Electric Brake Booster Control via Pressure Threshold Segmentation
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Solution Overview
Problem
Existing vehicle braking systems equipped with electric brake boosters face challenges in reducing manufacturing costs, weight, and installation space requirements, as they often necessitate powerful motors and complex transmissions, limiting their integration and efficiency.
Innovation Solution
A control device that utilizes a smaller, lighter electric brake booster in conjunction with a hydraulic unit, allowing for adjustable setpoint variables to manage brake pressure, enabling the electric brake booster to operate efficiently below a predefined limiting value and switching to hydraulic components for higher pressures, thereby reducing the need for powerful motors and complex transmissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a powerful motor and complex transmission are used in the electric brake booster, then high brake pressure can be achieved, but the manufacturing cost, weight, and installation space increase significantly
Solution Approach 1:
The braking system is divided into two functional segments: the electric brake booster handles braking up to a predefined pressure threshold, while the hydraulic unit (ESP/ABS system) handles pressure above this threshold. This segmentation allows each component to be optimized for its specific pressure range, enabling the use of a less complex, smaller motor in the brake booster while still achieving high overall brake pressure capability through the hydraulic unit's intervention when needed.
2Weight of stationary object
If a smaller, lighter electric brake booster is used, then manufacturing cost and installation space are reduced, but the ability to generate high brake pressure is compromised
Solution Approach 1:
The control device integrates multiple functions: it controls the electric brake booster for normal braking operations and simultaneously manages the hydraulic unit for high-pressure emergency braking. This multi-functionality allows the system to achieve high brake pressure capability without requiring the brake booster itself to be oversized, as the hydraulic unit provides the additional pressure boost when needed.
3Power
If the electric brake booster is designed for high power output, then high brake pressure is achieved, but the system weight and manufacturing cost increase
Solution Approach 1:
The system changes the operating parameters by introducing a predefined pressure threshold that determines when the hydraulic unit should intervene. This parameter-based control allows the electric brake booster to be designed for lower power output, as it only needs to handle braking up to the threshold pressure, while the hydraulic unit provides the additional power for high-pressure scenarios.
4Volume of moving object
If a compact brake booster design is used, then installation space is reduced, but the motor power and transmission complexity must be minimized
Solution Approach 1:
The high-pressure generation function is extracted from the electric brake booster and assigned to the hydraulic unit. This extraction allows the brake booster to be designed as a compact unit with simpler transmission requirements, as it only needs to generate pressure up to the predefined threshold. The complex high-pressure generation is handled separately by the hydraulic unit when needed.
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 solution results in a cost-effective, lighter, and more compact braking system that can achieve high brake pressures without significant weight or space penalties, ensuring reliable braking performance and easier integration, including in emergency situations.
Implementation Method 1
electric brake booster... establishing a first setpoint variable with respect to a brake pressure portion effectuated on the booster side to be generated in at least one wheel brake cylinder
Implementation Method 2
at least one hydraulic component of the braking system... establishing a second setpoint variable with respect to a setpoint functionality to be carried out with the aid of the at least one hydraulic component
Implementation Method 3
setpoint brake pressure requested by a driver... brake pressure portion effectuated on the driver side... brake pressure portion effectuated on the booster side
Data Source
AI summary
A control device for a braking system of a vehicle equipped with an electric brake booster includes an activating unit which is configured to output, taking into account at least one provided sensor signal regarding a setpoint brake pressure, at least one brake pressure control signal to the electric brake booster in such a way that, if the setpoint brake pressure is below a predefined limiting value, a brake pressure portion effectuated on the booster side is equal to a difference between the setpoint brake pressure and a brake pressure portion effectuated on the driver side, while once the predefined limiting value is exceeded by the setpoint brake pressure, the brake pressure portion effectuated on the booster side remains constant or decreases.