Hydraulic Block Mounting Flange for Stable Brake Pressure Control
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Solution Overview
Problem
Existing hydraulic blocks for vehicle braking systems lack an efficient mechanism for mechanically fastening and hydraulically interconnecting components, such as solenoid valves and pressure sensors, which affects the stability and reliability of brake pressure generation and slip control.
Innovation Solution
A hydraulic block design featuring a master brake cylinder borehole with a mounting part and fastening flange that includes through-holes and tubular collars for secure fastening to the vehicle bulkhead, along with a power cylinder borehole for power actuation, allowing for the integration of hydraulic components and improved brake pressure control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fastening methods are used for hydraulic components, then assembly is simple, but mechanical fastening stability and hydraulic interconnection reliability are insufficient
Solution Approach 1:
The mounting part integrates multiple functions: it provides mechanical fastening through threaded holes and collars, hydraulic interconnection through integrated bores aligned with hydraulic lines, and structural support for the master brake cylinder piston. This merging of fastening and hydraulic connection functions into a single component resolves the contradiction by improving reliability without requiring additional separate fastening structures.
Solution Approach 2:
The mounting part features tubular collars that are inserted into and nested within the hydraulic block's mounting holes. This nesting arrangement provides secure mechanical fastening while the collars themselves serve as structural elements that integrate with the hydraulic connection system, thereby improving fastening stability without proportionally increasing overall structural complexity.
2Reliability
If multiple hydraulic components are integrated into the hydraulic block, then hydraulic interconnection is improved, but manufacturing complexity increases
Solution Approach 1:
The mounting part is designed with pre-aligned bores and threaded holes that correspond to the required hydraulic line positions and fastening locations. This preliminary design of the mounting part allows for simplified integration of hydraulic components, as the alignment features are already in place, reducing the complexity of subsequent assembly and manufacturing operations.
3Ease of operation
If the master brake cylinder piston opening is exposed, then piston movement is free, but mechanical protection and secure fastening are compromised
Solution Approach 1:
The mounting part features a collar structure that is inserted into and nested within the hydraulic block's mounting hole. This nested collar provides mechanical protection for the piston opening area while maintaining sufficient clearance for piston movement. The collar acts as a protective sleeve that secures the opening without constraining piston operation.
Solution Approach 2:
The mounting part serves as an intermediary component between the master brake cylinder piston assembly and the hydraulic block. It provides the opening for piston movement while simultaneously offering threaded holes and collars for secure mechanical fastening to the bulkhead, thus mediating between the conflicting requirements of movement freedom and fastening stability.
Data Source
AI summary
For fastening an mounting part to a hydraulic block of a hydraulic power unit of a hydraulic power vehicle braking system, holes are configured in a fastening flange of the mounting part with collars, which are clampingly inserted in mounting holes of the hydraulic block. A perforated disk is situated on the fastening flange as a fastening part and is fastened by screws screwed into the mounting holes of the hydraulic block.