Rotary Position Sensor Integration in Hydraulic Brake Housing
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Solution Overview
Problem
Existing brake systems for motor vehicles with electric motors face inefficiencies due to the need for external plug-in connections between the rpm sensor, electric motor, and control unit, which complicates the routing of electrical wiring and cabling around the hydraulic unit's housing block.
Innovation Solution
A rotary position sensor is integrated into the housing block of the hydraulic unit, allowing direct signal tapping from the rotor and connection to the control unit through a shortest possible link, eliminating the need for external connections and providing a stable, form-fitting alignment and fixation within the unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If external plug-in connections are used between the rpm sensor, electric motor, and control unit, then the system can be assembled from separate components, but the routing of electrical wiring and cabling becomes complicated and increases device complexity
Solution Approach 1:
The rotary position sensor is integrated directly into the housing block of the hydraulic unit, merging the sensor, housing, and connection pathways into a single unified structure. This eliminates the need for separate plug-in connections and external wiring, thereby reducing device complexity while maintaining ease of manufacture through modular housing block production.
Solution Approach 2:
The rotary position sensor is extracted from the conventional external mounting position and relocated to an integrated position within the housing block. This extraction from the external environment and incorporation into the core structure eliminates the need for external plug-in connections and complex routing of electrical wiring.
2Device complexity
If the rotary position sensor is integrated into the housing block with direct connection, then wiring complexity is reduced, but the manufacturing precision required for the opening and sensor alignment increases
Solution Approach 1:
The opening for the rotary position sensor and its alignment features are pre-formed during the manufacturing of the housing block itself. This preliminary action ensures that the opening is precisely positioned and dimensioned before the sensor is installed, thereby reducing the manufacturing precision requirements for the final assembly while still achieving the desired alignment accuracy.
Data Source
AI summary
A device is provided for operating a brake system of a motor vehicle having an electric motor, which is configured for driving a pressure generation unit in order to generate hydraulic pressure; a housing block of a hydraulic unit, which is able to be connected to the pressure generation unit and the brake system of the motor vehicle; a control unit for controlling the electric motor; and a rotary position sensor of the electric motor, the electric motor being fixed in place on a first side of the housing block of the hydraulic unit, and the control unit being fixed in place on a second side, situated opposite from the first side, of the housing block of the hydraulic unit, and the rotary position sensor of the electric motor being situated in such a way that it detects a rotational frequency and/or an angular position of a rotor of the electric motor and is connected to the control unit by an opening developed in the housing block of the hydraulic unit. Also provided is a method for operating a brake system of a motor vehicle, and to a rotary position sensor.