CONTROL MODULE OF AN AIR TREATMENT SYSTEM OF A UTILITY VEHICLE

Abstract

A control module for an air treatment system of a utility vehicle comprises the following: a first and second pneumatic magnetic valve having a first or second coil, connecting pins, and armatures accommodated in the coils, a circuit carrier, and a module housing that is cast from a plastic material, into which housing the coils are cast. The connecting pins project from a first side of the module housing and are electrically connected to the circuit carrier. A plug-in connection for receiving a connection plug is formed in the module housing, wherein the plug-in connection has plug-in pins, which extend through the module housing and are electrically connected to the circuit carrier. The module housing has a mounting surface having pneumatic connections for installation on an air dryer housing of an air dryer.

Claims

1. A control module for an air treatment system of a commercial vehicle, wherein the control module comprises: a first pneumatic solenoid valve having a first coil, first connection pins and a first armature accommodated in the first coil, a second pneumatic solenoid valve having a second coil, second connection pins and a second armature accommodated in the second coil, a circuit carrier, and a module housing, which is cast from a plastic material and into which the first coil and the second coil are cast, wherein the first and second connection pin project from a first side of the module housing and are electrically connected to the circuit carrier, a plug-in connection for accommodating a connection plug is formed in the module housing, wherein the plug-in connection has plug-in pins which extend through the module housing, project from the first side of the module housing and are electrically connected to the circuit carrier, wherein the circuit carrier is covered or protected by a cover, which is fastened on the module housing, wherein the module housing has a mounting surface for contact with an air dryer housing of an air dryer, and wherein pneumatic connections of the first solenoid valve and the second solenoid valve are provided or exposed at the mounting surface.

2. The control module as claimed in claim 1, wherein the circuit carrier is pressed onto the connection pins and onto the plug-in pins.

3. The control module as claimed in claim 1, wherein furthermore cast in the module housing are: a first yoke of the first solenoid valve for forming a first closed magnetic circuit with the first armature, and a second yoke of the second solenoid valve for forming a second closed magnetic circuit with the second armature.

4. The control module as claimed in claim 1, wherein the mounting surface is formed on a lateral surface of the module housing.

5. The control module as claimed in claim 1, wherein the module housing has: a valve block part, in which the solenoid valves are accommodated and on which the mounting surface is formed, and a connection part, on which the plug socket and a pneumatic measuring connection are provided, wherein the mounting surface is formed only on the valve part.

6. The control module as claimed in claim 1, wherein the first armature and the second armature project beyond the mounting surface for direct connection to a connected air dryer.

7. The control module as claimed in claim 1, wherein the plug-in connection is exposed at a second side of the module housing, which is opposite the first side.

8. The control module as claimed in claim 7, wherein a pneumatic measuring connection is formed on the second side of the module housing and a pneumatic connection socket is formed on the first side of the module housing, wherein the measuring connection and the pneumatic connection socket are pneumatically connected to one another by the module housing, and a pressure sensor is mounted and contacted on the circuit carrier, which pressure sensor is connected to the pneumatic connection socket of the module housing for pressure measurement at a pneumatic line connected to the measuring connection.

9. The control module as claimed in claim 1, wherein a pneumatic measuring connection is formed in the mounting surface of the module housing and a pneumatic connection socket is formed on the first side of the module housing, wherein the measuring connection and the pneumatic connection socket are pneumatically connected to one another by the module housing, wherein a pressure sensor is mounted and contacted on the circuit carrier, which pressure sensor is connected to the pneumatic connection socket of the module housing for pressure measurement at a pneumatic line connected to the measuring connection.

10. The control module as claimed in claim 1, wherein an electronic control device is mounted and contacted on the circuit carrier for controlling the solenoid valves.

11. The control module as claimed in claim 1, wherein a second side of the cover, is formed as a contact surface for contact with the first side of the module housing and the cover has an outer edge, which is offset laterally outward with respect to the second side of the cover and extends to embrace or encompass the first side of the module housing.

12. The control module as claimed in claim 1, wherein the cover is formed from plastic as a cast part.

13. An air treatment system, comprising: a control module as claimed in claim 1, and an aid dryer having an air dryer housing and an air dryer cartridge, wherein the control module lies with its mounting surface against the air dryer housing and the solenoid valves are connected by their pneumatic connections to connections of the air dryer housing.

