Abstract: A parking brake for a wheel rotor having a brake pad associated therewith includes a housing defining first and second passages. First and second pistons are provided in the respective first and second passages. Spindles are threadably connected with each piston. A clutch unit is connected to the spindles. The clutch unit has a first condition allowing relative rotation between the spindles and the pistons such that the pistons are axially movable within the passages and into engagement with the brake pad in response to hydraulic pressure applied to the pistons. The clutch unit has a second condition preventing relative rotation between the spindles and the pistons such that pistons remains engaged with the brake pad when hydraulic fluid pressure is removed from the pistons.

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 brake system for actuating a pair of front wheel brakes and a pair of rear wheel brakes is selectively operable during a manual push-through mode. A primary power transmission unit actuates at least one of wheel brakes in a normal braking mode. A secondary power transmission unit actuates the front wheel brakes in a backup braking mode. A primary electronic control unit controls at least one of the primary power transmission unit and a pair of rear brake motors. A secondary electronic control unit controls at least one of the secondary power transmission unit and the rear brake motors. An ABS modulator arrangement is hydraulically interposed between at least one of first and second three-way valves and at least a selected wheel brake. A multiplex control valve arrangement is hydraulically interposed between the secondary power transmission unit and the front wheel brakes.

Abstract: A testing method includes the steps of: (1) providing a negative pressure generator; (2) generating a negative pressure in a fluid passageway and a chamber which are in fluid communication with a guiding section of a fluid reservoir wherein a second sensing element is affixed to a guiding section of the fluid reservoir; (3) transferring a fluid flow stream from the guiding section to the chamber via the fluid passageway and drawing a float having a first sensing element from an upper position to a lower position within the guiding section; (4) generating a signal via the first and second sensing elements as the float moves relative to the second sensing element within the guiding section; and (5) transmitting a signal to at least one of a control unit or a graphical user display.

Abstract: A control arrangement for a brake system having a plurality of electrically-controlled hydraulic valves includes a primary electronic control unit (“ECU”) including a primary microcontroller for selectively providing at least one of electrical power and a control signal in a normal non-failure braking mode. A secondary ECU is electrically connected to the primary ECU via a power connector and a controller area network (“CAN”) communication bus. The secondary ECU obtains electrical power from a wiring system of a vehicle associated with the brake system. A backup microcontroller is associated with a chosen one of the primary and secondary ECUs, receiving electrical power and a control signal from the secondary ECU. The backup microcontroller selectively provides at least one of electrical power and a control signal in a backup braking mode responsive to the control signal from the secondary ECU.

Abstract: A piston assembly for a disc brake assembly having a housing with a passage includes a piston provided in the passage and axially movable therein in response to hydraulic pressure. A rotatable spindle extends into the piston. A nut is threadably connected to the spindle such that rotation of the spindle results in axial movement of the nut within the passage to thereby axially move the piston. A damping member encircles the nut and has one of a sliding and rolling interface with the piston in response to relative axial movement between the nut and the piston to prevent rattling of the nut against the piston.

Abstract: A brake system includes a single chamber power transmission unit, a plurality of wheel brakes, and an iso/dump control valve arrangement associated with each wheel brake of the plurality of wheel brakes. A reservoir is hydraulically connected to the single chamber power transmission unit and to each of the iso/dump control valve arrangements. A pump piston is associated with at least one wheel brake. The pump piston is driven by a second electric motor for selectively providing pressurized hydraulic fluid from the reservoir to the iso/dump control valve arrangement of the at least one associated wheel brake. First and second switching valves are provided, and are two-position, three-way type valves, each hydraulically interposed between at least one iso/dump control valve arrangement and both of a selected pump piston and the output line of the single chamber power transmission unit. First and second electronic control units are provided.

Abstract: A brake system for selectively actuating at least one of a pair of front wheel brakes and a pair of rear wheel brakes includes a reservoir and a master cylinder. A power transmission unit is configured for selectively providing pressurized hydraulic fluid. A pair of rear brake motors selectively electrically actuate rear parking brakes. An electronic control unit controls at least one of the power transmission unit and the pair of rear brake motors. A normally-closed DAP valve is located hydraulically between the power transmission unit and at least one of a two-position three-way valve and at least the selected one of the pairs of wheel brakes. An isolation valve and a dump valve are associated with each wheel brake.

Abstract: A stability control system of a vehicle utilizing an electronic control unit that minimizes rollback of a vehicle as a result of wheel slip immediately following a hill start assist operation. The electronic braking control module controls actuation and de-actuation of vehicle brakes on an inclined surface. Immediately following a hill start assist operation on the inclined surface after each wheel brake is de-actuated for allowing forward movement of the vehicle up the hill, a split-mu road surface condition is detected in response to sensing wheel slip for each of the wheels. The electronic control unit determines a respective undriven, or non-dominant driven, wheel having the highest coefficient of friction among the undriven, or less dominant driven wheels, as determined by the wheel speeds.

