Gas Spring Pressure Modulator for ABS Friction Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing ABS system pressure modulators are large and susceptible to failure due to movable hydraulic line components, leading to reliability issues and increased friction from steel springs.
Innovation Solution
A compact pressure modulator design using a gas spring as the spring element, which eliminates the need for a steel spring and reduces the number of dynamic seals, incorporating a control piston and a single valve arrangement within a ferromagnetic housing with integrated electronic circuits and pressure sensors, and a brake booster for enhanced reliability and space efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a steel spring is used as the spring element, then the pressure modulator can provide the necessary restoring force, but the friction increases and the device becomes more complex
Solution Approach 1:
The patent replaces the mechanical steel spring with an electromagnetic actuator system consisting of a proportional magnet, armature, and control electronics. This substitution eliminates the physical spring component, reducing friction and simplifying the mechanical structure while maintaining the necessary restoring force through electromagnetic control.
Solution Approach 2:
The patent uses hydraulic fluid to provide lubrication and damping for the armature movement, replacing the need for a mechanical spring. The hydraulic system provides the necessary force control through fluid pressure while reducing friction and wear compared to a steel spring mechanism.
2Ease of operation
If a movable hydraulic line is provided in the pressure modulator, then the pressure modulation function can be achieved, but the susceptibility to malfunctions increases
Solution Approach 1:
The patent integrates the hydraulic line directly into the housing structure, merging the fluid conduit with the structural component. This eliminates separate movable hydraulic line components that could fail, while maintaining the pressure modulation function through the integrated design of the housing and hydraulic passages.
3Reliability
If multiple dynamic seals are used in the pressure modulator, then the sealing function can be ensured, but the number of components increases and costs rise
Solution Approach 1:
The patent eliminates the need for multiple dynamic seals by redesigning the system to use a single seal location at the interface between the armature and housing. This extraction of unnecessary sealing components reduces complexity and cost while maintaining adequate sealing through the simplified single-seal design.
4Volume of moving object
If the pressure modulator is designed to be compact, then the space requirement is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent divides the compact pressure modulator into modular functional sections (proportional magnet, armature assembly, hydraulic chambers, and electronic control) that can be manufactured and assembled with standard tolerances. This segmentation allows each component to be optimized independently, achieving compact overall dimensions without requiring excessive precision across the entire assembly.
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
The compact design reduces size and friction, increases functional reliability, and lowers costs by minimizing components, while the integrated electronics enhance EMC compatibility and reduce signal interference, ensuring effective pressure modulation for ABS systems.
Implementation Method 1
a spring element (106), in particular a gas spring, is provided which increases the volume of the hydraulic line (104) when the anti-lock function is activated
Implementation Method 2
a linear drive, in particular a proportional magnet with an armature, is provided and a movement of the armature causes the volume accumulator to open
Implementation Method 3
a hydraulic inlet (102) and a hydraulic outlet (103) which are connected to one another via a hydraulic line (104)
Data Source
Figure 1~4
AI summary
In a pressure modulator (100) for an ABS system with a housing (101) having a hydraulic inlet (102) and a hydraulic outlet (103) connected thereto via a hydraulic line (104), wherein a volume accumulator is provided which can be opened against a spring force of a spring element (106) and which increases the volume of the hydraulic line (104) when the anti-lock function is activated, wherein a linear actuator, in particular a proportional magnet (126), with an armature (105) is provided and a movement of the armature (105) causes the volume accumulator to open, the spring element (106) is designed as a gas spring.