Brake Modulator Relay Valve Cover Plate for Leak-Tolerant Assembly
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Solution Overview
Problem
Existing brake modulators for ABS systems face challenges with leakage, proper alignment, and high manufacturing costs due to complex tolerance requirements and the need for precise manufacturing.
Innovation Solution
The brake modulator incorporates a main cover with separate cover portions for supply and exhaust valves, and a relay valve cover plate that self-centers in the relay valve cylinder, allowing for easier assembly and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single main cover is used to close all valve cavities, then the structure is simpler, but alignment precision and sealing performance deteriorate due to complex tolerance requirements
Solution Approach 1:
The single main cover is segmented into multiple separate cover portions (first supply cover portion, second supply cover portion, first exhaust cover portion, second exhaust cover portion), each responsible for closing a specific valve cavity. This segmentation allows each cover portion to be manufactured with simpler tolerances while maintaining overall alignment precision through individualized fitting to their respective cavities.
2Manufacturing precision
If high precision manufacturing is used to ensure proper alignment, then alignment precision improves, but manufacturing cost increases
Solution Approach 1:
By dividing the cover into multiple separate portions, each portion can be manufactured using less expensive processes with relaxed tolerance requirements. The segmentation eliminates the need for high-precision complex tolerance chains that would be required for a single integrated cover, thereby reducing manufacturing costs while maintaining adequate alignment.
Solution Approach 2:
Each cover portion is designed to fit its specific valve cavity with appropriate local tolerances, rather than requiring uniform high precision across the entire cover structure. This allows optimization of manufacturing precision locally where needed, while using less expensive manufacturing for other areas.
3Reliability
If a relay valve cover plate is added to close the relay valve cylinder, then sealing performance improves, but device complexity increases
Solution Approach 1:
The relay valve cover plate is integrated with the main cover portions to form a unified sealing structure. The plate is arranged between the relay piston and the main cover, merging the sealing functions of multiple components into a coordinated assembly that improves overall sealing performance without requiring entirely separate sealing mechanisms.
Data Source
AI summary
A brake modulator (1) for providing an ABS brake function to a vehicle (200) includes: a main body (17), to provide a main pressure (pM) dependent on a brake request, a first ABS valve unit (47) configured to provide a first brake pressure (pB1) and a second ABS valve unit (53) configured to provide a second brake pressure (pB2), and a main cover (19) for closing of an assembly side (27) of the main body (17). A relay valve cover plate (137) is formed integrally with or separately from the main cover (19). The present disclosure further relates to a commercial vehicle (202) and to an assembly method (300) for a brake modulator (1).