14. The air treatment system as claimed in claim 13, wherein the first solenoid valve is formed as a regenerative solenoid valve for bypassing a non-return valve between the air dryer and an air pressure output, and the second solenoid valve is formed as a governor solenoid valve or control solenoid valve for outputting a pneumatic unloader control signal to a pneumatic control input of a connected compressor.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0029] The foregoing aspects and many of the attendant advantages will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts throughout the various views, unless otherwise specified:

[0030] FIG. 1 shows a side view of a control module according to an embodiment of the invention;

[0031] FIG. 2 shows a section through the control module of FIG. 1 according to one embodiment;

[0032] FIG. 3 shows a section through a control module according to a further embodiment with an accommodated electronic control device;

[0033] FIG. 4 shows an electropneumatic circuit diagram of an air treatment system with the control module according to an embodiment of the invention;

[0034] FIG. 5 shows an electropneumatic circuit diagram of an air treatment system with the control module according to a further embodiment; and

[0035] FIG. 6 shows the air treatment system according to one hardware design.

DETAILED DESCRIPTION

[0036] A control module 1 has, according to FIG. 1, 2, a module housing 2 formed as a die-cast body and a cover 3. A first solenoid valve 4 and a second solenoid valve 14 are cast in the module housing 2. The first solenoid valve 4 has a first coil 5, which is generally wound from a first copper wire, wherein the first coil is contacted via first connection pins 7, 8. A first armature 9, which is partially adjustable by the magnetic field of the first coil 5, is accommodated in the first coil 5. Furthermore, the first solenoid valve 4 generally has a first yoke 10 for closing the first magnetic field of the first coil 5, wherein the first yoke 10 can be seen in the section of FIG. 2 and generally extends to above and below the first coil 5.

[0037] The second solenoid valve 14 accordingly has a second coil 15 made from a second copper wire, second connection pins 17, 18 and a second armature 19 accommodated in the second coil 15, wherein the second magnetic field of the second coil 15 is closed accordingly by a second yoke 20.

[0038] The two coils 5, 15 and the two yokes 10, 20 are accommodated in the plastic material of the module housing 3, wherein the armatures 9 and 19 are accordingly partially adjustable in the coils 5, 15. The connection pins 7, 8, 17, 18 project out of an upper side 2a of the module housing 2. Furthermore, an electrical plug-in connection 12 is formed in the module housing 2, which plug-in connection has a plug socket 22 formed from the plastic material of the module housing 2, for example with a substantially rectangular cross-section according to FIG. 1, 2, and multiple, for example six, electrical plug-in pins 24 within the plug socket 22 so that an electrical connection plug for a power supply and, in particular for a bus connection, can be inserted into the plug-in connection 12, i.e. accordingly from below in FIG. 2. According to FIG. 2, the plug-in pins 24 project through the module housing 2 and emerge upward from the upper side 2a. Optionally and according to the embodiment shown here, a pneumatic measuring connection 26 for a pressure sensor 32 is furthermore formed in the module housing 2, wherein the pneumatic measuring connection 26 has, for example, a circular cross-section and extends from the underside 2b of the module housing 2, through the module housing 2, to the upper side 2a and, at the upper side 2a, accordingly forms a socket opening 27 to which the pressure sensor 32 is connected.

[0039] The cover 3 can in turn be formed, in particular, as a cast housing, for example as a die-cast part, or, for example, also as a pressed part from plastic material. A printed circuit board 28 serving as a circuit carrier is covered or protected by the cover 3. When the cover 3 is formed as a cast part, the printed circuit board 28 can be injection molded accordingly on its upper side 28a and its lateral surfaces; alternatively to this, the printed circuit board 28 is subsequently inserted into the cover 3. The printed circuit board 28 accommodates the connection pins 7, 8; 17, 18 of the two solenoid valves 4 and 14, wherein the connection pins 7, 8; 17, 18 can be pushed into the printed circuit board 28, preferably pushed through into press contacts of the printed circuit board 28; alternatively to this, they can also be soldered to contacts of the printed circuit board 28. Accordingly, the plug-in pins 24 of the electrical plug-in connection 12 are also accommodated on the printed circuit board 28, i.e. pushed in, pushed through and/or soldered.

[0040] According to the embodiment shown here, the pressure sensor 32 is mounted and electrically contacted on the underside 28b of the printed circuit board 28, wherein the pressure sensor 32 projects into the connection socket 27 of the module housing 22 and is accommodated therein, sealed via seals for example, so that the pressure sensor 32 can measure a pressure applied at the pneumatic measuring connection 26, in particular for measuring the system pressure or the pressure in a connected consumer circuit.

