Brake Actuation Sensor Layout Using PCB Flux Guides
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Solution Overview
Problem
Current brake actuation systems face challenges in achieving compactness and adaptability for different vehicle configurations and installation situations, particularly in limited engine compartment spaces, requiring flexible sensor arrangements and component integration.
Innovation Solution
The solution involves a compact brake actuation system with sensor signals transmitted via flow guide pieces to evaluation elements on the system circuit board, allowing for flexible design and placement of main components, including the ECU, HCU, and master brake cylinder, without the need for cables or plugs, and utilizing mechanical transmission mechanisms for sensor signal actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sensors are arranged directly near the ECU, then signal transmission is simplified, but the system loses flexibility for different installation situations and vehicle configurations
Solution Approach 1:
The patent introduces flux guide pieces that extend the sensing capability in spatial dimensions beyond the ECU housing. By using magnetic flux guides that protrude or extend into the brake fluid reservoir and other components, the system can detect sensor signals from locations distant from the ECU without requiring direct proximity, thus maintaining adaptability while simplifying signal transmission through magnetic field coupling rather than physical cable connections.
Solution Approach 2:
The flux guide pieces act as intermediaries between the sensor targets (located in various components like the brake fluid reservoir, piston, or motor) and the evaluation elements on the ECU circuit board. These flux guides transmit magnetic field signals across spatial gaps, enabling sensor functionality without direct mechanical or electrical connections, thereby simplifying the overall system architecture while maintaining installation flexibility.
2Volume of moving object
If a compact single-box design is implemented, then installation space is reduced, but the system loses adaptability for different vehicle layouts and mounting positions
Solution Approach 1:
The brake actuation device is designed as a universal single-box unit that can be adapted to different vehicle configurations (left-hand drive, right-hand drive, front-engine, mid-engine layouts) through flexible sensor placement using flux guides. The core ECU housing remains compact, but the extended flux guide capability allows the same basic design to serve multiple mounting positions and vehicle architectures, achieving universality without sacrificing compactness.
Solution Approach 2:
The system incorporates dynamic adaptability through the flexible arrangement of flux guide pieces that can be positioned to reach sensor targets in various locations depending on the specific installation requirements. This dynamic configuration capability allows the compact single-box design to adapt to different vehicle layouts while maintaining its space-saving benefits.
3Volume of moving object
If multiple sensor types are integrated into the ECU, then system compactness is improved, but the circuit board becomes more complex and harder to manufacture
Solution Approach 1:
The patent extracts the sensor evaluation elements from the main ECU circuit board and places them on separate evaluation boards or modules that are connected to the main ECU. This extraction simplifies the main circuit board design and manufacturing while still achieving compact integration, as the sensor processing functions are separated into dedicated modules that can be manufactured independently and then assembled with the main ECU housing.
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 approach results in a cost-effective, fail-safe, and adaptable brake actuation system that reduces installation complexity and weight, maintaining symmetry for both left-hand and right-hand drive vehicles, while ensuring low failure rates and high reliability.
Implementation Method 1
a flux guide (43) is provided which guides the magnetic flux of the sensor target (23) to the sensor element (24)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to an actuating device for a motor vehicle brake, having the following components: – an actuating device, in particular in the form of a brake pedal, – a pressure supply device (11), in particular a piston pump or double-stroke piston pump, – a piston-cylinder unit (master cylinder) (10) which can be actuated by means of the actuating device and is hydraulically connected to a pressure medium reservoir vessel (VB) and which forms at least two pressure spaces which are connected to hydraulic brake circuits, – a valve arrangement (HCU) having valves for setting brake pressures in a wheel-specific fashion and for disconnecting or connecting the wheel brakes to the pressure supply device (11) and the piston cylinder unit (10), – an electronic open-loop and closed-loop control unit (ECU), – at least one sensor device, having at least one sensor element or evaluation element (3, 4, 5, 24, 24a) and a sensor target (5a, 23, 23a) which is preferably based on an electromagnetic principle, for sensing a movement of a device component. According to the invention, there is provision that at least one sensor element or evaluation element (3, 4, 5, 24, 24a) of the sensor device is arranged on or in the electronic open-loop and closed-loop control unit (ECU), in particular on a system printed circuit board (PCB) of the open-loop and closed-loop control unit (25), and that a movement of the device component (10; 45; 46; 48) is transmitted to the electronic open-loop and closed-loop control unit (ECU) (25) via a sensor actuating device, in particular via a mechanical actuating mechanism (17, 18, 19) or via a sensor target (5a, 23, 23a) connected to the device component and magnetic flux conducting pieces (43, 43a, 43b) based on ferromagnetic materials.