Compensating Reservoir Depression for Brake Switching Unit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing compensating tanks for hydraulic motor vehicle brake systems face issues with packaging, transportation, and assembly due to the projection of the switching unit from the upper side, leading to defective welded connections and leaks under high filling pressures.
Innovation Solution
A depression in the housing holds the switching unit with a plastic base body, ensuring it does not project from the upper side, allowing for improved welding and precise positioning of the switching unit, preventing lateral offset and enabling a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the switching unit projects from the upper side of the compensating tank, then the plug connector is easily accessible, but the packaging and transport space is increased and welding quality deteriorates
Solution Approach 1:
The switching unit is nested within a depression in the housing upper part, with its base body composed of plastic that is welded into the depression. This nesting approach allows the plug connector to remain accessible while the switching unit itself does not project from the upper side, reducing packaging and transport space requirements.
2Ease of manufacture
If the switching unit projects from the upper side of the compensating tank, then assembly is simplified, but welding connection quality deteriorates under high filling pressures
Solution Approach 1:
The depression in the housing upper part is pre-formed to receive the switching unit base body. This preliminary action ensures proper positioning and alignment before welding, allowing the switching unit to be welded securely into the depression without projecting from the upper side, thereby maintaining welding connection quality under high filling pressures.
3Manufacturing precision
If the switching unit is held in a depression with pre-positioning, then welding precision is improved, but device complexity increases
Solution Approach 1:
The housing upper part is segmented to include a depression that receives the switching unit base body. This segmentation allows the switching unit to be pre-positioned and welded with high precision while the depression itself is formed as an integral part of the housing during molding, avoiding additional complex assembly steps or 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
This design enhances the welding process, preventing leaks and ensuring a secure, compact compensating tank that meets high-pressure demands without complex tooling, maintaining the switching point and passing production line tests.
Implementation Method 1
the switching unit having a base body composed of plastic, which base body is welded to the housing in the depression
Implementation Method 2
a device for monitoring the tank filling level having for example a reed switch as a switching element and for example a magnetic transducer as a transducer
Data Source
AI summary
A compensating tank for a hydraulic motor vehicle brake system, having a housing including a housing upper part and a housing lower part and having a device for monitoring the tank filling level of the compensating tank, including a switching unit, which is welded to the housing and has a plug connector, and including a sensor or switching element which can be switched by a transducer at a switching point S at which the switching unit generates a signal for an electronic control unit. The housing has a depression for holding the switching unit, with the switching unit having a base body composed of plastic, which base body is welded to the housing in the depression, and with the depression being provided such that the base body of the switching unit forms a planar surface with the housing.