Pedal Stroke Sensor Installation Structure for IDB Systems
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Solution Overview
Problem
Conventional pedal stroke sensors for brake pedals are complex in structure, making them difficult to package with Integrated Dynamic Brake (IDB) systems and prone to malfunction, which can lead to unexpected accidents and reduced product reliability.
Innovation Solution
The installation structure incorporates a magnet in the piston of the master cylinder interacting with detection sensors on a printed circuit board (PCB) within the Electronic Control Unit (ECU), allowing for the detection of absolute pedal position without a separate PCB, enabling a simplified structure and redundancy for stable displacement measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional pedal stroke sensor is directly mounted to each pedal separately from the IDB system, then the pedal angle can be detected, but the structure becomes complex requiring additional components such as cover, PCB, sensing unit, housing, and connector
Solution Approach 1:
The patent combines the pedal stroke sensor functions directly into the ECU by integrating a magnet on the piston and detection sensors on the PCB within the ECU. This eliminates the need for separate sensor housing, cover, and external mounting structures, thereby reducing device complexity while maintaining detection capability
Solution Approach 2:
The ECU is designed to serve multiple functions: it acts as both the control unit for the IDB system and the sensing unit for detecting piston displacement. The PCB in the ECU performs both control functions and sensing functions through integrated detection sensors, reducing the need for separate dedicated sensor components
2Measurement precision
If a conventional pedal stroke sensor is used with separate mounting, then the pedal displacement can be measured, but the packaging with IDB system becomes difficult
Solution Approach 1:
The sensor components (magnet and detection sensors) are integrated within the ECU assembly itself, allowing the ECU to be packaged together with the IDB system as a single unit. This eliminates the need for separate sensor mounting and connection processes, significantly easing the packaging and assembly manufacturing
3Device complexity
If a single sensing unit is used in the conventional pedal stroke sensor, then the structure is simpler, but the reliability reduces due to higher possibility of unexpected accidents during malfunction or destruction
Solution Approach 1:
The patent incorporates redundant detection sensors on the PCB within the ECU to detect piston displacement. This redundancy is built into the design beforehand to cushion against potential sensor failure, ensuring that if one sensor malfunctions or is destroyed, the system can still detect pedal displacement and maintain operation, thereby improving reliability
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 solution simplifies the pedal stroke sensor structure, facilitates easy packaging with the IDB system, and ensures reliable displacement measurement even if one sensor malfunctions, enhancing product reliability and safety.
Implementation Method 1
the first and second sensors detect a magnetic flux density of the magnet in response to movement of the piston
Data Source
AI summary
An installation structure of a pedal stroke sensor of an integrated dynamic brake (IDB) system is disclosed. The IDB system includes a hydraulic block, a hydraulic pressure generator, and an electronic control unit (ECU). The hydraulic block includes not only a master cylinder connected to a brake pedal but also a plurality of passages and valves needed to adjust a brake hydraulic pressure. The hydraulic pressure generator includes a motor that is connected to the hydraulic block and operates by an output signal of a detection sensor for sensing displacement of the brake pedal, thereby generating brake hydraulic pressure. The ECU controls the motor and the valves based on pressure information and pedal displacement information. The installation structure of the pedal stroke sensor includes a magnet installed in a piston that slidably moves within the master cylinder by interacting with the brake pedal. The detection sensor includes a first sensor and a second sensor that are spaced apart from each other by a predetermined distance in a movement direction of the piston in a manner that the first and second sensors detect a magnetic flux density of the magnet in response to movement of the piston.