Abstract:
A more reliable hydraulic brake device is proposed which is capable of regenerative cooperative control and eliminates wasteful consumption of electric power. In a hydraulic brake device capable of regenerative cooperative control, a hydraulic pressure adjusting device is provided to adjust the hydraulic pressure in the auxiliary hydraulic chamber to a desired value that is above the output hydraulic pressure value of the pressure adjusting valve. During regenerative cooperative control, the output hydraulic pressure of the pressure adjusting valve is supplied to the auxiliary hydraulic chamber as it is. During non-regenerative cooperative control the output hydraulic pressure of the pressure adjusting valve is increased corresponding to regenerative braking force and supplied to the auxiliary hydraulic chamber.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a vehicle brake device which permits regenerative cooperative control, and particularly to a reliable and inexpensive vehicle brake device. 
     U.S. patent publication Ser. No. 2002/0140283A1 discloses a vehicle brake device which can perform regenerative cooperative control. One of the brake devices disclosed in this patent publication is shown in  FIG. 4 . 
     This brake device  10  includes a brake pedal  11 , a hydraulic pressure generating device  12  for producing a predetermined hydraulic pressure by means of a power-driven pump, an electric control device  13  for controlling the brake device, a reservoir  14 , a cylinder  15 , a pressure adjusting valve  16 , hydraulic passages  17 ,  20 ,  21 , a master cylinder  18 , an auxiliary hydraulic chamber  19  that receives the output hydraulic pressure of the pressure-adjusting valve  16 , wheel cylinders  22 – 25  for imparting braking force to the vehicle wheels, electromagnetic proportional valves  26  and  27 , pressure sensors  28  and  29 , solenoid valves  28  and  29 , and check valves  32  and  33 . 
     In this brake device  10 , hydraulic pressure P 1  supplied from the hydraulic pressure generating device  12  is adjusted by the pressure adjusting valve  16  to a value P 2  corresponding to the brake operating force applied to the brake pedal  11  and the hydraulic pressure thus adjusted is introduced into the auxiliary hydraulic chamber  19 . The master cylinder  18  is activated by the introduced hydraulic pressure to generate hydraulic pressure P 4  corresponding to the hydraulic pressure in the auxiliary hydraulic pressure chamber  19  in hydraulic chambers  18   e  and  18   i  of the master cylinder  18 . The hydraulic pressure P 4 , which is output from the master cylinder  18 , is supplied to the wheel cylinders  22 – 25 , thereby producing braking force corresponding to the brake operating force. 
     For regenerative cooperative braking, a command is given from the electrical control device  13  to the electromagnetic proportional valves  26  and  27  to lower the hydraulic pressure in the auxiliary hydraulic chamber  19  from P 2  to P 3 . By arranging such that the hydraulic pressure in the auxiliary hydraulic chamber  19  can be reduced to any value below the output hydraulic pressure of the pressure adjusting valve  16 , the braking force produced under hydraulic pressure during regenerative cooperative braking can be reduced by an amount corresponding to the regenerative braking force, so that the regenerative braking force can be fully utilized for vehicle braking. 
     In the brake device of the JP patent publication 2002-264795, based on information from the pressure sensor  28 , the electromagnetic proportional valves  26  and  27  are activated to control the hydraulic pressure in the auxiliary hydraulic chamber  19  to a given value below the output hydraulic pressure value of the pressure adjusting valve  16 . Thus, if the pressure sensor  28  or electromagnetic proportional valves  26 ,  27  should fail during pressure adjustment, it is possible that the hydraulic pressure in the auxiliary hydraulic chamber  19  be reduced to 0 atm., so that the braking force may drop to zero. 
     An object of this invention is to solve this problem, thereby improving the reliability of a brake device used for regenerative braking. 
     SUMMARY OF THE INVENTION 
     According to this invention, there is provided a vehicle brake device comprising a hydraulic pressure generating device for generating a predetermined hydraulic pressure, a pressure adjusting valve for adjusting the hydraulic pressure supplied from the hydraulic pressure generating device to a value corresponding to brake operating force, an auxiliary hydraulic chamber, a master cylinder activated by hydraulic pressure supplied from the pressure adjusting valve into the auxiliary hydraulic chamber to generate hydraulic pressure corresponding to the hydraulic pressure in the auxiliary hydraulic chamber, and wheel cylinders activated by output hydraulic pressure from the master cylinder to impart braking force to vehicle wheels, further comprising a hydraulic pressure adjusting device for increasing and adjusting the hydraulic pressure of the auxiliary hydraulic chamber to a hydraulic pressure value that is not less than the output hydraulic pressure value of the pressure adjusting valve. 
