Hydraulic Brake Travel Sensor Layout for Precise Piston Positioning
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Solution Overview
Problem
The positioning precision of travel sensors in hydraulic braking systems is compromised due to the long distance between the master cylinder housing and the control module, leading to difficulties in electrical connection and assembly stress, affecting the interconnection precision and reliability of the braking apparatus.
Innovation Solution
A travel sensor is fastened to the inside of the hydraulic valve block, utilizing a magnet component and sensing element to detect piston movement, with a three-layer structure comprising the hydraulic valve block, master cylinder housing, and control module, ensuring precise positioning and interconnection, and using sealing rings to prevent liquid leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the travel sensor is disposed outside the master cylinder housing and electrically connected through a through hole in the hydraulic valve block, then the sensor can be installed, but the positioning precision deteriorates due to the long distance between the master cylinder housing and the control module
Solution Approach 1:
The travel sensor is merged with the hydraulic valve block by fastening it to the inside surface of the valve block. This integration eliminates the long-distance connection problem and ensures high positioning precision while maintaining ease of installation through the fastening mechanism.
2Ease of operation
If the travel sensor is connected through a long distance to the control module, then the electrical connection can be established, but the interconnection precision deteriorates
Solution Approach 1:
The travel sensor and control module are merged into a closely integrated structure where the sensor is fastened to the hydraulic valve block which is in turn connected to the control module. This eliminates long-distance connections and ensures high interconnection precision.
3Ease of operation
If the travel sensor is disposed outside the master cylinder housing, then the sensor can be accessed, but assembly stress increases affecting reliability
Solution Approach 1:
The travel sensor is merged with the hydraulic valve block structure, which provides mechanical support and protection. This integration reduces assembly stress by distributing loads through the rigid valve block while maintaining accessibility through the fastening design.
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 enhances the positioning precision of the travel sensor, improves interconnection precision between the sensor and control module, and reduces assembly stress, thereby increasing the reliability and effectiveness of the hydraulic braking apparatus.
Implementation Method 1
a magnet component 213 moves with the piston 211
Implementation Method 2
a travel sensor 400, fastened to the inside of the hydraulic valve block 100, and configured to detect movement of the magnet component 213
Data Source
AI summary
A hydraulic braking apparatus, a travel sensor, and a vehicle are provided. The hydraulic braking apparatus includes: a hydraulic valve block; a master cylinder housing disposed on one side of the hydraulic valve block, where a master cylinder part is disposed inside the master cylinder housing, and the master cylinder part includes a piston, a push rod, and a magnet component; a control module disposed on another side of the hydraulic valve block, where the control module includes a control substrate and a connector electrically connected to the control substrate; and a travel sensor fastened to the inside of the hydraulic valve block and configured to detect movement of the magnet component to determine a movement amount of the piston.