Master Cylinder Seal Installation Error Detection
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Solution Overview
Problem
The existing brake system master cylinders often have seals installed in reverse, which is not apparent until the brakes are used, posing a significant risk and requiring the replacement of the master cylinder.
Innovation Solution
A method is developed to detect incorrect seal installation by subjecting the master cylinder to a test pressure after assembly, using compressed air to identify any pressure drop indicative of reverse installation, allowing for immediate correction before the master cylinder is installed in a brake system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If seal installation is not verified during assembly, then manufacturing process is simple and fast, but seal installation error remains undetected until brake usage causing safety risks
Solution Approach 1:
The patent applies preliminary action by performing seal installation verification during the master cylinder assembly process before the brake system is activated. A test pressure is applied to the pressure chamber to check for leaks that would indicate reversed seal installation, allowing detection and correction before final installation in the vehicle.
Solution Approach 2:
The system uses the master cylinder's own pressure chamber and seal structure to perform the detection. The test pressure is applied through existing components (piston, pressure chamber, seal) without requiring external specialized equipment, making the detection system self-contained and simple.
2Reliability
If seal installation verification is performed using test pressure, then installation errors are detected, but the master cylinder requires additional testing equipment and time
Solution Approach 1:
The verification is performed as a preliminary step during assembly before the brake system is installed in the vehicle. This ensures that any seal installation errors are detected and corrected during manufacturing, avoiding the need for time-consuming replacements after installation.
Solution Approach 2:
The patent uses pneumatic testing by applying compressed air or gas to the pressure chamber to detect seal installation errors. This method is faster and cleaner than hydraulic testing with brake fluid, as it does not require draining or cleaning operations.
3Ease of manufacture
If compressed air is used for testing, then the master cylinder remains clean and is not soiled, but additional cleaning procedures are eliminated
Solution Approach 1:
The patent replaces hydraulic testing (using brake fluid) with pneumatic testing (using compressed air or gas). This substitution eliminates the risk of brake fluid contamination in the master cylinder, avoiding the need for cleaning procedures and ensuring the system remains clean during testing and subsequent packaging.
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 method effectively prevents the installation of seals in reverse, ensuring correct operation of the master cylinder and avoiding the need for discarding or replacing master cylinders, thus enhancing safety and reducing costs associated with activated brake systems.
Implementation Method 1
the seal in the master cylinder is subjected to a test pressure and, in the event of a pressure drop, the seal is considered to have been installed in reverse
Implementation Method 2
By preference, compressed air is used as the control fluid
Data Source
AI summary
A method is described for detecting an incorrectly installed seal in a master-cylinder having a seal. The master cylinder is subjected to a pressure comprised between approximately 0.3 and 0.6 MPa at the conclusion of master-cylinder assembly and, if there is a drop in the pressure, the seal is considered to have been installed in reverse in the groove of the master cylinder.