Compact Pneumatic Brake Valve Unit With Integrated Pilot Valves
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Solution Overview
Problem
Existing valve units for pressure modulation in compressed air brake systems are complex and costly due to their multi-part design and require intricate mechanical processing, leading to high production and assembly costs, as well as potential sealing issues.
Innovation Solution
A compact valve unit design with pilot valves aligned parallel to the parting plane of the valve housing, featuring a central insert with overmoulded magnetic coils and mechanical components, simplifying assembly and reducing component count, while ensuring effective sealing and protection from environmental influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the valve unit uses a multi-part design with separate housing components, then the assembly allows for modular construction and easier manufacturing, but the sealing complexity increases and potential sealing issues arise
Solution Approach 1:
The patent merges the pilot valves with the housing by integrating them directly into the valve housing structure, eliminating separate sealing interfaces between pilot valves and housing. This integration reduces the number of sealing elements required while maintaining modular benefits for the diaphragm valves, thus resolving the contradiction between modular construction and sealing reliability.
2Device complexity
If the valve unit uses a compact design with pilot valves aligned parallel to the parting plane, then the overall size is reduced and assembly complexity is simplified, but the internal space for magnetic coils and mechanical components is constrained
Solution Approach 1:
The patent aligns the pilot valves parallel to the parting plane rather than perpendicular to it, utilizing the horizontal dimension for valve placement. This dimensional reorientation creates vertical space within the housing for accommodating magnetic coils and mechanical components, thus resolving the contradiction between simplified assembly and adequate internal space.
3Ease of repair
If the valve unit uses traditional multi-part design, then component replacement and maintenance are straightforward, but production and assembly costs are high
Solution Approach 1:
The patent maintains segmentation by allowing the diaphragm valves to be separately replaceable from the housing, while integrating the pilot valves into the housing structure. This selective segmentation enables straightforward maintenance of wear-prone diaphragm components while reducing production complexity by eliminating separate pilot valve assemblies, thus resolving the contradiction between ease of repair and production complexity.
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
The design results in a compact, cost-effective valve unit with improved control properties and short switching times, reducing assembly complexity and enhancing protection of solenoid valves, thus addressing the complexity and cost issues of existing systems.
Implementation Method 1
a pilot valve (8, 9) each embodied as a 3/2-way solenoid valve
Implementation Method 2
When the control chamber is subjected to the high control pressure, the membrane is pressed against the valve seat, as a result of which the inner flow channel is shut off from the outer flow channel
Data Source
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AI summary
The invention relates to a valve unit (1.1, 1.2, 1.3) for modulating the pressure in a pneumatic brake system, said valve unit comprising a brake pressure inlet (3), a brake pressure outlet (4), a bleed outlet (5), an inlet valve (6) designed as a diaphragm valve, an outlet valve (7) designed as a diaphragm valve, and a pilot valve (8, 9; 8", 9") designed as a 3/2-way solenoid valve (8, 9) for each diaphragm valve (6; 7), the pilot valves being arranged in an elongate valve housing (2) which is sub-divided, by means of a joint face (10) running largely horizontally in the assembled position, into a main housing (11) and a housing cover (12, 12', 12"). In order to be able to design the valve unit (1.1, 1.2, 1.3) in a compact manner requiring only a small number of parts, the pilot valve (8; 8") of the inlet valve (6) as well as the pilot valve (9; 9") of the outlet valve (7) are arranged largely centrally above the diaphragms (16, 17) of the inlet valve (6) and the outlet valve (7) in the housing cover (12, 12', 12") when viewed in the longitudinal direction (13) and with the actuation axes (18, 19) of the pilot valves running parallel to the joint face (10), and in that the housing cover (12, 12', 12") includes a central insertion piece (30) which has valve bores (21, 22, 23) and control channels (24, 25, 26, 27, 28, 29) and into which the solenoids (31, 32) and the mechanical components (33, 34, 35, 36, 37, 37, 38) of the pilot valves (8, 9; 8", 9") are inserted, said insertion piece (30) being encapsulated with a plastic material (39).