Brake Booster Transmission Assembly With Relief Elements for Load Balancing
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Solution Overview
Problem
Existing electromechanical brake boosters suffer from asymmetrical rigidity in their transmission systems, leading to step changes in stiffness, high stresses, and uneven load distribution, which can result in component failure and reduced service life.
Innovation Solution
A transmission assembly with a rack module and relief elements, such as damping elements made of rubber or soft plastic, compensates for stiffness differences and gear wheel offsets, improving load distribution and reducing backlash, while converting rotational movement into linear movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a transmission system with indirect and direct load paths is used, then the brake booster can transmit force effectively, but asymmetrical rigidity causes step changes in stiffness leading to high stresses and reduced service life
Solution Approach 1:
The patent introduces a relief element with specific local properties (damping characteristics) at a critical location in the load path. This relief element has different stiffness characteristics than the surrounding rigid components, creating a localized zone that absorbs stress variations. The relief element is positioned between the cylindrical wheel and screw wheel to specifically address the stiffness mismatch in that region, allowing other parts of the transmission to maintain their rigid force transmission function.
Solution Approach 2:
The relief element acts as a pre-positioned cushioning component that anticipates and absorbs stress spikes before they can propagate through the transmission system. By placing this compliant element in advance within the load path, the system prepares for inevitable stiffness transitions and high-stress events, preventing damage to more critical components like gear wheels and racks before they occur.
2Force
If asymmetrical rigidity is present in the transmission system, then force can be transmitted, but step changes in stiffness cause high stresses and uneven load distribution
Solution Approach 1:
The relief element introduces a localized zone with different stiffness properties specifically where stress concentration occurs. This element has controlled compliance that allows it to deform under high stress, creating a stress-distributing effect at the critical interface between rigid components. The local quality of this damping element contrasts with the surrounding rigid structure, precisely where needed to mitigate stress peaks.
3Ease of operation
If conventional transmission arrangements are used, then the brake booster can operate, but gear wheel contact patterns are impaired leading to component failure
Solution Approach 1:
The relief element is positioned in advance within the load path to cushion against stress spikes before they can damage gear wheel contacts. This preventive measure protects the gear engagement surfaces from the harmful effects of asymmetrical rigidity and stiffness transitions, ensuring sustained operational functionality without compromising component durability.
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
Enhances mechanical load-bearing capacity, improves operating behavior, compensates for tolerances, and increases durability and robustness, thereby extending the service life and enhancing operational safety.
Implementation Method 1
At least one transmission arrangement 6 has at least one relief element 8 which is arranged effectively in a load path 7 of the at least one transmission arrangement 6. The relief element 8 can be designed to compensate for stiffnesses, in particular different stiffnesses, in the load path 7.
Implementation Method 2
featuring a relief element between cylindrical and screw wheels to absorb vibrations and distribute loads evenly
Data Source
AI summary
A transmission assembly for a brake booster of a vehicle is disclosed. The transmission assembly comprises a rack module having a base section and at least one tooth row section; and at least one transmission arrangement for transmitting a moment, such as a torque. The at least one transmission arrangement is in engagement with the at least one tooth row section of the rack module and has a shaft, a screw wheel carried by the shaft and a cylindrical wheel. The at least one transmission arrangement has at least one relief element, which is arranged effectively in a load path of the at least one transmission arrangement, and brake booster for a vehicle that comprises an electric motor, a push rod and a transmission assembly, which acts between the electric motor and the push rod.