Pneumatic Coupling Head with Detachable Filter Unit
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Solution Overview
Problem
Existing coupling systems for pneumatic brake systems require complex dismantling for filter unit replacement and maintenance, leading to increased weight, material usage, and assembly time.
Innovation Solution
A coupling system design featuring a detachable filter unit inserted into an insert recess within the coupling head housing, allowing for independent replacement and simplifying maintenance, with a preassembled filter unit that includes a sieve, bypass valve, and elastomer unit, eliminating the need for additional seals and reducing the number of parts and assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the filter unit is integrated into the coupling head housing with coupling connections, then the coupling system is structurally stable, but the maintenance and replacement of the filter unit requires complex complete dismantling of the coupling head
Solution Approach 1:
The coupling head housing is segmented into separate functional components: the main housing structure, the filter unit, and the coupling connections. The filter unit is designed as a separate, removable module that can be accessed and replaced without dismantling the entire coupling head, thereby simplifying maintenance while maintaining structural integrity of the overall system.
Solution Approach 2:
The filter unit is extracted from the traditional integrated design where it was part of the coupling connection structure. Instead, it is positioned in a dedicated filter unit receiving area with its own access path, allowing the filter unit to be removed and replaced independently while the coupling head remains assembled and functional.
2Weight of stationary object
If traditional coupling head design is used with integrated filter unit, then structural integrity is maintained, but weight and material usage increase
Solution Approach 1:
The sealing function is segmented and assigned to the filter unit itself rather than requiring a separate seal component. The filter unit incorporates sealing elements that ensure tightness between the filter unit and the coupling head housing, eliminating the need for additional seal materials and reducing overall weight while maintaining reliability.
Solution Approach 2:
The sealing function is merged into the filter unit structure. The filter unit is designed with integrated sealing surfaces and sealing elements that directly engage with the coupling head housing, combining the filtration and sealing functions into a single component that reduces material usage and weight.
3Productivity
If multiple separate components are used in coupling head, then functionality is comprehensive, but assembly time increases
Solution Approach 1:
The filter unit is designed as a pre-assembled module that integrates the filter element, sealing components, and mounting structure into a single unit. This modular design reduces the number of separate parts that need to be handled during assembly, as the filter unit can be installed as one complete assembly rather than multiple separate components, thereby reducing assembly time while maintaining comprehensive 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
Simplifies maintenance, reduces weight and material usage, and ensures easy filter unit replacement, maintaining system tightness without additional seals, while allowing for efficient pneumatic channel filtration and bypass functionality.
Implementation Method 1
a filter unit (10) that can be detachably inserted into the insertion recess (3)
Implementation Method 2
at least one elastomer unit (20) with valve lips
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a coupling system (K), in particular a coupling system (K) for pneumatically connecting a pneumatic brake system of a towing vehicle and a trailer, having a coupling head (1) with a coupling head housing (2). The coupling head housing (2) has at least one first coupling connection (2'), at least one second coupling connection (2"), and at least one insert recess (3) which is arranged in the coupling head housing (2) separately from the first coupling connection (2') and the second coupling connection (2"). The coupling system (K) additionally has a filter unit (10) which can be releasably inserted into the insert recess (3), and a part of the filter unit (10) provides a sealing surface (21) of a coupling connection (2") when the coupling system (K) is assembled.