Brake Line Installation Verification via Hydraulic Pressure Differential
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Solution Overview
Problem
Existing methods fail to reliably detect incorrect installation of brake lines in a brake system with a 'black and white split' configuration, where the primary circuit has a larger brake fluid volume than the secondary circuit, leading to undetected issues during assembly that manifest only under increased load conditions.
Innovation Solution
A method involving the actuation of the tandem master brake cylinder to fill and empty both brake circuits, with the measuring device assessing the braking behavior of a rotating wheel to determine correct or incorrect installation based on the available brake fluid volume, utilizing standard components like outlet valves and an ESP test routine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the brake system uses a black and white split configuration with different circuit volumes, then the brake system can handle varying axle loads, but incorrect brake line installation cannot be detected during normal operation
Solution Approach 1:
The patent applies preliminary action by performing a detection test before normal operation to identify incorrect brake line installation. The method involves actuating the master brake cylinder to transfer brake fluid between circuits and measuring pressure differences in advance, so that installation errors are detected before they cause safety issues during actual braking operations.
2Productivity
If brake lines are interchanged during assembly, then assembly becomes faster, but the incorrect installation remains undetected until load increase
Solution Approach 1:
The patent implements preliminary action by incorporating a detection step into the assembly process itself. After brake lines are connected, the system automatically or manually performs a pressure-based verification test to confirm correct installation before the vehicle enters service, ensuring that assembly speed does not compromise reliability.
Solution Approach 2:
The patent uses feedback by measuring pressure differences between brake circuits and comparing them against expected values. When pressure deviations exceed thresholds, the system provides feedback indicating incorrect installation, allowing immediate correction before the vehicle is deployed.
3Device complexity
If no additional detection equipment is added, then device complexity remains low, but the ability to detect installation errors is insufficient
Solution Approach 1:
The patent applies universality by using the existing master brake cylinder and brake fluid system for both their primary braking function and the secondary function of installation verification. The same hydraulic components that perform braking also enable detection when pressure differences are measured, eliminating the need for separate detection equipment.
Solution Approach 2:
The brake system performs self-verification by using its own internal pressure characteristics to detect installation errors. The system monitors its own hydraulic behavior during normal operation or test cycles, allowing it to self-diagnose incorrect brake line installation without external intervention or additional sensors.
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 a reliable check of brake line installation without additional equipment, ensuring defined braking behavior by differentiating between correct and incorrect installations, thus preventing premature brake fluid exhaustion and maintaining system functionality.
Implementation Method 1
the tandem master brake cylinder is actuated to build up pressure when the outlet valves are open in order to fill the primary reservoir and the secondary reservoir completely with brake fluid
Implementation Method 2
a measuring device, depending on the braking behavior, indicates whether the brake lines are installed correctly or incorrectly
Data Source
AI summary
A method for detecting an incorrect installation of brake lines (10, 11) of a brake system (1) for a multi-axle motor vehicle, wherein the brake system (1) comprises a primary circuit (2) having a first ESP subsystem (3), comprising a primary reservoir (4) for brake fluid and at least one outlet valve (13) which is assigned to the wheel brakes (VL, VR) of a first axle, and a secondary circuit (6) with a second ESP subsystem (7), comprising a secondary reservoir (8) for brake fluid and at least one outlet valve (13), which is assigned to the wheel brakes (HL, HR) of a second axle, wherein the primary circuit (2) provides a larger brake fluid volume than the secondary circuit (6), wherein two brake lines (10, 11) correspondingly connect a tandem main brake cylinder (12) to the primary circuit (2) and the secondary circuit (6) respectively. In a first step, the tandem main brake cylinder (12) is actuated in a pressure-building way with opened outlet valves (13) in order to completely fill the primary reservoir (4) and the secondary reservoir (8) with brake fluid and the outlet valves (13) are closed as soon as the reservoirs (4, 8) are completely filled, and in a further step, at least one rotating wheel of the first axle is braked by sustained actuation of the tandem main brake cylinder (12), and wherein a measuring device identifies a correct or defective installation of the brake lines (10, 11) depending on the braking behavior.