Hydraulic Brake Fluid Level Sensor Integration
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Solution Overview
Problem
The existing hydraulic brake assembly's bulky second cable connecting the hydraulic fluid level sensor to the central control unit is prone to damage and interference during maintenance, making assembly complex and costly due to exposure to temperature variations and physical hazards.
Innovation Solution
The hydraulic fluid level sensor is directly connected to the servomotor computer, eliminating the need for a second cable and reducing the overall cable length, allowing for a single cable connection to the central control unit and providing flexibility in sensor type and location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a second cable is used to connect the hydraulic fluid level sensor to the central control unit, then the sensor can be placed in the reservoir, but the cable becomes bulky and prone to damage during maintenance
Solution Approach 1:
The patent extracts and eliminates the second cable from the system by directly integrating the sensor's electrical connection to the computer of the electric booster. This removes the problematic bulky cable that extended from the reservoir to the central control unit, thereby improving reliability without adding complexity.
Solution Approach 2:
The patent merges the sensor's electrical connection path with the existing computer wiring by connecting the sensor directly to the computer of the electric booster. This consolidation eliminates the separate second cable and simplifies the overall assembly structure.
2Object-affected harmful factors
If the second cable is routed along the vehicle body to protect it from damage, then cable protection is improved, but the assembly process becomes more difficult and costly
Solution Approach 1:
The patent removes the second cable entirely from the system, thereby eliminating the need to route and protect it along the vehicle body. This extraction solves both the protection issue and the assembly complexity issue simultaneously.
Solution Approach 2:
Instead of protecting the cable by routing it carefully along the vehicle body, the patent inverts the approach by eliminating the cable's exposure to harmful environmental factors through direct integration with the booster computer.
3Adaptability or versatility
If the sensor is connected to the central control unit via a long cable, then the sensor can be placed in the reservoir, but the cable length increases making it bulky and interferes with maintenance
Solution Approach 1:
The patent extracts and removes the long second cable from the system by establishing a direct electrical connection between the sensor and the computer of the electric booster. This eliminates the cable length issue while maintaining sensor placement flexibility within the reservoir.
Solution Approach 2:
Instead of extending a long cable from the reservoir to the central control unit, the patent inverts the connection path by routing it directly to the nearby booster computer, thereby minimizing cable length while preserving adaptability.
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 configuration simplifies the assembly, reduces manufacturing costs, and enhances reliability by minimizing cable-related issues, while allowing vehicle manufacturers to choose sensor types and locations optimally.
Implementation Method 1
The sensor 12 is in one example of the REED bulb type or of the HALL effect type (or magnetic proximity sensor)
Implementation Method 2
In the case of a REED bulb sensor, it is formed by two electromagnetic strips and by an electromagnet
Data Source
Figure 1~2
AI summary
The assembly (14) has a master cylinder (16) connected to an electric brake assistance servomotor (15) by an assistance piston (23) that is actuated by an electric motor (22) of the servomotor. A hydraulic fluid reservoir (17) is mounted on the cylinder. The reservoir communicates with a master cylinder chamber for supplying hydraulic fluid to the cylinder. A hydraulic fluid level sensor (25) is situated in a reservoir wall for controlling the level of hydraulic fluid in the reservoir. The sensor is connected from the reservoir towards a controller (19) of the servomotor by a cable (26). The hydraulic fluid level sensor is a REED switch sensor or a Hall-effect sensor or magnetic proximity sensor.