Variable Load Valve Diaphragm Fixing Member Segmentation
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Solution Overview
Problem
Conventional variable load valves face challenges in redesign due to changes in performance specifications, requiring redesign of components like the piston, adjustment spring, and force transmitting member, which can lead to delays and resistance to electronic control systems, especially in emergency brake applications.
Innovation Solution
A variable load valve design featuring an annular-shaped first and second diaphragm member, a piston, and a force transmitting member with a pressure receiving surface, allowing for easy adjustment of load compensated pressure characteristics without relying on electronic control systems, by selecting different diaphragm fixing and force transmitting members to achieve desired performance curves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the piston, adjustment spring, force transmitting member, and spring are redesigned to match changed performance specifications or vehicle weight, then the load compensated pressure characteristic can be optimized, but the delivery date is delayed due to redesign time
Solution Approach 1:
The force transmitting member is divided into a main body portion and a separate diaphragm fixing member. This segmentation allows the diaphragm fixing member to be independently selected and replaced to adjust the effective area of the diaphragm, thereby changing the load compensated pressure characteristic without redesigning the entire force transmitting member or other components. This resolves the contradiction by enabling quick adaptation to different specifications through component selection rather than full redesign.
Solution Approach 2:
The invention changes the parameter of the effective area of the diaphragm by selecting different diaphragm fixing members with different dimensions. This parameter change allows the load compensated pressure characteristic to be adjusted to match different vehicle weights or performance requirements. By providing a set of pre-designed diaphragm fixing members with varying parameters, the system can quickly adapt to specification changes without time-consuming redesign, thus resolving the contradiction between optimization and delivery timing.
2Adaptability or versatility
If an electronic control system is employed to cope with performance specification changes, then redesign can be avoided, but users may feel resistance to using electronic control in emergency brake applications
Solution Approach 1:
The invention provides a mechanical solution (selectable diaphragm fixing members) to replace what would otherwise require an electronic control system. By offering a set of pre-designed diaphragm fixing members that can be selected based on performance specifications or vehicle weight, the system achieves adaptability through mechanical means rather than electronic control. This resolves the contradiction by maintaining user preference for mechanical systems in emergency brake applications while still providing the necessary adaptability to specification changes.
3Ease of manufacture
If the diaphragm fixing member is integrated into the valve body, then manufacturing is simpler, but redesign requires modifying the valve body structure which increases complexity and time
Solution Approach 1:
The force transmitting member is segmented into a main body portion and a separate diaphragm fixing member. This segmentation maintains manufacturing simplicity by allowing each component to be manufactured independently using standard processes, while simultaneously providing redesign flexibility. When performance specifications or vehicle weight change, only the diaphragm fixing member needs to be replaced rather than modifying the valve body structure. This resolves the contradiction by decoupling the manufacturing simplicity of individual components from the flexibility needed for adaptation.
Solution Approach 2:
The invention introduces a dynamic configuration where the diaphragm fixing member can be selected or replaced based on different operating conditions (vehicle weight, performance requirements). This dynamic approach allows the system to adapt to changing requirements without requiring changes to the main valve body structure. The separable design enables the system to transition between different configurations easily, resolving the contradiction between manufacturing simplicity and adaptability.
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
Enables flexible redesign and adjustment of load compensated pressure characteristics, simplifying the process and avoiding reliance on electronic controls, thus addressing the challenges of performance specification changes and enhancing assemblability while maintaining desired pressure characteristics.
Implementation Method 1
a first diaphragm member (41) bendable by a pressure inside a pilot chamber (32)
Implementation Method 2
the first diaphragm member (41) is bendable by a pressure inside the pilot chamber (32)
Implementation Method 3
a second diaphragm member (42) bendable by a pressure inside an output chamber (33)
Implementation Method 4
the second diaphragm member (42) is bendable by a pressure inside the output chamber (33)
Implementation Method 5
a piston (40) adapted to be axially displaced in accordance with a bending of the first diaphragm member (41) and a bending of the second diaphragm member (42), thereby generating a load compensated pressure
Data Source
Figure 1
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AI summary
Disclosed is a variable load valve (21) which comprises: a first diaphragm member (41) which is bendable by a pressure inside a pilot chamber for receiving an air pressure according to a vehicle weight; a second diaphragm member (42) which is bendable by a pressure inside an output chamber for outputting a load compensated pressure; a piston (40) adapted to be axially displaced in accordance with the bending of the first and second diaphragm members (41, 42), thereby generating the load compensated pressure; a force transmitting member (43) having a pressure receiving portion (43b) with a pressure receiving surface (43d) for receiving a pressing force caused by the bending of the second diaphragm member (42), and an extension portion (43c) extended radially from a fixed portion (43a), wherein the force transmitting member (43) is adapted to transmit, to the piston (40), a force according to the pressing force received from the second diaphragm member (42) through the pressure receiving surface (43d); and a diaphragm fixing member (45) formed separately from a block (25), and adapted to fix an outer peripheral portion of the second diaphragm member (42) to the block (25) and set an area of the pressure receiving surface (43d) of the force transmitting member (43).