Master Cylinder BLS Sensor Integration via Magnet Merging
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Solution Overview
Problem
Conventional master cylinders with Brake Light Stop Sensor Modules (BLS) face issues such as piston adhesion and defects in electronic stability control (ESC) or traction control system (TCS), leading to instability in brake lamp operation and increased structural complexity due to the need for additional components like sleeves and collars.
Innovation Solution
A compact master cylinder design where the BLS sensor module is integrated with a ring-shaped magnet on the primary piston, supported by a return spring, and a hall sensor is mounted adjacent to the magnet, reducing the length and complexity by eliminating the need for additional fixing members and enhancing magnetic flux detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnet is installed on the secondary piston with a sleeve, collar and spring member, then the brake lamp can be controlled, but the structure of parts increases and the length of the master cylinder increases
Solution Approach 1:
The patent merges the BLS sensor module components (magnet, hall sensor, and supporting spring) directly into the existing primary piston assembly. The magnet is installed in the spring accommodation groove of the primary piston, and the hall sensor is mounted on the cylinder body at the boosting apparatus fixing part. This integration eliminates the need for separate sleeves and collars, reducing part complexity while maintaining brake lamp control functionality.
Solution Approach 2:
The primary piston is given multiple functions: it not only performs its traditional braking function but also houses the magnet for the BLS sensor module. The spring accommodation groove, originally designed for spring storage, is now also used to support the magnet. This multi-functionality reduces the need for additional components and simplifies the overall structure.
2Reliability
If a magnet is installed on the secondary piston with additional fixing members, then the brake lamp can be controlled, but the length of the master cylinder increases
Solution Approach 1:
The patent repositions the BLS sensor module from the axial direction (along the length of the master cylinder) to the radial direction. The hall sensor is mounted on the outer surface of the cylinder body at the boosting apparatus fixing part, facing inward toward the magnet on the primary piston. This dimensional change allows the sensor module to be integrated into the existing radial space without extending the axial length of the master cylinder.
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 design ensures stable brake lamp operation by directly linking the magnet with the pedal and using a compact structure that minimizes the distance between the hall sensor and magnet, improving sensitivity and reducing the risk of failure in adverse conditions while maintaining a compact form factor.
Implementation Method 1
a hall sensor installed at an outer side of the cylinder body to correspond to the magnet and configured to control on/off operations of a brake lamp by sensing a magnetic flux density according to the reciprocating motion of the primary piston
Implementation Method 2
a return spring which is provided between the primary piston and the secondary piston, respectively
Data Source
AI summary
Disclosed is a master cylinder for a vehicle brake. The master cylinder includes a cylinder body provided with a hollow bore, a primary piston configured to perform a reciprocating motion in the hollow bore in linkage with a pedal, a secondary piston configured to move in linkage with the motion of the primary piston, and a Brake Light Stop (BLS) sensor module comprising a magnet provided at the primary piston and provided in a ring shape, and a hall sensor installed at an outer side of the cylinder body to correspond to the magnet and configured to control on/off operations of a brake lamp by sensing a magnetic flux density according to the reciprocating motion of the primary piston, wherein the magnet has both sides thereof supported by the primary piston and a return spring that is provided between the primary piston and the secondary piston, respectively.