Relay Valve Check Valve Insert for Pneumatic Brake Backflow Control
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Solution Overview
Problem
Conventional relay valves for pneumatic brake systems are complex and costly, with check valves often positioned externally due to constructional complexities, making them difficult to assemble and increasing manufacturing costs.
Innovation Solution
A relay valve design featuring a check valve as an insert at the pressurized fluid inlet, comprising two coaxial pieces with a snug fit and snap fit arrangement, made from elastomeric materials with varying thickness for leakproof sealing and unidirectional flow, simplifying assembly and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional check valves are used in relay valves, then backflow prevention is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The check valve is extracted as a separate insert component from the main relay valve body, allowing it to be manufactured independently and then inserted into the housing. This extraction simplifies the overall construction by separating the backflow prevention function from the main valve mechanism, reducing manufacturing complexity while maintaining reliability
Solution Approach 2:
The check valve is divided into two coaxial pieces that can be assembled together and then inserted as a unit into the relay valve housing. This segmentation allows for easier manufacturing and assembly of the check valve component itself, reducing the complexity of integrating it into the main valve system
2Reliability
If check valves are positioned externally, then backflow prevention is achieved, but assembly difficulty increases
Solution Approach 1:
The check valve insert is designed to be nested within the relay valve housing, with the two-piece check valve assembly fitting coaxially into the housing bore. This nesting arrangement allows the check valve to be integrated into the existing brake circuit without requiring external positioning, significantly easing the assembly process while maintaining backflow prevention functionality
3Reliability
If complex check valve designs are used, then backflow prevention is achieved, but manufacturing cost increases
Solution Approach 1:
By extracting the check valve as a separate insert component, it can be manufactured using simpler, more cost-effective processes independent of the main relay valve. This separation allows for optimized manufacturing of each component, reducing overall production costs while maintaining the required backflow prevention reliability
Solution Approach 2:
The two-piece check valve design allows for easier manufacturing and potential replacement of individual pieces if needed, reducing the cost of manufacturing defects and enabling more economical production methods compared to monolithic check valve designs
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
The simplified check valve design within the relay valve housing prevents backflow effectively, reduces assembly complexity, and lowers manufacturing costs while maintaining structural rigidity and leakproof sealing.
Implementation Method 1
the relay valve further comprises a check valve coaxially positioned with respect to the pressurized fluid inlet within the housing
Implementation Method 2
made from elastomeric materials with varying thickness for leakproof sealing
Data Source
Figure 1
Figure 2~2a
Figure 3
AI summary
The present invention relates to a relay valve for a pneumatic brake system. The relay valve comprises a housing, a first control pressure port receiving a first control brake pressure for applying, preferably a parking brake, a second control pressure port receiving a second control brake pressure for applying, preferably a service brake. It is noted that, for instance, a parking brake can be applied through the activation of a hand brake valve present in the driver's cabin whereas a service brake is activated via a brake pedal provided in the driver's cabin. Furthermore, in accordance with the present embodiment, the second control brake pressure is configured to be independently applied to that of the first control brake pressure, preferably the first control brake pressure and second control brake pressure are received from at least two independent pressurized fluid sources.