The present disclosure relates to vehicle brake systems and more specifically, to a brake system control module that automatically manages an evacuation and fill sequence in a brake system.
During an assembly of a vehicle, when a brake system control module is installed in the vehicle the brake system control module must undergo an evacuation cycle to evacuate passageways in the control module and connecting lines to the brake system of the vehicle. After the evacuation cycle, the control module undergoes a pressurized fill cycle to fill the control module and associated lines with a fluid (e.g., brake fluid). During this evacuation and fill process, the external machinery that provides the evacuation means and the pressurized fluid source to the brake system control module must synchronize commands to the brake system control module to start and stop the evacuation and fill cycles. This requires power and communication control hookups into the vehicle wiring which adds time to the vehicle assembly process and may add cost to the vehicle wiring. In addition, some evacuation and fill equipment suppliers do not have the technology to reliably perform this function.
In described examples, a method of automatically evacuating and filling a brake system includes providing a brake system control module, the brake system control module including a reservoir tank, sensors, a processor, and a memory. The method further includes determining if a low fluid level is detected in the reservoir tank. A value of the sensors is monitored to determine if the value of the sensors is less than or greater than evacuation (evac) and fill start and stop threshold. An evacuation and a filling of the brake system is automatically managed based on the value of the sensors.
In another described example, a brake system control module for use in a brake system includes a reservoir tank having a brake fluid level sensor. The brake system control module is configured to automatically determine if the brake fluid level sensor detects a low fluid level in the reservoir tank and monitor a value of sensors to determine if the value of the sensors is less than or greater than evac and fill start and stop thresholds. The brake system control module further manages an evacuation and a filling of the brake system based on the value of the sensors.
In still another described example, a method of automatically evacuating and filling a brake system includes providing a brake system control module, the brake system control module including a reservoir tank sensors, a processor, and a memory. The method further includes determining if a low fluid level is detected in the reservoir tank and monitoring a value of the sensors to determine if the value of the sensors is less than an evac start threshold. The method still further includes automatically managing an evacuation of the brake system and monitoring a value of the sensors to determine if the value of the sensors is greater than a fill start threshold. Finally, the method monitors the value of the sensors to determine if the value of the sensors is less than a fill stop threshold and automatically manages filling the brake system with a fluid.
As mentioned above, during an assembly of a vehicle, when a brake system control module is installed in the vehicle as part of a brake system, the brake system control module must undergo an evacuation cycle to evacuate passageways in the control module and connecting lines to components of the brake system (e.g., wheel brakes including calipers, wheel cylinders) of the vehicle. After the evacuation cycle, the controller undergoes a pressurized fill cycle to fill the control module and the associated connecting lines with a fluid (e.g., brake fluid). During this evacuation and fill process, the external machinery that provides the evacuation means and the pressurized fluid source to the brake system control module must synchronize commands to the brake system control module to start and stop the evacuation and fill cycles. This requires power and communication control hookups into the vehicle wiring which adds time to the vehicle assembly process and may add cost to the vehicle wiring. In addition, some evacuation and fill equipment suppliers do not have the technology to reliably perform this function.
Disclosed herein is an innovative method where the brake system control module is programmed to automatically manage the evacuation and fill process by accessing information that is readily available during the evacuation and fill process thereby overcoming the aforementioned disadvantages. More specifically, the brake system control module is configured and programmed to process information from one or more pressure sensors and/or a brake fluid level sensor to first activate and deactivate the evacuation cycle, and second activate and deactivate the fill cycle. The brake system control module is further programmed to record and manage data during the evacuation and fill process so that in the event of a failure during either of the evacuation cycle or the fill cycle, information can be downloaded to a computer and/or a display to determine the cause of the failure. The only electrical connection required to the brake system control module during the evacuation and fill process is an electrical power connection. There is no requirement for a communication connection to process command signals between the brake system control module and the external evacuation and fill equipment as in the current processes.
As mentioned above, the brake system control module 120 illustrated in
As described in patent application Ser. No. 16/206,856, the brake system control module 120 includes a brake fluid reservoir tank 122 having a brake fluid level sensor (BFLS) 124 and a brake pedal unit 126 coupled to a master cylinder pressure sensor 128, a last fill valve 130, and the brake pedal 104. The brake system control module 120 further includes a pedal simulator 132 coupled to a simulation valve 134, and a plunger assembly 136 coupled to first and second plunger valves 138, 140. The last fill valve 130 may be actuated to a closed position during various testing modes to determine the correct operation of other components of the brake system 100. The simulation valve 134 is coupled to an input chamber formed by an input piston and a primary piston in the brake pedal unit 126 and diverts fluid from the input chamber to the pedal simulator 132. A boost pressure sensor 142 is coupled to the plunger assembly 136 via the first plunger valve 138.
