Vehicle Brake System with Secondary Plunger Assembly
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Solution Overview
Problem
Existing vehicle braking systems face challenges in maintaining precise control, especially under adverse conditions, leading to wheel lock-up and loss of directional control, and require optimal slip levels at both front and rear axles for maximum braking performance.
Innovation Solution
A brake system with a master cylinder and a secondary plunger assembly that provides fluid pressure for normal braking, and a secondary brake module for manual push-through mode, using solenoid actuated valves and a ball screw mechanism to control pressure distribution between front and rear wheels, ensuring stable and efficient braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a driver applies excessive braking pressure under adverse conditions, then braking force increases, but wheel lock-up occurs resulting in loss of directional control
Solution Approach 1:
The ABS system continuously monitors wheel rotational behavior and uses this feedback to selectively apply and relieve brake pressure, maintaining wheel speed within an optimal slip range to prevent wheel lock-up while maximizing braking force
Solution Approach 2:
The system dynamically adjusts brake pressure in real-time based on wheel speed feedback, transitioning between pressure application and relief modes to maintain optimal slip conditions and prevent wheel lock-up
2Reliability
If ABS valves are used to control braking pressures on front and rear wheels, then optimum slip levels are achieved at both axles, but device complexity increases
Solution Approach 1:
The ABS valves perform multiple functions including pressure application, pressure dumping, and pressure holding for both front and rear wheels, allowing a single component to handle diverse braking control requirements across different axles
Solution Approach 2:
The brake system is divided into separate front and rear brake circuits with independent pressure control, allowing separate optimization of slip levels at each axle while managing complexity through modular control architecture
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 efficient braking by dynamically controlling pressure between front and rear wheels, reducing wheel lock-up and maintaining optimal slip levels, even in adverse conditions and during regenerative braking.
Implementation Method 1
The secondary brake module includes a ball screw mechanism and a motor. The motor rotates the ball screw mechanism which moves the plunger in the second direction
Implementation Method 2
using solenoid actuated valves and a ball screw mechanism to control pressure distribution between front and rear wheels
Data Source
AI summary
A brake system has a wheel brake and is operable under a non-failure normal braking mode and a manual push-through mode. The system includes a master cylinder operable by a brake pedal during a manual push-through mode to provide fluid flow at an output for actuating the wheel brake. A first source of pressurized fluid provides fluid pressure for actuating the wheel brake under a normal braking mode. A secondary brake module includes a plunger assembly for generating brake actuating pressure for actuating the wheel brake under the manual push-through mode.