Pneumatic Valve Cover Cylindrical Extension for Brake System
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Solution Overview
Problem
Conventional pneumatic trailer control valves face manufacturing challenges due to the complexity of incorporating safety rings, which can lead to leakage and increased assembly time, especially when machining metal or aluminum components, resulting in higher production costs and risks of fluid leakage under high pressure.
Innovation Solution
A pneumatic valve design that eliminates the need for safety rings by using a cylindrical extension integral with the cover to secure the first stationary member, combined with a housing slot system and internal passageways for fluid flow, ensuring secure locking and sealing without additional safety rings, thus simplifying manufacturing and reducing leakage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If safety rings are used to secure guide members in slots, then the guide members are firmly secured, but manufacturing complexity and assembly time increase
Solution Approach 1:
The patent removes the safety rings from the design entirely. Instead of using separate securing components, the guide members are directly retained by the slot structure and positioning features integrated into the housing, eliminating the need for additional safety rings while maintaining secure positioning
Solution Approach 2:
The securing function previously performed by separate safety rings is merged into the housing structure itself. The slots and positioning features are integrated directly into the housing, combining the guiding and securing functions into a single structural element, thereby reducing part count and assembly complexity
2Reliability
If safety rings are used to secure guide members, then the guide members are firmly secured, but assembly time increases
Solution Approach 1:
By removing the safety rings entirely, the assembly process is simplified. The guide members can be directly installed into the housing slots without the additional step of installing separate safety rings, significantly reducing assembly time while maintaining secure positioning through the integrated slot design
Solution Approach 2:
The housing structure with integrated slots and positioning features provides self-retaining capability for the guide members. The design is self-sufficient, requiring no additional external securing components, which eliminates the time-consuming assembly step of installing safety rings
3Manufacturing precision
If machining is performed on metal or aluminum components, then precise slots are created, but metal or aluminum chips are generated causing leakage risk
Solution Approach 1:
The patent eliminates the source of the problem by removing the need for complex machining operations. The design uses standardized components and simplified slot configurations that can be manufactured with minimal machining, thereby preventing chip generation while maintaining sufficient precision for proper component fit and function
Solution Approach 2:
The design accepts that some machining is necessary but converts the potential harm into a benefit by designing the slot and component interface to be tolerant of minor chip presence. The integrated sealing and positioning features ensure that even if minimal chips are present, they cannot cause leakage, transforming a potential failure mode into a robust design
4Reliability
If additional safety rings are added to secure guide members, then securing is improved, but production costs increase
Solution Approach 1:
By removing the safety rings from the design, the bill of materials is reduced, eliminating the cost of purchasing and inventorying these components. The integrated housing design requires no additional parts, directly reducing material costs while maintaining secure positioning
Solution Approach 2:
The securing function is merged into the housing structure, eliminating the need for separate safety ring components. This consolidation reduces part count, simplifies manufacturing processes, and lowers overall production costs while maintaining the same level of securing reliability through the integrated design
Data Source
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AI summary
The present invention relates to a pneumatic valve 200, preferably for controlling brakes of a trailer portion attached a vehicle portion. Pneumatic valve 200 comprises an cover 204 being symmetric around a longitudinal axis 202, wherein cover 204 includes a cylindrical extension 206, and a first stationary member 208 arranged coaxially to cover 204, and including a top surface 210, wherein the top surface 210 is in direct contact with cylindrical extension 206 of cover 204. In particular, cylindrical extension 206 is integral with cover 204 and is configured to facilitate securing the position of first stationary member 208. Pneumatic valve 200 in other words can be referred to as a Trailer Control Valve (TCV) in the vernacular of the persons skilled in the art of pneumatic brake systems for vehicles.