Abstract: A simulator valve includes a housing having a pedal simulator passage and a master cylinder passage extending therethrough. The master cylinder passage is located longitudinally between the first housing surface and the pedal simulator passage. An armature is located at least partially within the housing for selective longitudinally reciprocating motion with respect thereto between first and second armature positions. A poppet is located within the housing for selective longitudinally reciprocating motion with respect thereto between first and second poppet positions. The poppet defines a first valve and a second valve the poppet includes a poppet bore extending longitudinally therethrough and selectively occluded by the first valve. A damped flow fluid path selectively permits fluid communication therethrough from the master cylinder passage to the pedal simulator passage.

Abstract: A diagnostic method to identify a leak in a three-way valve for a vehicle brake system having a remote master cylinder which includes the steps of: (1) providing a pedal simulator having pressure medium; (2) de-energizing a secondary three-way valve; (3) retracting a dual acting plunger to the home position to drop the pressure in the boost circuit to zero while also monitoring the pressure at the output of a fluid separator via a secondary master cylinder pressure sensor; (4) determining a rate of pressure reduction at the output of a fluid separator via a secondary master cylinder pressure sensor; and (5) identifying a leak in at least one of a primary three-way valve and the secondary three way valve if the rate of pressure reduction is equal to or higher than a pre-determined rate.

Abstract: A method of conducting a diagnostic test to determine leakage within a brake system includes first providing a brake system having a plunger assembly including a housing defining a bore therein. The plunger assembly includes a piston slidably disposed therein such that movement of the piston pressurizes a pressure chamber when the piston is moved in a first direction. The pressure chamber of the plunger assembly is in fluid communication with an output, and wherein the plunger assembly further includes an electrically operated linear actuator for moving the piston within the bore. The linear actuator of the plunger assembly is actuated to provide pressure at the output of the plunger assembly at a first predetermined level. The pressure at the output of the plunger assembly is held for a predetermined length of time. The method further includes determining whether conditional criteria has been met indicating a leakage within the brake system.

Abstract: A hydraulic vehicle brake includes a housing and first and second brake pistons at least partially located within the housing. The brake pistons are configured to cooperatively press a common friction pad against a rotor of the vehicle brake. Each of the pistons is a hollow piston including a substantially solid piston bottom. A clamp beam laterally spans the piston bottoms of the first and second pistons within the housing. The clamp beam is configured to selectively apply longitudinally directed clamping force upon the pistons. A spindle is selectively driven for rotational motion by an electric motor. The spindle is interposed laterally between the first and second brake pistons within the housing. The spindle is configured to reciprocate the clamp beam longitudinally within the housing responsive to a direction of the rotational motion.

Abstract: A brake system for selectively actuating at least one of a pair of front wheel brakes and a pair of rear wheel brakes of a vehicle, one of which is hydraulically actuated and the other of which is electrically actuated, includes a reservoir. First and second integrated control units are in fluid communication with the reservoir and respective ones of the hydraulically actuated wheel brakes. The first and second integrated control units have first and second power transmission units connected to first and second electronic control unit, respectively. Each electronic control unit is configured to control a corresponding power transmission unit and a selected one of the electrically actuated wheel brakes on a contralateral side of the vehicle from the selected one of the hydraulically actuated wheel brakes which is actuated by the power transmission unit.

Abstract: A brake system for selectively actuating at least one wheel brake includes a reservoir and a power transmission unit for selectively providing pressurized hydraulic fluid for actuating at least a selected one of the wheel brakes during a braking event. A first electronic control unit at least partially controls at least one of the power transmission unit and a selected one of the pair of rear brake motors. A second electronic control unit at least partially controls at least one of the power transmission unit and an other one of the pair of rear brake motors. The first electronic control unit controls at least one SAP valve, an isolation valve, and a dump valve for a selected two of the wheel brakes, and the second electronic control unit controls at least one SAP valve, an isolation valve, and a dump valve for an other two of the wheel brakes.

Abstract: A method of determining a homing position of a piston within a plunger assembly for a vehicle brake system at the beginning of an ignition cycle of the vehicle includes first providing a plunger assembly having a housing defining a bore therein. The plunger assembly includes a piston slidably disposed in the bore for pressurizing fluid within a pressure chamber when the piston is moved in a first direction. The plunger assembly further includes an electrically operated linear actuator for moving the piston within the bore. The method further includes providing electrical power to the linear actuator of the plunger assembly. The linear actuator is actuated to retract the piston in a second direction opposite the first direction towards an end stop. The piston engaging with the end stop is then detected.

Abstract: A method of conducting a diagnostic test to determine leakage within a brake system includes first providing a brake system having a plunger assembly including a housing defining a bore therein. The plunger assembly includes a piston slidably disposed therein such that movement of the piston pressurizes a pressure chamber when the piston is moved in a first direction. The pressure chamber of the plunger assembly is in fluid communication with an output, and wherein the plunger assembly further includes an electrically operated linear actuator for moving the piston within the bore. The linear actuator of the plunger assembly is actuated to provide pressure at the output of the plunger assembly at a first predetermined level. The pressure at the output of the plunger assembly is held for a predetermined length of time. The method further includes determining whether conditional criteria has been met indicating a leakage within the brake system.

Abstract: A rotor for a motor includes a sensor ring, a rotor shaft and an over-molded body configured to couple the sensor ring to the rotor shaft. The rotor may further include at least one magnet and a magnet support where the magnet support is disposed between the at least one magnet and the rotor shaft. The over-molded body couples the sensor ring, the rotor shaft, the magnet support and the at least one magnet to each other.

