Integrated Pneumatic Module for Trailer Air Brake Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The current assembly process for trailer vehicles with compressed air systems is labor-intensive and costly due to the large number of components and connections, particularly the use of T-pieces, which increases the risk of errors and leaks.
Innovation Solution
A pneumatic module that integrates pneumatic valves, anti-lock braking system (ABS) or electronic braking system (EBS) control, and air suspension pressure distribution, reducing the need for external T-pieces and distributors by connecting directly to the modulator or being structurally integrated within it, using point-to-point connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional T-pieces and distributors are used to connect pneumatic components, then the system can be assembled with individual components, but the assembly effort and time increase significantly
Solution Approach 1:
The patent combines multiple pneumatic components (T-pieces, distributors, pressure reservoirs, valves) into a single integrated pneumatic module. This merging eliminates the need for separate connection pieces and reduces the number of individual components that need to be assembled, directly addressing the high assembly effort problem while maintaining system functionality.
Solution Approach 2:
The pneumatic module serves multiple functions simultaneously: it acts as a distribution point for compressed air, houses pressure reservoirs for both brake and air suspension systems, contains overflow valves, and provides connection points for multiple actuators. This multi-functionality reduces the overall component count while maintaining ease of manufacture.
2Reliability
If multiple T-pieces and connection points are used, then individual components can be connected, but the risk of assembly errors and leaks increases
Solution Approach 1:
By integrating multiple connection points and T-piece functions into a single factory-assembled pneumatic module, the patent reduces the number of field connections required. Fewer connections mean fewer potential leak points and reduced assembly errors, while the integrated design ensures proper sealing and connection integrity.
Solution Approach 2:
The pneumatic module is pre-assembled and pre-tested in the factory before installation on the trailer. This preliminary assembly allows for quality control and leak testing to be performed under controlled conditions, reducing the risk of assembly errors and leaks during final installation.
3Ease of manufacture
If traditional separate components are used, then the system can be customized for different trailer configurations, but the production costs increase
Solution Approach 1:
The integrated pneumatic module reduces the total number of parts that need to be handled, connected, and sealed during assembly. This consolidation directly reduces assembly time and labor costs, while the modular design still allows for customization through selection of different module configurations or add-on components.
Solution Approach 2:
The pneumatic system is segmented into modular units: the core pneumatic module and separate functional assemblies (brake system, air suspension system). This segmentation allows for standardized mass production of the core module while still enabling customization through optional add-ons, improving both productivity and cost efficiency.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a pneumatic module for a vehicle which is braked using compressed air, in particular for a trailer vehicle, wherein the vehicle has at least one pressure storage tank (5, 10) for compressed air, a pneumatic brake system (6, 7, 11) and an air spring system with support bellows (21), wherein an overflow valve (9), which ensures the pressure in the brake system in the event of a pressure loss in the air spring system, and an overload protection valve (12), which protects the brake system from overload, are integrated in the pneumatic module (23).