Relay Valve Bayonet Pre-Assembly for Pneumatic Brake Units
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Solution Overview
Problem
The assembly of existing relay valves for pneumatic valve units, particularly in commercial vehicle braking systems, is complex and costly due to the need for a two-part housing with intricate assembly processes.
Innovation Solution
A relay valve design featuring a bayonet connection between two assembly components, allowing for a pre-assembled unit that simplifies assembly by forming a single, integrated pre-assembly unit with precise axial guidance and optimized air flow, reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-part housing with intricate assembly processes is used, then the relay valve can be manufactured with modular components, but the assembly complexity and manufacturing costs increase
Solution Approach 1:
The relay valve is divided into two assembly parts (first assembly part with piston and second assembly part with valve components) that can be manufactured separately and then connected via bayonet connection. This segmentation allows independent manufacturing optimization while maintaining modular assembly capability.
Solution Approach 2:
The first assembly part and second assembly part are merged through a bayonet connection to form a pre-assembly unit that functions as an integrated component. This merging reduces the overall assembly complexity by pre-combining sub-components into a single installable unit.
2Ease of operation
If traditional assembly methods are used, then all components can be individually installed, but the manufacturing costs and assembly time increase
Solution Approach 1:
The first assembly part and second assembly part are pre-assembled into a pre-assembly unit before final installation into the housing. This preliminary assembly action reduces the time required for final installation and allows quality control to be performed on the pre-assembly unit separately.
Solution Approach 2:
The bayonet connection serves as an intermediary mechanism that facilitates the connection between the first and second assembly parts. This standardized connection interface enables quick and easy assembly while maintaining secure mechanical coupling.
3Ease of repair
If a two-part housing design is used, then component access and maintenance are improved, but the structural integrity and sealing reliability may be compromised
Solution Approach 1:
The bayonet connection incorporates angled locking surfaces and circumferential grooves that provide both mechanical strength and sealing capability. The curved locking surfaces distribute stress evenly while the grooves accommodate sealing elements to maintain reliability despite the modular design.
Data Source
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AI summary
The invention relates to a relay valve (10) for a pneumatic valve unit (14), for example for a valve unit for a braking system of a utility vehicle, which relay valve has a first assembly part (18) and a second assembly part (20). A hollow cylindrical guide portion (28) of a piston (24) of the relay valve (10) is or can be received, in an axially guided manner, in the first assembly part (18). The second assembly part (20) comprises additional valve components and the venting region of the relay valve (10). According to the invention, at least the first assembly part (18) and the second assembly part (20), when assembled, form a preassembled unit (26); the first assembly part (18) and the second assembly part (20) are joined by means of a bayonet connection (30) in order to produce the preassembled unit (26); and the preassembled unit (26) is inserted into an interior of a housing (12) of the valve unit (14), which interior is delimited by a cup-shaped inner wall (32), and the preassembled unit is fastened therein. Consequently, particularly simple and economical mounting of the preassembled unit (26) in a correspondingly designed housing (12) of the valve unit (14) is possible.