Integrated Brake Housing Layout for Lower Manufacturing Complexity
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Solution Overview
Problem
The existing integrated brake apparatus for vehicles has a large housing size and complex manufacturing due to the integration of components with different functions and manufacturing requirements, leading to high costs and limited flexibility in layout design.
Innovation Solution
The apparatus is designed with a first housing integrally forming the brake master cylinder and pump housing, and a second housing for the valve apparatus, allowing separate manufacturing and processing, reducing complexity and cost while improving flexibility and reliability by reducing sealed points and avoiding excessive height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If all components (brake master cylinder, pump, valve apparatus) are integrated on one housing, then integration is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The brake apparatus is divided into two separate housings: a first housing for the brake master cylinder and pump, and a second housing for the valve apparatus. This segmentation allows each housing to be manufactured according to its specific requirements without compromising overall integration, as the housings are subsequently assembled together.
2Area of moving object
If all components are integrated on one housing, then integration is achieved, but layout design flexibility is limited
Solution Approach 1:
By dividing the system into modular housing units, each can be independently designed and positioned according to specific layout requirements. The first housing contains the brake master cylinder and pump, while the second housing contains the valve apparatus, allowing flexible arrangement within the vehicle's available space.
3Ease of manufacture
If a single housing material is used for all components, then manufacturing is simplified, but it cannot meet different manufacturing requirements of different components
Solution Approach 1:
The housing is segmented into two separate units that can be manufactured from different materials or with different processing treatments. The first housing can be optimized for the brake master cylinder and pump, while the second housing can be optimized for the valve apparatus, with each meeting its specific manufacturing requirements.
Solution Approach 2:
After separate manufacturing, the two housings are assembled together to form the complete brake apparatus. This merging allows each housing to maintain its optimized characteristics while achieving overall system integration.
4Strength
If housing stiffness is increased for brake master cylinder, then abrasion resistance is improved, but it complicates manufacturing and increases cost
Solution Approach 1:
The housing is divided into two separate units, allowing the first housing (containing the brake master cylinder) to be manufactured with high stiffness and abrasion resistance without affecting the second housing. This eliminates the need for complex hardening processes on a unified housing structure.
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 design simplifies manufacturing, reduces the probability of sealing leakage, and enhances operational reliability while improving the flexibility of the brake apparatus' placement on a vehicle by avoiding excessive height, thus supporting efficient braking in both normal and fail-safe conditions.
Implementation Method 1
a pump, where the pump is configured to generate a hydraulic pressure when driven by the motor
Implementation Method 2
a brake master cylinder, where the brake master cylinder is configured to generate a hydraulic pressure under action of a brake pedal
Data Source
AI summary
The integrated brake apparatus includes a first housing and a second housing, where a first cylinder body of a brake master cylinder and the first housing are integrally formed; a motor disposed on the first housing; a pump whose pump housing is integrally formed with the first housing; a valve apparatus that is disposed in the second housing and is configured to control opening/closing of an oil passage between the brake master cylinder and a wheel brake and an oil passage between the pump and the wheel brake; and an electronic control unit configured to control the motor and the valve apparatus. The first housing, the second housing, and the electronic control unit are sequentially arranged in a vehicle width direction.