Modular Hydraulic Brake Actuation for Compact Low-Noise Control
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Solution Overview
Problem
Current hydraulic brake systems in vehicles face challenges such as limited compactness, noise generation, and increased complexity in electric vehicles, particularly in silent operation modes, along with demands for reduced size, enhanced reliability, and high feedback control accuracy, especially in electric and autonomous driving systems.
Innovation Solution
A modular hydraulic actuating system integrating a pressure supply device, electromotive drive, transmission mechanism, and valve arrangement with solenoid valves, combined in a main module that can be electrically or hydraulically connected to other system components, allowing for silent operation, high reliability, and precise feedback control, with optional redundancy for safety and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If components are integrated into a compact 1-box solution, then installation space is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent integrates the brake force booster, ABS/ESP assembly, vacuum pump, and master cylinder into a single 1-box structural unit. This merging of previously separate components (3-box solution) reduces installation space and simplifies system architecture while managing manufacturing complexity through modular design approaches.
Solution Approach 2:
The integrated 1-box assembly performs multiple functions simultaneously: brake force boosting, anti-lock braking (ABS), electronic stability control (ESP), and vacuum generation. This multi-functionality eliminates the need for separate assemblies and reduces overall system volume while maintaining all necessary braking functions.
2Length of stationary object
If the structural unit is made narrower and shorter for crash safety, then installation length is reduced, but accessibility for installation and maintenance deteriorates
Solution Approach 1:
The patent optimizes the spatial arrangement of components within the 1-box assembly by utilizing three-dimensional space efficiently. Components are arranged in compact configurations that reduce the overall length and width of the assembly for crash safety, while maintaining accessibility through strategic positioning of connection points and service interfaces.
3Volume of moving object
If electric motor and pump are integrated with valve block and cylinder-piston unit, then system compactness is improved, but noise generation increases
Solution Approach 1:
The patent extracts the electric motor and pump assembly from direct integration with the valve block and cylinder-piston unit, mounting them separately and connecting via hose lines. This separation reduces noise transmission to the bulkhead and passenger compartment while maintaining system compactness through coordinated positioning of the extracted components.
4Adaptability or versatility
If multiple sensors and plug connectors are added for electrical functions, then system functionality is enhanced, but installation complexity increases
Solution Approach 1:
The patent integrates multiple sensors (pedal travel sensors, fill level sensor) and electrical connection components directly into the 1-box assembly structure. This merging of electrical functions with the mechanical assembly reduces the number of separate installation steps and simplifies overall system installation while maintaining enhanced functionality.
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 modular system achieves a compact, reliable, and silent brake actuation with enhanced feedback control accuracy, suitable for electric and autonomous vehicles, reducing noise and improving installation accessibility while ensuring high system availability and safety.
Implementation Method 1
a valve arrangement with at least one solenoid valve
Implementation Method 2
the electromotive drive thereof
Data Source
AI summary
A device for a hydraulic actuating system, e.g., a motor vehicle brake, a clutch or a gear selector, may include the following components arranged in one housing, forming a main module: at least one pressure supply device driven by an electric motor drive, and a valve arrangement comprising at least one solenoid valve. The device may further include an electrical control unit (ECU) and valve output stages and sensors. The main module may be electrically and/or hydraulically connected to at least one further system component, which system component may include and actuating device and a travel simulator.