Abstract: A brake system with a wheel brake has a fluid reservoir and a valve assembly in fluid communication with the reservoir via a first conduit. The valve assembly is in fluid communication with the wheel brake via a second conduit. The valve assembly includes a bypass valve which only permits fluid flow from the first conduit to the second conduit when the fluid pressure within the first conduit is above a predetermined pressure level above atmospheric pressure. The valve assembly further includes a check valve in a parallel path arrangement relative to the bypass valve such that the check valve permits fluid flow from the second conduit to the first conduit, and prevents fluid flow from the first conduit to the second conduit. The brake system further includes a first source of pressurized fluid providing fluid pressure for actuating the wheel brake, wherein the first source of pressurized fluid is selectively in fluid communication with the second conduit.

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 rotor assembly for a motor includes at least one magnet, a magnet support having an end region, a rotor shaft and an over-molded body affixed to the at least one magnet and the magnet support. The over-molded body includes a first end and a second end. The rotor shaft may be disposed proximate to the first end of the over-molded body and the second end of the over-molded body is proximate to the end region of the magnet support.

Abstract: A system for controlling an electric brake for a wheel rotor having a brake pad associated therewith includes a housing defining a passage. An assembly is provided in the passage and includes a spindle rotatable about an axis and a piston aligned with the brake pad and axially movable in response to rotation of the spindle. A planetary gear stage includes a sun gear, a ring gear, and planetary gears. A first motor is coupled to the sun gear. A second motor coupled to the ring gear. A control system is configured to, in response to a detected braking event, rotate the first motor in a first direction to supply torque to the sun gear while the second motor is rotated in a second direction at varying speeds to supply torque to the ring gear such that the piston is cyclically moved towards and away from the brake pad to modulate a braking force on the rotor.

Abstract: A user-manipulable signal generating apparatus includes a base plate and an elongate pedal lever having first and second lever ends separated by a lever body. The first lever end is hingedly connected to the base plate. The second lever end is spaced apart from the base plate for pivotal movement with respect thereto. The lever body is configured to move pivotally between a predetermined home position and a maximum pivot position. An elongate resilient biasing beam has first and second beam ends longitudinally separated by a beam body. The first beam end is connected to the base plate. The second beam end is connected to the lever body. A sensor detects pivotal motion of the lever body and generate a signal responsive thereto. The beam body is biased toward an unflexed condition and, when in the flexed condition, urges the lever body in a return direction toward the home position.

Abstract: A braking system for a vehicle including front and rear wheels having wheel brakes includes a fluid displacement mechanism for supplying brake fluid to at least one of the wheel brakes. The fluid displacement mechanism includes a piston having a first position prior to braking and a second position for applying braking. A fluid accumulator is in fluid communication with the fluid displacement mechanism and stores brake fluid. A valve is in fluid communication with the fluid displacement mechanism and the accumulator and is configured to be closed while the piston moves from the second position towards the first position to prevent depletion of the accumulator.

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: A brake pad for a vehicle disk brake assembly includes a backing plate configured to support a brake lining. A plurality of openings extend through the backing plate to define retaining members. A shim includes a base and tabs extending into the openings to secure the shim to the backing plate. Each tab includes a first portion extending away from the base and a curved second portion extending from the first portion back towards the base.

Abstract: A disc brake assembly includes an anchor bracket, a guide pin, a sliding mechanism, and a damping member. The anchor bracket may have at least one bore formed therein. The guide pin may be adapted to be disposed in the at least one bore and slidably support a brake caliper relative to the anchor bracket. The sliding mechanism may be adapted to be disposed in the at least one bore and to slidably support the guide pin in the at least one bore. The damping member may damp sliding motion of the guide pin relative to the anchor bracket.

Abstract: A brake pedal unit includes a housing defining a bore formed therein. An input piston is slidably disposed in the bore. The input piston is connected to a brake pedal such that engagement of the brake pedal causes movement of the input piston within the bore of the housing of the brake pedal unit. The brake pedal unit is defined to be in an at rest position when the brake pedal in not engaged causing movement of the input piston. A primary piston is slidably disposed in the bore for pressurizing a primary chamber. A primary passageway permits fluid communication between the primary chamber and the reservoir, wherein fluid flow through the primary passageway is blocked when the brake pedal unit is in the rest position. A secondary piston is slidably disposed in the bore for pressurizing a secondary chamber.

Abstract: A method of calibrating a solenoid actuated valve includes: providing a brake system including a fluid pressure source: providing a valve having a solenoid, and wherein the valve is in fluid communication with the fluid pressure source; operating the fluid pressure source to provide a constant flow of fluid to the valve; energizing the solenoid of the valve with a constant current such that fluid flows through the valve; measuring the pressure of the fluid flowing at the valve; adjusting the current sent to the solenoid until a predetermined pressure has been obtained; storing a nominal current value of the current required to obtain the predetermined pressure; and calibrating the valve by adding a correction offset factor to the nominal current value for future actuation of the solenoid of the valve.