     Preferably, the hydraulic pressure adjusting device comprises a normally opened differential pressure control valve disposed in a hydraulic passage connecting between the auxiliary hydraulic chamber and the output side of the pressure adjusting valve, and a normally closed pressure increase control valve disposed in a hydraulic passage connecting between the auxiliary hydraulic chamber and the hydraulic pressure generating device. 
     As the differential pressure control valve and the pressure increase control valve, electromagnetic proportional valves as disclosed in the JP patent publication 2002-264795 may be used. 
     Preferably, the output of the pressure adjusting valve is set smaller than a target vehicle deceleration. Preferably, the output property of the pressure adjusting valve is set such that the gradient of pressure rise is small in a region where the brake operating force is small, and the gradient of pressure rise is large in a region where the brake operating force is large. 
     Preferably, the maximum value of the difference between the target vehicle deceleration and the output of the pressure adjusting valve is substantially equal to the maximum value of regenerative braking force obtained by feasible regenerative braking. Also, preferably, the target relation between the brake operating force and the vehicle deceleration is achieved by producing only braking force that is insufficient with the regenerative braking force by means of the differential pressure control valve and the pressure increase control valve. 
     During regenerative cooperative braking, required deceleration is produced by applying a braking force which is the sum of regenerative braking force and the braking force generated by the hydraulic brake device, to the vehicle. At this time, no command is given to the hydraulic pressure adjusting device to keep the hydraulic pressure adjusting device in an initial (non-operative) state. 
     On the other hand, during non-regenerative cooperative braking, the hydraulic pressure adjusting device is activated to generate a hydraulic pressure corresponding to the output hydraulic pressure of the pressure adjusting valve (that is, hydraulic pressure which includes a pressure increase corresponding to the regenerative braking force). The fluid pressure is introduced into the auxiliary hydraulic chamber to activate the master cylinder. 
     Thus, during regenerative cooperative braking, it is possible to store regenerative electric power without activating the hydraulic pressure adjusting device, namely without wastefully consuming electric power. 
     Also, even if the pressure sensor or hydraulic pressure adjusting device should fail, at least the output hydraulic pressure from the pressure adjusting valve is ensured for deceleration. Thus sensors or the like for fail-safeness are not necessary and it is possible to realize reduction in cost of the brake device. 
     The hydraulic pressure adjusting device may comprise a differential pressure control valve disposed in a hydraulic passage connecting between the auxiliary hydraulic chamber and the output side of the pressure adjusting valve, and a pressure increase control valve disposed in a hydraulic passage connecting between the auxiliary hydraulic chamber and the hydraulic pressure generating device. This makes it possible to use the hydraulic pressure generating device for supplying hydraulic pressure to the pressure adjusting valve also as a hydraulic pressure source for pressure increase during non-regenerative cooperative braking. This further increases the effect of simplification of the brake device and cost reduction. 
     Also, by setting the output of the pressure adjusting valve smaller than the target vehicle deceleration, regenerative cooperative control will not be complex. Also, by setting the output properties such that the gradient of pressure rise is small in a region where the brake operating force is small, and the gradient of pressure rise is large where the brake operating force is large, the effect of the brakes during failure improves. 
