Electromechanical Brake Booster Actuation Unit Design
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Solution Overview
Problem
Existing electromechanical brake boosters have complex assemblies with numerous individual parts, leading to increased production costs and potential reliability issues.
Innovation Solution
A simplified electromechanical brake booster design featuring an actuation unit with a power transmission element, a power take-up element, and a detection device, which allows for direct mechanical coupling and efficient power transmission to the brake cylinder, even in cases where the electric motor or transmission is defective, using a contact surface and return spring for preload and movement limitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex assembly with numerous individual parts is used in the brake booster, then the power transmission can be achieved, but the production cost increases and assembly becomes more difficult
Solution Approach 1:
The patent combines multiple functional elements into integrated components. The actuation element integrates the power input interface, the transmission interface, and the detection interface into a single component that directly couples to the power transmission element, eliminating the need for separate coupling mechanisms and reducing the total number of parts while maintaining reliable power transmission
Solution Approach 2:
The actuation element serves multiple functions simultaneously: it receives power input from the brake pedal, transmits mechanical power to the power transmission element, and provides a detection interface for actuation detection. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly
2Adaptability or versatility
If the electric motor or transmission is defective, then the brake booster should still function, but the complex assembly makes this backup capability difficult to implement
Solution Approach 1:
The actuation element serves as a mechanical intermediary that can directly couple the power input element to the power transmission element, bypassing the electric motor and transmission system. This intermediate mechanical coupling path allows the brake booster to function in failure modes where the motor or transmission is defective, while maintaining a relatively simple assembly structure
3Ease of operation
If the actuation element can move relative to the power transmission element, then adjustment is possible, but unwanted vibrations and noise occur
Solution Approach 1:
The return spring preloads the actuation element against the power transmission element in the rest position, establishing preliminary contact that prevents unwanted vibrations and noise. This preliminary mechanical engagement ensures stable coupling when the brake booster is not actively being actuated, while still allowing controlled movement during normal operation
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
The design reduces production costs, simplifies assembly, and ensures reliable brake power transmission, allowing the brake booster to function effectively even if the electric motor or transmission fails, while preventing unwanted vibrations and noise.
Implementation Method 1
The actuation element can be preloaded in a starting position via at least one return spring
Data Source
AI summary
A brake booster is comprised of an actuation unit, which can be coupled to a brake cylinder. The actuation unit is comprised of at least one actuation element that can be coupled to an electric motor via a transmission and at least one actuation element that can be coupled to a power input element. The actuation unit also includes at least one power transmission element that can be coupled to at least one actuation element in a power-transmitting manner, and at least one power take-up element that can be coupled or is coupled to an actuation detection device for the detection of an actuation of the electromechanical brake booster. The power take-up element can be coupled or is coupled to at least one actuation element. The power take-up element is configured to limit a relative movement of the actuation element relative to the power transmission element.