DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patent Rules, 2003
COMPLETE SPECIFICATION
(See sections 10 & rule 13)
1. TITLE OF THE INVENTION
AN INTEGRATED SYSTEM FOR SERVICE BRAKE AND SECONDARY BRAKE SYSTEM BY USING PILOT HYDRAULIC POWER
2. APPLICANT (S)
NAME NATIONALITY ADDRESS
BEML LIMITED IN BEML Soudha, No 23/1, 4th Main S.R. Nagar, Bengaluru- 560027, Karnataka, India.
3. PREAMBLE TO THE DESCRIPTION
COMPLETE SPECIFICATION

The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF INVENTION:
[001] The present invention relates to the field of braking systems for heavy-duty equipment. The present invention in particular relates to an integrated system and method for service brake and secondary brake system by using pilot hydraulic power.
DESCRIPTION OF THE RELATED ART:
[002] Loaders are heavy-duty equipment used in various industries for material handling and earthmoving tasks. Effective braking systems are crucial for ensuring operator safety and preventing accidents, especially when operating in challenging environments or when handling substantial loads. Conventional air over hydraulics brake systems in loaders often face limitations in terms of cost, air leakage, stopping power, reliability, high pressure air compressor which requires regular maintenance, and conventional air over hydraulics braking system requires additional secondary braking system in emergency situations (like engine off, or line leakage conditions).
[003] Reference may be made to the following:
[004] Publication No. GB1338571 relates to a dual braking system for a vehicle, more particularly for the tractor of a tractor-trailer combination, comprises a service braking function brake applying line and a secondary braking function brake applying line for emergency or parking brake applications which lines control the operation of brake actuators respectively, which actuators may be separate units or may be contained in a common housing; the system also incorporates an antiskid line with a skid control valve which is operable by a skid-detecting device to release the operative brake actuator when a tendency of a wheel to lock under braking is detected and to re-apply the previously operative brake actuator when the tendency for the wheel to lock has been overcome.
[005] Patent No. US7344199 relates to a brake system for braking a rotatable brake disk includes a primary brake piston engageable with the brake disk and a secondary brake piston engageable with the primary brake piston and operable to move the primary brake piston into engagement with the brake disk. Both pistons are operable in response to fluid pressure. A primary brake valve controls communication of fluid pressure to the primary brake piston. A secondary brake valve controls communication of fluid pressure to the secondary brake piston.
[006] Publication No. CN105083248 relates to a service braking system and aims to provide a service braking system which is simple in structure and convenient to operate so as to simplify the braking operation procedure, improve work efficiency and prolong the service life of a vehicle. According to the technical scheme, the system is provided with an energy accumulator, a braking valve, a pressure reduction valve, an electromagnetic valve, a controller, a brake and a liquid filling system used for filling liquid for the energy accumulator. The energy accumulator is communicated with a liquid inlet II of the electromagnetic valve through the braking valve and a pipeline. The energy accumulator is communicated with a liquid inlet I of the electromagnetic valve through the pressure reduction valve and a pipeline.
[007] Publication No. CN118651202 relates to a linkage auxiliary braking method and device for vehicle service braking and electronic equipment, and belongs to the technical field of vehicle control. The method comprises the steps that air pressure data collected by an air pressure sensor at a foot valve output port is obtained, and the stroke of a vehicle pedal is determined based on the air pressure data; and determining a deceleration of the vehicle after the EBI activates the auxiliary brake based on the travel; engine torque and vehicle speed in the vehicle acceleration process are obtained, and the whole vehicle mass is determined based on the engine torque and the vehicle speed; and based on the transmission system speed ratio and the rear axle speed ratio of the vehicle and the deceleration and the whole vehicle mass of the vehicle after the EBI activates auxiliary braking, the auxiliary braking torque is determined, and linkage auxiliary braking is conducted based on the auxiliary braking torque.
[008] Publication No. CN118418958 relates to an air brake system in the field of engineering machinery. The air brake system comprises a foot brake valve; a hand brake valve, a two-axle pneumatic control device and an air machine; the two-axle air control device comprises a first loop air cylinder, a second loop air cylinder, a second brake valve assembly and a spring energy storage brake air chamber set, wherein the first loop air cylinder, the second loop air cylinder, the second brake valve assembly and the spring energy storage brake air chamber set are connected with the foot brake valve and the hand brake valve. The second brake valve assembly controls whether the first loop air cylinder and the second loop air cylinder are communicated with the spring energy storage brake air chamber set or not. A first bridge pneumatic control device; the first-bridge air control device comprises a third loop air cylinder connected with the foot brake valve, a first brake valve assembly and a diaphragm type brake air chamber set.