     Besides, in the arrangement in which the maximum value of the difference between the target relation between the brake operating force and the vehicle deceleration and the output of the pressure adjusting valve is set such that the braking force by the maximum difference is substantially equal to the maximum value of regenerative braking obtained by feasible regenerative braking. The target relation between the brake operating force and the vehicle deceleration is achieved by producing only braking force that is insufficient with regenerative braking force by means of the differential pressure control valve and the pressure increase control valve. Thus it is not necessary to wastefully producing hydraulic pressure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other features and objects of the present invention will become apparent from the following description made with reference to the accompanying drawings, in which: 
         FIG. 1  is a sectional view showing a schematic structure of an embodiment of the brake device according to this invention; 
         FIG. 2  is a graph showing the relation between the brake operating force and the vehicle deceleration during regenerative cooperative control; 
         FIG. 3  is a graph showing the relation between the brake operating force and the vehicle deceleration during non-regenerative cooperative control; and 
         FIG. 4  is a sectional view showing a schematic structure of a conventional brake device which permits regenerative cooperative control. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1  shows the embodiment of this invention. This vehicle brake device  50  comprises a hydraulic pressure generating device  12  including an accumulator  12   a,  a pressure sensor  12   b  and a pump  12   d  driven by an electric motor  12   c,  an electrical control device  13  for controlling the brake device, a reservoir  14  storing brake fluid, a pressure adjusting device  40  including a pressure adjusting valve  16 , a master cylinder  18 , an auxiliary hydraulic chamber  19  for receiving the output hydraulic pressure of the pressure adjusting valve  16 , wheel cylinders  22 – 25  for imparting braking force to vehicle wheels, electromagnetic proportional valves  26 ,  27 , and pressure sensors  28 ,  29 . 
     The hydraulic pressure generating device  12  generates a predetermined hydraulic pressure P 1  by means of a pump  12   d,  stores it in the accumulator  12   a,  controls the electric motor  12   c  based on detection signals of the pressure sensor  12   b  to keep the hydraulic pressure P 1  between predetermined upper and lower limit values, and supplies the hydraulic pressure P 1  to the pressure adjusting valve  16 . 
     The pressure adjusting device  40  includes the pressure adjusting valve  16  which adjusts hydraulic pressure supplied from the hydraulic pressure generating device  12  to a value corresponding to the operating force applied to the brake pedal  11  and outputs it. It further includes an auxiliary piston  41  mounted in a cylinder  15  with its tip facing the auxiliary hydraulic chamber  19 , a simulator piston  42   b  provided in the auxiliary piston  41  with its front surface facing a simulator chamber  42   a,  an elastic member  42   c  for imparting a stroke corresponding to the brake operating force applied to the brake pedal  11  to the simulator piston  42   b,  and a distributing device  43  for distributing the brake operating force transmitted from the simulator piston  42   b  through the elastic member  42   c  and transmitting to the pressure adjusting valve  16  and auxiliary piston  41 . 
     The simulator chamber  42   a,  simulator piston  42   b  and elastic member  42   c  form a stroke simulator  42 . 
     The distributing device  43  comprises a rubber member  43   b  arranged in a cup-like member  43   a,  a tubular member  43   c  having one end thereof abutting the auxiliary piston  41  and the other end inserted in the cup-like member  43   a,  and a transmitting member  43   d  and a steel ball  43   e  mounted in the tubular member  43   c  so as to be disposed between the rubber member  43   b  and the pressure adjusting valve  16 . A gap g is formed between the rubber member  43   b  and an annular resin plate  43   f  mounted to the end of the tubular member  43   c  to protect the rubber member  43   b.    
     By providing this distributing device  43 , in the initial stage of brake operation, brake operating force is transmitted through the rubber member  43   b,  the transmitting member  43   d  and the steel ball  43   e  to the pressure adjusting valve  16 . When the brake operating force exceeds a certain value, the rubber member  43   b,  which is elastically deformed under compressive force and gets into the gap g, contacts the annular plate  43   f.  Thereafter, part of the operating force is distributed to the auxiliary piston  41  through the tubular member  43   c.  Thus, using this function, it is possible to impart such jumping properties that the initial rise of brake hydraulic pressure adjusted by the pressure adjusting valve  16  is steep, to the brake device. 
     Also, if the inner diameter of the tubular member  43   c  and the outer diameter of the transmitting member  43   d  change, the distribution ratio of the brake operating forces transmitted to the pressure adjusting valve  16  and the auxiliary piston  41  changes. Further, as the lengths of these members change, the time when the distribution starts changes. Thus it is possible to change the relation between the brake operating force and the output hydraulic pressure P 2  of the pressure adjusting valve by replacing the tubular member  43   c  and the transmitting member  43   d  with ones of different sizes. 
     While the distributing device  43  is a preferable element, it may be omitted and the brake operating force applied to the brake pedal  11  may be directly transmitted to the pressure adjusting valve  16 . 
