Brake Pressure Modulator Merging Independent Circuits

Solution Overview

Problem

The existing electronic brake systems for utility vehicles require a large installation space and high manufacturing costs due to spatially and structurally separate brake pressure modulators, which complicates the design and increases expenses for light to medium-weight vehicles.

Innovation Solution

A compact and cost-effective brake pressure modulator design integrates two independent pressure control circuits with a common electronic control module, incorporating a redundant control pressure path and forced venting mechanism to ensure safe braking in case of system failures, while minimizing the number of fail-safe components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If spatially and structurally separate brake pressure modulators are used for individual pressure control circuits, then reliable independent pressure control is achieved, but installation space requirement and manufacturing expense increase

Engineering Contradiction:

Improvereliable independent pressure controlVSAvoidinstallation space requirement

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent combines two independent pressure control circuits into a single integrated brake pressure modulator. The control unit houses both pressure control circuits with their respective electromagnetically actuatable valve arrangements, allowing independent control of front and rear axle brake pressures while occupying less space than separate modulators would require

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single brake pressure modulator is designed to perform multiple functions by integrating control for both front and rear axle brakes within one device. The control unit can independently regulate pressure for different axles, making the device universal for managing brake pressure across multiple circuits

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If spatially and structurally separate brake pressure modulators are used for individual pressure control circuits, then reliable independent pressure control is achieved, but manufacturing expense increases

Engineering Contradiction:

Improvereliable independent pressure controlVSAvoidmanufacturing expense

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines two independent pressure control circuits into a single integrated brake pressure modulator. The control unit houses both pressure control circuits with their respective electromagnetically actuatable valve arrangements, allowing independent control of front and rear axle brake pressures while occupying less space than separate modulators would require

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single brake pressure modulator is designed to perform multiple functions by integrating control for both front and rear axle brakes within one device. The control unit can independently regulate pressure for different axles, making the device universal for managing brake pressure across multiple circuits

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If a common electronic control module is used for multiple pressure control circuits, then device complexity and cost are reduced, but the risk of simultaneous failure of all circuits increases

Engineering Contradiction:

Improvedevice complexityVSAvoidrisk of simultaneous failure

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The control unit is segmented into multiple independent pressure control circuits, each with its own electromagnetically actuatable valve arrangement. This segmentation allows the system to maintain independent control paths for front and rear axles within a single device, reducing the risk that a failure in one circuit will affect the other

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each pressure control circuit within the common control unit is designed with local independence, having its own valve arrangement and control logic. This allows the system to maintain different operational states for different axles and isolates failures to specific circuits rather than causing system-wide failures

Inventive Principle:

Principle #3Local quality

4Ease of manufacture

If the number of fail-safe components is minimized to reduce costs, then manufacturing expense is reduced, but the ability to ensure safe braking in case of failure may be compromised

Engineering Contradiction:

Improvemanufacturing expenseVSAvoidability to ensure safe braking in case of failure

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The brake pressure modulator incorporates automatic failure detection and response mechanisms. The control unit monitors the operational status of each pressure control circuit and automatically activates backup valve arrangements or alternative control paths when a failure is detected, without requiring external intervention or additional complex safety systems

Inventive Principle:

Principle #25Self-service

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

This design reduces costs and installation space requirements, providing a reliable and safe braking system suitable for light utility vehicles by allowing independent control of brake pressures on each axle and preventing unintended braking through forced venting, thus ensuring continued operation even in case of electronic control failures.

Implementation Method 1

electromagnetically actuatable valve arrangements

Methodology Applied

Scientific EffectElectromagnetic actuation: Electromagnet

Implementation Method 2

a redundant control pressure path, by means of which a working pressure is passed to the working pressure connection

Methodology Applied

Scientific EffectPneumatic pressure transmission: Pressure Gradient

Implementation Method 3

at least one venting path

Methodology Applied

Scientific EffectPressure venting: Depressurisation

Data Source

PatentUS10093293B2Brake pressure modulator of an electronic braking system of a utility vehicle

Publication Date: 2018.10.09 ZF CV SYST EURO BV

AI summary

A brake pressure modulator (1) of an electronic braking system of a utility vehicle includes pressure control circuits (13, 14) respectively associated with a braking circuit of a vehicle axle, each pressure control circuit (13, 14) comprises a compressed air supply system (4, 5), at least one redundancy control pressure path (21), at least one ventilation path (19, 19a) and a common electronic control unit (2). Said pressure control circuits (13, 14) can be controlled independently from each other by the electronic control unit (2). Each pressure control circuit (13, 14) has an independent ventilation path (19, 19a) and at least one of the pressure control circuits (13, 14) has an independent redundancy control pressure path (21) and at least one other of the pressure control circuits (13, 14) comprises a device (16a) for forced venting in the event of a failure by means of the associated ventilation path (19a).