Trailer Brake Control Valve With Segmented Supplemental Pressure Path
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Solution Overview
Problem
Existing trailer control valves for hydraulic dual-line brake systems are complex and prone to faults, failing to meet the requirements of EU Directive 2015/68 for dual-line brake systems in agricultural and forestry vehicles.
Innovation Solution
A trailer control valve with a pressure-limiting valve and a shut-off valve arranged in series, where the shut-off valve is a 3/2-way solenoid switching valve, allowing for simplified control and reduced fault likelihood, with optional redundant control branches for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex valve arrangement is used to control the supplemental pressure outlet, then the control functionality is complete, but the device complexity increases and fault likelihood increases
Solution Approach 1:
The valve arrangement is segmented into two distinct valves: a pressure-limiting valve (36) that reduces supply pressure to supplemental pressure, and a shut-off valve (38) that controls the flow path to the supplemental pressure outlet (S). This segmentation allows each valve to perform a single function reliably, reducing overall system complexity and fault likelihood compared to a single complex multi-position valve.
Solution Approach 2:
The pressure-limiting valve (36) acts as an intermediary component between the supply pressure inlet (P) and the supplemental pressure outlet (S). It mediates the pressure reduction function, allowing the shut-off valve (38) to simply control flow without needing to handle pressure regulation, thereby simplifying the control logic and reducing fault points.
2Reliability
If a pressure-limiting valve and shut-off valve arranged in series are used, then the fault likelihood is reduced and control is simplified, but the device complexity increases compared to existing solutions
Solution Approach 1:
The pressure-limiting valve (36) is designed to automatically reduce supply pressure to the required supplemental pressure without requiring active control. This self-regulating feature reduces the control burden on the shut-off valve (38) and eliminates the need for complex pressure control logic, thereby reducing overall system complexity while improving reliability.
Solution Approach 2:
The system changes the pressure parameter automatically through the pressure-limiting valve (36), which maintains a constant supplemental pressure (between 15×10^5 Pa and 35×10^5 Pa) regardless of supply pressure variations. This parameter automation reduces control complexity and improves fault resistance.
3Ease of manufacture
If the shut-off valve is configured as a 3/2-way solenoid switching valve, then the control is simplified and cost is reduced, but the adaptability for different control modes is limited
Solution Approach 1:
The 3/2-way solenoid switching valve (38) is configured to perform multiple functions: it acts as a normal shut-off valve for routine operation, and can trigger emergency braking by directing pressure to the emergency brake circuit when activated. This multi-functionality maintains control mode flexibility while using a simple, cost-effective valve design.
Solution Approach 2:
The solenoid switching valve (38) provides dynamic control capability, allowing the system to switch between normal operation and emergency braking modes as needed. The electronic actuation enables rapid response while maintaining mechanical simplicity, balancing adaptability with ease of manufacture.
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 solution provides a cost-effective and reliable control of hydraulic dual-line brake systems, detecting leaks and defects to trigger emergency braking, ensuring safe operation of trailer vehicles.
Implementation Method 1
the outlet pressure of which can be reduced to a supplemental pressure by means of a pressure-limiting valve (36)
Implementation Method 2
a shut-off valve (38), in particular a 3/2-way solenoid switching valve, by means of which the supplemental pressure outlet (S) can be connected
Data Source
AI summary
A trailer control valve for controlling a hydraulic dual-line brake system of a trailer vehicle has an inlet for a hydraulic supply line of the towing vehicle, a tank outlet for an unpressurized return-flow line of the towing vehicle, a brake pressure outlet, and a supplemental pressure outlet. The brake pressure outlet can be connected in a stepped manner with an electronically controlled brake control valve to the supply pressure inlet or to the tank outlet. The supplemental pressure outlet can connect using a valve arrangement so that an outlet pressure of the supply pressure is reduced to a supplemental pressure at the supply pressure inlet or at the tank outlet. The valve arrangement has a pressure-limiting valve and a shut-off valve arranged in series. The shut-off valve can be a 3/2-way valve, which when not energized, the supplemental pressure outlet is connected to the tank outlet.