Hydraulic Block Return Line Design for Low Flow Resistance
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Solution Overview
Problem
Existing hydraulic block designs for externally powered vehicle brake systems face challenges in efficiently integrating and connecting various hydraulic components, such as brake fluid reservoirs, master brake cylinders, and pedal travel simulators, leading to increased flow resistance and complexity.
Innovation Solution
A hydraulic block with a cuboid design featuring cylindrical and stepped bores for the master brake cylinder, a pressure-resistant receptacle for the pedal travel simulator, and a return line system with multiple bores that connect the brake fluid reservoir, master brake cylinder, and pedal travel simulator, allowing for low flow resistance and a closed system without external communication or compressible media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple hydraulic components are integrated into a single hydraulic block, then system complexity is reduced and space is optimized, but flow resistance increases due to multiple internal connections
Solution Approach 1:
The hydraulic block is segmented into distinct functional zones with dedicated bores for each component (brake fluid reservoir, master brake cylinder, pedal travel simulator). The return line is further segmented into multiple parallel bores to distribute flow and reduce resistance, allowing each segment to optimize its function while maintaining overall system integration.
Solution Approach 2:
Multiple intermediate return bores act as mediators between the pedal travel simulator and the brake fluid reservoir. These intermediate channels provide multiple flow paths that reduce the hydraulic resistance that would exist in a single direct connection, effectively mediating the fluid flow between components.
2Reliability
If a closed hydraulic system is used without external communication, then system reliability improves, but manufacturing precision requirements increase
Solution Approach 1:
The return line functionality is merged into the hydraulic block structure itself through multiple bores that are directly formed in the block material. This integration eliminates the need for separate external return lines and their associated connection points, reducing the number of precision interfaces required while maintaining the closed system's reliability.
Solution Approach 2:
The hydraulic block serves multiple functions: it houses the brake fluid reservoir, master brake cylinder, and pedal travel simulator, while also providing the return line pathways through its integrated bores. This multi-functionality reduces the overall number of components and interfaces, lowering cumulative precision requirements compared to a system where each function is a separate component.
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 hydraulic block effectively integrates and connects hydraulic components, reducing flow resistance and system complexity, enabling efficient brake pressure control and slip control in externally powered vehicle brake systems.
Implementation Method 1
The pedal travel simulator is a pressure-resistant hydraulic accumulator for brake fluid, which is in particular spring-loaded, air-pressurized or gas-pressurized.
Implementation Method 2
The return enables a closed system, i.e. the back of the pedal travel simulator does not have to communicate with an environment or contain a compressible medium.
Data Source
AI summary
The invention relates to a hydraulic block (1) for a hydraulic power brake system of a vehicle with slip control. The invention proposes the passage of a bore (21), which communicates with a mounting (11) of a pedal travel simulator (7) by means of an encircling groove (12), parallel to an engine side (3) of the hydraulic block (1) between the engine side (3) and a main brake cylinder bore (2) in the hydraulic block (1), and the connection of said bore (21) by means of a transverse bore (23) to a further bore (24) which is parallel to the engine side (3) and connects the main brake cylinder bore (2) to a connection (8) for an unpressurized brake fluid storage tank, which can be placed onto the hydraulic block (1). The bores (21, 23, 24) form a return flow (26) of the pedal travel simulator (7), the return flow having a low flow resistance and making a closed system possible.