VALVE UNIT FOR MODULATING PRESSURE IN AN AIR-BRAKE SYSTEM
20170253223 · 2017-09-07
Inventors
Cpc classification
B60T8/3675
PERFORMING OPERATIONS; TRANSPORTING
International classification
B60T8/34
PERFORMING OPERATIONS; TRANSPORTING
B60T8/36
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The invention concerns a valve unit (1) for modulating pressure in a compressed air braking system, with a brake pressure input (3), a brake pressure output (4), and a purge output (5), an inlet valve (6) configured as a diaphragm valve, an outlet valve (7) configured as a diaphragm valve, and with, for each diaphragm valve (6, 7), respective precontrol valves (8, 9), which are each configured as a 3/2-way solenoid valve and are arranged in an elongate valve housing (2), which is divided by a division plane (10) that is largely horizontal in the installation position into a base housing (11) and a housing cover (12).
For effective sound damping of the compressed air emerging into the environment when the outlet valve (7) is open, the valve unit (1) at the purge output (5) is provided with a silencer (75) which comprises a largely cylindrical silencer housing (76) with an inlet opening (77), a calming chamber (78) arranged radially on the inside, a large outlet opening (79) and a silencer insert (80.1) arranged upstream of the outlet opening (79) inside the silencer housing (76) and made of an air-permeable and sound-deadening material, and which (75) is attached to the base housing (11) with base walls (83, 84) oriented parallel to the division plane (10) between the brake pressure input (3) and the brake pressure output (4).
Claims
1. A valve unit (1) for modulating pressure in a compressed air braking system, the valve unit comprising: with a brake pressure input (3), a brake pressure output (4) and a purge output (5), an inlet valve (6) configured as a diaphragm valve, an outlet valve (7) configured as a diaphragm valve, for each of the diaphragm valves (6, 7), respective precontrol valves (8, 9) which are each configured as a 3/2-way solenoid valve, an elongate valve housing (2) that is divided by a division plane (10) extending horizontally in an installation position into a base housing (11) and a housing cover (12), wherein the brake pressure input (3) and the brake pressure output (4) and the purge output (5) are arranged in the base housing (11), the diaphragm valves (6, 7) are arranged behind each other in the longitudinal direction (13) in the base housing (11) between the brake pressure input (3) and the brake pressure output (4), with parallel actuation axes (14, 15) and with an arrangement of diaphragms (16, 17) associated with the diaphragm valves in a common diaphragm plane parallel to and proximate to the division plane (10) and clamped between the base housing (11) and the housing cover (12), and wherein the precontrol valves (8, 9) are arranged in the housing cover (12), and a silencer (75) at the purge output (5), the silencer cylindrical silencer housing (76) with an inlet opening (77), a calming chamber (78) arranged radially inside the silencer, a large outlet opening (79) and a silencer insert (80.1, 80.2) arranged upstream of the outlet opening (79) inside the silencer housing (76) and made of an air-permeable and sound-deadening material, wherein the silencer (75) is attached to the base housing (11) with base walls (83, 84) oriented parallel to the division plane (10) between the brake pressure input (3) and the brake pressure output (4).
2. The valve unit as claimed in claim 1, wherein the silencer housing (76) consists of a pot-shaped cylindrical bottom housing (81) with a cylinder wall (82) and a housing floor (83), and of a flat housing lid (84), wherein in the installed state, the housing floor (83) of the bottom housing (76) faces the division plane (10), the inlet opening (77) lying against the purge output (5).
3. The valve unit as claimed in claim 2, wherein the outlet opening (79) of the silencer housing (76) is arranged in the cylinder wall (82) of the bottom housing (81) and extends relative to the brake pressure input (3), over an angular region of at most 270°.
4. The valve unit as claimed in claim 3, wherein the outlet opening (79) contains a plurality of webs (86) that are evenly distributed over a periphery of the bottom housing (81) and arranged between the housing floor (83) and an outer edge (85) of the bottom housing (81).
5. The valve unit as claimed in claim 1, wherein the housing floor (83) of the base housing (81) comprises at least one elevation (88, 88′) directed axially outward, which in the installed state engages in a corresponding recess in the base housing (11).
6. The valve unit as claimed in claim 1, wherein the silencer insert (80.1) has a partially cylindrical shell (89) which in the installed state, lies inside the silencer housing (76) against the outlet opening (79) of the silencer housing (76) and is reinforced by a circular flat floor portion (90).