[0041] According to FIG. 2, in particular, the cover 3 advantageously encompasses the module housing 2, i.e. it projects around the module housing 2 by means of an outer edge 3c, wherein a seal, for example a sealing ring 33 for sealing the connection between the upper side 2a of the module housing 2 and the underside 3b of the cover 3, is preferably provided.

[0042] The module housing 2 preferably has a left valve block 11a in FIGS. 1 to 3, into which the solenoid valves 4, 14 are cast, and a right connection part 11b, on which the electrical plug-in connection 12 and the pneumatic measuring connection 26 are formed. The connection part 11b is designed to be slimmer than the valve block 11a so that the connections 12, 26 are offset and thus protected. A mounting surface 2c, which can be seen in FIG. 1, is formed on the valve block 11a, which mounting surface therefore represents a lateral surface of the substantially square left region of the module housing 2. The solenoid valves 4, 14 advantageously project beyond the mounting surface 2c, for example by means of a first pneumatic connection 36 and a second pneumatic connection 37 of their inner armatures 9, 19, wherein rubber seals 36a, 37a, for example, are fitted in the pneumatic connections 36, 37. An air dryer 40 (shown in FIGS. 4 and 6) is connected to the mounting surface 2c, the air dryer housing 42 of which is seated directly on the mounting surface 2c so that the solenoid valves 4, 14 can be accordingly connected directly in the air dryer 40.

[0043] According to the embodiment of FIG. 3, an electronic control unit (microcontroller) 35 is furthermore mounted, i.e. fastened and electrically contacted, on the printed circuit board 28. In this case, the electronic control device 35 serves to control the solenoid valves 4 and 14, amongst other things; furthermore, it reads out a pressure measurement signal of the pressure sensor 32 and is connected to a bus system and an electrical power supply of the vehicle via the plug-in pins 24. To this end, according to the design in FIG. 6, an electrical connection plug 60 is plugged into the plug-in connection 12 as a CAN bus connection and for the electrical power supply.

[0044] The control module 1 of the embodiments of FIGS. 1 to 3 therefore already enables the required electrical and electropneumatic functions, i.e. the switching of the solenoid valves 4, 14 to initiate different operating modes of an air treatment system 50 of a vehicle, the data communication via a bus system and the electrical power supply and possibly a pneumatic pressure measurement. By fitting or directly mounting the control module 1 on the air dryer 40, an air treatment system shown in FIG. 6 is therefore formed as a block which is compact and also ensures good reliability owing to the lack of exposed wiring. According to FIG. 6, the control module 1 is seated directly on the air dryer housing 42 on which an air dryer cartridge 44 is also replaceably installed, for example via a screw closure or bayonet closure. A sound absorber 52 for a common air outlet is furthermore connected in FIG. 6.

[0045] FIGS. 4 and 5 show electropneumatic air treatment systems 50, 51 in which the control module 1 is inserted:

[0046] The air treatment system 50 according to FIG. 4 is provided for the connection of a compressor 55 and has the first solenoid valve 4, the second solenoid valve 14 and the air dryer 40—indicated here—with a non-return valve 53, a throttle 54 and a vent valve (purge valve) 56. The compressor 55 is connected to a compressed-air input 50a and, in delivery mode, delivers compressed air into a compressed-air inlet 50a of the air treatment system 50. In delivery mode, the compressed air is delivered through the air dryer cartridge 44 and the non-return valve 53 to a compressed-air output 50b for connected consumer circuits and possibly a compressed-air supply. The first solenoid valve 4 serves here as a regenerative solenoid valve; the second solenoid valve 14 serves here as a governor solenoid valve or control solenoid valve; however, the two solenoid valves 4, 14 of FIGS. 1 to 3 can essentially also be provided in an inverse arrangement. In regenerative mode, the electronic control device 35 outputs electrical control signals to the two solenoid valves 4, 14 so that these switch accordingly. The regenerative solenoid valve 4 is therefore switched to its open position and enables a regenerative flow from the compressed-air output 50b, through the open regenerative solenoid valve 4 and the throttle 54 and the air dryer cartridge 44 and the open vent valve 56, to a ventilation outlet 50c. To this end, the ECU 35 switches the governor solenoid valve (control solenoid valve) accordingly, so that compressed air from the compressed-air outlet 50b is output through the open control solenoid valve 14 via an unloader output 50d as a pneumatic control signal which switches off the compressor 55. The vent valve (purge valve) 56 is furthermore switched to its open position via the open control solenoid valve 14 (governor solenoid valve), so that the compressed air conducted through the air dryer cartridge 44 can be conducted to the ventilation output 50c via the open check valve 56.

