Lift Axle Control Module Reducing Regulator Cycling
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Solution Overview
Problem
Conventional lift axle control systems for heavy-duty vehicles are complex, expensive, and prone to premature failure due to cycling of the regulator, requiring two regulated relays and an inverter valve, which increases manufacturing costs and reduces reliability.
Innovation Solution
A simplified lift axle control module that maintains a constant regulated pressure, eliminating the need for cycling the supply side pressure by using a housing with load and lift bladder ports and a common vent port, along with a solenoid valve that switches between modes without affecting the regulator's input pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional lift axle control systems use two regulated relays and an inverter valve, then the system can control both load bladders and lift bladders, but the device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent combines the functions of two regulated relays and an inverter valve into a single integrated control module. This single module houses both a first regulated relay for controlling load bladders and a second regulated relay for controlling lift bladders, along with an inverter valve, all within one unified structure that shares a common air supply connection and housing.
Solution Approach 2:
The control module is designed as a universal component that performs multiple functions: it regulates air pressure to load bladders through the first regulated relay, regulates air pressure to lift bladders through the second regulated relay, and coordinates between them using the inverter valve. This multi-functional design eliminates the need for separate control units for each function.
2Adaptability or versatility
If conventional systems cycle the regulator supply side pressure when switching between lift axle deployment and retraction, then the regulator can control both modes, but the reliability decreases due to physical stress and premature failure
Solution Approach 1:
The control module segments the air supply paths by providing separate controlled connections to load bladders and lift bladders. The first regulated relay controls air supply to load bladders independently, while the second regulated relay controls air supply to lift bladders independently. This segmentation allows mode switching without requiring the main regulator to cycle its supply side pressure, as each relay independently manages its respective bladder group.
3Adaptability or versatility
If conventional systems use two regulated relays and an inverter valve, then complete control functionality is achieved, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple control components into a single manufactured unit. The housing contains all necessary elements (first regulated relay, second regulated relay, inverter valve, common air supply connection) as an integrated assembly, which simplifies manufacturing compared to assembling multiple separate components. This unified structure reduces manufacturing complexity and cost while maintaining complete control functionality.
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 solution reduces physical stress on the regulator, simplifies the system, and enhances reliability by maintaining a constant regulated pressure, thereby reducing manufacturing costs and improving the longevity of the control system.
Implementation Method 1
The first regulated relay 901 inflates load bladders 918 until the load bladders 918 are at the control air pressure determined by the regulator 906
Implementation Method 2
the inverter valve 903 transmits a control pressure to the second regulated relay 902, such that the lift bladders 920 are inflated to the control pressure
Implementation Method 3
the inverter valve 903 transmits a control pressure to the second regulated relay 902
Data Source
AI summary
A lift axle control module is disclosed that is simpler than prior art lift axle control systems, and does not require cycling the input pressure to the regulator. The module includes a housing fluidly connected to a first pressurized air supply and having one chamber with a load bladder port, a second chamber with a lift bladder port, and a common vent port. A pilot pressure is selectively provided for switching the module between the retracted and deployed modes. When the control module is set to the retracted mode, the lift bladders are pressurized to the system pressure, and the load bladders are vented. When the control module is set to the deployed mode, the lift bladders are vented and the load bladders are inflated and maintained at the regulated pressure.