Electromechanical Brake Booster Support Element Design
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Solution Overview
Problem
Conventional vacuum brake boosters are ineffective in future drive concepts with limited or no vacuum availability, necessitating the development of electromechanical brake boosters that are cost-effective, lightweight, and reduced in overall length.
Innovation Solution
An electromechanical brake booster design featuring a support element that attaches to the master brake cylinder to absorb forces, allowing the housing to be simplified and reducing weight and length, with cylindrical support elements and fastening mechanisms that securely connect to the transmission housing and vehicle bulkhead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the housing is designed to absorb forces from customer interface and transmission reaction, then the structural strength is improved, but the weight and production costs increase
Solution Approach 1:
The force absorption function is segmented from the housing and assigned to dedicated support elements. The housing is divided into functional zones: the support elements handle force absorption and mounting, while the housing provides protection and structural support. This segmentation allows each component to be optimized for its specific function, reducing the housing weight while maintaining overall structural strength.
Solution Approach 2:
Support elements act as intermediary components between the housing and the master brake cylinder. These intermediaries absorb and transmit forces, protecting the housing from direct mechanical loads. The support elements serve as mediators that handle the customer interface and transmission reaction forces, allowing the housing to be designed with reduced weight.
2Strength
If the housing is designed to absorb forces from customer interface and transmission reaction, then the structural strength is improved, but the production costs increase
Solution Approach 1:
The force absorption function is segmented from the housing and assigned to dedicated support elements. The housing is divided into functional zones: the support elements handle force absorption and mounting, while the housing provides protection and structural support. This segmentation allows each component to be optimized for its specific function, reducing the housing weight while maintaining overall structural strength.
Solution Approach 2:
Support elements act as intermediary components between the housing and the master brake cylinder. These intermediaries absorb and transmit forces, protecting the housing from direct mechanical loads. The support elements serve as mediators that handle the customer interface and transmission reaction forces, allowing the housing to be designed with reduced weight.
3Length of moving object
If the overall length of the electromechanical brake booster is reduced, then the space requirement is improved, but the structural stability may worsen
Solution Approach 1:
The support elements are arranged in a spatial configuration that provides structural stability without increasing the overall length. By utilizing the third dimension (vertical arrangement of support elements), the design achieves compactness in the axial direction while maintaining stability through proper distribution of support points in the radial and vertical dimensions.
Solution Approach 2:
The support elements are designed with optimal positioning and dimensions to provide dynamic structural stability. The support elements can be arranged to create triangular or multi-point support configurations that enhance stability while maintaining a compact overall length. The dynamic load paths are optimized to distribute forces efficiently throughout the compact structure.
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 solution reduces production costs, weight, and overall length while effectively supporting forces and enhancing installation variability, providing a robust and efficient braking system.
Implementation Method 1
an electric motor, a worm, which is driven by the electric motor
Implementation Method 2
a gear arranged in the housing, which couples the worm to the actuating piston in such a way as to translate a rotary movement of the worm into a translational movement of the actuating piston
Implementation Method 3
to absorb forces resulting from the customer interface and transmission reaction forces through the at least one support element
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The invention relates to an electromechanical brake booster (1, 100) for a motor vehicle, wherein at least one supporting element (2a, 2b), which extends substantially parallel to an adjustment axis (V) of the spindle (42), is fastened to a gearing housing bottom (61) of the gearing (60), wherein a master brake cylinder (7) can be fastened to the at least one supporting element (2a, 2b), and wherein the at least one supporting element (2a, 2b) is designed to support forces acting on the at least one supporting element (2a, 2b) in the axial and/or radial direction. The invention further relates to a brake system.