Zf Active Safety US Inc.

Kelsey-hayes Company

Zf Active Safety Gmbh

Other

Kelsey-hayes Corporation

Blaise J Ganzel

Joseph A Starr

Ronald L Sorensen

Gregory P Campau

Frank Einig

Thomas Weigert

Mark S Luckevich

Salvatore Oliveri

Andrew W Kingston

Patrick Hartman

Robert L Ferger

William P Caldwell

Joseph F Zeoli

Richard J Barron

Suat Ali Ozsoylu

Andreas Marx

Gerald M Sivulka

Mark Haller

Nicholas Alford

Patrick H Hool

Martin Hofmann

Thomas Wald

Deron Craig Littlejohn

Daniel Noll

Jeffrey E Shaya

Paul Warkentin

Dion Parker

Klaus Lemke

David Lopez-Larequi

David M Dokas

Axel Rüdell

Mikel Esandi Murguialday

John Cassidy

Richard A Swarich

Daniel Ryan Malwitz

Robert I Girkin

Andreas Bōrsch

Karl-Josef Adams

Iosu Oloriz Del Rosario

Michael Geider

Humphry Ormesher

Keith Johnson

Tim Ferguson

Ralph Branham

An electromechanical brake pressure generator unit () of a brake-by-wire brake system can only be activated electronically and comprises a master brake cylinder (), an electric motor () and a multi-stage intermediate transmission (). A spindle-nut unit () comprises a nut () having a centring surface () by way of which the piston () of the master brake cylinder () is centred.

Electromechanical brake pressure generator unit

A power transmission unit of a single-acting plunger type includes a ball screw, a ball nut driven by the ball screw, and a plunger piston coupled to the ball nut. A block housing at least partially encloses the plunger piston and the ball screw. A plunger chamber is at least partially defined by the block housing and a face of the plunger piston. The plunger chamber is selectively pressurized by reciprocal motion of the plunger piston with respect to the block housing driven by longitudinal motion of the ball nut. An electric motor selectively drives the ball screw to responsively reciprocate the plunger piston within the plunger chamber. A motor housing at least partially encloses the ball nut, the electric motor, and the plunger piston. The motor housing includes a block lip which is crimped to the block housing to maintain the motor housing in relation to the block housing.

Power transmission unit and brake systems using same

A brake system includes a reservoir and a master cylinder operable to provide a brake signal responsive to actuation of a brake pedal connected thereto. A power transmission unit is configured for selectively providing pressurized hydraulic fluid for actuating at least one of the pair of front wheel brakes and the pair of rear wheel brakes in a normal non-failure braking mode. A iso/dump valve arrangement is hydraulically interposed between the power transmission unit and a corresponding one of the wheel brakes. A fluid separator is hydraulically interposed between a selected one of the pair of front wheel brakes and a corresponding iso/dump valve arrangement. A normally open base brake iso valve is energized closed during normal non-failure braking mode. The base brake iso valve is open to place the master cylinder into fluid communication with at least one of the fluid separators during manual push-through braking mode.

Brake system with normal non-failure and manual front push-through modes

A brake system includes a reservoir and a motor-driven master cylinder operable during a backup braking mode by actuation of an electric motor of the master cylinder to generate brake actuating pressure for hydraulically actuating the pair of front wheel brakes and the pair of rear wheel brakes. A power transmission unit is configured for selectively providing pressurized hydraulic fluid to a PTU output for actuating the pair of front wheel brakes and the pair of rear wheel brakes in a normal non-failure braking mode. First and second two-position three-way valves are each hydraulically connected with the master cylinder, the power transmission unit, and a selected pair of the front and rear wheel brakes. Each of the first and second three-way valves selectively controls hydraulic fluid flow from a chosen one of the master cylinder and the power transmission unit to the selected pair of front and rear wheel brakes.

