Master Brake Cylinder Simulator Integration
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Solution Overview
Problem
Existing brake systems for vehicles have complex and costly components between the brake operating element and the master brake cylinder pressure chambers, leading to increased system extension and potential idle strokes, which complicates assembly and affects brake pedal feel and safety.
Innovation Solution
A master brake cylinder system with a simulator device that includes a simulator spring and piston, integrated into the master brake cylinder housing, reduces the number of components by using a simulator spring to enhance brake pedal feel and safety, and includes a separating valve to control the spring force, allowing for a more compact design and improved assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional components are used between the brake operating element and the master brake cylinder pressure chambers, then the brake system provides adequate braking function, but the system complexity and overall extension increase
Solution Approach 1:
The simulator device is integrated directly into the master brake cylinder housing, merging the simulator chamber with the pressure chambers. This eliminates the need for separate simulator housings and intermediate components, reducing system complexity while maintaining the braking function through the combined chamber structure
Solution Approach 2:
The master brake cylinder housing serves multiple functions: it contains the pressure chambers for brake fluid pressure generation and simultaneously houses the simulator chamber with the simulator piston and spring for brake pedal feel simulation. This multi-functionality eliminates the need for separate simulator device housings and reduces overall system complexity
2Reliability
If conventional components are used between the brake operating element and the master brake cylinder pressure chambers, then the brake system provides adequate braking function, but the overall extension along the displacement direction increases
Solution Approach 1:
The simulator chamber is nested within the master brake cylinder housing, with the simulator piston positioned between the simulator chamber and the second pressure chamber. This nesting arrangement allows the simulator components to occupy space within the existing housing volume rather than extending the overall length of the brake system
Solution Approach 2:
The simulator chamber is arranged with its longitudinal axis perpendicular to the displacement direction of the rod piston and floating piston. This dimensional reorientation allows the simulator spring to exert force in a direction perpendicular to the main braking force transmission, enabling compact integration without increasing the overall extension along the displacement direction
3Ease of operation
If a simulator spring is used to enhance brake pedal feel, then the brake operating feel is improved, but the device complexity increases due to additional components
Solution Approach 1:
The simulator device is merged with the master brake cylinder housing, sharing the same housing structure and integrating the simulator piston into the existing pressure chamber arrangement. This merging eliminates the need for separate simulator device housings and reduces the number of discrete components, simplifying the overall device while maintaining improved brake operating feel
Solution Approach 2:
The simulator spring and piston are integrated into the master brake cylinder assembly, where they serve the dual function of providing brake pedal feel simulation and participating in the hydraulic pressure transmission system. This multi-functionality reduces the need for separate components dedicated solely to pedal feel, thereby reducing device complexity
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 system complexity, eliminates idle strokes, and provides a comfortable brake operating feel while ensuring safety standards, with the option to increase spring force during emergency braking, and allows for cost-effective production using high-stiffness rubber springs.
Implementation Method 1
using a spring constant of the at least one simulator spring, a displacement/force characteristic of the brake operating feel may be established
Implementation Method 2
the simulator device has at least one separating valve via which the simulator chamber is able to be linked hydraulically to a brake fluid reservoir
Implementation Method 3
a simulator piston that is displaceable against the spring force of the simulator spring into the simulator chamber
Implementation Method 4
the at least one simulator spring is a rubber spring. Consequently, even when a cost-effective spring type is used for the at least one simulator spring, an advantageously high stiffness of it is ensured
Data Source
AI summary
A master brake cylinder system having a master brake cylinder housing having at least one first pressure chamber and a second pressure chamber, a rod piston at least partially displaceable into the first pressure chamber, a floating piston situated between the first pressure chamber and second pressure chamber, and a simulator device having a simulator piston, which is at least partially displaceable into the simulator chamber counter to a spring force of at least one simulator spring present in a simulator chamber, the simulator piston of the simulator device being situated as to the second pressure chamber so that the simulator piston is displaceable at least partially into the simulator chamber, using a pressure present in the second pressure chamber against the spring force of the at least one simulator spring. In addition, also described is a brake system for a vehicle having a master brake cylinder system.