Claims:I/We Claim:

1. An integrated braking system (100) of a vehicle comprising:
a reservoir (102) that is connected with a master cylinder (106) and supplies oil to the master cylinder (106) using a plurality of oil ports (104A-N) when integrated braking system (100) enables braking for the vehicle, wherein the master cylinder (106) receives the oil from the reservoir (102) and pressurizes the oil when a first input force is applied;
a brake pedal (110A and 110B) that is connected with the master cylinder (106) and transfers the first input force applied by a user, to the master cylinder (106) using a linkage;
a parking brake hand lever that is connected with a pull rod (226) and transfers a second input force applied by the user to a brake piston (204);
the brake piston (204) that is connected with the master cylinder (106) and an actuator (230) to provide the braking for the vehicle using at least one of the first input force or the second input force; and
a brake pack that comprises a friction discs with an internal spline (206), and steel plates, wherein the friction disc is coupled with a brake shaft (210), wherein the brake shaft (210) is coupled with a wheel shaft;
characterized in that,
wherein when in operation, (i) when the first input force is applied, a master cylinder piston and the brake piston (204) are in a closed loop and the master cylinder piston transfers the pressurized oil to the brake piston (204) to generate the axial load and transfer to the brake pack comprising the friction discs and steel plates and (ii) when the second input force is applied, a brake lever transfers the second input force to the actuator (230) to rotate and roll over balls (216) which are located on a ramp of the actuator (230) for generating a movement of the brake piston (204) and that generates the axial load, wherein the axial load generated using at least one of the first input force or the second input force is transferred to the brake pack to restrict a rotation of the wheel shaft to provide braking for the vehicle.

2. The integrated braking system (100) as claimed in claim 1, wherein the master cylinder (106) provides the pressurized oil to the brake piston (204) using an inlet adapter (220) to generate the axial load when the first input force is applied.

3. The integrated braking system (100) as claimed in claim 1, wherein the pull rod (226) is connected with the brake lever to generate a lever movement to rotate the actuator (230) when the second input force is provided by the pull rod (226).

4. The integrated braking system (100) as claimed in claim 1, wherein a master cylinder piston and the brake piston (204) are in a closed loop when the first input force is provided by the brake pedal (110A and 110B), wherein, in the closed loop, the master cylinder piston generates pressure by pressurizing the oil when the first input force is applied, transfers the pressurized oil with a generated pressure to the brake piston (204) and generates the axial load to the brake pack that comprising the friction disc that is coupled with the brake shaft (210) to restrict the rotation of wheels of the vehicle.

5. The integrated braking system (100) as claimed in claim 1, wherein the pull rod (226) moves the lever of a brake cylinder (202) to rotate the actuator (230) to generate the axial load when the second input force is applied, wherein the axial load is transferred to the brake pack using the brake piston (204) to restrict the rotation of the wheel shaft, wherein the restriction of the rotation of the wheel shaft provides braking to the vehicle.

6. The integrated braking system (100) as claimed in claim 2, wherein a sleeve (404) of an auto wear adjuster (228) is connected with the brake piston (204), wherein sleeve positions comprise the brake piston (204) at their initial position when at least one of the brake piston moves to an excess micron level.

7. The integrated braking system (100) as claimed in claim 6, wherein the auto wear adjuster (228) maintains a clearance provided to the brake piston (204) using a spring mechanism, wherein the auto wear adjuster (228) is connected with the brake piston (204).

8. The integrated braking system (100) as claimed in claim 6, wherein the auto wear adjuster (228) maintains a clearance provided to the brake piston (204) using bolt (402), sleeve (404), washer (406), spring (408) and nut (410), wherein a return position of the brake piston (204) is a pre-defined distance in the auto wear adjuster (228), wherein when the brake piston (204) moves than a pre-defined limit, piston (204) slips over the sleeve (404) and return to the pre-defined distance.

