Electrohydraulic Valve Unit Insulation for Compact Control Housing
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Solution Overview
Problem
Existing electrohydraulic control units for motor vehicle applications face challenges in reducing installation space requirements while ensuring electrical safety and ease of maintenance.
Innovation Solution
The control unit incorporates a plug housing made of plastics material that forms a dielectric resistance between the clamping contact and the metal valve housing, allowing for compact installation and easy maintenance by enabling relative movement of the valve unit and main housing for electrical contacting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the clamping contact is positioned close to the valve unit to minimize installation space, then the installation space requirement is reduced, but the risk of short-circuit current between the clamping contact and metal valve housing increases
Solution Approach 1:
The patent introduces a non-conductive plug housing as an intermediary component between the clamping contact and the metal valve housing. This plug housing physically separates the two conductive parts and provides dielectric resistance, preventing short-circuit currents while allowing the clamping contact to be positioned close to the valve unit for compact installation.
Solution Approach 2:
The patent extracts the electrical insulation function from the main housing structure and assigns it to a separate non-conductive plug housing component. This allows the insulating function to be specifically optimized without compromising the overall compact design, as the plug housing can be precisely sized and positioned to provide adequate dielectric resistance only where needed.
2Volume of moving object
If a air gap is used to provide dielectric resistance between the clamping contact and valve housing, then the installation space is reduced, but the electrical insulation becomes unreliable under vibrations and impact shocks
Solution Approach 1:
The non-conductive plug housing serves as a solid intermediary that provides consistent dielectric resistance regardless of vibrations or impact shocks. Unlike an air gap whose insulation properties can vary with distance changes, the solid plug housing maintains stable electrical insulation under dynamic conditions while occupying minimal space.
Solution Approach 2:
The patent changes the physical state of the dielectric medium from gas (air gap) to solid (plug housing material). This parameter change ensures that the dielectric resistance remains stable and predictable under vibrations and shocks, as solid materials maintain constant physical dimensions and electrical properties under mechanical stress.
3Ease of operation
If the clamping contact is freely accessible on the side facing the valve housing, then the assembly and electrical contacting is simplified, but the installation space perpendicular to the insertion direction increases
Solution Approach 1:
The non-conductive plug housing acts as an intermediary structure that provides a mounting surface for the clamping contact on the side facing the valve housing. This allows the clamping contact to be freely accessible for simplified assembly while the plug housing itself occupies minimal space, as it only needs to extend far enough to provide adequate dielectric resistance.
Solution Approach 2:
The patent positions the clamping contact accessibility in a direction parallel to the insertion direction rather than perpendicular to it. The plug housing extends in the insertion direction to provide the necessary dielectric resistance, while the clamping contact remains accessible from the side, effectively using different spatial dimensions to satisfy both accessibility and compactness requirements.
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 minimizes installation space, provides adequate electrical insulation to prevent short-circuit currents, and facilitates easy assembly and maintenance of the control unit.
Implementation Method 1
the plug housing forms a dielectric resistance between the clamping contact and the valve housing
Data Source
AI summary
The disclosure discloses a control unit for electrohydraulic actuation of motor vehicle assemblies, having a main housing and at least one valve unit which can be inserted into the main housing. The valve unit has a metal valve housing for receiving an electrically actuable valve, a plug housing which is fastened to the valve housing and is formed from a plastics material, and a connection contact which is received in the plug housing and can be electrically connected to the valve. A clamping contact for electrically connecting the connection contact of the valve unit to an actuating electronics system is connected to the main housing. The plug housing forms a dielectric resistance between the clamping contact and the valve housing. An installation space-saving and safe control unit is rendered possible owing to the fact that the plug housing forms a dielectric resistance between the clamping contact and the valve housing.