Bayonet Switching Unit for Hydraulic Brake Equalizing Container
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Solution Overview
Problem
Existing hydraulic motor vehicle brake systems face challenges with complex assembly, high costs, and non-replaceable switching units in expansion tanks, which can lead to increased costs and logistical issues during packaging and transport.
Innovation Solution
The expansion tank design features a cup-shaped section on the contact carrier that allows for a detachable connection with a complementary section on the housing, enabling quick and easy assembly of the switching unit, which can be replaced without tools, and is optimized for packaging by not protruding beyond the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the switching unit is permanently attached to the housing with a welded plug connector, then the structural integrity is improved, but the assembly complexity and manufacturing cost increase significantly
Solution Approach 1:
The switching unit is separated from the housing into two independent parts: a contact carrier with a cup-shaped section and a housing with a complementary section. This segmentation allows the switching unit to be assembled separately and attached to the housing, eliminating complex welding operations while maintaining structural integrity through the bayonet connection mechanism.
Solution Approach 2:
The contact carrier is pre-assembled with the switching element (reed switch) and plug connector before attachment to the housing. This preliminary assembly simplifies the final installation step, as the entire switching unit can be attached to the housing in a single bayonet connection operation without requiring complex on-site assembly or welding procedures.
2Stability of the object's composition
If the switching unit is permanently attached to the housing, then the structural stability is improved, but the replaceability and maintenance ease deteriorate
Solution Approach 1:
The connection between the switching unit and housing is made dynamic and reversible through the bayonet connection mechanism. This allows the switching unit to be easily detached and replaced when defective, while maintaining stable structural connection during normal operation. The bayonet connection provides both mechanical stability and operational flexibility.
Solution Approach 2:
The design enables the switching unit to be discarded (removed) from the housing when defective and replaced with a new unit. The bayonet connection facilitates this discarding and recovering process, allowing quick removal of the faulty switching unit and installation of a replacement without requiring complex disassembly or special tools.
3Ease of manufacture
If the switching unit protrudes from the top of the expansion tank, then the assembly is simplified, but the packaging efficiency and transport space utilization deteriorate
Solution Approach 1:
The switching unit is nested within the housing structure by integrating it into the side wall area rather than protruding from the top. The contact carrier with cup-shaped section is attached to the housing in a manner that utilizes the existing housing volume, allowing the switching unit to be contained within the overall footprint of the expansion tank without increasing its external dimensions.
Solution Approach 2:
The switching unit is repositioned from a vertical protrusion at the top to a horizontal integration into the side wall structure. This dimensional change allows the switching unit to be accommodated within the side profile of the housing, utilizing the lateral space rather than increasing the vertical height, thereby improving packaging efficiency.
4Manufacturing precision
If a flag is attached to the contact carrier extending into the guide tube, then the switching point positioning is achieved, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The flag for positioning and the contact carrier are merged into a single integrated component. The contact carrier with cup-shaped section incorporates the positioning function directly, eliminating the need for a separate flag attachment step. This integration simplifies assembly while maintaining precise positioning of the switching point through the geometric relationship between the cup-shaped section and the guide tube.
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 design simplifies assembly, reduces costs, and ensures precise positioning of the switching element, allowing for easy replacement and improved handling during transport and installation, while preventing incorrect assembly and damage.
Implementation Method 1
a magnetic sensor passes the switching point, the switching contacts of the reed switch close
Implementation Method 2
a float equipped with a magnet switches the reed contact
Data Source
Figure 1
Figure 2~4
Figure 5~8
AI summary
The invention relates to an equalizing container (40) for a hydraulic motor vehicle brake system, having a housing (47) comprising a housing upper part and a housing lower part, and having an apparatus for monitoring the container filling level of the equalizing container (40), comprising a switching unit (41) which is fastened to the housing (47) and has a plug connector (42) and a contact support (44) which protrudes with one section (49) into a guide tube (53) which extends into a container interior space, and to a sensor or switching element which is arranged on the contact support (44) in the region of the guide tube (53) and can be switched by means of a sensor (4) at a switching point S, at which the switching unit (41) generates a signal for an electronic control unit. In order to provide an equalizing container (40) which is improved with regard to switching behaviour, exchangeability of the switching unit, mounting and costs, it is proposed according to the invention that the contact support (44) has a cup-shaped section (46) which interacts with a complementary section (48) which is formed on the housing (47), in order to make a releasable connection of the switching unit (41) to the housing (47) possible, wherein that section (49) of the contact support (44) which carries the sensor or switching element extends centrally from a base (50) of the cup-shaped section (46) and a housing (43) of the plug connector (42) is arranged on the contact support (44) perpendicularly in relation to a longitudinal axis L of the switching unit (41).