Electric Brake System Master Cylinder Segmentation
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Solution Overview
Problem
Existing electric brake systems face issues with hydraulic pressure leakage from the master cylinder, which can lead to a failure in generating the intended braking force and degrade the pedal effort feeling for the driver, posing safety risks and affecting production quality.
Innovation Solution
The electric brake system incorporates a master cylinder with first and second chambers, a simulation device, and a hydraulic pressure supply device, along with backup flow paths and valves, to selectively deliver hydraulic pressure to either the simulation flow path or the wheel cylinder, ensuring hydraulic pressure is not leaked and providing a consistent pedal feeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the simulator valve is installed at the oil flow path connecting the simulation device to the oil reservoir, then the simulation device can provide pedal reaction force, but hydraulic pressure may leak through the simulator valve causing braking force failure
Solution Approach 1:
The patent divides the hydraulic system into separate functional circuits: a simulation circuit (connecting master cylinder to simulation device) for providing pedal reaction force, and a braking circuit (connecting master cylinder to wheel cylinder) for generating braking force. This segmentation isolates the simulation function from the braking function, preventing pressure leakage in one circuit from affecting the other. The simulation device includes its own dedicated oil flow path and simulator valve, separated from the main braking pressure path.
Solution Approach 2:
The patent introduces a communication hole as an intermediary element that selectively connects or isolates the simulation chamber from the braking pressure source. The communication hole can be opened to allow hydraulic pressure to reach the simulation device for providing pedal reaction force, or closed to isolate the simulation circuit when braking force is required, preventing pressure leakage from affecting the braking system.
2Reliability
If the simulator valve is closed to prevent hydraulic pressure leakage, then braking force reliability is improved, but the simulation device cannot provide pedal reaction force
Solution Approach 1:
The system dynamically switches between different operational modes by controlling the communication hole and simulator valve. The communication hole can be opened or closed based on whether simulation function or braking function is prioritized. The simulator valve can be opened to allow pressure through the simulation circuit when pedal reaction force is needed, or closed to prevent leakage when braking reliability is the priority, enabling adaptive operation based on system requirements.
3Reliability
If hydraulic pressure is delivered to both simulation device and wheel cylinder through separate paths, then both pedal feeling and braking force are maintained, but system complexity increases
Solution Approach 1:
The master cylinder serves multiple functions simultaneously: it generates hydraulic pressure for both the simulation device (providing pedal reaction force) and the wheel cylinder (generating braking force). The simulation device itself is designed with multi-functionality, serving both as a pressure indicator and as a source of pedal reaction force through its spring mechanism. This reduces the need for separate dedicated components for each function.
Solution Approach 2:
The simulation device is nested within the master cylinder assembly, with the simulation chamber integrated into the master cylinder structure. The communication hole is formed within the master cylinder body, and the simulator valve is integrated into the simulation device assembly. This nested arrangement allows multiple functions to be housed within a compact integrated structure, reducing overall system complexity despite the multiple functions performed.
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 effectively prevents hydraulic pressure leakage, ensures stable braking force generation, and maintains the intended pedal effort feeling, enhancing safety and production reliability by isolating the hydraulic pressure delivery to either the simulation or wheel cylinder.
Implementation Method 1
a master cylinder connected to a first reservoir storing oil therein, provided with first and second chambers and first and second pistons respectively provided at the first and second chambers, and configured to discharge oil according to a pedal effort of a brake pedal
Implementation Method 2
the hydraulic pressure supply device is configured to generate hydraulic pressure by converting a rotational force of a motor into a rectilinear movement to pressurize a piston
Implementation Method 3
a simulation device configured to provide a reaction force according to the pedal effort of the brake pedal, and provided with a simulation chamber that is connected to the master cylinder and a simulation flow path to accommodate oil therein
Data Source
AI summary
An electric brake system is disclosed. The electric brake system comprises a master cylinder connected to a first reservoir storing oil therein, provided with first and second chambers and first and second pistons respectively provided at the first and second chambers, and configured to discharge oil according to a pedal effort of a brake pedal; a simulation device configured to provide a reaction force according to the pedal effort of the brake pedal, and provided with a simulation chamber that is connected to the master cylinder and a simulation flow path to accommodate oil therein; a hydraulic pressure supply device configured to generate hydraulic pressure using a rotational force of a motor that is activated in response to an electrical signal output corresponding to a displacement of the brake pedal; and a hydraulic control unit configured to deliver the hydraulic pressure delivered from the hydraulic pressure supply device to a wheel cylinder provided at each of wheels, and connected to the first and second chambers of the master cylinder through first and second backup flow paths and connected to the hydraulic pressure supply device through a hydraulic flow path, wherein hydraulic pressure provided from the master cylinder is selectively delivered to the simulation flow path and the first and second backup flow paths.