Integrated Electronic Brake Hydraulics With Mechanical Backup
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Solution Overview
Problem
Conventional electronic brake systems face challenges in stability, reliability, and safety due to complex component interactions, which can lead to unstable hydraulic pressure generation and increased risk of abnormal operation modes when electrical components fail.
Innovation Solution
An electronic brake system with an integrated master cylinder and hydraulic control unit that includes a reservoir, hydraulic pressure supply device, and electronic control unit, utilizing a complex network of hydraulic flow paths and valves to stabilize and control hydraulic pressure distribution to wheel cylinders, ensuring stable operation even in abnormal conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an electronic brake system with electrical signal control is used to implement various braking functions, then braking versatility is improved, but system reliability deteriorates when electrical components fail
Solution Approach 1:
The brake system is divided into two independent subsystems: an electronic brake system for normal operation and a mechanical backup system for abnormal conditions. The master cylinder is segmented into a master chamber connected to the mechanical system and simulation chambers connected to the electronic system, allowing independent operation of each subsystem.
Solution Approach 2:
A mechanical backup system is pre-configured to activate when the electronic system fails. The mechanical linkage between the brake pedal and master cylinder is maintained throughout, providing an immediate fallback mechanism that requires no electrical power or electronic components to function.
2Stability of the object's composition
If multiple hydraulic circuits and valves are added to stabilize hydraulic pressure, then braking stability is improved, but device complexity increases
Solution Approach 1:
The master chamber and simulation chambers are merged into a single integrated master cylinder assembly, sharing common structural components and hydraulic fluid. The electronic control unit consolidates control of multiple valves and actuators into a single control device, reducing overall system complexity while maintaining pressure stability.
Solution Approach 2:
The hydraulic pump serves multiple functions: it generates hydraulic pressure for normal braking operation, maintains pressure in the simulation chambers during electronic operation, and can be controlled to support both independent and combined braking modes. The master cylinder structure serves both mechanical and electronic hydraulic functions simultaneously.
3Ease of manufacture
If an integrated master cylinder design is used to reduce component count, then ease of manufacture is improved, but manufacturing precision requirements increase
Solution Approach 1:
The integrated master cylinder is segmented into distinct functional chambers (master chamber and simulation chambers) with separate pistons and sealing arrangements. This segmentation allows each chamber to be manufactured and tested independently before final assembly, reducing the overall manufacturing precision requirements while maintaining the integrated design benefits.
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 system achieves stable and reliable braking performance, reduces component count and weight, improves durability, and enhances assembly and manufacturing efficiency, ensuring consistent braking pressure and safety.
Implementation Method 1
a hydraulic pressure supply device provided to generate a hydraulic pressure by operating a hydraulic piston according to an electrical signal output in response to a displacement of the brake pedal
Implementation Method 2
a hydraulic control unit including a first hydraulic circuit provided to control the hydraulic pressure to be transferred to two wheel cylinders, and a second hydraulic circuit provided to control the hydraulic pressure to be transferred to the other two wheel cylinders
Data Source
AI summary
The present disclosure relates to an electronic brake system. The electronic brake system includes a reservoir in which a pressurized medium is stored, an integrated master cylinder having a master chamber and a simulation chamber, a reservoir flow path provided to communicate the integrated master cylinder with the reservoir, a hydraulic pressure supply device provided to generate a hydraulic pressure by operating a hydraulic piston according to an electrical signal output in response to a displacement of the brake pedal, a hydraulic control unit including a first hydraulic circuit provided to control the hydraulic pressure to be transferred to two wheel cylinders, and a second hydraulic circuit provided to control the hydraulic pressure to be transferred to the other two wheel cylinders, and an electronic control unit configured to control valves based on hydraulic pressure information and displacement information of the brake pedal.