Abstract: An air management system and method are provided. The system includes a pressurized air source. A manifold block is coupled to the pressurized air source and includes a plurality of suspension valves in fluid communication with the pressurized air source for controlling air flow to and from a plurality of air springs. An accumulator is coupled to the manifold block for storing air. An accumulator valve is in fluid communication with the plurality of suspension valves and the accumulator to allow exhausted air from the plurality of air springs into the accumulator. An electronic control unit is electrically coupled to the plurality of suspension valves and the accumulator valve for controlling a sequence of operating the accumulator valve and the plurality of suspension valves to provide enhanced exhaust flow from the plurality of air springs to maintain the vehicle in a level orientation while lowering the vehicle.

Abstract: An air management system and method are provided. The system includes a compressor and a reservoir tank coupled to the compressor. A manifold block has a plurality of valves and is coupled to the reservoir tank and the compressor for controlling air flow. At least one pressure sensor is coupled to the manifold block. The compressor includes a boost valve for selectively directly connecting the reservoir tank and an air inlet of the compressor. An electronic control unit is coupled to the valves, compressor, and the at least one pressure sensor and is configured to provide pressurized air from the reservoir tank to the air inlet, determine a pressure difference between the manifold block and the boost valve, and retain pressure in the manifold block in response to the pressure difference being less than a predetermined amount to reduce startup torque of the compressor without exhausting the manifold block.

Abstract: An air management system and method are provided. The system includes a pressurized air source. A manifold block is coupled to the pressurized air source and includes a plurality of suspension valves in fluid communication with the pressurized air source for controlling air flow to and from a plurality of air springs. An accumulator is coupled to the manifold block for storing air. An accumulator valve is in fluid communication with the plurality of suspension valves and the accumulator to allow exhausted air from the plurality of air springs into the accumulator. An electronic control unit is electrically coupled to the plurality of suspension valves and the accumulator valve for controlling a sequence of operating the accumulator valve and the plurality of suspension valves to provide enhanced exhaust flow from the plurality of air springs to maintain the vehicle in a level orientation while lowering the vehicle.

Abstract: An air management system and method are provided. The system includes a compressor and a reservoir tank coupled to the compressor. A manifold block has a plurality of valves and is coupled to the reservoir tank and the compressor for controlling air flow. At least one pressure sensor is coupled to the manifold block. The compressor includes a boost valve for selectively directly connecting the reservoir tank and an air inlet of the compressor. An electronic control unit is coupled to the valves, compressor, and the at least one pressure sensor and is configured to provide pressurized air from the reservoir tank to the air inlet, determine a pressure difference between the manifold block and the boost valve, and retain pressure in the manifold block in response to the pressure difference being less than a predetermined amount to reduce startup torque of the compressor without exhausting the manifold block.

Abstract: A brake by wire system is integrated with a brake transmission solenoid interlock (BTSI) unit to prevent a vehicle transmission from being shifted out of a park mode into a drive mode until a brake system operational state is determined. The BTSI is activated by a supplemental control unit, which generates a transmission release signal generated by a controller in response to simultaneous presence of a brake intent signal from one or more brake pedal sensors and a determination of an operational state of the brake system. The supplemental control unit includes a switch responsive to the transmission release signal to close the BTSI activating circuit and permit release of the transmission. In a split brake system with two brake controllers, the supplemental control unit may include a switch controlled by a logic (OR, AND) circuit or a pair of switches in an equivalent logical circuit configuration.

Abstract: A disc brake caliper assembly has a housing with a bore. A piston in the bore is movable between applied, retracted and knock-back positions. The piston is activatable by hydraulic pressure to move from the retracted position to the applied position; and a retracting seal is effective in the absence of the hydraulic pressure to move the piston from the applied position to the retracted position. A linkage adjacent the piston carries a stop; and an actuator is responsive to an end of brake activation signal to cause the linkage to engage the stop with the piston when the piston is retracted from its applied position to its retracted position so as to prevent the piston from moving from the retracted position to the knock-back position. The actuator is preferably a comparatively weak electric motor that stalls as the stop engages the piston; and the stall is sensed to end motor activation. The end of brake activation signal is preferably provided by a brake position or pressure sensor.

