Hydraulic Unit Adapter Plate for Flexible Bulkhead Mounting
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Solution Overview
Problem
Existing hydraulic power brake systems face challenges in being adaptable to customer-specific requirements and cost-effective manufacturing, as they require custom-designed connecting plates and precise mounting positions, leading to increased production and testing costs.
Innovation Solution
A hydraulic unit with an additional adapter plate that can be independently selected, allowing for flexible spatial arrangement and attachment to a motor vehicle bulkhead, including adjustable rotation and tilt, to accommodate various installation conditions without altering the hydraulic unit's design, thereby reducing manufacturing and testing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a custom-designed connecting plate is used for each customer-specific requirement, then the hydraulic unit can be precisely adapted to specific mounting positions, but the manufacturing complexity and testing costs increase
Solution Approach 1:
The connecting plate is divided into two separate components: a standard connecting plate that is part of the serially produced hydraulic unit, and an additional adapter plate that is customized for specific mounting requirements. This segmentation allows the main hydraulic unit to be manufactured in series without customization, while only the adapter plate needs to be adapted to customer-specific requirements, thereby reducing overall manufacturing complexity and testing costs.
Solution Approach 2:
The additional adapter plate acts as an intermediary component between the standard connecting plate and the bulkhead. It mediates between the fixed design of the hydraulic unit and the variable mounting requirements of different customers, enabling adaptation without modifying the main hydraulic unit. This intermediary approach allows serial production of the core product while still meeting customized installation needs.
2Manufacturing precision
If the hydraulic unit is designed for a specific mounting position, then the connecting plate can be optimized for that position, but the unit cannot be installed in confined spaces or alternative locations
Solution Approach 1:
The additional adapter plate introduces dynamic adaptability to the mounting system. It can be rotated around the connecting plate to different angles and positions, allowing the hydraulic unit to be installed in various locations including confined spaces. This dynamic adjustment capability transforms a static, position-fixed design into a flexible system that maintains manufacturing precision while achieving installation versatility.
3Device complexity
If the connecting plate is integrated into the hydraulic unit housing, then the structure is simplified, but the unit cannot be rotated or repositioned relative to the bulkhead
Solution Approach 1:
The connection system is segmented into the integrated connecting plate (part of the hydraulic unit housing) and the separate additional adapter plate. This segmentation preserves the structural simplicity of the main unit while adding rotational capability through the detachable adapter plate, which can be oriented at different angles relative to the connecting plate.
Data Source
AI summary
A hydraulic unit of a hydraulic power brake system. The hydraulic unit includes a connecting plate for fastening the hydraulic unit to a bulkhead of a motor vehicle. The hydraulic unit additionally comprises an additional adapter plate which is adapted to connect the connecting plate to the bulkhead in order to at least partially establish a relative spatial arrangement of the hydraulic unit relative to the bulkhead.