[009] Publication No. CN118046878 relates to a service braking system and method and a vehicle. The service braking system comprises an air storage cylinder used for storing compressed air and providing a braking air source for vehicle braking; the brake air chamber is connected with the air storage cylinder, forms a brake air path and is used for receiving the compressed air and controlling a brake to brake the vehicle under the action of the compressed air; the combination valve is arranged on the brake gas circuit and used for controlling the brake gas circuit to be opened and closed, the combination valve comprises a control end, an electromagnetic valve and an exhaust end, and the gas inlet end and the exhaust end of the combination valve are both connected with the electromagnetic valve; the air inlet end of the brake valve is connected with the air outlet end of the air storage cylinder, the air outlet end of the brake valve is connected with the control end of the combination valve, and the brake valve is used for controlling the combination valve to be switched between a brake mode and a release mode; and the anti-lock control unit is in communication connection with the electromagnetic valve and is used for controlling the vehicle to be in an anti-lock state through the anti-lock control signal.
[010] Publication No. CN212980169 relates to an air ejection hydraulic brake system with an auxiliary air path, which is characterized by comprising an air compressor, an air dryer communicated with the air compressor and a secondary circuit protection valve connected with the air outlet end of the air dryer, and the secondary circuit protection valve is connected with a service brake pipeline system through a service brake air outlet. And the secondary circuit protection valve is connected with an auxiliary braking pipeline system through an auxiliary braking air outlet.
[011] Publication No. CN201816582 relates to a secondary snub brake main valve, which comprises an upper valve body, a middle valve body and a lower valve body, wherein the upper valve body is connected, sealed and fixed with the middle valve body through a piston cylinder body, the upper edge of the lower valve body is matched, nested, sealed and fixed with the lower edge of the middle valve body, an upper piston assembly and a lower piston assembly are respectively sheathed in the piston cylinder body and the middle valve body, an upper valve assembly and a lower valve assembly are respectively arranged in the middle valve body and the lower valve body, the side surface of the middle valve body and the side surface of the lower valve body are respectively provided with an air inlet and an air outlet, and the upper piston assembly comprises an upper piston, a spring covering clamp and a top rod seat.
[012] Publication No. JPH061220 relates to the braking power of an auxiliary brake by applying a service brake only for a short time where a brake pedal is stepped on, and controlling the air pressure on the input side of an air master by controlling a discharge valve to the specified value not exceeding the set pressure of a differential pressure regulating valve. a control brake 9 operates a service brake only for a short time where a brake pedal is stepped in, operates a discharge valve thereafter, reduces the air pressure P2 on the secondary side to the pressure P3, reduces the ratio of the service brake and increases the braking power by the auxiliary brake.
[013] Publication No. JPH061218 relates to the sense of physical disorder from the braking feeling of a vehicle having no auxiliary brake by detecting the air pressure on the input side of an air master, and controlling of a bypass passage from opening to closing when the air pressure exceeds the specified value. a control unit energizes a bypass valve and switches it to the specified position when the air pressure P on the secondary side exceeds the specified value P1 (P>P1).
[014] Patent No. US705592 relates to an air-brake system; and it consists in the construction and arrangement of parts hereinafter fully set forth, and pointed out particularly in the claims.
[015] Patent No. US9371844 relates to the brake system includes a pedal, a pedal simulator, and a brake pedal unit. The brake pedal unit includes an input piston connected to the brake pedal for operating the pedal simulator during a normal braking mode. The brake pedal unit further includes first and second output pistons actuated by the input piston during a manual push through mode such that the first output piston generates brake actuating pressure at a first output of the brake pedal unit, and the second output piston generates actuating pressure at a second output of the brake pedal unit.
[016] In old conventional braking system, more items are required & components are costlier, difficult to maintain air and hydraulic combined circuit, and additional secondary braking system is required in emergency conditions (since braking is a priority and safety feature) which intern requires additional power and increase the cost of equipment.