Abstract: An electrical system architecture for a vehicle brake by wire system provides three electrical power sources: an electric generator, an electric power storage device such as a battery, and a third source which may be either an electric generator or storage device. An electric circuit has a common node and (1) connects the first electric generator to the common node through a first diode, (2) connects the first electric power storage device to the common node through a second diode, (3) connects the electric power source to the common node through one of the first and second diodes, and (4) connects the common node to the electric power inputs of control unit through circuit breaker devices. A sub-circuit within the electric circuit interconnects the first and second diodes, the common node and the first and second circuit breaker devices and isolates them within a zone protected from short circuits to points outside the zone.

Abstract: A brake by wire system is integrated with a brake transmission solenoid interlock (BTSI) unit to prevent a vehicle transmission from being shifted out of a park mode into a drive mode until a brake system operational state is determined. The BTSI is activated by a supplemental brake control unit, which receives a transmission release signal from a brake system controller upon receipt of a brake intent signal from one or more brake pedal sensors after a diagnostic program has determined the brake system operational state. The supplemental brake control unit includes a switch responsive to the transmission release signal to close the BTSI activating circuit and permit release of the transmission. In a split brake system with two brake controllers, the supplemental brake control unit may include a switch controlled by a logic (OR, AND) circuit or a pair of switches in an equivalent logical circuit configuration.

Abstract: A brake system and method of controlling the system are disclosed. The system provides secondary hydraulic braking in a de-energized mode. The system includes a wheel brake associated with wheels of a vehicle typically at each corner of the vehicle. The wheel brake typically includes a caliper or drum for deceleration of the vehicle. The system includes a master cylinder in fluid communication with the wheel brake. In the de-energized mode, the master cylinder operates the wheel brake. A solenoid isolation valve decouples the master cylinder from the wheel brake when the system is in a normal, i.e., an energized, mode. As such, the master cylinder is isolated from the wheel brake and is prevented from operating the wheel brake. Alternatively, in the de-energized mode, the isolation valve couples the master cylinder with the wheel brake to provide the secondary hydraulic braking.

Abstract: A disc brake caliper assembly is provided that includes a housing having a bore. A piston is arranged within the bore and is movable between normal retracted and knock-back positions. A linkage is adjacent to the piston and is movable between first and second positions with a clearance between the piston and the linkage in the first position. The clearance undesirably permits the piston to move to the knock-back position during severe operating conditions. An actuator, which also may be used as part an electric parking brake, moves the linkage from the first position to the second position to eliminate the clearance when the linkage is moved from the first position to the second position where the linkage abuts the piston. The linkage is connected to the caliper housing by a support. The linkage prevents the piston from moving from the normal retracted position to the knock-back position.

Abstract: A parking brake assembly for an automotive drum brake is provided. The parking brake assembly replaces a conventional mechanical strut with an electronic strut actuator subassembly that provides for parking brake engagement and disengagement, sensing of brake lining wear and adjustment of brake shoe-to-drum clearance.

Abstract: An electrical system architecture for a vehicle brake by wire system provides three electrical power sources: an electric generator, an electric power storage device such as a battery, and a third source which may be either an electric generator or storage device. An electric circuit has a common node and (1) connects the first electric generator to the common node through a first diode, (2) connects the first electric power storage device to the common node through a second diode, (3) connects the electric power source to the common node through one of the first and second diodes, and (4) connects the common node to the electric power inputs of control units through circuit breaker devices. A sub-circuit within the electric circuit interconnects the first and second diodes, the common node and the first and second circuit breaker devices and isolates them within a zone protected from short circuits to points outside the zone.

Abstract: A parking brake assembly for an automotive drum brake is provided. The parking brake assembly replaces a conventional mechanical strut with an electronic strut actuator subassembly that provides for parking brake engagement and disengagement, sensing of brake lining wear and adjustment of brake shoe-to-drum clearance.

Abstract: A brake system and method of controlling the system are disclosed. The system provides secondary hydraulic braking in a de-energized mode. The system includes a wheel brake associated with wheels of a vehicle typically at each corner of the vehicle. The wheel brake typically includes a caliper or drum for deceleration of the vehicle. The system includes a master cylinder in fluid communication with the wheel brake. In the de-energized mode, the master cylinder operates the wheel brake. A solenoid isolation valve decouples the master cylinder from the wheel brake when the system is in a normal, i.e., an energized, mode. As such, the master cylinder is isolated from the wheel brake and is prevented from operating the wheel brake. Alternatively, in the de-energized mode, the isolation valve couples the master cylinder with the wheel brake to provide the secondary hydraulic braking.

