Modular Hydraulic Brake Actuation Assembly for Variant Flexibility
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Solution Overview
Problem
Conventional hydraulic brake actuation assemblies require different designs for various operational variants, leading to high production costs due to limited common parts, and lack efficient mechanisms for both mechanical and electro-hydraulic operations.
Innovation Solution
The design consists of two pre-assembled subassemblies, where the first subassembly is standardized for all variants, allowing for cost-effective mass production, and the second subassembly is modular to accommodate different operational modes, including purely mechanical and electro-hydraulic operations, with a pressure reducing valve system and actuation pistons that allow for flexible adaptation and fine control of braking force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different designs are used for each operational variant, then the hydraulic brake actuation assembly can be optimized for specific operations, but the production cost increases due to limited common parts
Solution Approach 1:
The brake actuation assembly is divided into a first subassembly containing spools and actuation pistons, and a second subassembly containing additional actuation pistons and contact surfaces. This segmentation allows the first subassembly to be standardized across all variants while the second subassembly is modified for different operational modes, enabling mass production of common components and reducing overall production costs.
Solution Approach 2:
The first subassembly is designed with universal components that can be used across all operational variants. The spools and actuation pistons in the first subassembly serve multiple functions and can accommodate different operational modes when combined with different second subassemblies, thereby reducing the need for variant-specific designs and lowering production costs.
2Ease of manufacture
If a standardized first subassembly is used for all variants, then mass production becomes cost-effective, but the ability to accommodate different operational modes must be achieved through the second subassembly
Solution Approach 1:
The brake actuation assembly is divided into a first subassembly containing spools and actuation pistons, and a second subassembly containing additional actuation pistons and contact surfaces. This segmentation allows the first subassembly to be standardized across all variants while the second subassembly is modified for different operational modes, enabling mass production of common components and reducing overall production costs.
3Ease of operation
If mechanical operation is used, then the system can be operated by foot or hand, but the structure requires direct mechanical coupling which increases complexity
Solution Approach 1:
The first subassembly is designed with universal components that can be used across all operational variants. The spools and actuation pistons in the first subassembly serve multiple functions and can accommodate different operational modes when combined with different second subassemblies, thereby reducing the need for variant-specific designs and lowering production costs.
4Measurement precision
If electro-hydraulic operation is used with control valves, then precise control of braking force is achieved, but the system complexity and cost increase
Solution Approach 1:
Different subassemblies are configured with different local qualities to achieve precise control where needed. The second subassembly can be equipped with control valves for electro-hydraulic variants to provide precise braking force control, while mechanical variants use simpler direct actuation. This localized differentiation allows precise control functionality to be added only where required, minimizing overall system complexity.
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 approach enables the production of cost-effective hydraulic brake actuation assemblies with a standardized complex subassembly and adaptable simpler subassembly, ensuring efficient operation across multiple variants while maintaining safety and fine control of braking force, even in case of electro-hydraulic actuation failure.
Implementation Method 1
at least one first spring (44) is located between the first spool (41) and the first actuation piston (42) along the first axis (40)
Implementation Method 2
hydraulic brake actuation assembly
Data Source
Figure 1
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AI summary
A hydraulic brake actuation assembly (10) comprises a first and a second subassembly, wherein the first subassembly (20) comprises a first spool (41) and a first actuation piston (42) which are moveable along a first axis (40) respectively, and comprises a second spool (51) and a second actuation piston (52) which are moveable along a second axis (50) respectively, wherein the second subassembly (60; 60') comprises a third and a fourth actuation piston (62; 63), wherein the third actuation piston is moveable along the first axis, wherein it has a third contact surface (64), which is able to contact a first contact surface (43) of the first actuation piston, wherein the fourth actuation piston is moveable along the second axis, wherein it has a fourth contact surface (65) which is able to contact a second contact surface (53) of the second actuation piston.