Hydraulic Modulator Housing Groove Structure for Weight Reduction
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Solution Overview
Problem
Conventional housing blocks for electronically controllable power-brake systems face challenges with increasing weight and material costs due to the growth in size and complexity of control units, which affect the overall dimensions and manufacturing costs.
Innovation Solution
A housing block design featuring a recess on one long side, formed as a groove, which is closed on the sides and open towards the surroundings, allowing for reduced material usage and weight while maintaining a stable structure for mounting electronic components, and incorporating pressure-medium-conducting channels outside the recess area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the housing block is designed with a larger mounting side to accommodate growing control units, then the control unit mounting capability is improved, but the weight and material costs increase
Solution Approach 1:
The patent removes material from the interior of the housing block to create a hollow cavity, transitioning from a solid to a hollow structure. This dimensional change allows the mounting side area to remain large for control unit accommodation while significantly reducing the overall material volume, weight, and manufacturing costs.
2Weight of stationary object
If material is removed from the housing block to reduce weight and costs, then weight and material costs decrease, but structural stability and pressure-medium impermeability may be compromised
Solution Approach 1:
The hollow cavity is strategically positioned and dimensioned to remove material where it is least needed for structural integrity and sealing. The cavity formation process maintains the density and continuity of the remaining material in critical areas, ensuring that pressure-medium impermeability and structural stability are preserved while achieving weight reduction.
Data Source
AI summary
A cuboidal housing block, particularly for a hydraulic modulator to generate, control or regulate a hydraulic pressure in a brake circuit of an electronically controllable power-brake system. Housing blocks have, inter alia, a mounting side which is provided for mounting an electronic control unit. To save on weight and material, a recess is provided on one long side of the housing block, the recess being in the form of a groove that is closed on the sides and otherwise open toward the surroundings of the housing block. The recess is bounded lengthwise by bars, an outer flank of these bars transitioning seamlessly into the mounting side and enlarging its area.