7. The valve unit as claimed in claim 1, wherein the silencer insert (80.2) has two partially cylindrical shells (91, 92) which are arranged coaxially to each other and radially spaced apart, and are connected by a circular floor portion (93) and circumferentially directly connected together, and of which the radially outer shell (92), in the installed state, lies on the inside against the outlet opening (79) of the silencer housing (76).
8. The valve unit as claimed in claim 1, wherein the silencer insert (80.1, 80.2) is a braid of mineral fibers, metal fibers or plastic fibers.
9. The valve unit as claimed in claim 1, wherein the silencer insert (80.1, 80.2) is a sintered component of metal or plastic.
10. The valve unit as claimed in claim 1, wherein characterized in that the silencer insert (80.1, 80.2) is a porous casting of metal or plastic.
11. The valve unit as claimed in claim 1, wherein the base housing (11) of the valve unit (1) has an underside facing away from the division plane (10 and has a recess (94) in which the silencer housing (76) is at least partially inserted in the installed state.
12. The valve unit as claimed in claim 1, wherein the silencer housing (76) is fixed to the valve housing (2) by a screw connection (95, 96, 97) of the housing lid (84) to the base housing (11).
13. The valve unit as claimed in claim 1, wherein a connecting channel (55′) inside the base housing, adjacent to the silencer and open toward the silencer is closed in the installed state by the housing floor (83) of the silencer housing (76), and wherein sealing elements (100, 101) are arranged between the housing walls (98, 99) of the base housing (11) delimiting the connecting channel (55′) and the housing floor (83).
Description
[0034] For further clarification of the invention, a drawing of several exemplary embodiments is attached to the description. This shows:
[0035]
[0036]
[0037]
[0038]
[0039]
[0040]
[0041]
[0042]
[0043]
[0044]
[0045]
[0046] First, with reference to
[0047] A brake pressure input 3, a brake pressure output 4, a purge output 5, an inlet valve 6 configured as a diaphragm valve, an outlet valve 7 configured as a diaphragm valve, and for each diaphragm valve 6, 7 a precontrol valve 8, 9 configured as a 3/2-way solenoid valve, are arranged in an elongate valve housing 2. The valve housing 2 is divided by a division plane 10, that is largely horizontal in the installation position, into a base housing 11 and a housing cover 12. The brake pressure input 3 and the brake pressure output 4 are arranged with horizontal orientation, largely axially opposite in the longitudinal direction 13 of the valve housing 2, and the purge output 5 is arranged for example inbetween, oriented vertically downward in the base housing 11. The two diaphragm valves 6, 7 are arranged in the base housing 11 between the brake pressure input 3 and the brake pressure output 4, with parallel actuation axes 14, 15 and diaphragms 16, 17 arranged in a common diaphragm plane, largely corresponding to the division plane 10, being clamped between the base housing 11 and the housing cover 12, behind each other in the longitudinal direction 13. The two precontrol valves 8, 9 however are arranged in the housing cover 12.
[0048] The precontrol valve 8 of the inlet valve 6 and the precontrol valve 9 of the outlet valve 7 are arranged in the housing cover 12 in the longitudinal direction 13, with orientation of their actuation axes 18, 19 parallel to the division plane 10, largely centrally over the diaphragms 16, 17 of the inlet valve 6 and the outlet valve 7. The housing cover 12 has a central insert part 30 provided with valve bores 20, 21; 22, 23 and control channels 24, 25, 26; 27, 28, 29, in which the magnetic coils 31, 32 and the mechanical components of the precontrol valves 8, 9 and the respective valve core 33, 36, the respective valve rotor 34, 37 and the respective valve spring 35, 36 are inserted, and around which a plastic 39 is molded.
[0049] In the present case, the precontrol valves 8, 9 are configured as separate solenoid valves which, each with opposing switching direction and with valve seat 40, 41 facing the diaphragm 16, 17 of the assigned inlet valve or outlet valve 6, 7, are each arranged axially parallel and radially adjacent to each other in the insert part 30. The insert part 30 consists of the input-side part 42 and an output-side part 43 which surround the magnetic coils 31, 32 and the mechanical components 33-35; 36-38 of the solenoid valves 8, 9 at the end. Connecting cables 44 of the magnetic coils 31, 32 are routed inside the overmolding 39 of the housing cover 12 and terminate in a connecting bush 45 formed by the over-molding 39.
