Two-Stage Electromagnetic Valve for Brake Fluid Control
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Solution Overview
Problem
Existing electromagnetic control valves in electronically controlled brake systems face challenges in providing quick and predictable responses to electromagnetic fields, leading to inefficiencies in fluid flow control, particularly under low to moderate driving conditions where noise and pulsation issues affect driving comfort.
Innovation Solution
The design of an electromagnetic valve with a spring-biased armature and a coaxially surrounding coil assembly, where the armature is axially movable to control fluid flow between passageways in a hydraulic valve block, utilizing a valve seat member with a cylindrical tubular portion and a flange to limit movement, ensuring precise fluid control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a conventional electromagnetic valve design is used, then the structure is simple, but the response speed and predictability are insufficient
Solution Approach 1:
The valve body is divided into multiple functional sections including a first valve body portion, a second valve body portion, and a valve seat member. Each section performs a specific function: the first portion houses the electromagnetic coil and armature for rapid actuation, the second portion provides fluid passage routing, and the valve seat member provides precise sealing. This segmentation allows each component to be optimized for its specific function, improving overall response speed while maintaining manageable complexity through modular design.
Solution Approach 2:
The patent introduces a cylindrical tubular portion with a flange structure that extends radially outward from the main valve body axis. This radial extension provides a mounting surface for the valve seat member and creates a stable friction-fit connection. By adding this radial dimension to the otherwise axial flow path, the design achieves better structural stability and positioning precision without significantly increasing the axial length, thus improving response predictability with controlled complexity.
2Speed
If the armature is made freely movable for quick response, then responsiveness improves, but noise and pulsation increase
Solution Approach 1:
The valve seat member incorporates a localized frustoconical sealing surface that contacts the armature at a specific point or small area. This localized contact geometry provides precise control over the closing action, ensuring that the armature seats smoothly and predictably. The frustoconical shape concentrates the sealing force at the tip, creating a well-defined sealing point that reduces turbulence and pulsation while maintaining rapid response. This local quality optimization allows the armature to move freely for quick response while minimizing noise and fluid pulsation through controlled sealing geometry.
3Ease of manufacture
If the valve seat member is loosely fitted for easy assembly, then ease of manufacture improves, but fluid flow control precision deteriorates
Solution Approach 1:
The valve seat member features a cylindrical tubular portion that is frictionally retained within a cylindrical opening in the valve body. This nested configuration allows the valve seat member to be press-fitted into place during assembly, providing a secure interference fit that ensures precise positioning and repeatable fluid flow control. The nested structure maintains manufacturing precision through the friction fit while still allowing for relatively simple assembly processes compared to threaded or welded connections. The cylindrical geometry of the nested portions ensures proper alignment and concentricity, achieving both ease of manufacture and precision fluid control.
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 solution enables improved responsiveness and reduced noise and pulsation in brake fluid pressure generation, enhancing driving comfort by providing efficient and predictable braking responses, even under low to moderate driving conditions.
Implementation Method 1
An armature is axially moveable within the valve body and is spring biased in one axial direction
Implementation Method 2
An electromagnetic coil coaxially surrounds the armature and is operable to effect axial movement of the armature in an axial direction opposite the one direction
Data Source
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AI summary
The present invention provides a two-stage electromagnetic valve (50) for use in controlling fluid flow between first and second passageways (P1;P2) in a hydraulic valve block (2), comprising: a one-piece valve body (200) defining a central axis (B) and having a central opening (201) therethrough, the central opening (201) having a first diameter, the valve body (200) having a lower end (204) adapted to be inserted into a bore (19) of the valve block (2) and provided with a lower cylindrical opening (207), the lower end (204) of the valve body (200) including a radially inwardly extending shoulder (218) defining a valve seat (218) and a cylindrical tubular portion (216) extending downwardly from the valve seat (218), the cylindrical tubular portion (216) having a second diameter smaller than the first diameter; an armature (206) axially moveable within the valve body (200) and spring (224) biased in one axial direction (57A); a closing element (30) carried by a lower end (210) of the armature (206); an electromagnetic coil (64') coaxially surrounding the armature (206) and operable to effect axial movement of the armature (206) in an axial direction (57B) opposite the one direction (57A); a cage (246) having a central opening (251) therethrough, the cage (246) having an upper end (248) attached to the lower end (210) of the armature (206) and a lower end (250); and a poppet (226) having a bore (238) therethrough, the poppet (226) disposed within the central opening (251) of the cage (246) and spring (244) biased away from the lower end (210) of the armature (206); the lower end (250) of the cage (246) having a radially inwardly extending cage shoulder (252) defining a cage opening (254); a lower end of the poppet (226) is engageable with the valve seat (218); and a seal (262) carried by the lower end (204) of the valve body (200), the seal (262) engageable with the bore (19) of the valve block (2).