Brake Cylinder Locking Mechanism for Emergency Force Transfer
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Solution Overview
Problem
Conventional brake systems are complex and space-consuming due to a large number of parts, and they fail to efficiently convert brake pedal force and stroke into braking force and motion during emergency operations without significant losses.
Innovation Solution
A brake system with a brake cylinder that includes a push rod, a piston, an elastic simulator element for pedal feel simulation, and a locking element that forms a rigid connection between the push rod and piston during emergency operations, reducing the need for separate pedal simulators and locking valves, and ensuring efficient operation in both normal and emergency modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional power brake system with separate pedal feel simulator and actuator is used, then the brake pedal feel is simulated, but the system becomes complicated and space-consuming due to a large number of parts
Solution Approach 1:
The patent combines the pedal feel simulator and the actuator into a single integrated unit. The simulator element is positioned within the actuator housing, and both components work together as one assembly rather than separate units. This merging eliminates the need for multiple discrete parts while maintaining both the pedal feel simulation function and the actuation function.
Solution Approach 2:
The actuator housing serves multiple functions: it provides structural support for the actuator mechanism, contains the simulator element, and houses the fluid distribution pathways. The simulator element itself serves dual purposes by providing both the compliance function and serving as a structural component within the integrated assembly.
2Reliability
If a direct hydraulic connection is made between brake cylinder and wheel brakes in emergency mode, then the system activates fallback braking, but force and stroke transmission suffers substantial losses
Solution Approach 1:
The patent replaces the traditional flexible simulator element with a rigid mechanical connection for emergency braking. A lockable rod provides a rigid mechanical link between the brake pedal and the actuator, eliminating the compliance of the simulator element during emergency operation. This rigid connection ensures efficient force and stroke transmission without the energy losses associated with flexible elements.
Solution Approach 2:
The system dynamically switches between two connection modes: during normal operation, the flexible simulator element provides compliance; during emergency operation, the rigid mechanical connection is engaged via a locking mechanism. This dynamic transition allows the system to optimize performance for each operating mode, eliminating transmission losses when rigid connection is required.
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 system provides a compact design with reliable and efficient operation by mimicking conventional brake pedal feel in normal mode and ensuring effective force transmission during emergencies, reducing parts and complexity while maintaining safety and efficiency.
Implementation Method 1
an elastic simulator element (13) arranged between the second piston (14) and the push rod (3) for pedal feel simulation
Implementation Method 2
a hydraulic chamber (11) formed within the brake cylinder housing (4) between the first piston (14) and an inner surface of the brake cylinder housing (4)... configured for being selectively fluidly connected with the wheel brakes
Data Source
AI summary
The present invention relates to a brake system for a vehicle. The proposed brake system (1) comprises an actuation unit for actuating wheel brakes of the vehicle in a normal operating mode of the brake system (1). Further, the system (1) comprises a brake cylinder (2) for pressurizing the wheel brakes of the vehicle in an emergency operating mode of the brake system (1). The brake cylinder (2) comprises a brake cylinder housing (4) and a push rod (3) being displaceable within the brake cylinder housing (4) by operation of a brake pedal (5). The brake cylinder (2) further comprises a piston (14) movably arranged within the brake cylinder housing (4). The piston (14) has a first surface and a second surface opposite the first surface. A hydraulic chamber (11) is formed within the brake cylinder housing (4) between the first surface of the piston (14) and an inner surface of the brake cylinder housing (4). The hydraulic chamber (11) is configured for being selectively fluidly connected with the wheel brakes. The brake cylinder (2) further comprises an elastic simulator element (13) arranged between the second surface of the piston (14) and the push rod (3) for pedal feel simulation. The brake cylinder (2) further comprises a locking element (22) configured to selectively mechanically couple the push rod (3) with the piston (14) to provide a rigid connection between the push rod (3) and the piston (14) during the emergency operating mode.