Brake Control Unit Eliminates Reserve Volume in Master Cylinder
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional brake systems face challenges in ensuring reliable deceleration when the brake actuating travel of the master brake cylinder reaches its maximum possible distance, leading to a need for a reserve volume that increases the cylinder length and potentially compromises safety by extending into the passenger compartment.
Innovation Solution
A control unit that assesses the brake actuating travel using sensor signals from rotation, motor current, rod travel, or differential travel sensors to determine when the maximum distance is reached, allowing for continued brake fluid conveyance to the wheel brake cylinder, eliminating the need for a reserve volume and enabling a shorter master brake cylinder and brake booster design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a reserve volume is provided in the master brake cylinder to ensure brake actuating travel is not exhausted, then braking reliability is improved, but the master brake cylinder length increases and may extend into the passenger compartment
Solution Approach 1:
The control unit acts as an intermediary between the driver's brake input and the brake fluid delivery system. When the movable piston approaches its limiting travel position, the control unit activates the hydraulic pump to supplement brake fluid delivery to the wheel brake cylinders, ensuring continued braking capability without requiring extended master cylinder length.
Solution Approach 2:
The patent replaces the traditional mechanical reserve volume approach with an electronically controlled hydraulic pump system. Instead of relying on physical space within the master brake cylinder, the system uses sensor detection of piston position combined with electronic control to activate pump-assisted brake fluid delivery, substituting mechanical design constraints with an active control system.
2Object-affected harmful factors
If the brake booster is designed to be shorter to reduce injury risk in crashes, then safety is improved, but the brake actuating travel may be insufficient to achieve reliable deceleration
Solution Approach 1:
The system dynamically adjusts the brake fluid delivery mechanism based on real-time detection of piston travel conditions. When the movable piston reaches its limiting travel position, the control unit activates the hydraulic pump to continue delivering brake fluid to the wheel brake cylinders, ensuring that deceleration reliability is maintained despite the shortened brake booster and master cylinder assembly.
3Measurement precision
If a supply pressure sensor is installed to detect master brake cylinder pressure, then pressure monitoring is improved, but device complexity increases
Solution Approach 1:
The control unit utilizes existing sensor signals from the brake system (such as rod travel sensors or differential travel sensors) to indirectly determine the operational state of the master brake cylinder and activate the hydraulic pump when needed. This self-service approach allows the system to monitor and respond to brake system conditions without requiring additional supply pressure sensors, thereby maintaining measurement capability while avoiding increased device complexity.
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
This solution ensures reliable vehicle deceleration without a reserve volume, reduces the risk of injury by allowing a shorter brake booster installation, and eliminates the need for a supply pressure sensor, while providing improved brake actuating sensation and pedal feedback.
Implementation Method 1
with the aid of at least a sensor signal, which is in regard to a distance moved by a driver braking-force transmission component of a brake actuating element or by a booster force transmission component of a brake booster
Implementation Method 2
provided by a rotation sensor or a motor current sensor of an electric motor of the brake booster
Implementation Method 3
Alternatively, or in addition, in further view of a rod travel signal of a rod travel sensor on the driver braking-force transmission component
Implementation Method 4
Additionally taking into consideration a differential travel signal of a differential travel sensor of the brake booster
Implementation Method 5
a pump control unit of the at least one hydraulic pump; to activate the pump control unit in such a manner, that with the aid of the at least one hydraulic pump, brake fluid is conveyed from a brake fluid reservoir into the at least one wheel brake cylinder
Data Source
AI summary
A control unit for a brake system of a vehicle. Using a sensor signal, provided by a sensor and is in regard to a distance moved by a driver braking-force transmission component or by a booster force transmission component, the control unit discerns if a movable piston of a master brake cylinder of the brake system is moved by a brake actuating distance equal to a specified, limiting brake actuating distance, and, possibly, to output at least one control signal to a pump control unit of at least one hydraulic pump of the brake system. The pump control unit can be activated by the at least one control signal so that brake fluid may be conveyed from a brake fluid reservoir of the brake system into at least one wheel brake cylinder of the brake system using at least one hydraulic pump controlled by the pump control unit.