Vehicle Brake Input Device Segmentation and Integration
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Solution Overview
Problem
Conventional vehicle brake systems, particularly electric boosters, face limitations in layout flexibility and downsizing, making them less applicable to various vehicles due to integrated design and limited location options for the input device, which restricts their general-purpose use and increases manufacturing costs.
Innovation Solution
The integration of a master cylinder and a stroke simulator forms the input device, allowing for a separate configuration that shortens piping and enables downsizing, enhancing versatility and reducing manufacturing costs by making components common across different vehicle types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the input device and electric brake actuator are assembled as a single integrated unit, then the brake system structure is simplified, but the degree of freedom for layout is reduced and the device size increases
Solution Approach 1:
The brake system is divided into two separate devices: the input device (containing master cylinder and stroke simulator) and the electric brake actuator. This segmentation allows each device to be optimized independently for size and function, while maintaining structural simplicity through clear functional separation.
2Ease of manufacture
If the master cylinder and stroke simulator are provided separately, then the piping between them can be longer for easier assembly, but the overall device size increases and mounting space requirements increase
Solution Approach 1:
The master cylinder and stroke simulator are integrated into a single input device housing, forming a compact unified structure. This merging eliminates the need for external piping between separate components, significantly reducing the overall device volume while maintaining assembly feasibility through integrated design.
3Ease of manufacture
If the input device is designed with fixed configuration, then the manufacturing process is simplified, but the adaptability to different vehicle types is reduced
Solution Approach 1:
The input device is designed with universal mounting features and standardized interfaces that allow it to be adapted to different vehicle types (gasoline-fueled, hybrid, and electric vehicles). The separate device configuration enables flexible installation in various mounting spaces while maintaining consistent manufacturing processes through modular design elements.
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 allows for a more compact and versatile brake system design, suitable for hybrid and electric vehicles with limited mounting space, reducing manufacturing costs and improving the applicability to various vehicle types.
Implementation Method 1
a stroke simulator that is provided side by side with the master cylinder, is in communication with the master cylinder, and applies in a pseudo manner a force counteracting the operation of the brake operating member to the brake operating member
Data Source
AI summary
An input device of a vehicle brake system which is downsized and has an improved general versatility in comparison with conventional vehicle brake systems is provided. An input device 14 includes: a master cylinder 34 that produces a fluid pressure in accordance with an input of an operation of a brake operating member 12; and a stroke simulator 64 which is provided side by side with the master cylinder 34 and which applies in a pseudo manner a force counteracting the operation of the brake operating member 12 to the brake operating member 12. The master cylinder 34 and the stroke simulator 64 are formed integrally.