assembled
3Ease of manufacture
If plastic materials are used for cover portions, then manufacturing cost is reduced, but sealing performance may deteriorate
Solution Approach 1:
The patent employs composite construction by combining plastic material for the cover body with integrated sealing elements (such as rubber gaskets or sealing beads) that provide the necessary sealing properties. This composite approach allows the cover to benefit from the low cost and ease of manufacturing of plastic while maintaining reliable sealing through the specialized sealing materials
Data Source
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AI summary
The invention refers to a brake modulator (1) for providing an ABS brake function to a vehicle (200), comprising a main body (17), to provide a main pressure (pM) dependent on a brake request, a first ABS valve unit (47) configured to provide a first brake pressure (pB1) and a second ABS valve unit (53) configured to provide a second brake pressure (pB2), and a main cover (19) for closing of an assembly side (27) of the main body (17). The brake modulator is characterized by a relay valve cover plate (137) formed integrally with or separately from the main cover (19). The invention further relates to a commercial vehicle (202) and to an assembly method (300) for a brake modulator (1).