Abstract: A disc brake caliper assembly has a housing with a bore. A piston in the bore is movable between applied, retracted and knock-back positions. The piston is activatable by hydraulic pressure to move from the retracted position to the applied position; and a retracting seal is effective in the absence of the hydraulic pressure to move the piston from the applied position to the retracted position. A linkage adjacent the piston carries a stop; and an actuator is responsive to an end of brake activation signal to cause the linkage to engage the stop with the piston when the piston is retracted from its applied position to its retracted position so as to prevent the piston from moving from the retracted position to the knock-back position. The actuator is preferably a comparatively weak electric motor that stalls as the stop engages the piston; and the stall is sensed to end motor activation. The end of brake activation signal is preferably provided by a brake position or pressure sensor.

Abstract: A brake by wire system provides the capability of both travel and force sensors on a brake apply input member such as a brake pedal and also provides redundancy in sensors by providing the signal from a sensor responsive to travel or position of the brake pedal to a first controller and the signal from a sensor responsive to force applied to the brake pedal to a second controller. The first and second controllers are connected by a bi-directional communication link whereby each controller may communicate its received one of the sensor signals to the other controller. In at least one of the controllers, linearized versions of the signals are combined for the generation of first and second brake apply command signals for communication to brake apply units. If either controller does not receive one of the sensor signals from the other, it nevertheless generates its brake apply command signal on the basis of the sensor signal provided directly to it from the sensor.

Abstract: A braking assembly for providing a braking force to a wheel brake of a vehicle based upon receipt of an electrical brake signal is provided. The brake assembly comprises an actuator including a motor that applies and releases a piston within an actuator body. The actuator is fluidly connected to a wheel brake whereby the wheel brake can be applied and released. A solenoid valve is interposed between the actuator and the wheel brake on a primary fluid path for opening and closing the fluid connection. A step piston is placed within a secondary fluid path between the actuator and the wheel brake and operates to momentarily increase fluid displacement applied to the wheel brake when the solenoid valve closed.

Abstract: Improved control for a hydraulic system useful in automotive braking applications, particularly in dry interface automotive braking applications, includes the use of a valve for holding pressure in a hydraulic system constant while relieving the pressure load on the pressure source. Preferably, the valve is a normally-open solenoid valve that is closed and opened in response to a desired pressure being sensed at a pressure actuated mechanism, such as a brake caliper. The use of the improved control for a hydraulic system improves brake response times during ABS applications, and increases the energy efficiency and life expectancy of the pressure providing motor.

Abstract: A brake by wire system provides the capability of both travel and force sensors on a brake apply input member such as a brake pedal and also provides redundancy in sensors by providing the signal from a sensor responsive to travel or position of the brake pedal to a first controller and the signal from a sensor responsive to force applied to the brake pedal to a second controller. The first and second controllers are connected by a bi-directional communication link whereby each controller may communicate its received one of the sensor signals to the other controller. In at least one of the controllers, linearized versions of the signals are combined for the generation of first and second brake apply command signals for communication to brake apply units. If either controller does not receive one of the sensor signals from the other, it nevertheless generates its brake apply command signal on the basis of the sensor signal provided directly to it from the sensor.

Abstract: A brake pedal for a motor vehicle brake-by-wire brake system including a pedal lever resiliently flexible in beam bending, a foot pad on the pedal lever, and a mounting for the pedal lever on a body of the motor vehicle which constitutes the pedal lever a variable stiffness cantilever spring. The mounting for the pedal lever includes a socket for an inboard end of the pedal lever, a stationary reaction surface on the body of the motor vehicle, and a pedal lever reaction surface on the pedal lever which faces and diverges from the stationary reaction surface in a release position of the pedal lever. The stationary reaction surface and the pedal lever reaction surface become progressively engaged concurrent with resilient flexure of the pedal lever in cantilever spring bending to vary the stiffness of the cantilever spring.