TCS ESC Modulator Segmentation for Compact Braking
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Solution Overview
Problem
The existing electronic-pneumatic braking systems for vehicles, particularly heavy goods vehicles and articulated trucks, require large nominal diameters in valves for TCS/ESC modulators, leading to increased size and cost without impairing TCS and ESC functions.
Innovation Solution
The system incorporates a solenoid valve and a changeover valve device with reduced nominal diameters, where the solenoid valve is used exclusively for pneumatically controlling the changeover valve, allowing for proportional modulation of supply pressure and reducing the overall size and cost of the solenoid valve, while the changeover valve is designed to control the pneumatic relay valve, allowing for efficient TCS/ESC functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large nominal diameters are used in valves for TCS/ESC modulator, then TCS and ESC functions can be performed, but the overall size and manufacturing cost increase
Solution Approach 1:
The valve system is segmented into multiple specialized valves (solenoid valve, changeover valve, pneumatic relay valve) with smaller nominal diameters, replacing a single large-diameter valve. Each valve performs a specific function in the pneumatic control circuit, enabling TCS/ESC operations without requiring large dimensions in any individual component.
Solution Approach 2:
The pneumatic relay valve serves multiple functions: it amplifies the control signal from the solenoid valve, controls the pneumatic two-way valve, and enables both TCS and ESC operations through a unified control mechanism. This multi-functionality allows the system to maintain complex braking operations while using smaller, more compact valve components.
2Reliability
If large nominal diameters are used in valves for TCS/ESC modulator, then TCS and ESC functions can be performed, but manufacturing cost increases
Solution Approach 1:
The system divides the valve functionality into separate, smaller-diameter components that are easier and less expensive to manufacture. Instead of producing one or two large-diameter valves, the system uses multiple smaller valves (solenoid valve with nominal diameter DN 0.8-1.2, changeover valve with DN 0.6-1.0, pneumatic relay valve with DN 0.8-1.2), reducing material costs and manufacturing complexity.
Solution Approach 2:
The invention changes the nominal diameter parameter of the valves from large dimensions to smaller dimensions (DN 0.6-1.2 range), while compensating for the reduced flow capacity through the use of a pneumatic relay valve that amplifies the control signal. This parameter change significantly reduces manufacturing costs while maintaining functional performance.
3Device complexity
If solenoid valve is used for controlling both changeover valve and pneumatic relay valve, then control function is simplified, but large nominal diameter is required in solenoid valve
Solution Approach 1:
The control function is segmented between the solenoid valve and the pneumatic relay valve. The solenoid valve (small diameter DN 0.8-1.2) controls only the changeover valve, while the pneumatic relay valve (small diameter DN 0.8-1.2) handles the control of the pneumatic two-way valve. This segmentation allows both valves to maintain small dimensions while collectively providing the complete control function.
Solution Approach 2:
The pneumatic relay valve acts as an intermediary between the solenoid valve and the pneumatic two-way valve. It receives a small control signal from the solenoid valve via the changeover valve and amplifies it to control the larger pneumatic flows required for TCS/ESC operations. This intermediary function allows the solenoid valve to remain small while still controlling the necessary pneumatic flows.
4Adaptability or versatility
If independent valve elements are used for ABS, TCS and ESC functions, then each function can be independently controlled, but structural complexity increases
Solution Approach 1:
The control functions for ABS, TCS, and ESC are merged into a unified modulator design where the solenoid valve, changeover valve, and pneumatic relay valve work together as an integrated system. The changeover valve switches between different control modes (ABS vs. TCS/ESC), while the pneumatic relay valve provides unified control for the pneumatic two-way valve, reducing structural complexity while maintaining independent control capability for each function.
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 configuration reduces the size and manufacturing costs of the solenoid valve and changeover valve, allowing for effective TCS/ESC functions with reduced nominal diameters, resulting in a more compact and cost-effective electronic-pneumatic braking system.
Implementation Method 1
the solenoid valve (7) is designed in such a way that it is switched from its rest position into its actuating position in order to perform a TCS/ESC function
Data Source
AI summary
An electronic-pneumatic braking system for a vehicle, for example for a heavy goods vehicle or an articulated truck, includes a TCS/ESC modulator (1), enabling control functions for a traction control system (TCS) and a vehicle stability control system (ESC). The TCS/ESC modulator (1) includes a pneumatic relay valve (2), a solenoid valve (7) and a changeover valve device (11). In order to achieve a compact size and cost savings during manufacture, only control pressure can be applied to the solenoid valve (7) and to the changeover valve device (1), while only the pneumatic relay valve (2) has a large nominal size for conveying the supply pressure to at least one wheel brake and for venting the latter. As a result, the changeover valve device (11) can be structurally integrated in a TCS/ESC modulator (1) intended for carrying out the TCS/ESC functions.