Brake-by-wire Piston Pry-back Prevention via Dynamic Compensation
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Solution Overview
Problem
Traditional hydraulic brake systems face responsiveness issues due to rotor deflection, which causes brake pads to recede into the caliper housing and hydraulic fluid to flow back, leading to excessive clearance and reduced braking performance under various road conditions and vehicle maneuvers.
Innovation Solution
A Brake-By-Wire (BBW) system with a pry-back prevention module that uses a controller and actuator to manage hydraulic fluid flow by closing a compensation opening in the master cylinder, preventing fluid flow-back during rotor deflection, and opening it to relieve pressure when necessary, thereby maintaining optimal brake pad alignment and responsiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake system uses traditional hydraulic fluid flow through open compensation openings, then the system structure remains simple, but rotor deflection causes hydraulic fluid flow-back and excessive brake pad clearance
Solution Approach 1:
The compensation opening transitions from a static open state to a dynamically controlled state. The controller monitors rotor position and actively opens or closes the compensation opening based on real-time operating conditions, allowing the system to adapt between maintaining brake pad clearance during deflection and relieving pressure during normal operation
Solution Approach 2:
The compensation opening acts as an intermediary element between the hydraulic fluid reservoir and the caliper piston cavity. By controlling this opening's state, the system mediates hydraulic fluid flow to prevent both flow-back during rotor deflection and pressure buildup during normal operation, resolving the contradiction between reliability and complexity
2Reliability
If the compensation opening remains open to relieve pressure, then the system operates simply, but hydraulic fluid flows back to the reservoir causing excessive brake pad clearance
Solution Approach 1:
The controller receives feedback about rotor position and deflection state, then adjusts the compensation opening state accordingly. This feedback loop prevents hydraulic fluid flow-back by closing the opening when rotor deflection is detected, maintaining proper brake pad alignment without requiring physical constraints on fluid movement
3Reliability
If the compensation opening is closed to prevent fluid flow-back, then brake pad alignment is maintained, but pressure builds up in the hydraulic system
Solution Approach 1:
The compensation opening's state is dynamically adjusted based on operational needs. During rotor deflection, the opening closes to prevent fluid flow-back and maintain brake pad alignment. During normal operation, the opening opens to relieve hydraulic pressure, preventing the pressure buildup problem while maintaining reliability during critical moments
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
The BBW system effectively minimizes excessive clearance between the rotor and brake pad, enhancing braking responsiveness without requiring additional hardware, by using software-based pry-back prevention to manage hydraulic fluid flow and maintain optimal brake performance across different driving conditions.
Implementation Method 1
The actuator is adapted to controllably move the piston within the piston cavity... A compensation opening is defined by the housing and is in fluid communication between the reservoir and the piston cavity
Implementation Method 2
The piston is adapted to close the compensation opening preventing hydraulic fluid flowback, and open the compensation opening to relieve fluid pressure
Data Source
AI summary
A Brake-By-Wire (BBW) system for a vehicle includes a brake rotor, a caliper, a master cylinder, and a controller. The caliper is adapted to exert a hydraulic force upon the brake rotor during a braking action. The master cylinder includes a housing, a piston, an actuator, and a hydraulic fluid reservoir. The housing defines a piston cavity. The actuator is adapted to controllably move the piston within the piston cavity. A compensation opening is defined by the housing, and is in fluid communication between the reservoir and the piston cavity. A fluid opening is defined by the housing, and is in fluid communication between the caliper and the piston cavity. The controller is configured to receive a vehicle condition signal and send a command signal to the actuator that effects closure of the compensation opening based on the vehicle condition signal to prevent hydraulic fluid flowback to the hydraulic fluid reservoir.