[017] In order to overcome above listed prior art, the present invention aims to provide integrated system for service brake and secondary brake system by using pilot hydraulic power. The integrated technology for service brake and secondary brake system by using pilot hydraulic power makes the system simple, cost effective and reliable hydraulic brake control system.
OBJECTS OF THE INVENTION:
[018] The principal object of the present invention is to provide integrated system for service brake and secondary brake system by using pilot hydraulic power.
[019] Another object of the present invention is to provide cost effective integrated service brake and secondary brake system designed specifically for all types of wheel loaders.
[020] Yet another object of the present invention is to provide an integrated service brake and secondary brake system which is simple, less components and eliminated additional emergency system, intern reduces the cost of the equipment.
SUMMARY OF THE INVENTION:
[021] The present invention relates to an integrated system and method for service brake and secondary brake system by using pilot hydraulic power. The system provides proportional braking force to each wheel, ensuring balanced stopping power and stability during braking maneuvers. Additionally, the hydraulic nature of the system allows for precise control and modulation of braking force, enabling smooth deceleration and maneuverability, even when operating on uneven terrain or carrying heavy loads.
BREIF DESCRIPTION OF THE INVENTION
[022] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments.
[023] Figure 1 shows an integrated system and method for service brake and secondary brake system.
[024] Figure 2 shows flowchart according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION:
[025] The present invention provides an integrated system and method for service brake and secondary brake system by using pilot hydraulic power. In the present invention, the available pressurized oil from the pilot manifold connected to the brake valve through the check valves, when the operator depresses the brake pedal, the brake valve opens and pressurized oil will act on the multiple disc brake which result slow/stop the equipment. Referring to figure 1 an integrated system for service brake and secondary brake system by using pilot hydraulic power comprises hydraulic tank (1), pilot hydraulic pump (2), manifold block (3), accumulator (5,6,7,8, 14), connecting ports (21,13,17,18), check valve (9,10), accumulator (11,12), brake valve (15), brake pedal (16), wet multiple disc brake with axle (19,20).
[026] The accumulators which are connected after the check valves will serve as an emergency braking system. When the equipment is in off or low pressure within the system, the stored pressurized oil in the accumulator will supply the oil to the braking system circuit which in turn energy available for braking application.
[027] Furthermore, the hydraulic brake system is engineered for durability and minimal maintenance requirements. The sealed hydraulic components are protected from environmental contaminants and wear, prolonging their lifespan and reducing the need for frequent servicing. The spring energy is used to stop the machine automatically when hydraulic pressure is absent and the setup and the working mechanism is completely different.
[028] The integrated system for service brake and secondary brake system provides superior stopping power and control compared to mechanical braking systems, particularly under heavy loads or adverse conditions. Since accumulators serves as a secondary (emergency) braking system, the conventional emergency braking system can be eliminated and compare to the conventional system the present invention is simple, less components and eliminated additional emergency system, intern reduces the cost of the equipment.
[029] Figure 2 shows the flowchart according to the present invention. The method includes:
[030] Step 1. When the wheel loader engine is started, the Pilot pump (2) coupled with the transmission delivers pressurized oil to both Pilot circuit as well as braking system also.
[031] Step 2. The pressure oil is tapped from the Pilot manifold (3) line and which charges the accumulators (11) and (12) as a backup energy for emergency braking purpose. The accumulator contains compressed Nitrogen gas, it stores the hydraulic oil at the required pressure.
[032] Step 3. When the equipment is needs to be stopped during an emergency condition the brake pedal needs to be engaged to apply the brakes.
[033] Step 4. While engine ON condition:
[034] The brake line tapped from the Pilot manifold (3) which directly charges the brake line accumulators (11) and (12) through check valves (10), and readily available to the brake valve spool (15). When brake pedal (16) is depressed (brake applied), intern brake valve pushes the spool and readily available pressure oil will connects to the brakes (19) and (20).
[035] Step 5. When the engine is OFF condition:
[036] When engine if OFF condition, Pilot pump will not supply oil, but the charged accumulators will supply oil to the brake system. When brake pedal is depressed intern spool will open the oil path and pressurized oil from the accumulator will connect to the brakes.
