Relay Valve with Flow Limiting Orifice for Controlled Braking
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Solution Overview
Problem
Conventional hydraulic brake systems face issues with sudden braking during component failures, leading to skidding and loss of control, as they are designed for rapid full braking force application and lack effective gradual modulation.
Innovation Solution
A hydraulic system incorporating a relay valve with three positions and a pilot valve, allowing for controlled fluid supply and discharge through a flow limiting orifice to gradually apply braking force, preventing skidding and maintaining control during failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydraulic circuits are designed for rapid full braking force application, then braking efficiency is improved, but the machine may skid and loss of control occurs during emergency conditions or component failures
Solution Approach 1:
The relay valve is divided into three distinct positions (first position for fluid supply, second position for fluid discharge, third position for restricted discharge via flow limiting orifice), allowing segmented control of braking force application. This segmentation enables the system to provide both rapid braking when needed and controlled gradual braking during failures, resolving the contradiction between braking efficiency and control stability.
2Ease of operation
If numerous single-chambered valves are used to effect braking on the wheel, then braking control is improved, but individual modulation is required which causes delay in application of brakes
Solution Approach 1:
Multiple valve functions are merged into a single relay valve with three positions. The relay valve integrates fluid supply, fluid discharge, and restricted discharge functions that would otherwise require multiple separate valves. This merging eliminates the need for individual modulation of numerous valves, reducing brake application delay while maintaining braking control.
3Reliability
If brakes are applied in a gradual manner to avoid skidding of the wheels, then control stability is improved, but braking efficiency is reduced
Solution Approach 1:
The relay valve provides dynamic control of braking force through its three positions, allowing the system to adapt braking intensity to operational needs. The third position with flow limiting orifice enables gradual braking when control stability is prioritized, while the first position enables rapid full braking when braking efficiency is critical. This dynamic adjustability resolves the contradiction between control stability and braking efficiency.
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 system enables gradual retardation of the machine, minimizing the risk of skidding and maintaining control by modulating the relay valve between supply, discharge, and flow limiting positions, ensuring safe and controlled braking.
Implementation Method 1
The third position is configured to restrictively discharge fluid from the brake cylinder to the tank via a flow limiting orifice
Data Source
AI summary
A hydraulic system for a brake system of a machine includes a relay valve coupled to a brake cylinder, a pump, and a tank. The relay valve includes a first position to allow supply of fluid from the pump to the brake cylinder, and a second position to allow discharge of fluid from the brake cylinder to the tank. Further, the relay valve includes a third position to restrictively allow discharge of fluid from the brake cylinder to the tank via a flow limiting orifice. A pilot valve coupled to the relay valve and configured to modulate the relay valve between the first position, the second position and the third position.