Brake system with fault-tolerant features

A brake system includes a reservoir and a master cylinder operable to provide a brake signal responsive to actuation of a brake pedal connected thereto. A power transmission unit is configured for selectively providing pressurized hydraulic fluid for actuating at least one of the pair of front wheel brakes and the pair of rear wheel brakes in a normal non-failure braking mode. A plurality of iso/dump valve arrangements are each hydraulically interposed between the power transmission unit and a corresponding one of the wheel brakes. A plurality of two-position three-way valves are each hydraulically connected with the master cylinder, the power transmission unit, and at least a selected wheel brake of the pair of front wheel brakes. The three-way valves selectively control hydraulic fluid flow from a chosen one of the master cylinder and the power transmission unit to the corresponding one of the front wheel brakes.

Brake system with front brake source selection

A brake system for hydraulically actuating a pair of front wheel brakes and a pair of rear wheel brakes includes a master cylinder fluidly connected to a reservoir and operable to provide a brake signal responsive to actuation of a brake pedal connected thereto. The master cylinder is selectively operable during a manual push-through mode by actuation of the brake pedal to generate brake actuating pressure at an output for hydraulically actuating a selected one of the pair of front and rear wheel brakes. A first power transmission unit is configured for actuating the selected one of the pair of front and rear wheel brakes. A second power transmission unit is configured for actuating the other one of the pair of front and rear wheel brakes. A first electronic control unit is provided for controlling at least one of the first and second power transmission units.

Apparatus and method for control of a hydraulic brake system

A brake system includes a tandem power transmission unit selectively driven by a first electric motor to provide pressurized hydraulic fluid to primary and secondary output lines. A plurality of iso/dump control valve arrangements is provided, with each being associated with a selected wheel brake and selectively provides slip control to the selected wheel brake. A first traction control iso valve is hydraulically interposed between the tandem power transmission unit and at least a selected iso/dump control valve arrangement via the primary output line. A second traction control iso valve is hydraulically interposed between the tandem power transmission unit and at least an other iso/dump control valve arrangement via the secondary output line. A DAP power transmission unit is driven by a second electric motor for selectively providing pressurized hydraulic fluid to the iso/dump control valve arrangement of at least one associated wheel brake.

Fault-tolerant brake system

A brake system for actuating at least one wheel brake includes a reservoir and a master cylinder operable to provide a brake signal responsive to actuation of a brake pedal connected thereto. The master cylinder is selectively operable during a manual push-through mode to generate brake actuating pressure to at least one output for hydraulically actuating at least one wheel brake. A power transmission unit is configured for actuating at least one of the wheel brakes in a non-failure normal braking mode. A secondary braking module is configured for selectively providing hydraulic fluid to each of the wheel brakes in an enhanced braking mode. The secondary braking module includes a pump motor driving at least one pump unit. Each pump unit is operatively connected to a fluid accumulator associated with the correlated wheel brake for selectively varying an amount of hydraulic fluid provided to the wheel brake.

Brake system with fluid storage secondary brake module

A brake system includes a source of pressurized hydraulic fluid, a plurality of wheel brakes, and an iso/dump control valve arrangement associated with at least one wheel brake. A reservoir is connected to the source of pressurized fluid and to the iso/dump control valve arrangement. A fast-replenishing circuit includes a FR iso valve, a venting valve, and a replenishing check valve. The venting and replenishing check valves are interposed between the source of pressurized fluid and the reservoir. The FR iso valve is interposed between the source of pressurized fluid and the iso/dump control valve arrangement. When the source of pressurized fluid reaches a predetermined stroke position, the FR iso valve is energized to restrict movement of fluid from at least one iso/dump control valve arrangement to the source of pressurized fluid. The source of pressurized fluid is re-stroked to draw fluid from the reservoir through the replenishing check valve.

Fast replenishing brake system

A fluid separator includes a separator housing defining a longitudinal bore having first and second bore ends. A first fluid passage is in fluid communication with the bore at the first bore end. A second fluid passage is in fluid communication with the bore adjacent the second bore end. A third fluid passage is in fluid communication with a portion of the bore spaced apart from both the first and second bore ends. A free-floating piston is located inside the bore and configured for longitudinal movement with respect to the bore responsive to fluid pressure within the bore. A biasing spring urges the piston toward the second bore end. An end cap is located at the second bore end. The end cap is maintained on the housing via at least two retainers.

