Integrated Valve Control Unit for Commercial Vehicle Pressure Modulators
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Solution Overview
Problem
Existing valve control units for commercial vehicle pressure modulators are complex, costly, and prone to faults, requiring significant space and complex assembly, with separate interfaces for magnetic coils and pressure sensors leading to susceptibility to mechanical damage and electrical faults.
Innovation Solution
A compact valve control unit design where magnetic valves and pressure sensors are integrated within a one-piece housing, with microstructured sensors mounted on top and electrical interfaces directly accessible, eliminating the need for additional hose connections and allowing for simplified assembly and reduced fault susceptibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate interfaces for magnetic coils and pressure sensors are used, then electrical contacting is achieved, but mechanical damage and electrical faults increase
Solution Approach 1:
The patent combines separate interfaces for magnetic coils and pressure sensors into a single integrated electrical interface. The circuit board serves as a common platform where both coil contacts and sensor contacts are electrically connected, eliminating the need for separate pneumatic and electrical interfaces. This merging reduces the number of connection points, minimizing mechanical damage risks and electrical faults while simplifying the overall interface structure.
2Reliability
If additional hose connections are used for pressure sensors, then pneumatic pressure measurement is achieved, but mechanical damage and leakage risks increase
Solution Approach 1:
The patent extracts the pressure sensor from its traditional location requiring hose connections and relocates it directly to the housing. The sensor is mounted on the housing surface with its measurement element in direct contact with the pneumatic chamber, eliminating the intermediate hose connection. This extraction of the sensor from the hose connection system removes the leakage risk and mechanical damage vulnerability while simplifying assembly.
3Ease of manufacture
If complex assembly with separate components is used, then valve control functionality is achieved, but production cost and assembly time increase
Solution Approach 1:
The patent merges multiple separate components (magnetic valves, pressure sensors, electrical interfaces) into an integrated assembly where all elements are mounted on a single housing with a common circuit board. This consolidation reduces the total number of components, simplifies production processes, and lowers assembly time while maintaining full valve control functionality. The integrated design eliminates the need for complex routing of pneumatic lines and electrical connections between separate components.
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 results in a cost-effective, space-efficient valve control unit with reduced mechanical and electrical fault risks, enabling direct measurement of pneumatic pressures without additional hoses and simplified assembly, enhancing reliability and ease of production.
Implementation Method 1
magnetic valves are thus formed in a preferably one-piece housing or a housing body by means of magnetic coils accommodated in the housing and valve cartridges inserted in valve bores
Implementation Method 2
The microstructured pressure sensors (are) placed directly on the top of the housing as sensor hybrids or hybrid chip arrangements
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a valve control unit, particularly for a pressure modulator of a commercial vehicle. Said valve control unit (1) comprises a valve control housing (2), solenoid valves (4, 5, 6) which are provided with solenoids (16) and internal valve pieces (4a, 5a, 6a) inserted into the solenoids (16), and a pneumatic interface (14). The solenoids (16) are accommodated inside the valve control housing (2). Pressure sensors (10) for measuring pneumatic pressures are accommodated in or on the valve control unit, preferably on the top surface. Valve bores (3), into which the internal valve pieces (4a, 5a, 6a) are inserted, extend within the valve control housing (2). Air ducts (12) extend between the pneumatic interface (14), the valve bores (3), and the pressure sensors (10), inside the valve control housing (2). The solenoids (16) and pressure sensors (10) are contacted with an electrical interface (8). Advantageously, the valve control housing (2) is embodied as a single piece.