Electric Brake Booster Lever Mechanism for Compact Return Force
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Solution Overview
Problem
Existing electric brake boosters are bulky due to the large dimensioning of the return spring and assistance piston, making them difficult to integrate into vehicles effectively.
Innovation Solution
Incorporating a lever mechanism that reduces the force required for the return spring, allowing for a smaller size by utilizing a lever of the second kind connected to the assistance piston, which compresses the cut-off spring and tilts to return the actuating piston and assistance piston to their rest position, thereby reducing the spring's force requirement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional return spring is used to return the actuating piston and assistance piston to the rest position, then the necessary force (e.g., 100N) is provided, but the brake booster becomes bulky and difficult to integrate into vehicles
Solution Approach 1:
A lever of the second kind is introduced as an intermediary mechanical element between the return spring and the assistance piston. The lever has its fulcrum on the assistance piston and its second end supported against the rear end-of-travel stop, creating a mechanical advantage system that multiplies the return spring force while allowing the spring itself to be much smaller
Solution Approach 2:
The invention changes the force parameter relationship by using the lever mechanism to provide a mechanical advantage. The lever transforms a small force from a compact return spring into a larger effective force (e.g., 100N) needed to overcome friction and return the brake components to rest position, thereby decoupling the spring size from the required force output
2Volume of moving object
If the dimensioning of the return spring is reduced to make the brake booster smaller, then the integration into vehicles is facilitated, but the force required to return the control rod and brake pedal may be insufficient
Solution Approach 1:
The lever of the second kind acts as a force multiplier intermediary. The first end of the lever connected to the assistance piston receives the return spring force, while the second end pushes against the rear end-of-travel stop, which in turn transmits the multiplied force to the control rod and brake pedal assembly, ensuring sufficient return force despite the small spring size
Solution Approach 2:
The lever mechanism merges multiple functions: it serves as both a force amplifier for the return spring and a structural link between the assistance piston and the brake pedal assembly. This consolidation allows the system to achieve both compact size and adequate return force simultaneously
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 configuration significantly reduces the size of the brake booster while maintaining the necessary force for the control rod and brake pedal, with the return spring exerting only a fraction of the original force, facilitating easier integration into vehicles.
Implementation Method 1
the booster piston is provided with a lever of the second kind connected in an articulated manner by its first end to the rear of the assistance piston and supported by an intermediate point close to its first end, against the plunger piston
Implementation Method 2
thanks to the multiplier effect produced by the lever for returning the actuating piston and the assistance piston to the rest position
Data Source
AI summary
The booster (100) has an assistance piston (6) provided with a lever (5), where a support point (51) of the lever is articulated to a back part of the assistance piston and supported against a plunger piston (8) by an intermediate point (52) of the lever. An end (53) of the lever rests against a rear limit (13) that is formed by a housing (1) of the booster and defines a rest position of the booster. A return spring (41) pushes back the assistance piston that carries the support point. A cut spring (9) is compressed by the plunger piston that is supported against the intermediate point.