Electromechanical Brake Booster Centering Assembly
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Solution Overview
Problem
Conventional vacuum brake boosters are ineffective in future drive concepts where little or no vacuum is available, necessitating the development of alternative brake pressure buildup devices, such as electric motor brake boosters, which require simpler and cost-effective production methods.
Innovation Solution
An electromechanical brake booster design featuring a housing with centering openings and insertion openings for mounting pins, allowing efficient assembly line production, and a bearing plate for precise centering of the electric motor with respect to the gear unit, reducing production costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional vacuum brake boosters are used, then brake pressure buildup is achieved through vacuum assistance, but they become ineffective in future drive concepts where little or no vacuum is available
Solution Approach 1:
The patent replaces the vacuum-based mechanical system with an electromechanical system consisting of an electric motor and gear unit that directly generates brake pressure through a control piston, eliminating dependency on vacuum availability while maintaining brake pressure buildup effectiveness
Solution Approach 2:
The invention changes the fundamental operating parameter from vacuum pressure to electric motor-driven mechanical pressure, allowing the brake booster to function in drive concepts where vacuum is unavailable by transitioning to an alternative pressure generation mechanism
2Adaptability or versatility
If electric motor brake boosters are developed to replace vacuum brake boosters, then brake pressure buildup is achieved without vacuum, but production costs and manufacturing complexity increase
Solution Approach 1:
The housing is divided into two separable half-housings that can be manufactured independently and assembled through precision centering openings and insertion openings, allowing for simplified manufacturing processes and reduced production costs while maintaining the electromechanical functionality
Solution Approach 2:
Centering openings and insertion openings are pre-formed in the half-housings during manufacturing, enabling automatic self-centering during assembly without requiring additional alignment operations or complex fixtures, thereby reducing manufacturing complexity and cost
3Manufacturing precision
If precision centering is achieved through traditional alignment methods, then component positioning accuracy is maintained, but assembly time and production complexity increase
Solution Approach 1:
The centering openings and insertion openings are designed to automatically self-center the half-housings and mounting pins during assembly through geometric constraints, eliminating the need for external alignment tools or complex positioning procedures, thus maintaining high precision while significantly improving assembly efficiency
Data Source
AI summary
An electromechanical brake booster, the second half housing being able to be centered on the first half housing by engaging a first mounting pin protruding from the first centering opening into the first insertion opening and by engaging a second mounting pin protruding from the second centering opening into the second insertion opening. A method for producing an electromechanical brake booster for a motor vehicle is also described.