Brake Apparatus Stroke Sensor Integration via Valve Housing Through-Hole
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Solution Overview
Problem
Existing brake control systems face challenges in cost-effectively integrating a stroke sensor to detect the stroke amount of a brake pedal, particularly in terms of wiring layout and connection to the control unit.
Innovation Solution
A brake apparatus configuration where the stroke sensor is disposed between the master cylinder housing and the valve housing, with its output transmitted through a through-hole in the valve housing to the control unit, allowing internal connection similar to other electromagnetic valves, thus reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the stroke sensor is mounted in the master cylinder to detect brake operation amount, then the detection function is achieved, but the wiring layout becomes complex and cost increases
Solution Approach 1:
The stroke sensor is integrated into the valve housing structure, merging the sensor mounting function with the existing housing. The sensor is disposed between the master cylinder housing and valve housing, with its output transmitted through a through-hole in the valve housing to the control unit, eliminating separate wiring paths and reducing overall system complexity
Solution Approach 2:
The valve housing serves as an intermediary structure that houses the stroke sensor and provides a through-hole for signal transmission. This intermediary arrangement allows the sensor to be positioned optimally for detection while providing a direct path to the control unit, avoiding complex external wiring
2Measurement precision
If the stroke sensor is mounted in the master cylinder, then the stroke detection is enabled, but the attachment cost increases
Solution Approach 1:
The stroke sensor is combined with the valve housing assembly rather than being a separate mounted component. The sensor is disposed within the space between the master cylinder housing and valve housing, utilizing existing structural space and eliminating the need for additional mounting hardware and complex installation procedures
Solution Approach 2:
The valve housing is designed to serve multiple functions: it houses the electromagnetic valves, provides structural support, and integrates the stroke sensor mounting. This multi-functionality reduces the need for separate sensor housing structures, thereby reducing manufacturing and attachment costs
3Device complexity
If the stroke sensor output is transmitted via a through-hole in the valve housing, then the internal connection is achieved similar to other electromagnetic valves, but the housing structure becomes more complex
Solution Approach 1:
The valve housing is segmented to include a specific through-hole portion that accommodates the stroke sensor signal transmission. This segmentation allows the housing to be manufactured using standard processes while providing the necessary opening for sensor integration, balancing structural integrity with connection simplicity
Data Source
AI summary
An object of the present invention is to provide a brake apparatus that allows low-cost attachment of a stroke sensor that detects a stroke amount of a brake pedal. The brake apparatus is configured in such a manner that the stroke sensor that detects an amount of an axial stroke of a piston is disposed between one side surface of a master cylinder housing and one side surface of a valve housing, and an output of the stroke sensor is transmitted via a through-hole formed on the valve housing when being transmitted to a control unit attached to an opposite side surface-side of the valve housing.