9. A method of providing braking to a vehicle using an integrated braking system (100) comprising;
providing a first input force from a user, wherein the first input force is provided using brake pedals (110A and 110B);
pressurizing, using a master cylinder (106), oil received from a reservoir (102) when the first input force is provided using brake pedals (110A and 110B) by the user;
generating the axial load by transferring the pressurized oil to the brake piston (204) to generate the axial load using the brake pack including the friction disc and steel plates when the first input force is applied by the user, wherein a master cylinder piston and the brake piston (204) are in a closed loop when the first input force is applied by the user;
providing a second input from a user using a parking brake hand lever;
actuating the parking brake hand lever and transferring the second input force to a brake lever which is connected to an actuator (230);
generating the axial load by rotating the actuator (230) and roll over balls which are located on a ramp of the actuator for generating a movement of the brake piston when the second input is applied,
transferring the axial load generated from at least one of the first input or the second input to the brake pack restrict a rotation of the wheel shaft to provide braking for the vehicle. , Description: BACKGROUND
Technical Field
[0001] The embodiments herein generally relate to a braking assembly, more particularly to an integrated braking system for a vehicle that integrates a service brake and a parking brake of the vehicle.
Description of the Related Art
[0002] In commercial brake systems, both a service brake and a parking brake include independent braking operations with different components in a vehicle. In the exiting braking system, periodic brake adjustment is done by bleeding. The existing braking system requires a separate parking brake system for the vehicle. The existing braking system fully depends on a hydraulic closed-loop system. When a small failure in a seal or bundy pipe then the brake system will not works. In the exiting mechanical braking system, transfer force loss is high due to too many hinge connections and the pedal effort is high.
[0003] Accordingly, there remains a need for an improved braking system to utilize a brake cylinder of the vehicle for both the service brake and the parking brake.
SUMMARY
[0004] In view of the foregoing, an embodiment herein provides an integrated braking system of a vehicle includes a reservoir, a master cylinder, a brake pedal, a parking brake hand lever, a brake piston and a brake pack. The reservoir is connected with the master cylinder and supplies oil to the master cylinder using a plurality of oil ports when the integrated braking system enables braking for the vehicle. The master cylinder receives the oil from the reservoir and pressurizes the oil when a first input force is applied. The brake pedal is connected with the master cylinder and transfers the first input force applied by a user to the master cylinder using a linkage. The parking brake hand lever is connected with a pull rod and transfers a second input force applied by the user to the brake piston. The brake piston is connected with the master cylinder and an actuator to provide the braking for the vehicle using at least one of the first input force or the second input force. The brake pack includes a friction disc with an internal spline and steel plates. The friction disc is coupled with a brake shaft. The brake shaft is coupled with a wheel shaft. When in operation, (i) when the first input force is applied, a master cylinder piston and the brake piston are in a closed loop and the master cylinder piston transfers the pressurized oil to the brake piston to generate the axial load and transfer to the brake pack including the friction disc and steel plates and (ii) when the second input force is applied, a brake lever transfers the second input force to the actuator to rotate and roll over balls which are located on a ramp of the actuator for generating a movement of the brake piston and that generates the axial load. The axial load generated using at least one of the first input force or the second input force is transferred to the brake pack to restrict a rotation of the wheel shaft to provide braking for the vehicle.
[0005] In some embodiments, the master cylinder provides the pressurized oil to the brake piston using an inlet adapter to generate the axial load when the first input force is applied.

[0006] In some embodiments, the pull rod is connected with the lever to generate a lever movement to rotate the actuator when the second input force is provided by the pull rod.

[0007] In some embodiments, a master cylinder piston and the brake piston are in a closed loop when the first input force is provided by the brake pedal. In the closed loop, the master cylinder piston generates pressure by pressurizing the oil when the first input force is applied, transfers the pressurized oil with a generated pressure to the brake piston and generates the axial load to the brake pack that comprising the friction disc that is coupled with the brake shaft to restrict the rotation of wheels of the vehicle.

