Solenoid Valve Core Simplification for Brake Systems
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Solution Overview
Problem
Conventional solenoid valves for brake systems are difficult to manufacture due to their complex shape and require high manufacturing costs, particularly because of the need for intricate cutting processes and welding in assembling the valve core and sleeve.
Innovation Solution
A solenoid valve design featuring a cylindrical valve core with a simplified structure, a dome-shaped sleeve, and a filter member with a check valve, which allows for easier assembly and reduced manufacturing processes through a latching mechanism instead of welding, and includes a filter member with a filtering part and check valve to manage oil flow effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional valve core design with multiple stair-shaped stepped portions and through-holes is used, then the valve can perform its braking function, but the manufacturing process becomes complex and costly due to multiple cutting operations
Solution Approach 1:
The valve core is divided into multiple functional segments: a cylindrical body portion, a head portion with external threads, and an integrated seal groove. This segmentation allows each part to be manufactured independently with simpler processes and then assembled, reducing the complexity of single-piece manufacturing while maintaining functional reliability
Solution Approach 2:
The seal groove is integrated directly into the valve core body during manufacturing, eliminating the need for separate sealing components and complex assembly steps. This merging of functions reduces manufacturing complexity while ensuring reliable sealing performance
2Strength
If the sleeve is coupled to the valve core through a welding process, then the assembly is secure, but the work effort increases and assembling productivity decreases
Solution Approach 1:
The welding process is replaced with a mechanical interference fit system. The sleeve has an internal diameter that slightly exceeds the valve core's external diameter, allowing assembly through pressing or light interference fitting. This mechanical connection achieves sufficient structural strength while dramatically improving assembly speed and productivity by eliminating thermal processing steps
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 design simplifies the manufacturing process, reduces costs, and enhances productivity by eliminating the need for complex cutting and welding, while ensuring reliable oil flow management and extended valve life with the durable check valve.
Implementation Method 1
a check valve to permit oil to flow back when braking operation is released
Implementation Method 2
a filtering part to filter oil
Implementation Method 3
an exciting coil to move the armature
Data Source
AI summary
A solenoid valve for a brake system, which has a simple constitution and can be easily manufactured with reduced manufacturing costs, is disclosed. A valve core is formed in a cylindrical shape, and has a through-hole formed in a longitudinal direction of the valve core and a fluid passage formed in a radial direction of the valve core so as to communicate with the through-hole. A sleeve is coupled to an outer surface of the valve core. The sleeve has a dome-shaped shielding portion at one end, and a flange portion to be fixed to a modulator block at the other end. An armature is slidably mounted in the sleeve. An exciting coil is provided to move the armature. A valve seat is fixed in the valve core, and has a first orifice. A plunger is mounted in the valve core. The plunger moves by movement of the armature to open or close the first orifice. A restoring spring is provided to press the plunger toward the armature. A filter member is coupled to the valve core to surround an outer surface and an end portion of the valve core, which are to be received in a bore of the modulator block. The filter member includes a filtering part to filter oil, a second orifice to rectify oil flow, and a check valve to permit oil to flow back when braking operation is released.