[037] The accumulator stored energy source serves as fail-safe technology and provide backup system for braking and the system proves to be safer for operating the equipment on different gradient work locations. This invention is more reliable and it can be implemented on Wheel Loaders models like BL200-1, BL30-1 and BL40, Wheel Dozers models like BD14W, BD30W-1 and BL14TH.
[038] Numerous modifications and adaptations of the system of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the true spirit and scope of this invention.
,CLAIMS:WE CLAIM:
1. An integrated system and method for service brake and secondary brake system by using pilot hydraulic power comprises hydraulic tank (1), pilot hydraulic pump (2), manifold block (3), accumulator (5,6,7,8, 14), connected after the check valves (9,10), using connecting ports (21,13,17,18), check valve accumulator (11,12), brake valve (15), brake pedal (16), wet multiple disc brake with axle (19,20) wherein the accumulators , connected after the check valves serves as an emergency braking system and when the equipment is in off or low pressure within the system, the stored pressurized oil in the accumulator supplies the oil to the braking system circuit which in turn energy available for braking application.
2. The integrated system and method for service brake and secondary brake system by using pilot hydraulic power, as claimed in claim 1, wherein the sealed hydraulic components are protected from environmental contaminants and wear, and the spring energy is used to stop the machine automatically when hydraulic pressure is absent.
3. The integrated system and method for service brake and secondary brake system by using pilot hydraulic power, as claimed in claim 1, wherein the equipment is in off or low pressure within the system, the stored pressurized oil in the accumulator will supply the oil to the braking system circuit which in turn energy available for braking application.
4. The integrated system and method for service brake and secondary brake system by using pilot hydraulic power, as claimed in claim 1, wherein the spring energy stops the machine automatically when hydraulic pressure is absent and the setup and the working mechanism is completely different.
5. The integrated method for service brake and secondary brake system by using pilot hydraulic power, includes following steps:
a) When the wheel loader engine is started, the Pilot pump (2) coupled with the transmission delivers pressurized oil to both Pilot circuit as well as braking system also
b) The pressure oil is tapped from the Pilot manifold (3) line and which charges the accumulators (11) and (12) as a backup energy for emergency braking purpose.
c) The accumulator contains compressed Nitrogen gas, stores the hydraulic oil at the required pressure.
d) When the equipment is needs to be stopped during an emergency condition the brake pedal needs to be engaged to apply the brakes.
6. The integrated system and method for service brake and secondary brake system by using pilot hydraulic power, as claimed in claim 1, wherein it can be implemented on wheel loaders and wheel dozers.
7. The integrated system and method for service brake and secondary brake system by using pilot hydraulic power, as claimed in claim 1, wherein while engine ON condition, the brake line tapped from the Pilot manifold (3) which directly charges the brake line accumulators (11) and (12) through check valves (10), and readily available to the brake valve spool (15) and when brake pedal (16) is depressed (brake applied), intern brake valve pushes the spool and readily available pressure oil will connects to the brakes (19) and (20).
8. The integrated system and method for service brake and secondary brake system by using pilot hydraulic power, as claimed in claim 1, wherein when engine if OFF condition, pilot pump will not supply oil, but the charged accumulators will supply oil to the brake system and when brake pedal is depressed intern spool will open the oil path and pressurized oil from the accumulator will connect to the brakes.
9. The integrated method for service brake and secondary brake system by using pilot hydraulic power includes following steps:
a) When the wheel loader engine is started, the Pilot pump (2) coupled with the transmission delivers pressurized oil to both Pilot circuit as well as braking system also.
b) The pressure oil is tapped from the Pilot manifold (3) line and which charges the accumulators (11) and (12) as a backup energy for emergency braking purpose. The accumulator contains compressed Nitrogen gas, it stores the hydraulic oil at the required pressure.
c) When the equipment is needs to be stopped during an emergency condition the brake pedal needs to be engaged to apply the brakes.
d) While engine ON condition, brake line tapped from the Pilot manifold (3) which directly charges the brake line accumulators (11) and (12) through check valves (10), and readily available to the brake valve spool (15) and when brake pedal (16) is depressed (brake applied), intern brake valve pushes the spool and readily available pressure oil will connects to the brakes (19) and (20),
e) When the engine is OFF condition pilot pump will not supply oil, but the charged accumulators will supply oil to the brake system. And when brake pedal is depressed intern spool will open the oil path and pressurized oil from the accumulator will connect to the brakes.