Cable-Coupled By-Wire Brake Actuator With Relief Pocket
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Solution Overview
Problem
Existing by-wire vehicle control systems for functions like braking lack a cost-effective solution that allows drivers to override the by-wire command for increased braking effort, while seamlessly integrating with traditional manual activation methods.
Innovation Solution
A cable-coupled by-wire actuator system where the actuator-end is wrapped around a pulley within a housing, allowing the driver to override by-wire braking by further depressing the pedal, with a cable relief pocket to manage slack and prevent kinking, and an electric motor controlling the pulley's rotation for commanded braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a by-wire brake actuator is cable-coupled to the driver brake pedal to enable both by-wire and manual brake activation, then cost-effectiveness and versatility are improved, but cable slack management and potential kinking during override conditions worsen
Solution Approach 1:
The cable relief pocket extracts and isolates the problematic cable slack from the critical cable routing path. By creating a dedicated storage space within the actuator housing, the solution removes the harmful effect of slack accumulation that would otherwise cause kinking and reliability issues during override conditions.
Solution Approach 2:
The cable relief pocket provides beforehand cushioning by pre-configuring a slack absorption mechanism. Before override conditions occur, the pocket is positioned and sized to accommodate the expected cable slack, preventing sudden kinking or binding when the driver overrides the by-wire command.
2Measurement precision
If the actuator uses a pulley system with cable wrapping to achieve precise braking control, then positioning accuracy is improved, but cable slack accumulation during override conditions worsens
Solution Approach 1:
The cable relief pocket extracts the slack management function from the pulley-cable interaction. Instead of complicating the pulley system with additional tensioning or routing mechanisms, the solution separates the slack accommodation function into a dedicated pocket space, simplifying overall cable management.
Solution Approach 2:
The cable relief pocket introduces a spatial dimension solution to a one-dimensional problem. By creating a three-dimensional storage volume within the actuator housing, the system manages cable slack in a radial/outboard direction rather than attempting to control it through the linear pulley-cable path.
3Reliability
If the cable relief pocket is positioned radially outboard of the pulley to accommodate slack, then cable slack management is improved, but actuator housing complexity increases
Solution Approach 1:
The cable relief pocket merges with the existing actuator housing structure rather than being a separate component. By integrating the slack accommodation space into the housing itself, the solution avoids adding external complexity while maintaining reliable cable slack management.
Solution Approach 2:
The actuator housing serves multiple functions: it contains the pulley mechanism, protects internal components, and provides the cable relief pocket for slack management. This multi-functionality reduces overall system complexity by eliminating the need for separate cable management components.
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
Enables cost-effective by-wire and manual brake activation integration, allowing drivers to increase braking effort and ensures smooth operation by managing cable slack and preventing kinking through the cable relief pocket, enhancing the overall braking system's reliability and usability.
Implementation Method 1
an electric motor of the actuator rotates the pulley to a commanded position/angle to achieve a corresponding braking effort
Implementation Method 2
The actuator housing includes a cable relief pocket radially outboard of the pulley to accommodate slack in the cable during an override condition
Data Source
AI summary
A cable-coupled by-wire control of a vehicle control function traditionally activated by driver manipulation of a pedal is achieved though the agency of a Bowden cable having a first end fastened to the driver pedal, and a second end coupled to a by-wire actuator. The by-wire actuator has a pulley on which the second end of the cable is fastened, an electric motor coupled to the pulley to permit by-wire activation of the vehicle control function by rotation of the pulley in a direction to pull on the pedal with the cable. A relief chamber of the actuator radially outboard of the pulley accommodates slack in the cable within the actuator caused by driver manipulation of the pedal during by-wire activation of the control function.