[0008] In some embodiments, the pull rod moves the lever in the brake cylinder to rotate the actuator and to generate the axial load when the second input force is applied. The axial load is transferred to the brake pack using the brake piston to restrict the rotation of the wheel shaft. The restriction of the rotation of the wheel shaft provides braking to the vehicle.In some embodiments, a sleeve of an auto wear adjuster is connected with the brake piston. Sleeve positions include the brake piston at their initial position when at least one of the brake piston moves to an excess micron level.
[0009] In some embodiments, the auto wear adjuster maintains a clearance provided to the brake piston using bolt, sleeve, washer, spring and nut. A return position of the brake piston is a pre-defined distance in the auto wear adjuster. When the brake piston moves than a pre-defined limit, piston slips over the sleeve and returns to the pre-defined distance.
[0010] In another aspect, a method of providing braking to a vehicle using an integrated braking system including (i) providing a first input force from a user, (ii) pressurizing oil to brake cylinder using a master cylinder, oil received from a reservoir when the first input force is provided using brake pedals by the user, (iii) generating the axial load by transferring the pressurized oil to the brake piston to generate the axial load using the brake pack including the friction disc and steel plates when the first input force is applied by the user, (iv) providing a second input from a user using a parking brake hand lever, (v) actuating the parking brake hand lever and transferring the second input force to a brake lever which is connect to an actuator through pull rod, (vi) generating the axial load by rotating the actuator and roll over balls which are located on a ramp of the actuator for generating a movement of the brake piston when the second input is applied and (vii) transferring the axial load generated from at least one of the first input or the second input to the brake pack to restrict a rotation of the wheel shaft to provide braking for the vehicle. A master cylinder piston and the brake piston are in a closed loop when the first input force is applied by the user
[0011] The system and method reduce frequent brake setting and uneven pedal travel for performance improvement. The integrated braking system removes an uneven brake pedal travel and frequent brake setting for a vehicle. The auto wear adjuster maintains a clearance provided to the brake piston using a spring mechanism. The auto wear adjuster is connected with the brake piston. The master cylinder consumes the necessary oil from the reservoir to avoid a vacuum in the closed loop when the brake piston is adjusted to the next position over the sleeve.
[0012] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:
[0014] FIG. 1 illustrates an exemplary view of an integrated braking system of a vehicle according to some embodiments herein;
[0015] FIG. 2 illustrates an exemplary view of a brake cylinder assembly of the integrated braking system of a vehicle of FIG. 1 according to some embodiments herein;
[0016] FIG. 3 illustrates a cross sectional view of the brake cylinder of the integrated braking system of a vehicle of FIG. 1 according to some embodiments herein;
[0017] FIG. 4 illustrates an auto wear adjuster of the integrated braking system of a vehicle of FIG. 1 according to some embodiments herein; and
[0018] FIGS. 5A and 5B are flow diagrams of a method of providing braking to a vehicle using an integrated braking system of FIG. 1 according to some embodiments herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0020] As mentioned, there remains a need for an improved braking system to utilize the brake cylinder for both the service brake and the parking brake. Referring now to the drawings, and more particularly to FIG. 1 through 5B, where similar reference characters denote corresponding features consistently throughout the figures, preferred embodiments are shown.
[0021] FIG. 1 illustrates an exemplary view of an integrated braking system 100 of a vehicle according to some embodiments herein. The integrated braking system 100 of a vehicle includes a reservoir 102, a plurality of oil ports 104A-N, a master cylinder 106, brake cylinders 108A and 108B, brake pedals 110A and 110B, a brake pedal pivot 112 and a pull rod. In some embodiments, the brake pedals 110A and 110B are coupled to a left-hand side brake cylinder or a right-hand side brake cylinder. In some embodiments, an oil port 104B is compensating another oil port by transferring pressure. The reservoir 102 is connected with the master cylinder 106 and supplies oil to the master cylinder 106 using the plurality of oil ports 104A-N. In some embodiments, the plurality of oil ports 104A-N includes a compensating port 104B and oil outlet port 104N. The master cylinder 106 receives the oil from the reservoir 102 when the integrated braking system 100 enables the braking for the vehicle. The master cylinder 106 pressurizes the received oil when a first input force is applied using a pedal by a user. The first input force is applied by the user using the brake pedals 110A and 110B together or separately based on a requirement to provide braking for the vehicle. The