Structural Valve Unit for Trailer Brake Control
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Solution Overview
Problem
Existing brake systems for commercial vehicles with trailers require multiple separate valve arrangements, leading to increased assembly and maintenance costs, noise issues due to switching and venting, and a risk of compressed air leaks.
Innovation Solution
A structural valve unit that can be electronically controlled to switch between connecting the trailer-side pressure line to the control pressure line or supply pressure line, integrating the functions of previously separate valves and reducing the need for separate relay and ABS valves, while incorporating a noise attenuator to minimize noise during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate valve arrangements are used to control trailer brake pressure, then the system can provide reliable brake control functionality, but the assembly and maintenance costs increase
Solution Approach 1:
The patent combines multiple separate valve arrangements (relay valve, ABS valve, and control valve) into a single integrated valve unit. This merging reduces the number of separate components that need to be assembled and maintained, thereby lowering assembly and maintenance costs while preserving the complete brake control functionality including electronic stability control, anti-lock braking, and trailer brake control
Solution Approach 2:
The integrated valve unit is designed to perform multiple functions simultaneously: it serves as a relay valve for brake pressure control, an ABS valve for anti-lock braking, and a control valve for trailer brake activation. This multi-functionality eliminates the need for separate specialized valves while maintaining all required brake control capabilities
2Adaptability or versatility
If multiple separate valve arrangements are used, then the system can handle different brake control modes, but the risk of compressed air leaks increases
Solution Approach 1:
By merging multiple valve functions into a single integrated valve unit with unified sealing systems, the patent reduces the total number of potential leak points. The integrated design ensures that all brake control modes (manual, electronic stability control, anti-lock braking, and trailer control) operate through a single sealed system, eliminating risks associated with multiple connection points between separate valves
3Adaptability or versatility
If multiple separate valve arrangements are used, then the system can provide comprehensive brake control, but noise from switching and venting processes increases
Solution Approach 1:
The integrated valve unit consolidates all switching and venting operations into a single housing with unified noise attenuation measures. This merging allows for more effective noise containment and reduction compared to multiple separate valves, as all compressed air switching and venting processes occur within one enclosed space that can be treated as a single noise source
Solution Approach 2:
The patent introduces a noise attenuator as an intermediary element within the integrated valve unit housing. This noise attenuator acts as a mediator that absorbs and dampens the noise generated by compressed air switching and venting processes, reducing the harmful noise output while preserving the full brake control functionality
4Ease of manufacture
If a structural valve unit integrates multiple valve functions, then assembly and maintenance costs are reduced, but the device complexity increases
Solution Approach 1:
While integrating multiple functions, the valve unit is designed with segmented internal structures that separate different valve chambers and control mechanisms. This segmentation allows for modular assembly and maintenance of complex functions while presenting a unified external interface, reducing assembly complexity despite the integrated functionality
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 reduces assembly and maintenance costs, minimizes noise, and eliminates the risk of compressed air leaks by integrating valve functions within a single unit, allowing for precise control of brake pressure and venting, thus enhancing the reliability and efficiency of the brake system.
Implementation Method 1
a valve arrangement for selectively connecting either the supply pressure line or the control pressure line to the trailer control valve
Implementation Method 2
the attenuation of which can be expensive
Data Source
AI summary
A brake system (1) for a commercial vehicle (100) with a trailer includes a trailer control valve (24), a supply pressure line (46), a control pressure line (44), a valve arrangement for selectively connecting either the supply pressure line (46) or the control pressure line (44) to the trailer control valve (24), and an electronic control unit (10) that is arranged to perform electronic brake control. The valve arrangement is embodied as a structural valve unit (40), that can be switched by the electronic control unit (10) between the switching states connecting a trailer-side pressure line (52) to the control pressure line (44), and connecting the trailer-side pressure line (52) to the supply pressure line (46), and is arranged to subject the trailer-side pressure line (52) to a control pressure in a brake control situation depending on corresponding commands of the electronic control unit (10).