Integrated Brake Master Cylinder and Stroke Simulator
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Solution Overview
Problem
The existing vehicle brake systems with electric boosters have long hydraulic communication paths, which affect the operator's feeling and response to the brake pedal operation, and require complex assembly, particularly when integrating a stroke simulator with the master cylinder.
Innovation Solution
A vehicle brake system with an integrated input device that includes a master cylinder and a stroke simulator, where the simulator piston is accommodated in a chamber with an opening on the side of the brake operation element, reducing hydraulic paths and simplifying assembly by allowing easier insertion and attachment, and utilizing a holding unit to secure the simulator piston and receiving member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stroke simulator is attached to an attachment member (e.g., dashboard) mounted on a vehicle body, then the assembly is facilitated, but the hydraulic communication path becomes long, deteriorating the operator's feeling and response
Solution Approach 1:
The master cylinder and stroke simulator are integrated into a single input device assembly, with the simulator accommodation chamber positioned adjacent to the master cylinder. This merging eliminates the need for long external hydraulic communication paths while maintaining ease of assembly as a pre-integrated unit.
2Volume of moving object
If the simulator accommodation chamber is closed, then the structure is compact, but the insertion of the simulator piston becomes difficult
Solution Approach 1:
The simulator piston and urging members are pre-assembled into the simulator accommodation chamber through an opening portion before the chamber is sealed. This preliminary action allows easy insertion during assembly while maintaining a compact closed structure in the final configuration.
Solution Approach 2:
The simulator accommodation chamber is designed with a segmented structure that includes an opening portion, allowing the chamber to be opened for assembly and then closed for compact operation. This segmentation enables both easy insertion and compact final structure.
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 improves the responsiveness and operational feeling of the brake system by shortening hydraulic communication paths and simplifying the assembly process, while maintaining the structure around the brake operation element in a compact and organized manner.
Implementation Method 1
the simulator piston being movable against an urging force of urging members by being driven by the hydraulic pressure in the simulator accommodation chamber
Implementation Method 2
the urging members which are disposed between the simulator piston and the receiving member and which urge the simulator piston
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An input device of a vehicle brake system integrally includes an integrally provided master cylinder 34 and a stroke simulator 64 which communicate via a hydraulic communication path. The stroke simulator 64 is provided with a simulator piston 68 accommodated within a simulator accommodation chamber 64c. The simulator accommodation chamber 64c has an opening portion 64e enabling the insertion of the simulator piston 68 into the simulator accommodation chamber 64c from the side on which the brake pedal is disposed relative to the dashboard 2.