Abstract: 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.

Abstract: 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.

Abstract: An electric brake for a wheel rotor having a brake pad includes a housing with a passage. A piston assembly in the passage includes a spindle and a piston. The spindle is rotatable to cause the piston to move axially relative to the brake pad. A drive assembly includes a motor. A gear train is connected to the motor and the spindle. A coupling mechanism is coupled to the gear train and has a first condition enabling torque transmission from the motor to the spindle to axially move the piston to apply braking force to the brake pad. The coupling mechanism has a second condition disabling torque transmission from the motor to the spindle is prevented which permits the piston to retract and reduce the braking force on the brake pad without stopping or reversing the motor.

Abstract: 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.

Abstract: A brake clip for a disc brake assembly having a brake pad received in an anchor bracket includes a shim configured to be received in the anchor bracket. The shim includes a base leg and opposing upper and lower legs extending from the base leg to define a receiving space. At least one of the upper and lower legs includes a retaining member extending in a first direction. A spring is provided in the receiving space for receiving the brake pad. The spring includes a base and a pair of projections extending from the base. At least one of the projections includes a retaining member that cooperates with the at least one retaining member on the shim to allow for a predetermined amount of relative movement between the shim and the spring in the first direction.

Abstract: An anti-rotation sleeve for an electric brake system having a shaft received in and movable relative to a passage of a housing includes a body extending along a centerline from a first end to a second end. An inner surface defines a passage for receiving the shaft and pockets extending radially from the passage configured to provide sliding interfaces with tabs on the shaft. Projections provided on an outer surface of the body and extending parallel to the centerline cooperate with the housing to prevent rotation of the sleeve relative to the housing. Each projection is aligned with a normal direction of one of the interfaces.

Abstract: 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.

Abstract: An actuator assembly for a vehicle brake is described. It comprises a carrier assembly (22) on which an activating carriage (88) for a brake lining is guided linearly. Moreover, an electric motor fastened to the carrier assembly (22) is provided which is coupled drivingly to the activating carriage via a gear unit and a spindle drive such that the activating carriage can be displaced selectively between a retracted position and an extended position. In addition, the actuator assembly comprises a locking assembly (106) for selectively immobilizing in rotation an output shaft (38) of the electric motor. The locking assembly (106) here comprises a locking lever (114) which at a first end (116) is mounted rotatably on the carrier assembly (22) and at a second opposite end (118) is coupled to a locking actuator (112). A locking tooth (124) is moreover positioned between the first end (116) and the second end (118). A method for activating an actuator assembly for a vehicle brake is furthermore presented.

Abstract: 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.

Abstract: 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.

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 extend into and are connected with each piston. A clutch unit is connected to the spindles and includes a motor. The clutch unit has a first condition allowing for rotation of the spindles in response to hydraulic pressure applied to the pistons such that the pistons are axially movable within the passages and relative to the spindles into engagement with the brake pad. The clutch unit has a second condition for rotating the spindles to drive the pistons into the brake pad and apply the parking brake.

Abstract: 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.

Abstract: 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. The master cylinder is selectively operable to generate brake actuating pressure at an output for hydraulically actuating a pair of hydraulically actuated wheel brakes in a manual push-through operation. A power transmission unit is configured to selectively generate pressurized hydraulic fluid for actuating the pair of hydraulically actuated wheel brakes. First and second two-position three-way valves are hydraulically connected to respective ones of the pair of hydraulically operated brakes and to both the master cylinder and the power transmission unit. The first and second three-way valves each are configured to selectively switch the respective hydraulically operated brake to receive fluid from a selected one of the master cylinder, in a backup braking mode, and the power transmission unit, in a normal non-failure braking mode.

Abstract: 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.

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 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 coiled filter for use in a hydraulic braking system of a vehicle comprises a coiled mesh-like structure which is configured to be installed around a first surface of a cylindrical hydraulic component. The coiled filter is configured to have an internal spring force as a retention force which couples the filter to the first surface of the cylindrical hydraulic component. The filter may be pre-coiled prior to installation by plastically deforming to a diameter that is smaller than the diameter of the cylindrical hydraulic component on which the filter is installed.

Abstract: A ball nut assembly comprises a spindle having a longitudinal axis, a ball nut, and bearing elements supporting the ball nut on the spindle. First, second, third, and fourth ball nut deflectors are between the ball nut and the spindle. First, second, and third planes extend parallel to the axis. The first and fourth ball nut deflectors are in the first plane, the second ball nut deflector is in the second plane, the third ball nut deflector is in the third plane. Furthermore, the second and third ball nut deflectors are on opposite sides of the first plane. A first acute angle is between the first and second planes and a second acute angle is between the first and third planes.

Abstract: A brake system for actuating a pair of front wheel brakes and a pair of rear wheel brakes includes a reservoir and a deceleration signal transmitter. First and second power transmission units are configured for selectively providing pressurized hydraulic fluid during a braking event. The first power transmission unit actuates a selected one of the front wheel brakes and a selected one of the rear wheel brakes. The second power transmission unit actuates the other one of the front wheel brakes and the other one of the rear wheel brakes. First and second electronic control units control the first and second power transmission units. A pair of rear brake motors selectively electrically actuate rear wheel brakes. Multiplex control of each of the pairs of front and rear wheel brakes is provided by an arrangement of first and second parallel valves for each wheel brake.

Abstract: A fastener assembly is provided for helping to secure a mounting bracket to a housing of a vehicle caliper assembly having a piston axially movable for applying braking force to a brake pad. The fastener assembly includes a guide device including guide pin secured to the housing and having a head and a shaft extending into a bore in the mounting bracket. A sleeve includes a first portion configured to extend into the bore and a second portion provided inside the first portion and encircling and engaging the shaft for damping relative movement between the guide pin and the bore in response to vehicle vibrations. A flexible seal encircles the shaft and is connected to the guide pin and the sleeve such that axial movement of the guide pin relative to the bore changes the length of the seal.