Structural Redesign and Functional Integration of an Electrohydraulic Brake Valve for Enhanced Performance and Manufacturability ZF Commercial Vehicle Solutions, Limited

Format:

Book

Conference/Event

Author/Creator:

R, Thangarajan, author.

Conference Name:

Advances in Design, Materials, Manufacturing, and Surface Engineering (ADMMS'26) (2026-02-06 : Chennai, India)

Language:

English

Physical Description:

1 online resource cm

Place of Publication:

Warrendale, PA SAE International 2026

Summary:

The Electrohydraulic Brake Valve (EBV) is a vital component in full-power brake systems for heavy-duty and off-highway vehicles, providing precise hydraulic pressure modulation through electrical control. Traditionally, EBV housings are manufactured using bar-machined components, which offer durability but contribute significantly to the overall weight and cost of the assembly. In response to increasing demands for lightweight and cost-effective solutions, this study presents a targeted design optimization of the EBV housing.The redesigned housing adopts a casting-based geometry, integrates sensor ports for pressure monitoring, and includes a nameplate mounting provision for customer identification. Material substitution and structural simplification were employed to enhance manufacturability and performance. Finite Element Analysis (FEA) was used to validate the mechanical integrity of the new design under operational conditions. The optimized EBV assembly achieved a weight reduction of approximately 60% and a cost reduction of nearly 25%, demonstrating the effectiveness of design-led innovation in improving manufacturability

Notes:

Vendor supplied data

Publisher Number:

2026-28-0002

Access Restriction:

Restricted for use by site license