     As the pressure adjusting valve  16 , one is shown in which pressure adjustment is carried out with a spool  16   a.  The auxiliary piston  41  is provided with a pressure increase port A 01 , output port A 02 , and pressure reducing port A 03 . Changeover of connection between these ports and the adjustment of the degree of opening of these ports are carried out by displacing the spool  16   a.    
     The pressure increase port A 01  is normally in communication with the hydraulic pressure generating device  12  through an annular fluid chamber C 2  provided around the auxiliary piston  41 , and an input port A 1  formed in the cylinder  15 . The pressure reducing port A 03  is normally in communication with the reservoir  14 , which is at the atmospheric pressure, through the simulator chambers  42   a  holes formed in the auxiliary piston  41 , an-annular fluid chamber C 1  provided around the auxiliary piston  41 , and a drain port A 3  formed in the cylinder  15 . The output port A 02  communicates with an output port A 2  formed in the cylinder  15  through an annular fluid chamber C 4  provided around the auxiliary piston  41 . 
     When the spool  16   a  is pushed back by a return spring  16   b  and at an illustrated position (original position), the pressure adjusting valve  16  is in a pressure reduced state with the output port A 2  communicating with the pressure reducing port A 03  through a passage in the spool  16   a.  When the brake pedal  11  is stepped in and the spool  16   a  is pushed in leftwardly in  FIG. 1  from the illustrated position, the passage in the spool  16   a  is shut off both from the pressure reducing port A 03  and the pressure increase port A 01 . Now the pressure adjusting valve  16  is in an output hold state. When the spool  16   a  is pushed in further leftwardly, the passage in the spool  16   a  communicates with the pressure increase port A 01 , so that the wheel cylinders  22 – 25  are now in a pressure increase state. 
     The spool  16   a  of the pressure adjusting valve  16  moves to a balance point where the force which is the sum of the thrust by the hydraulic pressure introduced into the fluid chamber C 3  and the load of the return spring  16   b  balances with the brake operating force applied through the distributing device  43 . Thus, the degree of opening of a valve portion formed between the pressure increase port A 01  and the shoulder of the spool  16   a  when the output port A 2  communicates with the input port A 1  and a valve portion formed between the pressure reducing port A 03  and the shoulder of the spool  16   a  when the output port A 2  communicates with the drain port A 3  are adjusted, so that the hydraulic pressure P 2 , which is outputted through the output port A 2 , will be at a level corresponding to the brake operating force. 
     The input port A 1  and the output port A 2  are connected to the auxiliary hydraulic chamber  19  through a hydraulic passage  17  having a meeting point. In the hydraulic passage  17  extending from the output port A 2  to the meeting point, there are provided the pressure sensor  28 , the normally open electromagnetic proportional valve  26 , which functions as a differential pressure control valve, and a check valve  32 , which is arranged parallel to the electromagnetic proportional valve  26  (in which the direction of checking is completely opposite to that of the check valve of the device of patent publication 2002-264795). Further, in the hydraulic passage  17  from the input port Al to the meeting point, there is provided a normally closed electromagnetic proportional valve  27 , which functions as a pressure increase control valve. 
     The master cylinder  18  includes the master cylinder piston  18   a  which is activated under the hydraulic pressure introduced into the auxiliary hydraulic chamber  19  on its back to generate a hydraulic pressure P 4  corresponding to the hydraulic pressure P 3  in the auxiliary hydraulic chamber  19  (P 4  is substantially equal to P 3 ). 
     In the brake device  50 , the output property of the pressure adjusting valve  16  is set to be smaller than the target relation between the brake operating force and the vehicle deceleration. Specifically, as shown in  FIGS. 2 and 3 , it is so set that in a region where the brake operating force is small, the gradient of pressure rise is small, and in a region where the brake operating force is large, the gradient of pressure rise is large. The gradient of the first-stage pressure rise is preferably as small as possible in view of the regenerative efficiency. The gradient of the second stage pressure rise is preferably as close to the required vehicle deceleration as possible in view of braking performance during failure. 
