Brake Pedal Sensor Contact Spring Assembly for Tolerance Compensation
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Solution Overview
Problem
There is a conflict between the need for cost-effective and reliable brake systems in motor vehicles, where inexpensive components often compromise reliability.
Innovation Solution
A brake system with a contact spring system that connects the control circuit board to the sensor circuit board, featuring individually preloaded electrical contact elements to ensure reliable signal transmission, compensating for tolerances and allowing for a simple and inexpensive design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inexpensive components are used in the brake system, then the manufacturing cost is reduced, but the reliability of the system deteriorates
Solution Approach 1:
The contact elements are designed with specific parameter ranges: projecting length of at least 2mm (preferably at least 5mm) and preload forces between 0.1N and 10N. These parameter specifications ensure reliable electrical contact while maintaining cost-effective design, resolving the contradiction between inexpensive components and system reliability
Solution Approach 2:
The contact elements are preloaded before actual operation to compensate for manufacturing tolerances and ensure reliable contact. This preliminary action prevents contact failures during operation, maintaining reliability while using simple, inexpensive components
2Reliability
If the contact spring system uses individually installed contact elements, then the electrical contact reliability is improved, but the assembly complexity increases
Solution Approach 1:
Multiple contact elements are combined into a single integrated component that can be installed as one unit. The contact elements are arranged in parallel within a common structure, allowing simultaneous installation of all contact elements through a single assembly operation, thereby reducing assembly complexity while maintaining individual contact reliability
Solution Approach 2:
The contact spring system housing serves multiple functions: it holds and positions multiple contact elements, provides electrical isolation between them, and facilitates collective installation. This multi-functional design simplifies assembly while ensuring reliable individual contacts
3Manufacturing precision
If the projecting length of contact elements is increased to compensate for axial tolerances, then the tolerance compensation capability is improved, but the device complexity increases
Solution Approach 1:
The projecting length of contact elements is specified as a simple geometric parameter (at least 2mm, preferably at least 5mm) that provides tolerance compensation without requiring complex mechanisms. This parameter-based solution achieves precision compensation while maintaining design simplicity
Solution Approach 2:
The tolerance compensation function is segmented into the projecting length of contact elements, which independently handle axial tolerances. This separation allows the rest of the system to remain simple while achieving precision through the specific geometric feature of the contact elements
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 contact spring system ensures reliable electrical contact and assembly, maintaining system reliability while reducing costs by compensating for axial and radial tolerances, thus addressing the conflict between cost and reliability.
Implementation Method 1
The contact elements bear in individually preloaded fashion against electrical contact pads
Implementation Method 2
the contact elements can be jointly installed with the housing
Data Source
AI summary
A brake system for a motor vehicle comprises an electronic control unit with a control circuit board a hydraulic block through which hydraulic channels extend and which has a brake cylinder bore a piston which is displaceable in the brake cylinder bore by a brake pedal, and a pedal travel sensor with a sensor circuit board. The pedal travel sensor is configured to detect the position of the piston in the brake cylinder bore. The brake system furthermore has a contact spring system that connects the control circuit board to the sensor circuit board, for transmission of signals, in non-destructively detachable fashion. Here, the contact spring system has electrical contact elements which bear in individually preloaded fashion against electrical contact pads of the control circuit board and/or of the sensor circuit board.