Simulator Valve Leak Detection in Vehicle Brake Systems
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Solution Overview
Problem
Current vehicle brake systems lack an effective method to diagnose leaks in simulator valves, which can lead to inefficient braking performance and potential safety issues during adverse conditions.
Innovation Solution
A diagnostic method that energizes specific valves and a plunger assembly to maintain pressure in a boost circuit, allowing for the identification of leaks by measuring pressure deterioration rates, with optional steps to test the pedal simulator for leaks, using a combination of sensors and electronic control units to provide user interface signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a brake system uses a simulator valve to control brake fluid flow, then braking performance is improved, but the risk of undetected leaks causing safety issues increases
Solution Approach 1:
The system performs a self-diagnostic test before normal operation by isolating the simulator valve in a test configuration, pressurizing the circuit with a test pump, and monitoring for leaks. This preliminary detection prevents undetected leaks from compromising safety during actual braking operations.
Solution Approach 2:
A three-way valve serves as an intermediary to switch the simulator valve between its normal braking function and a diagnostic test configuration. This intermediary component enables the system to test for leaks without affecting normal braking performance while maintaining system reliability.
2Measurement precision
If the brake system includes diagnostic testing capabilities, then detection accuracy improves, but device complexity increases
Solution Approach 1:
The three-way valve serves multiple functions: it directs brake fluid during normal operation and redirects it during diagnostic testing. The test pump and pressure sensor are integrated into the existing brake system architecture, allowing these components to serve both diagnostic and operational functions, thereby reducing overall system complexity.
Solution Approach 2:
The brake system performs self-diagnosis by using its own components (three-way valve, test pump, pressure sensor) to test for leaks in the simulator valve. This self-service capability eliminates the need for separate external diagnostic equipment, reducing system complexity while maintaining high detection accuracy.
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 method enables the accurate detection of leaks in simulator valves, ensuring optimal brake system performance and safety by maintaining pressure levels and providing timely alerts to users, thereby preventing issues like excessive stopping distances and loss of directional control.
Implementation Method 1
applying a plunger in the plunger assembly to achieve a predetermined pressure level within a boost circuit
Implementation Method 2
identifying a leak in a simulator valve via a signal from an ECU to a vehicle user interface if the pressure in the boost circuit deteriorates at or more than a pre-determined rate
Data Source
AI summary
A diagnostic method to identify a leak in a simulator valve for a vehicle brake system comprising the steps of: (1) energizing a secondary three-way valve, a pumping valve, a simulator test valve, and a plurality of apply valves in order to maintain a pressure medium from a plunger assembly within a boost circuit; (2) applying a plunger in the plunger assembly to a predetermined pressure level; (3) holding the plunger in position within the plunger assembly; and (4) identifying a leak in a simulator valve via a signal from an ECU to a vehicle user interface if the pressure in the boost circuit deteriorates at or more than a pre-determined rate.