Abstract: An electromechanical brake apparatus includes a housing supporting an inboard brake pad and an oppositely facing outboard brake pad for selective frictional contact with a rotor interposed longitudinally therebetween. An adjuster ramp assembly indirectly receives torque from the motor unit. A spindle is provided for selectively moving the inboard brake pad longitudinally. The spindle is operatively connected with the adjuster ramp assembly to indirectly receive torque from the motor unit therethrough. A leading ramp assembly is configured to transmit applied torque from the motor unit to the adjuster ramp assembly via at least one ramp ball longitudinally interposed therebetween. A predetermined amount and direction of torque is applied to each of the adjuster ramp assembly and the leading ramp assembly to assist with a selected one of (1) service brake application and (2) service brake release functions. The electromechanical brake apparatus is operative, at different times, for both functions.

Abstract: An electromechanical brake apparatus includes a housing supporting an inboard brake pad and an oppositely facing outboard brake pad for selective frictional contact with a rotor interposed longitudinally therebetween. The housing includes a mechanism cavity located longitudinally between the inboard pad and a motor having a motor output shaft. An adjuster ramp assembly indirectly receives torque from the motor. A spindle is operatively connected with the adjuster ramp assembly to indirectly receive torque from the motor therethrough. A leading ramp assembly is configured to transmit applied torque from the motor to the adjuster ramp assembly. The leading ramp assembly receives stepped-up torque from the motor via the motor output shaft and a ball thrust bearing at least partially located radially between the motor output shaft and an actuator ramp of the leading ramp assembly.

Abstract: A diagnostic method to identify a leak in simulator valve in a vehicle brake system includes the steps of: (1) providing a simulator partially filled with a pressure medium and a de-energized simulator valve; (2) energizing a pumping valve, a secondary three-way valve, and a plurality of apply valves; (3) applying and retracting a plunger in a plunger assembly at least two cycles so that a predetermined pressure is achieved; (3) holding a plunger in position within the plunger assembly while maintaining a replenishing check valve in a closed/de-energized position and energizing the simulator valve; (4) obtaining a measured master cylinder secondary pressure decay; (5) comparing the measured master cylinder secondary pressure decay to a predetermined pressure decay value; and (7) identifying a leak in the simulator valve if the measured master cylinder secondary pressure decay does not match the predetermined master cylinder secondary pressure decay.

Abstract: A method of detecting brake fade for a vehicle brake system having wheel brakes susceptible to brake fade, includes the steps of: (a) providing a brake system including wheel brakes; and (b) determining the presence of brake fade within the vehicle system utilizing adaptive references maps, and wherein the adaptive reference maps include storing vehicle deceleration data and brake system fluid volume at different pressure points in a histogram.

Abstract: A pedal simulator connected to a master cylinder to provide brake pedal response to a driver. The pedal simulator includes first and second reaction force members with an adjustable gap to change brake pedal feeling. A component of the pedal simulator includes a deformable portion that is used to adjust the gap to achieve a desired brake pedal response.

Abstract: 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.

Abstract: An electrically actuated parking brake has a single electric motor producing a torque, a first torque limiting device with a first spring force, and a second torque limiting device with a second spring force. The first torque limiting device fully transmits a first portion of the torque to a first spindle until a first clamp force overcomes the first spring force and the second torque limiting device fully transmits a second portion of the torque to a second spindle until a second clamp force overcomes the second spring force. When the first clamp force overcomes the first spring force and the second spring force overcomes the second clamp force, the first portion of the torque that exceeds the first spring force is transmitted to the second spindle by the second torque limiting device.

Abstract: A roller screw system includes a spindle defining a longitudinal axis about which the spindle rotates. A nut at least partially radially surrounds the spindle. The nut is configured for longitudinal motion with respect to the spindle. At least one non-helically grooved roller is interposed radially between the spindle and the nut. A cage maintains the at least one roller in position radially between the spindle and the nut and supports the at least one roller for rotational motion. The nut is moved in longitudinally in a duty cycle responsive to transmission of rotational motion from the spindle to the at least one roller, and transformation of rotational motion of the at least one roller to longitudinal motion of the nut. A home position of the nut and a home position of the cage both move longitudinally after a predetermined number of duty cycles.

Abstract: A disc brake assembly includes a brake shoe, an anti-rotation member extending outward from the brake shoe, a displaceable brake piston that supports the brake shoe, an end face of the brake piston, and a recessed area in the end face. The brake shoe is displaceable along an axis. The end face is perpendicular to the axis and faces the brake shoe. The anti-rotation member has a stop surface and a diversion surface. The recessed area engages the stop surface to stop rotation of the brake piston in a first direction and the recessed area engages the diversion surface to allow rotation of the brake piston in a second direction. The first and second directions are opposite.

Abstract: An electric parking brake for a vehicle brake system includes a caliper, a piston, a spindle, an adjuster nut, a ring-like member affixed to the piston, and a biasing member. The piston may be disposed within a cavity of the caliper. The spindle is configured to drive the axial movement of the adjuster nut between a retracted position and an extended position via a threaded engagement wherein the adjuster nut is disposed within the piston. The biasing member may be disposed between the ring-like member and the adjuster nut so that, as the adjuster nut moves from an extended position to a retracted position which corresponds to a control signal, the biasing member urges the piston away from the rotor.

Abstract: A brake piston for a disc brake assembly has a body portion and an end face of the body portion. An annularly extending first portion of the end face has a first radius and an annularly extending second portion of the end face has a second radius that is less than the first radius. A plurality of first ribs extend radially inward from the first portion to the second portion and a plurality of second ribs extends radially outward from the second portion to the first portion. The first and second ribs are interspaced. The second portion and the second ribs are recessed into the end face relative to the first portion and the first ribs.