The brake system control module 120 further includes solenoid actuated first and second isolation valves 144, 146, solenoid actuated apply valves 148, 150, 152, 154 solenoid actuated dump valves 156, 158, 160, 162. In this example, the first isolation valve 144 controls fluid flow to the front wheels, and the second isolation valve 146 controls fluid flow to the rear wheels. The apply valves 148, 150, 152, 154 allow pressurized brake fluid into respective wheel brakes to increase pressure during an apply mode, and the dump valves 156, 158, 160, 162 relieve brake fluid from wheel brakes during the dump mode. Wheel brake pressure is held constant during a hold mode by closing both the apply valves 148, 150, 152, 154 and the dump valves 156, 158, 160, 162.
During the vehicle assembly process, when the brake system control module 120 is in a state where the evacuation and fill process can be initiated the brake system control module 120 can automatically initiate the evacuation cycle and then automatically initiate the fill cycle once the evacuation cycle is complete. During this time, values of the pressure sensors 128, 142 are monitored to determine if the values are greater than or less certain evacuation (evac) and fill start and stop thresholds. Ranges for the evacuation and fill thresholds are configured to track the evacuation and fill cycles and confirm that the evacuation and fill cycles have started and have stopped. The evacuation and fill thresholds are to be set to a specific value within the defined ranges and are adjusted as needed for each specific brake system. The evacuation and fill thresholds are based on the effects of sensor noise, tolerance stack up, and sensor resolution. An example relationship between the evac and fill start and stop thresholds may be as follows: −1 bar<evac start threshold<=fill stop threshold<=evac stop threshold<=fill start threshold<=10 bar. In addition, automatic cycling may be enabled by the manufacturing or a “no start” calibration in the brake system control module and disabled when a vehicle operational calibration is installed. If this option is chosen, a means to allow the evacuation and fill process would be agreed with the vehicle OEM to allow cycling during an evacuation and fill process using the vehicle OEM's assembly plant repair equipment.
At 318, a decision is made to determine if the value of the pressure sensors 128, 142 are greater than a fill start threshold. The fill start threshold can be in a range from 2 bar to 10 bar. If the decision at 318 is YES, then at 320 the fill cycle is started, as will be explained below with reference to
At 324, a decision is made to determine if fault flags are not equal to zero. Some example faults may include hardware or electronic faults, such as a coil fault in the brake system control module 120 or an insufficient (low) voltage supplied to the brake system control module 120. If the decision at 324 is YES, then at 326 the progress status is updated to indicate that the evac cycle has faulted and at 336 the evac cycle is exited. If the decision at 324 is NO, then at 328 a decision is made to determine if the brake system control module 120 receives a cancel evac message from the plant equipment over a communications link. If the decision at 328 is YES, then at 330 the progress status is updated to indicate that the evac cycle is terminated and at 336 the evac cycle management process is exited. If the decision at 328 is NO, then at 332 a decision is made to determine if the value of the pressure sensors 128, 142 are greater than an evac stop threshold. The evac stop threshold can be in a range from 0 bar to 7 bar. If the decision at 332 is YES, then at 334 the progress status is updated to indicate that the evac cycle has finished and the evac cycle management process exits at 336. If the decision at 332 is NO, then the evac cycle management process exits at 336.
At 516, a decision is made to determine if the value of the fluid level sensor 124 is greater than a low fluid threshold. In alternative examples, more than one brake fluid level sensor may be located in the reservoir tank 122. Thus, the evac and fill cycles 500, 600 can change based on the levels of the multiple brake fluid level sensors. If the decision at 516 is YES, then at 518 the evac cycle is flagged as finished and the fill cycle is flagged as started as indicated at 520, as will be explained below with reference to
At 524, a decision is made to determine if fault flags are not equal to zero. Some example faults may include hardware or electronic faults, such as a coil fault in the brake system control module 120 or an insufficient (low) voltage supplied to the brake system control module 120. If the decision at 524 is YES, then at 526 the progress status is updated to indicate that the evac cycle has faulted and at 532 the evac cycle is exited. If the decision at 524 is NO, then at 528 a decision is made to determine if the brake system control module 120 receives a cancel evac message from the plant equipment over a communications link. If the decision at 528 is YES, then at 530 the progress status is updated to indicate that the evac cycle is terminated and at 532 the evac cycle management process is exited. If the decision at 528 is NO, then the evac cycle management process exits at 532.
Described above are examples of the subject disclosure. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the subject disclosure, but one of ordinary skill in the art may recognize that many further combinations and permutations of the subject disclosure are possible. Accordingly, the subject disclosure is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. In addition, where the disclosure or claims recite “a,” “an,” “a first,” or “another” element, or the equivalent thereof, it should be interpreted to include one or more than one such element, neither requiring nor excluding two or more such elements. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. Finally, the term “based on” is interpreted to mean based at least in part.