InvestigationIntotheMethodofIgnitioninFordBrake.docVIP

Investigation Into the Method of Ignition in Ford Brake Pressure Switches Introduction This investigation is a follow up on studies and testing done by NHTSA, Ford, Renaissance Engineering, and others into the fires caused by the use of a Texas Instruments pressure switch in Ford stepper motor cruise control systems. The mode of failure of the switch has been defined and verified in all of the studies. However, the actual method of ignition and how it affects the timing and circumstances related to fire eruption has not been addressed. Background Ford, in the design of their Next Generation cruise control system, incorporated the use of a brake pressure switch to disconnect the source of battery potential from the electromagnetic clutch when the brake was depressed with sufficient force. The purpose of this switch is to disconnect the cruise control under a condition of unwanted acceleration. The system design which incorporates this switch has the electromagnetic clutch either energized at all times or, in diesel models only, energized only when the ignition is turned on. This design condition eliminates the need in the cruise electronics to cope with the energizing and de-energizing of the electromagnetic clutch. Ford utilized a brake pressure switch manufactured by Texas Instruments. This switch is threaded into the master cylinder and is designed in such a way that the brake fluid pressure is used to open the contacts when the fluid is pressurized. The design of the switch is such that it would, over time and repeated brake application cycles, leak or force brake fluid through the fluid barrier material (Kapton, made by DuPont) allowing brake fluid to enter the electrical contact area above the seal. This would lead to excessive contamination of the fluid in the switch area with copper produced by corrosion of the contacts. Data regarding vehicles which have reported switch fires from both NHTSA and Ford indicates that they have had mileage ranging fro