[0047] The use of the control module 1 in the air treatment system 51 of FIG. 5 is furthermore also possible. The first solenoid valve 4 and the second solenoid valve 14 here are both formed as 3/2 solenoid valves, with the functionality of the components shown according to the air treatment system 50 of FIG. 4. In contrast to FIG. 4, however, the vent valve 56 in FIG. 5 is controlled by the regenerative solenoid valve 4. The terms “comprising” or “comprise” are used herein in their broadest sense to mean and encompass the notions of “including,” “include,” “consist(ing) essentially of,” and “consist(ing) of. The use of “for example,” “e.g.,” “such as,” and “including” to list illustrative examples does not limit to only the listed examples. Thus, “for example” or “such as” means “for example, but not limited to” or “such as, but not limited to” and encompasses other similar or equivalent examples. The term “about” as used herein serves to reasonably encompass or describe minor variations in numerical values measured by instrumental analysis or as a result of sample handling. Such minor variations may be in the order of ±0-25, ±0-10, ±0-5, or ±0-2.5, % of the numerical values. Further, The term “about” applies to both numerical values when associated with a range of values. Moreover, the term “about” may apply to numerical values even when not explicitly stated.

[0048] Generally, as used herein a hyphen “-” or dash “—” in a range of values is “to” or “through”; a “>” is “above” or “greater-than”; a “≥” is “at least” or “greater-than or equal to”; a “<” is “below” or “less-than”; and a “≤” is “at most” or “less-than or equal to.” On an individual basis, each of the aforementioned applications for patent, patents, and/or patent application publications, is expressly incorporated herein by reference in its entirety in one or more non-limiting embodiments.

[0049] It is to be understood that the appended claims are not limited to express and particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments which fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, it is to be appreciated that different, special, and/or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims.

[0050] The present invention has been described herein in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. The present invention may be practiced otherwise than as specifically described within the scope of the appended claims. The subject matter of all combinations of independent and dependent claims, both single and multiple dependent, is herein expressly contemplated.

LIST OF REFERENCE SIGNS (PART OF THE DESCRIPTION)

[0051] 1 Control module [0052] 2 Module housing [0053] 2a First side, in particular upper side of the module housing 2 [0054] 2b Second side, in particular underside of the module housing 2 [0055] 2c Mounting surface [0056] 3 Cover [0057] 3a Upper side of the cover [0058] 3b Underside of the cover [0059] 3c Outer edge of the cover 3 [0060] 4 First solenoid valve [0061] 5 First coil [0062] 7, 8 First connection pins [0063] 9 First armature [0064] 10 First yoke [0065] 11a Valve block of the module housing 2 [0066] 11b Connection part of the module housing 2 [0067] 12 Plug-in connection [0068] 14 Second solenoid valve [0069] 15 Second coil [0070] 17, 18 Second connection pins [0071] 19 Second armature [0072] 20 Second yoke [0073] 22 Plug socket [0074] 24 Plug-in pins [0075] 26 Pneumatic measuring connection [0076] 27 Connection socket [0077] 28 Printed circuit board, circuit carrier [0078] 28a Upper side of the printed circuit board 28 [0079] 28b Underside of the printed circuit board 28 [0080] 32 Pressure sensor [0081] 33 Sealing ring [0082] 35 Electronic control device, microcontroller [0083] 36 First pneumatic connection [0084] 36a Rubber seal in the first pneumatic connection 36 [0085] 37 Second pneumatic connection [0086] 37a Rubber seal in the second pneumatic connection 37 [0087] 40 Air dryer [0088] 42 Air dryer housing [0089] 44 Air dryer cartridge [0090] 50, 51 Air treatment system [0091] 50a Compressed-air input of the air treatment system 50 [0092] 50b Compressed-air output [0093] 50c Ventilation outlet [0094] 50d Unloader output [0095] 52 Sound absorber [0096] 53 Non-return valve [0097] 54 Throttle [0098] 55 Compressor [0099] 56 Vent valve (purge valve) [0100] 60 Electrical connection plug