Brake Plunger Sensor Housing With Isolated Detection Chamber
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Solution Overview
Problem
Existing brake devices suffer from reduced operational lifespan of sensor units due to exposure to grease, wear debris, and compressed air, which affects their functionality and durability.
Innovation Solution
A housing device with separate piston and sensor chambers, utilizing a sensor unit to detect plunger position and movement contactlessly, protected by a partition and a non-ferromagnetic material, ensuring the sensor unit is isolated from piston chamber contaminants and compressed air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor unit is placed in the piston chamber to detect plunger position and movement, then the detection function is achieved, but the sensor unit is exposed to grease, wear debris, and compressed air which reduces its operational lifespan
Solution Approach 1:
The housing device is divided into two separate chambers: a piston chamber for the plunger and piston components, and a sensor chamber for the sensor unit. This segmentation isolates the sensor from contaminants (grease, wear debris, compressed air) while maintaining the detection function through the partition wall, thereby extending sensor operational lifespan without compromising reliability
Solution Approach 2:
A partition wall with a magnetic field-permeable section acts as an intermediary between the piston chamber and sensor chamber. This intermediary structure allows the magnetic field from the plunger to transmit position and movement information to the sensor unit without direct physical contact, preventing contaminant exposure while maintaining detection reliability
2Duration of action of moving object
If the sensor unit is isolated from the piston chamber to protect it from contaminants, then the sensor durability is improved, but the detection precision may be affected by the partition wall
Solution Approach 1:
The partition wall is designed with non-uniform properties: most of the wall provides mechanical separation and protection, while a specific local section is made magnetic field-permeable (using non-ferromagnetic material) to allow magnetic field transmission. This local quality differentiation maintains both sensor protection and detection precision by enabling magnetic field passage at the critical detection point while preserving structural integrity elsewhere
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
Enhances the durability and operational lifespan of the sensor unit by preventing contamination and mechanical contact, allowing precise and reliable braking operations without additional reinforcement.
Implementation Method 1
The sensor unit is configured to identify this movement, i.e., a stroke of the piston. The sensor unit can include at least one Hall sensor and, additionally or alternatively, a reed switch, which are/is configured to sensor-identify a magnetic field emanating from the plunger
Implementation Method 2
For example, the piston chamber and the sensor chamber can be fluidically separated from each other by a partition. The piston chamber and the sensor chamber can also be hermetically separated from each other by the partition. In this way, liquid, grease, or also air can be prevented from passing between the piston chamber and the sensor chamber
Data Source
AI summary
A housing device for a brake device for a vehicle, including: a piston chamber for accommodating a plunger, which is movable linearly in the piston chamber by an actuation by a driver; and a sensor chamber, which is separated from the piston chamber, and which includes a sensor unit, which is configured to detect a position and/or a movement of the plunger in the piston chamber, to effect a braking operation of the vehicle. Also described are a related plunger, a brake device, a method, an apparatus, and a computer readable medium.