Relay Valve Module With Shuttle Valve for Balanced Axle Braking
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Solution Overview
Problem
Existing pneumatic brake systems for commercial vehicles face issues with component tolerances leading to unequal braking forces on both sides of the vehicle axle, destabilizing the vehicle due to differences in brake pressures, particularly in electronic braking force limitation and automatic emergency braking functions.
Innovation Solution
A relay valve module with a shuttle valve system that allows for the control of higher pressure between brake control pressure and pilot control pressure, using an electro-pneumatic pilot control unit to convert electronic brake specifications into service brake pressure, enabling improved transfer between pneumatic and electronic control of brake pressures, and allowing for redundancy in case of faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If component tolerances in ABS valves and pilot valves are used, then manufacturing costs are reduced and device complexity is simplified, but brake pressure equality on both sides of the vehicle axle deteriorates, causing vehicle instability
Solution Approach 1:
A shuttle valve is introduced as an intermediary component between the pilot control unit and the relay valve. This shuttle valve selectively transmits the higher of two control pressures (from the service brake line or the parking brake line) to the relay valve control port, ensuring that brake pressures on both sides of the axle are equalized while allowing the use of standard tolerance components throughout the system.
2Ease of manufacture
If a single relay valve module is used for both axle modulator and trailer control module functions, then manufacturing costs are reduced through identical parts, but device versatility requirements increase
Solution Approach 1:
The relay valve module is designed with universal functionality to operate in two different configurations: as an axle modulator when connected to service brake and parking brake lines, and as a trailer control module when connected to trailer supply and control lines. The same hardware performs both functions by responding to different pressure source connections, eliminating the need for separate dedicated modules and reducing manufacturing costs.
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
This solution ensures more stable braking by equalizing brake pressures across both sides of the vehicle axle, enhancing safety and reducing manufacturing costs through the use of identical parts and simplified logistics.
Implementation Method 1
a shuttle valve (20) having a first shuttle valve inlet (20.1), a second shuttle valve inlet (20.2), and a shuttle valve outlet (20.3). The first shuttle valve inlet (20.1) is connected to the brake pressure port (4) for receiving the brake control pressure (pBS), the second shuttle valve inlet (20.2) is connected to the pilot control unit (12) for receiving the pilot control pressure (pVS), and the shuttle valve outlet (20.3) is connected to the relay valve control connection (10.4) for controlling the higher of the brake control pressure (pBS) or the pilot control pressure (pVS) at the relay valve control port (10.4)
Implementation Method 2
The pilot control unit (12) has an electrically switchable inlet valve (14) and an electrically switchable outlet valve (16)
Data Source
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AI summary
The invention relates to a relay valve module (1) for an electronically controllable pneumatic brake system (202) for the actuation of wheel brakes of a commercial vehicle (200), which can be used as an axle modulator (AVP) or as a trailer control module (TVP). The relay valve module has a supply connection (2) for receiving a supply pressure (p V), a brake control pressure connection (4) for receiving a brake control pressure (p BS), at least one first service brake connection (6) for controlling a service brake pressure (p B), a relay valve (10) and an electropneumatic pilot control unit (12) for providing a pilot control pressure (p VS). Furthermore, a changeover valve (20) is provided, which has a first changeover valve input (20.1), a second changeover valve input (20.2) and a changeover valve output (20.3). The first changeover valve input (20.1) is connected to the service brake control pressure connection (4) for receiving the brake control pressure (p BS), the second changeover valve input (20.2) is connected to the pilot control unit (12) for receiving the pilot control pressure (p VS) and the changeover valve output (20.3) is connected to a relay valve control connection (10.4), for controlling the respective higher one of the brake control pressure (p BS) and the pilot control pressure (p VS) on the relay valve control connection (10.4). The invention further relates to a brake system (200), to a method for production and to a commercial vehicle (200).