Electronic Hydraulic Brake System Backup Master Cylinder
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Solution Overview
Problem
Existing electronic hydraulic brake systems cannot perform manual bleeding operations or maintain brake functionality when power is cut off, as they rely on an electronic control unit (ECU) for operation, limiting after-service capabilities and increasing system complexity and cost.
Innovation Solution
The system incorporates a backup master cylinder connected to the brake pedal and a main master cylinder driven by a motor, utilizing normal open valves to transfer oil pressure between the two, allowing manual bleeding and maintaining brake functionality even without ECU power, by opening valves when power is cut off to allow oil pressure from a reserve unit to flow to the main master cylinder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the system uses a motor-driven main master cylinder controlled by ECU, then brake control precision is improved, but the system cannot perform manual bleeding or maintain functionality when power is cut off
Solution Approach 1:
The system divides the master cylinder function into two separate units: a motor-driven main master cylinder for precision brake control and a pedal-driven backup master cylinder for manual operations. This segmentation allows each unit to specialize in its function while maintaining overall system capability for both automated and manual modes
Solution Approach 2:
The backup master cylinder acts as an intermediary that can supply hydraulic pressure to the main master cylinder when the ECU is powered off. This intermediary mechanism enables manual bleeding operations and maintains brake functionality during power loss without compromising the precision control capability when powered
2Extent of automation
If the system relies on ECU power for operation, then automation level is improved, but after-service capabilities and manual operation become impossible when power is cut off
Solution Approach 1:
The backup master cylinder is designed as a pre-prepared contingency system that activates automatically when ECU power is cut off. This prior cushioning ensures that manual bleeding and brake operations remain possible during power loss, enhancing after-service capability without reducing automation during normal operation
Solution Approach 2:
The backup master cylinder serves multiple functions: enabling manual bleeding operations, maintaining brake functionality during power loss, and providing a fallback mechanism for after-service operations. This multi-functionality increases system adaptability without compromising automated brake control
3Ease of operation
If additional devices are added to enable manual bleeding, then manual operation capability is improved, but system complexity and manufacturing cost increase
Solution Approach 1:
The backup master cylinder is designed to serve multiple purposes: enabling manual bleeding, maintaining brake functionality during power loss, and providing after-service capability. This multi-functionality allows manual operation capability to be improved without proportionally increasing system complexity, as one component fulfills multiple roles
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables manual bleeding operations without additional devices and reduces system weight and manufacturing costs by allowing pedal pressure to be transferred to the main master cylinder, ensuring brake functionality even when power is off, thus enhancing after-service capabilities and simplifying the system design.
Implementation Method 1
When power of the ECU is cut off, the backup master cylinder may supply oil pressure to the main master cylinder
Implementation Method 2
allowing pedal pressure to be transferred to the main master cylinder
Implementation Method 3
a main master cylinder driven by a motor in response to control of an electronic control unit (ECU)
Data Source
AI summary
An electronic hydraulic brake system may include: a main master cylinder driven by a motor in response to control of an electronic control unit (ECU), and supplying oil pressure to wheel cylinders; and a backup master cylinder forming a reaction force on a brake pedal in response to pressure of the brake pedal. When power of the ECU is cut off, the backup master cylinder may supply oil pressure to the main master cylinder.