Pneumatic Brake Module Snap-Fit Piston for Variable Air Control
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Solution Overview
Problem
Existing pneumatic brake control modules for vehicles lack efficient mechanisms for controlling compressed air flow to adjust braking force, particularly in trailer-brake systems, where infinite variability and secure snap-fit assembly are essential.
Innovation Solution
A pneumatic brake control module with a housing, first and second pistons, and a pneumatic valve that allows compressed air to be supplied and exhausted through a plate valve mechanism, utilizing a telescopic structure with a snap-fit assembly of tubular parts and flexible arms for secure assembly and adjustable braking force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional rigid assembly method is used for tubular parts, then manufacturing precision is improved, but device complexity and ease of manufacture deteriorate
Solution Approach 1:
The second piston is divided into two separate tubular parts (first tubular part and second tubular part) that are assembled together using a snap-fit mechanism. This segmentation allows each part to be manufactured independently with standard tolerances, then quickly assembled through the elastic arms engaging with the circumferential groove, eliminating complex rigid assembly procedures while maintaining assembly precision.
Solution Approach 2:
The snap-fit mechanism utilizes elastic deformation of the arms as a parameter change to achieve secure assembly. The arms are designed with elastic properties that allow them to deform during assembly and then maintain a stable engaged state with the circumferential groove, providing both ease of assembly and manufacturing precision without requiring complex fastening procedures.
2Ease of manufacture
If a snap-fit mechanism with elastic arms is used, then ease of manufacture is improved, but reliability deteriorates due to potential involuntary re-opening
Solution Approach 1:
The first tubular part is inserted into the second tubular part, forming a nested structure. The elastic arms of the second tubular part engage with the circumferential groove of the first tubular part from the inside, creating a secure interlocking connection. This nested arrangement ensures that the connection cannot inadvertently open during operation, as the arms are contained within the first tubular part's groove structure.
Solution Approach 2:
The snap-fit mechanism is designed with elastic arms that provide a cushioning effect during assembly and operation. The elasticity of the arms absorbs mechanical stresses and prevents sudden disengagement, ensuring reliable connection stability while maintaining ease of assembly through the simple snap-fit action.
3Adaptability or versatility
If multiple separate components are used for the piston structure, then adaptability is improved, but device complexity increases
Solution Approach 1:
The first tubular part and second tubular part are merged into a single integrated second piston assembly through the snap-fit connection. The elastic arms and circumferential groove form an inherent connecting structure that combines multiple functional elements (support, end stop, telescopic structure, spring element accommodation) into one adaptable piston unit, reducing the number of separate components while maintaining structural versatility.
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
Enables infinitely variable braking force control and secure snap-fit assembly, ensuring reliable operation and ease of manufacturing, while preventing involuntary re-opening of the snap-fit mechanism.
Implementation Method 1
The actuated first piston opens a plate valve within the second piston against a restoring force of a spring element
Implementation Method 2
The first tubular part is snap-fitted to the second tubular part... The flexible arms are designed to be elastically deformable
Data Source
Figure 1a~1b
Figure 1c
Figure 2a~2b
AI summary
Provided is a component (38) for a pneumatic brake control module. The component (38) comprises a first tubular part (10) that is snap-fitted to a second tubular part (24), and a telescopic structure with a spring element, arranged between the tubular parts (10, 24).