Horizontal Pilot Valve Arrangement for Compact Pneumatic Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing design of electropneumatic actuating systems for vehicle braking systems requires complex constructions and additional bores in the air distributor housing, leading to increased installation volume, air consumption, and response time due to the need for multiple pilot valves and pneumatic channels.
Innovation Solution
The pilot control unit is designed with pilot valves positioned next to each other with their connections protruding vertically, allowing direct connection to the pilot control chamber of the consumer, eliminating the need for additional bores and channels, and using a fluid guiding element for horizontal arrangement, which reduces the pneumatic volume and eliminates unnecessary pneumatic lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pilot valves are placed in vertical bores in the air distributor housing, then the pilot valves can be connected to the relay valve, but the construction becomes complex requiring additional non-vertical bores and an additional cap
Solution Approach 1:
The patent transitions from vertical bore arrangement to horizontal bore arrangement in the air distributor housing. The pilot valves are now positioned horizontally adjacent to each other, with their pilot control connections extending horizontally to the relay valve, eliminating the need for complex non-vertical bores and additional caps while maintaining pneumatic connectivity.
Solution Approach 2:
The patent integrates the pilot control connections of multiple pilot valves into a common horizontal bore structure within the air distributor housing. Instead of requiring separate vertical and non-vertical bores for each valve, the design merges these connections into a unified horizontal arrangement, reducing the number of additional components needed.
2Ease of operation
If ducts lead to the pilot control chamber forming a large air volume, then the pneumatic consumer can be activated, but the response time increases and air consumption increases
Solution Approach 1:
The patent extracts and eliminates unnecessary intermediate ducts and large air volumes from the pneumatic control path. By positioning pilot valves horizontally adjacent to each other and connecting them directly to the relay valve through horizontal bores, the design removes redundant pneumatic pathways, thereby reducing the air volume that needs to be pressurized and vented, which directly reduces response time and air consumption.
3Adaptability or versatility
If three electropneumatic pilot valves are accommodated in the pilot control unit, then the brake circuit can be controlled, but the installation volume increases
Solution Approach 1:
The patent merges multiple pilot valves into a compact horizontal arrangement within a single air distributor housing. By positioning the three pilot valves adjacent to each other horizontally and integrating their connections into a unified horizontal bore structure, the design reduces the overall installation volume compared to traditional vertical arrangements that require additional space for caps and non-vertical connections.
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 design results in a compact, cost-effective, and efficient pneumatic control system with reduced air consumption and faster response times, as well as simplified assembly and testing, allowing for a modular system with standardized parts.
Implementation Method 1
The actuating system is designed as a two-channel electropneumatic or electrohydraulic axle modulator for a braking system of a vehicle
Implementation Method 2
Axle modulators in brake systems are used to modulate a brake pressure to the connected brake circuits of an axle
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to an electropneumatic pilot unit (32) for controlling a pneumatic consumer (7), the pilot unit (32) having: at least two electromagnetic pilot valves (4, 5, 6), each of which has: - a coil (38) for producing a magnetic flux along a valve axis (A), - an armature that can be displaced in the axial direction (x) of the valve axis (A), - a valve seat that can be closed and released by the armature, - a pneumatic inlet connection and a pneumatic outlet connection (6b). The pilot unit is characterised in that at least two of the pilot valves (4, 5, 6) lie adjacent to one another with parallel valve axes (A) and that each pilot valve (4, 5, 6) has a connection (6b) jutting towards a common underside (32b) for connection to a pilot chamber (50) of the consumer (7) controlled by the pilot valves (4, 5, 6).