Vehicle brake system and method of detecting piston location of a plunger assembly

1. A method of determining a homing position of a piston within a plunger assembly for a vehicle brake system at the beginning of an ignition cycle of the vehicle, the method comprising:

(a) providing a plunger assembly having a housing defining a bore therein, wherein the plunger assembly includes a piston slidably disposed in the bore for pressurizing fluid within a pressure chamber when the piston is moved in a first direction, and wherein the plunger assembly further includes an electrically operated linear actuator for moving the piston within the bore;

(b) providing electrical power to the linear actuator of the plunger assembly;

(c) actuating the linear actuator to retract the piston in a second direction opposite the first direction towards an end stop;

(d) detecting the piston engaging with the end stop; and

(e) subsequently to step (d), actuating the linear actuator to advance the piston in the first direction by a forward predetermined distance, thereby placing the piston in a homing position.

2. The method of claim 1 , wherein in step (d), the piston engaging with the end stop is detected by detecting an increase of electrical current of the linear actuator to a predetermined current value.

3. The method of claim 1 , wherein in step (d), the piston engaging with the end stop is detected by detecting a reduction in speed of the piston to a predetermined speed value.

4. The method of claim 1 , wherein the end stop of the plunger assembly includes a spring element.

5. The method of claim 4 , wherein in step (d) contact of the piston with the end stop compresses the spring element.

6. The method of claim 4 , wherein in step (d), the piston engaging with the end stop is detected by a reduction in speed of the piston to a predetermined speed value as the spring element is compressed by engagement of the piston.

7. The method of claim 1 , wherein the linear actuator includes a motor.

8. The method of claim 7 , wherein the linear actuator further includes a ball screw mechanism operated by the motor.

9. The method of claim 1 , wherein the brake system is provided with a fluid reservoir and the plunger assembly further includes a port in fluid communication with the fluid reservoir and with the pressure chamber when the piston is in a first position, and wherein the port is prevented from being in fluid communication with the pressure chamber when the piston is in a second position caused by the spacial relationship between a seal and the port within the housing of the plunger assembly.

10. The method of claim 9 , wherein subsequently to step (d);

(f) measuring the difference between the retracted position of the piston and a linear zero position of the piston wherein the port is positioned adjacent the seal by a relatively small distance such that the port is in fluid communication with the fluid reservoir and with the pressure chamber.

11. The method of claim 10 , wherein in step (f), the difference is measured by:

(g) advancing the piston in the first direction from the retracted position; and

(h) detecting a pressure increase in the pressure chamber of the plunger assembly, thereby detecting movement of the seal relative to the compensation port causing loss of fluid communication between the reservoir and the pressure chamber.

12. The method of claim 11 , wherein subsequently to step (h), the method further comprises:

(i) retracting the piston in a second direction opposite the first direction causing a pressure increase in a second pressure chamber within the plunger assembly; and

(j) detecting a pressure decrease in the second pressure chamber of the plunger assembly, thereby detecting movement of the seal relative to the compensation port.

13. A method of determining a homing position of a piston within a plunger assembly for a vehicle brake system at the beginning of an ignition cycle of the vehicle, the method comprising:

(a) providing a plunger assembly having a housing defining a bore therein, wherein the plunger assembly includes a piston slidably disposed in the bore for pressurizing fluid within a pressure chamber when the piston is moved in a first direction, and wherein the plunger assembly further includes an electrically operated linear actuator for moving the piston within the bore;

(b) providing electrical power to the linear actuator of the plunger assembly;

(c) actuating the linear actuator to retract the piston in a second direction opposite the first direction towards an end stop;

(d) detecting the piston engaging with the end stop; and

(e) subsequently to step (d), actuating the linear actuator to stop movement of the piston.

14. A method of detecting the position of a piston relative to a compensation port and seal configuration of a plunger assembly, the method comprising:

(a) providing a fluid reservoir;

(b) providing a plunger assembly having a housing defining a bore therein, wherein the plunger assembly includes a piston slidably disposed in the bore for pressurizing fluid within a pressure chamber when the piston is moved in a first direction by a linear actuator, and wherein the plunger assembly includes a port in fluid communication with the fluid reservoir and with the pressure chamber when the piston is in a first position, and wherein the port is prevented from being in fluid communication with the pressure chamber when the piston is in a second position caused by the spacial relationship between a seal and the port within the housing of the plunger assembly;

(c) positioning the piston in a retracted position; and

(d) measuring the difference between the retracted position of the piston and a linear zero position of the piston wherein the port is positioned adjacent the seal by a relatively small distance such that the port is in fluid communication with the fluid reservoir and with the pressure chamber.

15. The method of claim 14 , wherein in step (d), the difference is measured by:

(e) advancing the piston in the first direction from the retracted position; and

(f) detecting a pressure increase in the pressure chamber of the plunger assembly, thereby detecting movement of the seal relative to the compensation port causing loss of fluid communication between the reservoir and the pressure chamber.

16. The method of claim 15 , wherein subsequently to step (f), the method further comprises:

(f) retracting the piston in a second direction opposite the first direction causing a pressure increase in a second pressure chamber within the plunger assembly; and

(g) detecting a pressure decrease in the second pressure chamber of the plunger assembly, thereby detecting movement of the seal relative to the compensation port.