Commercial Vehicle Brake Pressure Valve for Fail-Safe Mode Switching
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Solution Overview
Problem
Traditional pressure regulating valves for air braking systems in commercial vehicles lack the accuracy, speed, and adaptability required for advanced driving automation levels, particularly failing to ensure safe braking during system power failures.
Innovation Solution
An automatic pressure regulating valve with a switching valve, quick-acting intake and exhaust valves, and a pressure sensor, allowing for real-time, accurate regulation of brake chamber pressure, enabling seamless transitions between manual and electronic braking modes, and ensuring operation during power failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional pressure regulating valves are used in air braking systems, then the system structure is simple, but the pressure regulating accuracy is low and response time is delayed
Solution Approach 1:
The pressure regulating valve is divided into multiple independent functional modules: switching valve, quick-acting intake valve, quick-acting exhaust valve, and relay valve. Each module performs a specific function, allowing for precise pressure control while maintaining manageable system complexity through modular design.
Solution Approach 2:
A relay valve is introduced as an intermediary component to amplify and transmit control signals. The relay valve receives control pressure from the switching valve and translates it into proportional pressure regulation at the brake chamber, enabling accurate pressure control without requiring the main valve to handle full braking force directly.
2Speed
If traditional pressure regulating valves are used, then the device complexity is low, but the pressure response time is delayed and braking pressure is insufficient
Solution Approach 1:
The switching valve is positioned upstream to pre-regulate control pressure before it reaches the quick-acting valves. This preliminary action ensures that when braking is required, the quick-acting intake and exhaust valves can respond immediately with full pressure differential, eliminating response delays without requiring an overly complex direct-actuation system.
Solution Approach 2:
The traditional purely mechanical linkage is replaced with a pneumatic control system using compressed air as the control medium. The switching valve uses pneumatic pressure to control the quick-acting valves, which in turn control the brake chamber pressure. This pneumatic substitution enables faster response times compared to mechanical linkages while maintaining system simplicity.
3Adaptability or versatility
If a one-way valve is used in the automatic pressure regulating valve, then the structure is simplified, but the adaptability is reduced to only single brake stop in case of power failure
Solution Approach 1:
The switching valve is designed as a dynamic component that can change its connectivity configuration based on system state. It can switch between connecting the manually controlled port to the control chamber (for normal operation) and maintaining connectivity during power failures. This dynamic adaptability allows the system to handle multiple braking scenarios without requiring a one-way valve restriction.
Solution Approach 2:
The switching valve serves multiple functions: it acts as a normal control valve during powered operation, serves as a backup control mechanism during power failures, and enables both single and multiple brake stops. This multi-functionality provides adaptability across different operating conditions without increasing overall system complexity, as the same valve structure performs multiple roles.
4Extent of automation
If electro-pneumatic braking system is implemented for intelligent braking, then the braking intelligence is improved, but the reliability during power failure is compromised
Solution Approach 1:
The switching valve is designed with inherent fail-safe characteristics that provide beforehand cushioning against power failure scenarios. The valve's default position and connectivity ensure that manual braking control remains functional even when electronic control power is lost. This prior design consideration ensures reliability during power failures without sacrificing the electro-pneumatic automation capabilities during normal operation.
Solution Approach 2:
The switching valve automatically detects system state (powered or power-failed) and self-adjusts its control function without requiring external intervention. During normal operation, it enables electronic control; during power failure, it automatically maintains manual control capability. This self-service behavior ensures continuous reliability across different power states while maintaining high automation levels during powered operation.
Data Source
AI summary
An automatic pressure regulating valve for multiple levels of driving automation of a commercial vehicle includes an upper valve body, a lower valve body, a piston, a main valve core assembly, a switching valve, a quick-acting intake valve, and a quick-acting exhaust valve. The switching valve, the quick-acting intake valve and the quick-acting exhaust valve are all mounted at an upper end of the upper valve body. The piston is located in a chamber formed by the upper valve body and the lower valve body to divide the chamber into an upper control chamber and a lower chamber. The main valve core assembly is mounted in the lower valve body. The automatic pressure regulating valve is applicable to a commercial vehicle allowing for multiple levels of driving automation.