Pre-filling Device for Hydro-Boosted Braking Systems
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Solution Overview
Problem
Conventional pre-filling devices for braking systems with hydro-boosted braking in agricultural vehicles fail to maintain pre-filling pressure within narrow margins due to variations in hydro-boost pressure, leading to inconsistent braking behavior.
Innovation Solution
A pre-filling device incorporating a mechanical valve and hydraulic valve that adjusts pre-filling pressure through a reciprocating movement within the pre-filling channel, isolating a first area connected to the pre-filling channel and a second area at atmospheric pressure, with a stop element to maintain constant pressure independent of hydro-boost pressure variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pre-filling device with a spring element and pair of balls is used, then the pre-filling pressure is generated based on hydro-boost pressure, but the pre-filling pressure varies significantly when hydro-boost pressure varies, preventing maintenance within narrow margins
Solution Approach 1:
The patent replaces the conventional mechanical spring element with a hydraulic valve system that uses hydraulic pressure to regulate the pre-filling pressure. The hydraulic valve receives control signals from a control unit and actively adjusts the pressure, substituting passive mechanical elasticity with active hydraulic control to achieve consistent pressure despite hydro-boost variations.
Solution Approach 2:
The patent introduces a control unit that receives feedback about the actual pre-filling pressure and the hydro-boost pressure, then adjusts the hydraulic valve accordingly. This closed-loop feedback system allows the controller to compensate for pressure variations and maintain the pre-filling pressure within narrow margins (3-4 bar) regardless of hydro-boost fluctuations.
2Adaptability or versatility
If hydro-boost pressure varies between 20-25 bar in agricultural vehicles, then the pre-filling pressure varies accordingly, but this leads to inconsistent braking behavior
Solution Approach 1:
The control unit continuously monitors the hydro-boost pressure and the resulting pre-filling pressure, then adjusts the hydraulic valve to compensate for variations. This feedback mechanism ensures that despite hydro-boost pressure varying between 20-25 bar in agricultural vehicles, the pre-filling pressure remains consistent, ensuring uniform braking behavior across different operating conditions.
Solution Approach 2:
The patent changes the control parameter from passive spring pressure to active hydraulic pressure control. The hydraulic valve can dynamically adjust the pre-filling pressure parameter based on control signals, allowing the system to adapt to varying hydro-boost conditions while maintaining consistent braking performance through parameter optimization.
3Power
If a mechanical valve hydro-booster is used, then hydro-boost pressure can be generated, but there is no mechanism to keep pre-filling pressure within narrow margins upon varying hydro-boost pressure
Solution Approach 1:
The patent introduces a hydraulic valve as an intermediary component between the hydro-boost system and the pre-filling channel. This intermediary device receives the variable hydro-boost pressure and, through control signals from the control unit, regulates it to produce a precise and stable pre-filling pressure, thereby decoupling the precision requirement from the power generation function.
Solution Approach 2:
The patent substitutes the mechanical valve in the hydro-booster with a controlled hydraulic valve system that offers more precise pressure regulation. While the mechanical valve provides basic hydro-boost function, the hydraulic valve with electronic control achieves the precision needed to maintain pre-filling pressure within narrow margins, combining power generation with precision control.
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
Ensures high uniformity in pre-filling braking, reduces pressurized fluid usage, and results in energy savings and decreased pollutant emissions.
Implementation Method 1
a hydraulic valve configured to adjust the pre-filling pressure by means of a reciprocating movement inside the pre-filling channel upon varying of the pressure in the hydro-boosted braking system
Implementation Method 2
the hydraulic valve includes a first area in connection with the pre-filling channel at the pre-filling pressure and a second area, isolated from the first, kept at atmospheric pressure
Implementation Method 3
a pre-filling device comprising a mechanical valve and a hydraulic valve, wherein the hydraulic valve is configured to adjust the pre-filling pressure
Data Source
AI summary
A pre-filling device for a braking system. The pre-filling device includes a pre-filling channel, a pre-filling pressure being inside the channel when the braking system is in a rest and hydro-boost position, and a mechanical valve configured to be opened following a transition from the rest and hydro-boost position to a working position of the braking system; and a hydraulic valve cooperating with the mechanical valve setting the pre-filling pressure inside the channel. The hydraulic valve includes in a first area, facing the mechanical valve, a hole communicating with the channel, and in a second area, hydraulically isolated from the first area, a preloaded resilient element in a chamber held at atmospheric pressure. The hydraulic valve is configured to be connected or not to be connected, by a reciprocating movement inside the channel, to a hydro-booster device and to keep a predetermined pre-filling pressure upon varying of the hydro-boost pressure.