Electronic Pneumatic Spring Controller Air Consumption
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Solution Overview
Problem
Mechanical air suspension valves in rail vehicles face a design conflict between rapid load correction and minimizing dynamic air consumption, often resulting in excessive air consumption during route driving, especially in arcs.
Innovation Solution
Introducing a switching mechanism that can interrupt air flow between the mechanical valve and the air spring or pressure source, allowing for electronic or electrical control, which reduces dynamic air consumption to zero and enables the use of larger mechanical valves for faster level correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If mechanical valves with three valve cross sections are used to correct secondary spring travel quickly, then the speed of level correction is improved, but dynamic air consumption increases excessively during route driving
Solution Approach 1:
The air suspension system is segmented into two independent control paths: a mechanical valve path for rapid level correction and an electronic switching valve path for air consumption control. The mechanical valve (VEN) handles large deviations quickly, while the electronic switching valve (SAM) controls the actual air flow to the air spring, allowing the system to achieve fast correction without continuous air consumption during normal operation.
Solution Approach 2:
The electronic switching valve (SAM) acts as an intermediary between the mechanical valve (VEN) and the air spring (LUF). It controls the air flow from the mechanical valve to the air spring, enabling the system to decouple the speed of correction from air consumption. The switching valve can be closed during route driving to stop air consumption while allowing the mechanical valve to remain ready for rapid correction when needed.
2Speed
If mechanical valves are fully open during route driving to maintain level, then the speed of level correction is improved, but air consumption becomes excessive
Solution Approach 1:
The system dynamically switches between different valve states based on operating conditions. During route driving, the electronic switching valve (SAM) is closed to stop air consumption, while the mechanical valve (VEN) remains mechanically ready. When level correction is needed, the switching valve opens to allow rapid air flow. This dynamic control allows the system to maintain readiness for fast correction without continuous air consumption.
Solution Approach 2:
The mechanical valve (VEN) is self-actuating through the linkage (GES) that responds automatically to height differences between the valve and the lower attachment point. The electronic switching valve (SAM) controls when this self-service mechanism is allowed to operate, enabling rapid correction when needed while preventing excessive air consumption during normal route driving.
3Speed
If larger mechanical valve cross sections are used to increase correction speed, then the speed of level correction is improved, but device complexity increases
Solution Approach 1:
The system replaces the need for a single complex mechanical valve with multiple cross sections with a simpler mechanical valve combined with an electronic switching valve. The mechanical valve can be designed with a larger cross section for fast correction without the complexity of multiple cross sections, while the electronic switching valve provides the selective control function, reducing overall mechanical complexity.
Data Source
Figure 1
AI summary
Disclosed is a railway vehicle (SCH) comprising at least one pneumatic spring (LUF) for supporting a body. At least one mechanically actuated valve (VEN) is disposed in at least one air supply/discharge tube (LEI) of the at least one pneumatic spring (LUF) in order to control air exchange of the at least one pneumatic spring (LUF). At least one switching means (SAM, SAM'') is provided between the at least one mechanical valve (VEN) and the at least one pneumatic spring (LUF) in the at least one air supply/discharge tube (LEI) in order to control air exchange. Alternatively, at least one switching means (SAM") is arranged between the at least one mechanical valve (VEN) and at least one pressure source (DRU) while at least one additional switching means (SAM') is placed in a tube (LEI') that connects the at least one mechanical valve (VEN) to an environment (UMG) in order to control air exchange.