Hydraulic Actuator Layout for Compact Brake and Clutch Packaging
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Solution Overview
Problem
Existing hydraulic actuation systems for motor vehicle brakes and gear actuators face challenges in achieving compactness, weight reduction, and cost-effectiveness while accommodating different vehicle configurations and installation scenarios, with limitations in packaging optimization, accessibility, ventilation, and noise reduction.
Innovation Solution
The actuation device features a compact, modular design with a rectangular base form, symmetrical layout for left- and right-hand drives, parallel arrangement of piston cylinder and pressure supply units, and a sound-damping intermediate housing, allowing for flexible installation angles and reduced noise transmission, along with direct electrical connections and optimized hydraulic and electrical accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If components are integrated into a compact assembly, then installation space is reduced, but accessibility for installation and maintenance deteriorates
Solution Approach 1:
The actuation device is divided into modular components (actuator unit, valve unit, reservoir) that can be independently accessed and serviced. The valve unit with its connection surfaces allows for modular assembly and disassembly, improving accessibility while maintaining compact overall dimensions.
Solution Approach 2:
Connection surfaces and standardized interfaces are introduced as intermediaries between components, enabling easy coupling and decoupling of modules. This allows maintenance personnel to access and replace individual components without disassembling the entire compact assembly.
2Volume of moving object
If the assembly is made narrower and shorter, then packaging optimization improves, but ventilation and heat dissipation deteriorate
Solution Approach 1:
The actuator axis is oriented perpendicular to the longitudinal axis of the first cylinder piston unit, creating a three-dimensional arrangement that optimizes space utilization while maintaining adequate ventilation pathways in multiple directions for heat dissipation.
3Adaptability or versatility
If multiple plugs and sensors are added, then functionality increases, but installation complexity increases
Solution Approach 1:
Multiple sensors (pedal path sensors, fill level sensor) and electrical connections are integrated into a unified control unit with a standardized plug interface. This merging of multiple functions into a single modular unit reduces installation complexity while maintaining full functionality.
Solution Approach 2:
The control unit serves multiple functions simultaneously (sensor integration, signal processing, actuator control) through a single standardized interface, reducing the number of separate connections and sensors needed while maintaining comprehensive system functionality.
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 results in a lightweight, cost-effective, and highly adaptable actuation system that achieves a slim, space-saving configuration, improved ventilation, and reduced noise levels, enhancing packaging efficiency and ease of installation while maintaining high safety and performance standards.
Implementation Method 1
an intermediate housing or element, in particular a sound-damping intermediate housing or element can still be arranged between the drive and the first housing
Data Source
AI summary
An actuation device for a hydraulic actuation system, e.g., a motor vehicle brake or an electrified clutch actuator, may include a connection for an actuation device; a pressure supply device, driven by an electromotor drive, in the form of a piston or double-stroke piston pump; a piston cylinder unit that may be actuated by means of the actuation device; and an electronic control unit. An axis of the piston cylinder unit and an axis of the pressure supply device may be arranged in parallel.