Parking Brake Relay Valve Segmentation for Maintenance
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Solution Overview
Problem
The high degree of integration of compressed air treatment systems and parking brake modules in commercial vehicles leads to increased repair work due to defects, as both systems are intricately linked, making maintenance and replacement of components, especially the relay valve, labor-intensive and inefficient.
Innovation Solution
The parking brake system is separated into two distinct modules, with the valve device integrated into the compressed air treatment system and the relay valve in a separate module, allowing for easier maintenance and replacement of the relay valve without additional assembly work, and incorporating a bistable solenoid valve for safe operation and pulse-width-modulated control for trailer braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the parking brake module is highly integrated into the compressed air treatment system, then space efficiency is improved, but repair complexity increases
Solution Approach 1:
The parking brake system is divided into two separate modules: a first module integrated into the compressed air treatment system containing the valve device, and a second module containing the relay valve and spring-loaded brake cylinders. This segmentation allows the relay valve to be replaced independently without disturbing the compressed air treatment system, thereby reducing repair complexity while maintaining space efficiency through selective integration.
2Productivity
If the relay valve is integrated into the compressed air treatment system, then assembly efficiency is improved, but maintenance time increases
Solution Approach 1:
The system separates the relay valve into a standalone second module that can be quickly exchanged without additional assembly work. This segmentation maintains assembly efficiency during manufacturing while dramatically reducing maintenance time, as the relay valve can be replaced independently without disturbing the integrated first module containing the valve device.
3Device complexity
If a standard solenoid valve is used for trailer control, then component simplicity is improved, but braking control precision decreases
Solution Approach 1:
The solenoid valve for trailer control is designed with pulse-width modulated (PWM) capability, allowing continuous pressure modulation through variable duty cycle control. This dynamic control method enables gradual braking effects and precise braking control for trailers while maintaining relatively simple valve hardware, achieving high control precision without excessive component complexity.
4Reliability
If a bistable solenoid valve is used for parking brake control, then safety is improved, but energy consumption increases
Solution Approach 1:
The bistable solenoid valve operates by applying electrical pulses to switch between two stable positions (brake applied and brake released). Once switched, the valve maintains its position without requiring continuous power, consuming energy only during state transitions. This periodic actuation method ensures high safety and reliability by preventing unintended brake activation while minimizing energy consumption compared to continuously powered systems.
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 separation reduces repair complexity and enhances vehicle safety by allowing for independent trailer braking and preventing sudden parking brake activation or deactivation, while enabling efficient pressure modulation and monitoring, thus reducing maintenance efforts and ensuring reliable operation.
Implementation Method 1
a solenoid valve (30), which is coupled to the pressure supply (48) independently of the bistable solenoid valve (36) and generates a non-zero trailer control pressure at a trailer control port (26) in its switch position shown
Implementation Method 2
the at least partially bistable valve device comprises a bistable solenoid valve in order to avoid an undesired closing or opening of the parking brake in the event of a defect
Implementation Method 3
a relay valve, which receives the control pressure of the valve device and, depending on the control pressure, pressurizes or vents at least one spring-loaded brake cylinder (18)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a parking brake system (10) for a vehicle (12), comprising an at least partially bistable valve unit (14) to generate a control pressure for controlling at least one function of the parking brake system (10), and a relay valve (16) which receives the control pressure from the valve unit (14) and either pressurizes or bleeds at least one spring-loaded cylinder (18) according to the control pressure. According to the invention, the valve unit (24) is integrated into a first module (20) integrated into a compressed air production system (24), and the relay valve (16) is arranged in a second module (22) which is arranged at a distance from the first module (20) and the compressed air production system (24).