brake pedal 110A and 110B are connected with the master cylinder 106 using a linkage to transfer the first input force to the master cylinder 106. The pull rod is connected with the brake cylinders 108A and 108B and a parking brake hand lever to obtain a second input force applied by the user to provide braking for the vehicle. In some embodiments, the brake cylinders 108A and 108B includes one or more components such as a brake piston, seals, a friction disc with an internal spline, steel discs, a brake shaft, an actuator, balls, a bleed adapter, an inlet adapter, a bolt, a lever and an auto wear adjuster. In some embodiments, a brake pack includes the brake cylinders 108A and 108B. In some embodiments, the brake cylinders 108A and 108B include a housing to accommodate the one or more components. The brake piston is connected with the master cylinder 106 and the actuator to provide the braking for the vehicle using the first input force or the second input force. The friction disc is coupled with the brake shaft to restrict a wheel shaft rotation. In some embodiments, the brake shaft is coupled with the wheel shaft to provide braking for the vehicle.
[0022] In some embodiments, the master cylinder 106 provides the pressurized oil to the brake cylinder 108A and 108B using the bundy pipe and inlet adapter when the first input force is applied. The oil received from the reservoir 102 is pressurized using the master cylinder 106 using the first input force that is provided using the brake pedals 110A and 110B by the user. The pressurized oil is provided to a brake piston using an inlet adapter to generate an axial load when the first input force is provided using the brake pedals 110A and 110B by the user. In some embodiments, a master cylinder piston and the brake piston are in a closed loop. when the first input force is applied, the master cylinder piston transfers the pressurized oil to the brake piston to generate the axial load using the brake pack comprising the friction disc and steel plates. The axial load is transferred to a brake pack to restrict the rotation of the wheel shaft to provide braking for the vehicle. In some embodiments, the brake pack includes friction discs and steel plates.
[0023] The second input force is provided by the user using the parking brake hand lever. The parking brake hand lever is actuated and transferred the second input force to a brake lever which is connected to the actuator. The second input force is transferred to the actuator to rotate and roll over balls which are located on a ramp of the actuator for generating a movement of the brake piston and that generates the axial load. In some embodiments, push force is generated when applying the second input force and the push force is converted into the axial load using a brake piston movement. The axial load is transferred to the brake pack to restrict the rotation of the wheel shaft to provide braking for the vehicle.
[0024] In some embodiments, a sleeve of the auto wear adjuster is connected with the brake piston. Positions of the sleeve include a brake piston position even when the brake piston moves to an excess micron level.
[0025] With reference to the FIG. 1, FIG. 2 illustrates an exemplary view of a brake cylinder assembly of the integrated braking system 100 of the vehicle of FIG. 1 according to some embodiments herein. The brake cylinder assembly 108 includes a brake piston 204, seals, a friction disc with an internal spline, steel plates, a brake shaft 210, an actuator 230, balls 216, a bleed adapter 218, an inlet adapter 220, a bolt 222, a lever 224, a pull rod 226 and an auto wear adjuster 228. In some embodiments, the brake piston 204 is connected with the master cylinder 106 and provides braking using a first input force received from the brake pedals 110A and 110B. In some embodiments, the brake piston 204 provides the braking using a second input force received from a parking brake hand lever. In some embodiments, the actuator 230 directly actuates the brake pack when the second input force is received. The friction disc with the internal spline and the steel plates are coupled with the brake shaft. The brake shaft is coupled to the wheel shaft. The friction disc with the internal spline transfers the axial load as torque using the first input and the second input to reduce the rotation of the wheel shaft to provide braking for the vehicle. In some embodiments, when the second input force is applied on the pull rod 226, the pull rod 226 pulls the lever 224 and enables the rotation of the actuator 230. The balls 216 rolls over a ramp of the actuator 230 to move the brake piston 204 when the actuator 230 rotated. An actuator movement expands the brake piston 204 to generate the axial load. The axial load is transferred to the brake pack to restrict the rotation of the wheel shaft to provide braking for the vehicle.
[0026] In some embodiments, a master cylinder piston and the brake piston 204 is in a closed loop when the first input force is provided by the brake pedals 110A and 110B. The bleed adapter 218 outlets air inside the brake cylinder while bleeding and completely fill with oil to make a closed loop. In the closed loop, the master cylinder piston generates the pressure by pressurizing the oil and transfers the pressure to the brake piston as an axial force to the brake pack to restrict the rotation of the wheels of the vehicle.