     It is preferable that the maximum value of the difference between the target relation between the brake operating force and the vehicle deceleration and the output property of the pressure adjusting valve  16  is set to be substantially equal to the maximum value of the regenerative braking force obtained by feasible regenerative braking (about 2 Mpa in terms of hydraulic pressure). It is also preferable that only the braking force that is short with regenerative braking force is generated by means of the electromagnetic proportional valves  26 ,  27  to achieve the target relation between the brake operating force and the vehicle deceleration. 
     With the thus structured brake device  50 , during regenerative cooperative braking, as shown in  FIG. 2 , the braking force generated by the hydraulic pressure of the brake device  50  plus the regenerative braking force is applied to the vehicle to generate a required deceleration. At this time, no command is given to the electromagnetic proportional valves  26 ,  27  (hydraulic pressure adjusting device) to keep the electromagnetic proportional valves  26 ,  27  at their initial state. 
     On the other hand, during non-regenerative cooperative braking, the electromagnetic proportional valves  26 ,  27  are activated to generate hydraulic pressure P 3  corresponding to the output hydraulic pressure P 2  of the pressure adjusting valve  16  (which is the hydraulic pressure in which pressure increase corresponding to the regenerative braking force is added as shown in  FIG. 3 ). It is introduced into the auxiliary hydraulic chamber  19  to activate the master cylinder  18 , thereby producing a required deceleration with the hydraulic pressure only. 
     Thus, during regenerative cooperative braking, it is possible to store regenerative electric power without activating the electromagnetic proportional valves  26 ,  27 , i.e. without a waste of electric power. 
     Also, even if the pressure sensor  28  or the electromagnetic proportional valves  26 ,  27  fail, since at least the output hydraulic pressure P 2  from the pressure adjusting valve  16  is ensured for vehicle deceleration, a sensor or the like is not needed for failsafeness, so that it is possible to reduce the cost of the brake device. 
     In the illustrated brake device  50 , to the wheel cylinders  22  and  23 , which are in one line, hydraulic pressure is supplied from the auxiliary hydraulic chamber  19  through a hydraulic passage  20 , and to the wheel cylinders  24  and  25 , which are in the other line, hydraulic pressure produced in the master cylinder  18  is supplied through a hydraulic passage  21 . Even if hydraulic pressure is not produced in the auxiliary hydraulic chamber  19  due to failure in the hydraulic pressure generating device  12  or devices in lines connecting thereto, the auxiliary piston  41 , which is prevented from moving in a normal state under the hydraulic pressure in the auxiliary hydraulic chamber  19 , is moved by the brake pedal  11 . Thus the brake operating force is directly transmitted to the master cylinder  18 , so that at least hydraulic pressure which can be manually produced is ensured. This is preferable from a fail-safe viewpoint. 
     Like the device of  FIG. 4 , a tandem master cylinder may be employed to supply the output hydraulic pressure of the master cylinder to the wheel cylinders in two lines. This structure is also high in safety. 
     As described above, the brake device of this invention is provided with the hydraulic pressure adjusting device which increases the hydraulic pressure in the auxiliary hydraulic chamber to any hydraulic pressure value above the output hydraulic pressure value of the pressure adjusting valve, and is adapted to achieve the target relation between the brake operating force and the vehicle deceleration with the braking force obtained by the output hydraulic pressure of the pressure adjusting valve and the regenerative braking force during regenerative cooperative braking. 
     On the other hand, during non-regenerative cooperative braking, it is adapted to realize the target relation between the brake operating force and the vehicle deceleration with only the braking force by hydraulic pressure by increasing the hydraulic pressure introduced into the auxiliary hydraulic chamber by the hydraulic pressure adjusting device by an amount corresponding to regenerative braking force. Thus, there will be no useless power consumption. Also, regenerative cooperative control is possible in which regenerative braking force can be used for braking without a waste. Also, even if the pressure sensors or hydraulic pressure adjusting device should fail, vehicle deceleration that differs little from deceleration at a normal time is obtained. Thus, a reliable and inexpensive vehicle brake device can be realised. 
     In the arrangement in which the hydraulic pressure adjusting device is formed of the differential pressure control valve and pressure increase control valve using the electromagnetic proportional valves, there is no need to separately provide a hydraulic pressure source for pressure increase. Thus it is possible to further simplify the brake device and reduce its cost.