Structural Redesign and Functional Integration of an Electrohydraulic Brake Valve for Enhanced Performance and Manufacturability

The Electrohydraulic Brake Valve (EBV) is a critical component in full-power brake systems, particularly in heavy-duty and off-highway vehicles, where precise braking control and system reliability are paramount. This paper presents a comprehensive cost and weight optimization initiative focused on the EBV housing, which currently accounts for approximately 75% of the total assembly weight due to its bar-machined construction. The project involved a complete redesign of the EBV housing with the dual objective of reducing mass and enhancing functionality. Key improvements include the integration of sensor ports for real-time pressure monitoring, a dedicated provision for nameplate mounting to support customer traceability, and a transition to a cast-based design optimized through advanced core modeling. Material substitution and structural simplification were explored to further improve manufacturability and cost-efficiency. Finite Element Analysis (FEA) was employed to validate the structural integrity of the redesigned housing under operational loads. The optimized design achieved a 62% reduction in weight and a 25% reduction in manufacturing cost, without compromising performance or safety. Additionally, the inclusion of dual-port pressure monitoring enhances system diagnostics and risk mitigation. This paper demonstrates how a systematic approach to design optimization, material selection, and functional integration can significantly improve the performance and sustainability of critical brake system components in demanding vehicle applications. Keywords: Electrohydraulic Brake Valve (EBV), Housing Optimization, Finite Element Analysis (FEA), Weight and Cost Reduction, Sensor Port Integration, Off-Highway Vehicle Braking Systems.