[0027] The bolt 222 acts as a hinge and supports to transfer the second input force to the actuator 230. The lever 224 is connected with the pull rod 226. In some embodiments, parking brake hand lever force is transferred to the lever 224 using the pull rod 226 through a cable or a linkage rod which makes the pull rod movement when we apply parking or emergency brake. The pull rod movement generates the axial load to restrict the rotation of the wheels of the vehicle. In some embodiments, the actuator 230 rotates and roll over balls 216 which are located on a ramp of the actuator 230 when the pull rod 226 moved using the second input force is applied by the user. In some embodiments, the pull rod 226 is connected with the lever 224 to generate a lever movement to rotate the actuator 230
[0028] With reference to the FIG. 2, FIG. 3 illustrates a cross sectional view of the brake pack of the integrated braking system 100 of the vehicle of FIG. 1 according to some embodiments herein. The brake pack includes ‘N’ number of friction discs 304 and ‘N’ number of steel plates 306. In a brake cylinder 202, the oil from master cylinder 106 pressurizes the brake piston 204 to pressurize and avoid leakage. Seals 302 are placed on outer and inner locations of the brake piston 204 to receive and transfer the pressurized oil from master cylinder 106 to the brake piston 204.
[0029] With reference to the FIG. 2, FIG. 4 illustrates the auto wear adjuster 228 of the brake cylinder 108 of the integrated braking system 100 of the vehicle FIG. 1 according to some embodiments herein. The auto wear adjuster 228 includes a bolt 402, a sleeve 404, a washer 406, a spring 408 and a nut 410. The auto wear adjuster 228 is located inner side of the brake cylinder 108 and connected with the brake piston 204 to control a pre-defined clearance provided to the brake assembly. In some embodiments, the nut 410 is a stopper. In some embodiments, the sleeve 404 is connected with the brake piston 204. The brake piston 204 is interference fitted over the sleeve 404. The sleeve 404 moves when the brake piston 204 moves. The bolt 402 is a fixed member fitted with housing and carries all parts of the auto wear adjuster 228. The washer 406 is a supporting member for sleeve 404 and moves along with the sleeve 404. Whenever the sleeve 404 is actuated, the spring 408 is compressed to generate a return force to make the brake piston 204 to predefined return distance. In some embodiments, if sleeve 404 moves to a home position, then the brake piston 204 moves to the home position. The nut 410 makes the spring 408 in compression to act as a stopper for washer 406 to control the movement of the sleeve 404. For example, the brake piston 204 moves more than the pre-determined clearance when the brake is applied, the auto wear adjuster 228 moves the brake piston 204 to the pre-defined return distance. In some embodiments, as an alternate design, the integrated braking system 100 fixes the auto wear adjuster 228, the brake piston 204 and the sleeve 404 in the housing of the brake cylinder 202. When the brake piston 204 moves, the bolt 402 compresses the spring 408 as the sleeve 404 is a fixed member. If piston travel exceeds a pre-defined setting in the auto wear adjuster 228, then the sleeve 404 moves to the required next position.
[0030] With reference to the FIGS. 1 to 4, FIG. 5A and 5B are a flow diagram of a method of providing braking to a vehicle using an integrated braking system 100 of FIG. 1 according to some embodiments herein. At step 502, the first input force is provided by the user. At step 504, the oil received from the reservoir 102 is pressurized using the master cylinder 106 when the first input force is provided using the brake pedals 110A and 110B by the user. At step 506, the axial load is generated by transferring the pressurized oil to the brake piston 204 to generate the axial load using the brake pack including the friction disc and steel plates when the first input force is provided using the brake pedals 110A and 110B by the user. At step 508, the second input is provided from the user using the parking brake hand lever. At step 510, the parking brake hand lever is actuated and transferred the second input force to the brake lever which is connected to the actuator 230. At step 512, the axial load is generated by moving the brake piston 204 with the brake lever when the second input is applied. At step 514, the axial load is generated rotating the actuator 230 and roll over balls which are located on a ramp of the actuator for generating a movement of the brake piston when the second input is applied . At step 516, the axial load is generated from at least one of the first input or the second input is transferred to a brake pack to restrict the rotation of the wheel shaft to provide braking for the vehicle. The brake pack includes friction discs and steel plates.
[0031] In some embodiments, the axial force is generated using the first input force and the second input force at a same time to restrict the rotation of the wheel shaft to provide braking for the vehicle with an even brake pedal travel.
[0032] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.