Brake Modulator Guide Body Inserts for Symmetrical Air Distribution

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Solution Overview

Problem

The complex shaping of brake modulators with transverse compressed air connections leads to asymmetrical pressure build-up and requires complex manufacturing, including undercuts, which increases costs and reduces manufacturing simplicity.

Innovation Solution

A brake modulator design featuring two relay valves with guide body inserts that form delivery ducts from compressed air ports to valve seats, allowing for symmetrical pressure distribution and simplified manufacturing without undercuts, using plastics parts and a light alloy die-casting main housing with radial and transverse bores.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If transverse compressed air connections are used in brake modulators, then compact construction is achieved, but complex shaping with undercuts is required

Engineering Contradiction:

Improvecompact constructionVSAvoidmanufacturing complexity

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The brake modulator is divided into a main housing and separate guide body inserts. The guide body inserts contain the complex transverse bore configurations and delivery ducts, while the main housing remains simple and easy to manufacture. This segmentation allows the complex geometry to be isolated in removable inserts rather than requiring complex shaping of the entire housing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Guide body inserts act as intermediary components that mediate between the simple main housing and the complex pneumatic requirements. These inserts contain the transverse bores and delivery ducts, providing the necessary complex geometry without requiring the main housing itself to be complex. The inserts can be easily removed and replaced if needed.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If transverse compressed air connections are used, then compact construction is achieved, but subsequent machining is required

Engineering Contradiction:

Improvecompact constructionVSAvoidmanufacturing efficiency

Core Design Contradiction:

Volume of moving objectVSProductivity

Solution Approach 1:

By segmenting the brake modulator into a main housing and separate guide body inserts, the complex transverse bore configurations are contained within the inserts. These inserts can be manufactured separately using appropriate processes and then assembled into the simple main housing, eliminating the need for subsequent machining of the main housing itself.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The complex transverse bore configurations and delivery ducts are preliminarily formed within the guide body inserts during their manufacturing process. This preliminary action allows the complex geometry to be created in advance in a controlled manner, eliminating the need for subsequent machining operations on the main housing after assembly.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If compressed air ports are provided from opposite sides and axially offset, then connection versatility is achieved, but asymmetrical pressure build-up occurs

Engineering Contradiction:

Improveconnection versatilityVSAvoidpressure distribution uniformity

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The guide body inserts are designed with symmetrical transverse bore configurations relative to the central axis of the brake modulator. This symmetrical arrangement ensures that compressed air is distributed evenly to relay valves on opposite sides, creating uniform pressure build-up despite the ports being positioned on opposite sides for connection versatility.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The guide body inserts serve multiple functions: they provide the transverse bore configurations for versatile connection options, they contain the delivery ducts for compressed air distribution, and they ensure symmetrical pressure distribution through their balanced geometry. This multi-functionality achieves connection versatility without compromising pressure distribution uniformity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10259436B2Brake modulator for a compressed air braking system of a vehicle

Publication Date: 2019.04.16 ZF CV SYST EURO BV

AI summary

A brake modulator (1) for a compressed air braking system (80) of a vehicle is disclosed. The brake modulator (1) has a main housing (8) and two relay valves (2, 3). Each relay valve is configured with a delivery valve seat (31, 131) and a vent valve seat (30, 130) and a vent position, wherein compressed air inlets (2d, 3d) are connected via a transverse bore (27) to a common compressed air inlet port (25, 26), and a delivery duct (12a, 112a) extends in the axial direction (A) in each relay valve (2, 3). The relay valves (2, 3) have guide body inserts (12, 112) which are inserted into a longitudinal bore (29) of the main housing (8), which longitudinal bore (29) extends in the axial direction (A), and the relay valves (2, 3) in each case have the delivery duct (12a, 112a).