Fluid separator and brake systems using same

A brake system for hydraulically actuating a pair of front wheel brakes and a pair of rear wheel brakes includes master cylinder fluidly connected to a reservoir and operable to provide a brake signal responsive to actuation of a brake pedal connected thereto. The master cylinder is selectively operable in a manual push-through mode. First and second power transmission units are in fluid communication with the reservoir and selected front and rear wheel brakes. An electronic control unit selectively controls at least one of the first and second power transmission units. First and second two-position three-way valves are each hydraulically connected with a respective power transmission unit, the master cylinder, and a respective front wheel brake. The first and second two-position three-way valves are configured to place the master cylinder in push-through fluid-supplying connection with at least a corresponding one of the pair of front wheel brakes.

Apparatus and method for a hydraulic brake system including manual push-through

An unloading valve is disclosed. A housing defines a primary and secondary pump inlets, and collective and bypass pump outlets. The housing defines a bypass seat. A tappet has first and second tappet ends longitudinally spaced by a tappet body. The tappet is configured for selective longitudinal reciprocal motion between first and second tappet positions. A tappet shoulder is located on an external surface of the tappet body for selective sealing engagement with the bypass seat to allow fluid flow in a bypass direction and resist fluid flow in a collection direction longitudinally opposite the bypass direction. The primary and secondary pump inlets are in fluid communication with the collective pump outlet for flow in the collection direction when the fluid pressure at the primary and secondary pump inlets combined is below a predetermined bypass pressure and the tappet is located in the first tappet position.

Unloading valve and brake system using same

A hydraulic brake wear detection apparatus and a method for detecting a degree of pad wear of a brake pad of a hydraulic brake includes a caliper piston located at least partially within a caliper cavity and attached to the brake pad. The caliper piston includes a piston cavity extending from a caliper piston rim into a caliper piston body at a location longitudinally opposite, and spaced from, the brake pad. An internal piston is located at least partially within the piston cavity and is entirely enclosed in an internal space defined cooperatively by the piston cavity and the caliper cavity for reciprocal longitudinal motion with respect to the internal space. The internal piston is reciprocated by a predetermined volume of pressurized hydraulic fluid responsive to wear of the brake pad.

Hydraulic brake wear detection apparatus and method

A brake system for actuating front and rear wheel brakes includes a reservoir and a master cylinder operable by actuation of a brake pedal connected to the master cylinder to generate brake actuating pressure at a first output for hydraulically actuating the front wheel brakes. A power transmission unit is configured for selectively providing pressurized hydraulic fluid for actuating the front wheel brakes. A pair of rear brake motors selectively electrically actuate respective rear wheel brakes. An electronic control unit controls at least one of the power transmission unit and the rear brake motors. A two-position three-way valve is hydraulically connected with the master cylinder and the power transmission unit and with the front wheel brakes. The three-way valve selectively controls hydraulic fluid flow from a chosen one of the master cylinder and the power transmission unit to at least one of the front wheel brakes.

Hydraulic brake boost

A brake system for hydraulically actuating a pair of front wheel brakes and a pair of rear wheel brakes includes a reservoir and a master cylinder fluidly connected to the reservoir and operable to provide a brake signal. A first power transmission unit is in fluid communication with the reservoir, a selected one of the rear wheel brakes, and a first fluid separator corresponding to a selected one of the front wheel brakes. A first electronic control unit is configured to control the first power transmission unit. A second power transmission unit is in fluid communication with the reservoir, the other one of the front wheel brakes, and a second fluid separator corresponding to an other one of the front wheel brakes. A second electronic control unit is configured to control the second power transmission unit.

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Ann Arbor, MI, United States of America

Blaise J Ganzel