Master Cylinder Position Sensor Integration for Brake Reliability
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Solution Overview
Problem
Existing master cylinder assemblies for automotive braking systems face reliability issues in detecting brake pedal actuation due to the use of additional displaceable position transmitter elements and electrically operated detection units, which increases the risk of malfunctions.
Innovation Solution
A master brake cylinder arrangement that includes a displaceable piston, a force input member coupled to the piston, an elongate locator element, and a detection unit with a magnetic field sensor, where the position transmitter element is designed to interact with the detection unit, allowing for reliable detection of brake pedal actuation without additional displaceable elements and reducing the risk of malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional displaceable position transmitter elements and electrically operated detection units are provided, then brake pedal actuation detection capability is improved, but the risk of malfunctions increases
Solution Approach 1:
The patent extracts the position transmitter function from separate displaceable elements and integrates it directly into the piston structure. The piston itself serves as the position transmitter, eliminating the need for additional displaceable position transmitter elements and reducing system complexity while maintaining detection accuracy.
Solution Approach 2:
The piston is designed to serve multiple functions simultaneously: it acts as both the hydraulic actuator for brake pressure generation and the position transmitter for detection. This multi-functionality reduces the number of separate components needed, thereby reducing malfunction risk while maintaining detection capability.
2Reliability
If a non-contact Hall effect position sensor is used, then detection reliability is improved, but device complexity increases
Solution Approach 1:
The detection unit is integrated directly into the master cylinder housing, merging the detection function with the existing structural components. This integration approach reduces device complexity by eliminating separate mounting structures and connection elements while maintaining non-contact detection reliability.
Solution Approach 2:
The patent uses the piston's magnetic properties as an intermediary between the physical displacement and the Hall effect sensor detection. The magnetic field generated by the piston serves as a mediator that enables non-contact position detection without requiring direct mechanical connection or complex sensor mounting.
3Volume of moving object
If the detection unit is integrated into the master cylinder, then system compactness is improved, but manufacturing complexity increases
Solution Approach 1:
The master cylinder is divided into functional modules: the housing integrated with the detection unit, the piston assembly with magnetic properties, and the sealing components. This segmentation allows each module to be manufactured separately using optimized processes and then assembled, reducing overall manufacturing complexity while achieving compact integration.
Solution Approach 2:
The patent employs injection molding techniques with modified material parameters to integrate the detection unit housing directly into the master cylinder body. By changing the manufacturing parameters (using thermoplastic materials with magnetic properties or embedding sensors during molding), the complex integrated structure can be produced in a single manufacturing step rather than through multiple assembly operations.
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 solution provides a more reliable detection of brake pedal actuation, reducing the risk of malfunctions and ensuring accurate braking force application in both driver-decoupled and hydraulic brake systems.
Implementation Method 1
a detection unit that is designed to detect a displacement of the position transmitter element
Data Source
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AI summary
The invention relates to a main brake cylinder arrangement (10) for a motor vehicle brake system, comprising: at least one piston (44), which can be displaced along a displacement axis (V) and, together with a housing arrangement (12), delimits a pressure chamber; a force input member (19), which is displaceable according to a brake pedal actuation and is coupled or can be coupled to the piston (44) for common displacement; an elongated position encoder element (60), which is displaceable according to an actuation of the force input member (18); a detection unit (66), which is designed to detect a displacement of the position encoder element (60); and a receiving region (64), which is designed to receive the position encoder element (60) at least in sections. According to the invention, the ends (62, 68) of the position encoder element (60) are each arranged in a different housing region (F, S), which is arranged in a fluid path between the first and second housing region (F, S).