Brake Valve Housing with Interchangeable Inserts
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Solution Overview
Problem
The complexity and high cost of equipping vehicles with different braking systems are due to the need for various valve devices with distinct designs and housings, leading to small production quantities and increased expenses.
Innovation Solution
A valve device with a standardized housing and interchangeable inserts, allowing the same housing type to be used for different brake systems by selecting appropriate inserts that modify the pressure medium path for specific functions, reducing the need for multiple housing types and enabling easy conversion between configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different valve devices with distinct designs and housings are used for different brake systems, then the functionality for specific brake systems is ensured, but the device complexity and manufacturing costs increase due to small production quantities
Solution Approach 1:
The valve device is segmented into a standardized housing and interchangeable functional inserts. Each insert contains specific pressure medium paths and valve components tailored to different brake system requirements. This segmentation allows the housing to remain uniform while the inserts provide system-specific functionality, reducing overall device complexity and enabling standardized manufacturing of the housing component.
Solution Approach 2:
A universal standardized housing is designed that can accommodate multiple types of functional inserts for different brake systems (service brake, parking brake, combined systems). The housing includes standardized mounting features, connection interfaces, and internal structures that work with various inserts, allowing one housing design to serve multiple brake system configurations and reducing the need for multiple housing variants.
2Adaptability or versatility
If multiple housing types are produced for different valve devices, then the specific functional requirements of different brake systems are met, but the manufacturing costs increase due to small production quantities of each housing type
Solution Approach 1:
A universal standardized housing is designed that can accommodate multiple types of functional inserts for different brake systems (service brake, parking brake, combined systems). The housing includes standardized mounting features, connection interfaces, and internal structures that work with various inserts, allowing one housing design to serve multiple brake system configurations and reducing the need for multiple housing variants.
Solution Approach 2:
The valve device is segmented into a standardized housing and interchangeable functional inserts. Each insert contains specific pressure medium paths and valve components tailored to different brake system requirements. This segmentation allows the housing to remain uniform while the inserts provide system-specific functionality, reducing overall device complexity and enabling standardized manufacturing of the housing component.
3Adaptability or versatility
If plug elements are used to adapt pressure medium ducts for different valve functions, then the duct routing can be adapted, but the positioning precision requirements increase and permanent positioning must be ensured
Solution Approach 1:
The valve device is segmented into a standardized housing and interchangeable functional inserts. Each insert contains specific pressure medium paths and valve components tailored to different brake system requirements. This segmentation allows the housing to remain uniform while the inserts provide system-specific functionality, reducing overall device complexity and enabling standardized manufacturing of the housing component.
Solution Approach 2:
The functional inserts act as intermediaries between the standardized housing and the specific brake system requirements. Each insert is a pre-assembled module containing the necessary valves, seals, and pressure medium paths configured for a specific brake system type. This intermediary approach eliminates the need for precise plug element positioning during final assembly, as the inserts are designed to be installed as complete functional units with standardized interfaces.
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 approach allows for the production of valve devices with the same housing type in large numbers, reducing costs and simplifying the adaptation to different brake systems, while maintaining functionality through the selection of appropriate inserts and pressure medium paths.
Implementation Method 1
the relay valve provides control pressure with a larger quantity of pressure medium
Implementation Method 2
pressure medium channels which are in particular bores in the housing, for conducting pressure medium
Data Source
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AI summary
The invention relates to a valve device (1) for brake control of a pressure medium-operated brake system of a vehicle and to a brake system (130) comprising said valve device (1). The valve device (1) comprises a housing (8) which in turn has several pressure medium ducts (58 to 64, 80 to 86). The valve device (1) further comprises a relay valve which provides a pneumatic control pressure, which is fed to said relay valve via at least one of the pressure medium ducts (58 to 64, 80 to 86), involving a higher amount of pressure medium. The valve device (1) comprises at least one insert (2 to 2'''') which is pneumatically connected to at least two pressure medium ducts (58, 66). The two pressure medium ducts (58, 66) are or can be pneumatically connected to each other by said insert (2) via a pneumatic connection. At least these two pressure medium ducts (58, 66), which are or can be connected to each other, and their pneumatic connection or connection possibility by the insert (2) define together a pressure medium path. According to the invention, the profile of the pressure medium path is different due to the nature of the respectively selected housing (8) as a function of the housing that is in each case selected and/or is or can be switched in a different manner due to the respectively selected insert (2 to 2'''') as a function of said insert (2 to 2''''). The housing (8) is selected from a set of housings (8) which have several different pressure medium ducts, in particular bores, but which are otherwise similar or essentially similar. The insert (2 to 2'''') is selected from a set of several different inserts (2 to 2'''').