[0050] The diaphragms 16, 17 of the inlet valve 6 and the outlet valve 7, because of their shaping, each lie on a valve seat 46, 47 of a cylindrical central channel 48, 49, which can be connected to or shut off from a cylindrical ring channel 53, 54 arranged coaxially thereto by loading the control chamber 51, 52, delimited by the respective diaphragm 16, 17 and an inner wall 50 of the housing cover 12 facing the division plane 10, with a low or high control pressure. The ring channel 53 of the inlet valve 6 is connected to the brake pressure input 3. The central channel 48 of the inlet valve 6 is connected via a connecting channel 55 to the ring channel 54 of the outlet valve 7, which is in turn connected to the brake pressure output 4. The cylindrical ring channel 49 of the outlet valve 7 is connected to the purge output 5. Hence the brake pressure output 4 can be alternately connected to or shut off from the brake pressure input 3 via the inlet valve 6. Hence the brake pressure output 4 can be alternately connected to or shut off from the brake pressure input 5 via the inlet valve 7. In the present embodiment of the valve unit 1, the insert part 30 of the housing cover 12 extends up to the division plane 10 between the base housing 11 and the housing cover 12, and completely delimits the control chamber 51, 52 of the diaphragm valves 8, 9.
[0051] The valve unit 1 has the switch functions “build up pressure”, “maintain pressure”, and “reduce pressure”. In the “build up pressure” switch function of the valve unit 1, the inlet valve 6 is opened and the outlet valve 7 is closed, so that the brake pressure introduced via the brake valve at the brake pressure input 3 is conducted unchanged to the brake pressure output 4 and to at least one wheel brake cylinder connected thereto. Since the “build up pressure” switch function corresponds to the rest state of the valve unit 1, the precontrol valve 8 of the inlet valve 6, when its magnetic coil 31 is unpowered, connects the control chamber 51 of the inlet valve 6 via the control channel 24, valve bore 21, longitudinal grooves 57 in the valve rotor 34, and a central bore 56 in the valve core 33, to a control channel 25 carrying a low control pressure which is connected to the purge output 5 in a manner not shown.
[0052] The diaphragm 16, shown lying on the valve seat 46 of the inlet valve 6 in
[0053] In the “maintain pressure” switch function of the valve unit 1, the inlet valve 6 and the outlet valve 7 are closed so that the brake pressure, present at the brake pressure output 4 and at the at least one wheel brake cylinder connected thereto, is held constant. To set this switch function, only the precontrol valve 8 of the inlet valve 6 is switched by powering its magnetic coil 31, whereby the respective valve rotor 34 is drawn axially inward from the valve seat 40 against the return force of the valve spring 35. As a result, the control chamber 50 of the inlet valve 6 is connected via the control channel 24 and valve bore 21 to the control channel 26 carrying the high control pressure, which is connected to the brake pressure input 3 via a further control channel 60 arranged in the base housing 11.
[0054] In the “reduce pressure” switch function of the valve unit 1, the inlet valve 6 is closed and the outlet valve 7 opened so that the brake pressure output 4 and at the at least one wheel brake cylinder connected thereto are purged via the purge output 5. To set this switch function, both precontrol valves 8, 9 are switched by powering of their magnetic coils 31, 32. By powering the magnetic coils 32 of the precontrol valve 9 assigned to the outlet valve 7, the respective valve rotor 37 is drawn axially inward away from the valve seat 41, against the return force of the valve spring 38, whereby the control chamber 52 of the outlet valve 7 is connected via the control channel 27 and valve bore 24 to a control channel 28 carrying the low control pressure, which is connected to the purge output 5 in a manner not shown.
[0055] The “maintain pressure” and “reduce pressure” switch functions of the valve unit 1 are antilock functions with which a braking-induced locking of the at least one assigned wheel is avoided. These switch functions are controlled by a corresponding actuation of the precontrol valves 8, 9 by a control unit of the anti-lock system, in which the signals from the wheel speed sensors are analyzed to detect an impending or existing locking of the braked wheels.
[0056] Because the precontrol valves 8, 9 are arranged lying when the valve unit 1 is in the installation position, i.e. in the longitudinal direction 13 parallel to the division plane 10 of the valve housing 2, the installation height of the valve cover 12 is very low and hence the dimensions of the entire valve unit 1 are particularly compact. This is particularly advantageous since, to achieve a short reaction time of the wheel brakes concerned when the anti-lock functions are actuated, such valve units 1 are arranged as close as possible to the assigned wheel brake cylinders and the installation space available there is normally small.
