Brake Booster Pushrod-Pedal Coupler for Side-Load Relief
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Solution Overview
Problem
In brake booster assemblies, misalignment between the brake pedal and pushrod can result in side loads on the pushrod, leading to stick-slip issues during brake pedal operation, which existing technologies like ball-type interfaces may not fully mitigate without additional considerations for assembly and component design.
Innovation Solution
A pushrod-pedal coupler with a coupler hinge that has a coupler hinge axis offset from the pedal pivot axis and longitudinal axis, utilizing hinge pins and clevis structures to connect the pushrod and pedal, allowing for efficient force transmission while reducing side loads and preventing stick-slip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a ball type interface is used between the pushrod and brake booster, then side load effects are mitigated, but assembly complexity and manufacturing considerations increase
Solution Approach 1:
A coupler assembly is introduced as an intermediary component between the pushrod and brake pedal. The coupler includes a coupler body with a coupler bore receiving the pushrod, and a pedal attachment portion with a pedal pivot axis. This intermediary structure accommodates both the pushrod longitudinal axis and pedal pivot axis within its geometry, allowing misalignment without direct side loading on the pushrod itself.
Solution Approach 2:
The connection system is segmented into distinct functional portions: the pushrod attachment portion (coupler bore), the coupler body (which provides the hinge mechanism), and the pedal attachment portion (pedal pivot axis). This segmentation allows each component to be optimized independently - the coupler body specifically designed with offset axes to handle misalignment while the pushrod maintains its primary function.
2Ease of operation
If the brake pedal and pushrod are not fully aligned, then ease of installation is improved, but side loads cause stick-slip issues in pushrod movement
Solution Approach 1:
The coupler assembly introduces dynamic capability to the connection system through the coupler hinge mechanism. The pedal pivot axis is offset from the pushrod longitudinal axis, allowing the connection to dynamically adapt to misalignment conditions. This dynamic geometry enables the system to accommodate installation variations while maintaining smooth pushrod movement through the hinge mechanism that absorbs angular deviations.
Data Source
AI summary
A brake booster assembly having a brake booster body and a pushrod as well as a pushrod-pedal coupler are provided. The pushrod travels along a pushrod axis when being pushed. The brake booster assembly includes a pushrod-pedal coupler. The pushrod-pedal coupler comprises a pushrod-attachment end arranged on the pushrod and defining a longitudinal axis parallel to the pushrod axis. A pedal-attachment end is configured to be attached to a pedal and having a pedal pivot axis around which the pedal pivots when being pushed. The pedal pivot axis extends across the longitudinal axis. A coupler hinge is arranged between the pushrod-attachment end and the pedal-attachment end and connects the pushrod-attachment end with the pedal-attachment end. The coupler hinge has a coupler hinge axis that extends across the longitudinal axis and the pedal pivot axis. The pedal pivot axis and the coupler hinge axis are offset along the longitudinal axis.