Brake Assist Crimping Mechanism for Single Spring Adaptability
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Solution Overview
Problem
Current brake assist systems with electric motors require a large number of trigger springs to accommodate different vehicle types, leading to complex manufacturing and installation processes.
Innovation Solution
A brake assist system with a crimping area on the control rod allows for the use of a single trigger spring, adjusted and secured by crimping, to achieve varying trigger forces, simplifying manufacturing and installation by eliminating the need for multiple springs and specific spring stops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple trigger springs with different forces are used to accommodate different vehicle types, then the adaptability to different vehicle requirements is improved, but the device complexity and manufacturing complexity increase due to requiring large numbers of different spring types
Solution Approach 1:
The patent applies universality by designing a single trigger spring that can serve multiple vehicle types with different trigger force requirements. The spring is designed with a standardized body that can be adjusted to provide different forces through modification of the stop component, eliminating the need for multiple specialized spring types while maintaining adaptability to various vehicle specifications
Solution Approach 2:
The patent implements parameter changes by modifying the trigger spring's effective parameters (such as the stop position or spring compression) rather than changing the entire spring component. This allows a single spring design to provide varying trigger forces by adjusting parameters like the stop location on the control rod, thereby accommodating different vehicle requirements without increasing device complexity
2Adaptability or versatility
If multiple trigger springs with different forces are used for different vehicle types, then the adaptability is improved, but the ease of manufacture deteriorates due to requiring large numbers of different spring types
Solution Approach 1:
The patent applies universality by designing a single trigger spring that can serve multiple vehicle types with different trigger force requirements. The spring is designed with a standardized body that can be adjusted to provide different forces through modification of the stop component, eliminating the need for multiple specialized spring types while maintaining adaptability to various vehicle specifications
Solution Approach 2:
The patent implements preliminary action by pre-designing the trigger spring with standardized dimensions and properties that can accommodate various vehicle types. The spring is manufactured once with optimal characteristics, and then adapted to different applications through simple adjustments like modifying the stop position, rather than manufacturing multiple specialized springs from scratch
3Ease of manufacture
If a single trigger spring is used with adjustment and crimping, then the ease of manufacture is improved through large-scale consistency, but the manufacturing precision requirement increases to ensure proper crimping and trigger force
Solution Approach 1:
The patent applies self-service by designing the crimping mechanism to be self-aligning or self-regulating. The control rod or mounting structure incorporates features that guide the crimping process and ensure proper positioning, reducing the skill level and precision required from the operator while maintaining manufacturing quality
Solution Approach 2:
The patent introduces an intermediary element (such as a standardized stop component or mounting feature) that mediates between the single trigger spring design and the various vehicle type requirements. This intermediary provides reference surfaces or positioning features that simplify the crimping process and ensure consistent, precise results without requiring high operator skill
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables consistent and efficient production of brake assist systems with reduced parts and streamlined assembly, ensuring the required trigger force is achieved without distortion, facilitating large-scale manufacturing and easier installation.
Implementation Method 1
an extremity of the trigger spring presses against the sleeve of the helper piston
Implementation Method 2
a crimping area for securely crimping the trigger spring stop in the adjusted compression position
Data Source
AI summary
A system includes a helper piston that includes an axial sleeve that is integral with a guide bracket and that has a threaded exterior surface; a translationally fixed but rotational translation nut that has internal threads that complement those of the helper piston and that supports a gear connected to a drive motor; a plunger piston pushed by the helper piston and connected to a control rod; a trigger spring between the helper piston and the stop carried by the control rod for triggering brake assistance; a stop including a stop sleeve and a flange that is applied to the trigger spring, where the body of the control rod has a crimping area for securing the stop by crimping in an adjusted compression position.