[0057] Due to the orientation of the solenoid valves 8, 9 with valve seats 40, 41 arranged adjacent to the diaphragms 16, 17 or the control chambers 50, 51 of the assigned diaphragm valves 6, 7, for both precontrol valves 8, 9 the pilot volumes to be filled or emptied on switching are particularly small. Advantageously, this leads to particularly short switching reaction times of the diaphragm valves 6, 7 when the solenoid valves 8, 9 are switched.
[0058] Assembly of the valve unit 1, and its overhaul in which the diaphragms 16, 17 are to be replaced with new ones, are substantially simplified due to the over-molding 39 of the insert part 30 containing the magnetic coils 31, 32 and the mechanical components 33-35, 36-38 of the precontrol valves 8, 9. Also, due to the plastic over-molding 39 of the insert part 30, the connecting bush 45 of the magnetic coils 31, 32 can be arranged flexibly according to the requirements of the respective vehicle manufacturer, i.e. if required with different bush shape and different orientation, at various places on the housing cover 12. Also, the over-molding 39 optimally protects the solenoid valves 8, 9 from the penetration of moisture and dirt particles from the outside.
[0059]
[0060] The shackle element 62, produced integrally by sheet metal pressing and punching, is attached to the base housing 11 and with its largely flat pressure plate 63 lies on a flat outer wall 64 of the housing cover 12 oriented parallel to the division plane 10 of the valve housing 2, generating a spring-elastic pretension force. In the longitudinal direction 13 of the valve housing 2, the shackle element 62 is provided on one side with two hinge arms 65, 66 which laterally surround the housing cover 12 and the base housing 11 and are attached to the base housing 12 via a hinge pin 69 engaging in a hinge bore 65, 66. Opposite the hinge arms 65, 66 in the longitudinal direction 13, the shackle element 62 is provided with a fixing tab 70 which is oriented largely parallel to the pressure plate 63 and has a bore 71 via which the shackle element 62 is screwed to the base housing 11 by means of a screw 72, generating a spring-elastic pretension force. In order to be able to make the fixing tab 70 smaller and hence the shackle element 62 more stable, the base housing 11 has a post-like protrusion 73 opposite the hinge pin 69 in the longitudinal direction 13, which protrudes over the division plane 10 vertically in the direction of the housing cover 12 and has a threaded bore 74 for screw connection of the fixing tab 70.
[0061] In comparison with a conventional flange bolting of the housing cover 12 to the base housing 11, fixing via the shackle element 62 is more economic to produce and takes up less installation space. Also, in this way the valve housing 2 can be opened and re-closed with lower assembly complexity for maintenance and repair purposes, in particular for overhaul of the valve unit in which for example the diaphragms of the diaphragm valves 6, 7 can be replaced.
[0062] The silencer 75 comprises a largely cylindrical silencer housing 76 with an inlet opening 77, a calming chamber 78 arranged radially on the inside, a large outlet opening 79 and a silencer insert 80.1 arranged upstream of the outlet opening 79 inside the silencer housing 76 and made of an air-permeable and sound-deadening material, and is attached to the base housing 11 with base walls 83, 84 oriented parallel to the division plane 10 of the valve housing 2 between the brake pressure input 3 and the brake pressure output 4.
[0063] As shown in particular from the perspective views of
[0064] When the outlet valve 7 is opened, compressed air flows at relatively high pressure out of the brake line portion connected to the brake pressure output 4, as indicated by the flow arrows 87 in the section view of
[0065] As evident from the perspective view of
[0066] In a first embodiment according to
[0067] In a second embodiment according to
[0068] The silencer insert 80.1, 80.2 may be made as a braid of mineral fibers, metal fibers or plastic fibers, as a sintered component of metal or plastic, or as a porous casting of metal or plastic.
[0069] As can be seen particularly clearly in the section view of
[0070] In the section view of
REFERENCE NUMERALS
[0071] 1 Valve unit [0072] 2 Valve housing [0073] 3 Brake pressure input [0074] 4 Brake pressure output [0075] 5 Purge output [0076] 6 Inlet valve, diaphragm valve [0077] 7 Outlet valve, diaphragm valve [0078] 8 Precontrol valve of inlet valve 6, solenoid valve [0079] 9 Precontrol valve of inlet valve 7, solenoid valve [0080] 10 Division plane [0081] 11 Base housing [0082] 12 Housing cover [0083] 13 Longitudinal direction of valve housing 2 [0084] 14 Actuation axis of inlet valve 6 [0085] 15 Actuation axis of outlet valve 7 [0086] 16 Diaphragm of inlet valve 6 [0087] 17 Diaphragm of outlet valve 7 [0088] 18 Actuation axis of precontrol valve 8 [0089] 19 Actuation axis of precontrol valve 9 [0090] 20 Valve bore of precontrol valve 8 [0091] 21 Valve bore of precontrol valve 8 [0092] 22 Valve bore of precontrol valve 9 [0093] 23 Valve bore of precontrol valve 9 [0094] 24 Control channel of precontrol valve 8 [0095] 25 Control channel of precontrol valve 8 [0096] 26 Control channel of precontrol valve 8 [0097] 27 Control channel of precontrol valve 9 [0098] 28 Control channel of precontrol valve 9 [0099] 29 Control channel of precontrol valve 9 [0100] 30 Insert part [0101] 31 Magnetic coil of precontrol valve 8 [0102] 32 Magnetic coil of precontrol valve 9 [0103] 33 Valve core of precontrol valve 8 [0104] 34 Valve rotor of precontrol valve 8 [0105] 35 Valve spring of precontrol valve 8 [0106] 36 Valve core of precontrol valve 9 [0107] 37 Valve rotor of precontrol valve 9 [0108] 38 Valve spring of precontrol valve 9 [0109] 39 Over-molding, plastic [0110] 40 Valve seat of precontrol valve 8 [0111] 41 Valve seat of precontrol valve 9 [0112] 42 Input-side part of insert part 30 [0113] 43 Output-side part of insert part 30 [0114] 44 Connecting cable [0115] 45 Connecting bush [0116] 46 Valve seat of inlet valve 6 [0117] 47 Valve seat of outlet valve 7 [0118] 48 Central channel of inlet valve 6 [0119] 49 Central channel of outlet valve 7 [0120] 50 Inner wall of housing cover 12 [0121] 51 Control chamber of inlet valve 6 [0122] 52 Control chamber of outlet valve 7 [0123] 53 Ring channel of inlet valve 6 [0124] 54 Ring channel of outlet valve 7 [0125] 55, 55′ Connecting channel [0126] 56 Central bore of valve core 33 [0127] 57 Longitudinal groove in valve rotor 34 [0128] 58 Central bore of valve core 36 [0129] 59 Longitudinal groove in valve rotor 37 [0130] 60 Control channel of precontrol valve 8 [0131] 61 Control channel of precontrol valve 9 [0132] 62 Shackle element [0133] 63 Pressure plate of shackle element 62 [0134] 64 Outer wall of housing cover 12 [0135] 65 Hinge arm of shackle element 62 [0136] 66 Hinge arm of shackle element 62 [0137] 67 Hinge bore in hinge arm 65 [0138] 68 Hinge bore in hinge arm 66 [0139] 69 Hinge pin of hinge arm 65, 66 [0140] 70 Fixing tab of shackle element 62 [0141] 71 Bore in fixing tab 70 [0142] 72 Screw [0143] 73 Protrusion of base housing 11 [0144] 74 Threaded bore in protrusion 73 [0145] 75 Silencer [0146] 76 Silencer housing [0147] 77 Inlet opening [0148] 78 Calming chamber [0149] 79 Outlet opening [0150] 80.1 Silencer insert, first embodiment [0151] 80.2 Silencer insert, second embodiment [0152] 81 Bottom housing of silencer housing 76 [0153] 82 Cylinder wall of bottom housing 81 [0154] 83 Base wall or housing floor of silencer housing 76 [0155] 84 Base wall or housing lid of silencer housing 76 [0156] 85 Outer edge of bottom housing 81 [0157] 86 Web of bottom housing 81 [0158] 87 Flow arrows [0159] 88, 88′ Elevation, web of base wall 83 [0160] 89 Shell of silencer insert 80.1 [0161] 90 Floor portion of silencer insert 80.1 [0162] 91 Inner shell of silencer insert 80.2 [0163] 92 Outer shell of silencer insert 80.2 [0164] 93 Floor portion of silencer insert 80.2 [0165] 94 Recess of base housing 11 [0166] 95 Screw [0167] 96 Screw [0168] 97 Screw [0169] 98 Housing wall of base housing 11 [0170] 99 Housing wall of base housing 11 [0171] 100 Sealing element, sealing strip [0172] 101 Sealing element, sealing strip