Driver Brake Force Simulator Using Nested Disk Springs
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Solution Overview
Problem
Existing vehicle braking systems face challenges in providing a cost-effective and space-efficient driver brake force simulator that can replicate a progressive brake actuation feel, while integrating seamlessly into hydraulic systems and ensuring driver comfort.
Innovation Solution
The use of multiple disk springs with varying spring stiffness characteristic curves, combined with a coil spring, allows for a compact design that simulates a progressive force-displacement curve, reducing installation space requirements and enhancing comfort without increasing the overall size of the simulator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple disk springs with varying stiffness characteristics are used, then a progressive brake actuation feel is achieved, but the device complexity increases
Solution Approach 1:
The braking system is segmented into multiple independent disk springs (first disk spring, second disk spring, third disk spring) each with different stiffness characteristics. These segmented springs work in sequence to create the progressive brake actuation feel, where each spring engages at different compression stages to provide varying resistance levels.
Solution Approach 2:
Each disk spring is assigned a specific local stiffness characteristic - the first disk spring has higher stiffness for initial resistance, the second has medium stiffness for intermediate compression, and the third has lower stiffness for final compression. This local differentiation of spring properties creates the progressive force-displacement curve without requiring a complex unified mechanism.
2Volume of stationary object
If multiple disk springs are used to reduce installation space, then the simulator becomes more compact, but the manufacturing complexity increases
Solution Approach 1:
The multiple disk springs are arranged in a nested configuration where they share a common mounting structure and compression axis. The springs are positioned concentrically or in parallel within the same spatial envelope, allowing them to be installed in a compact arrangement that minimizes the overall volume of the brake force simulator while maintaining the progressive stiffness characteristics.
3Manufacturing precision
If disk springs with different thicknesses and shapes are used to create progressive curves, then the simulation characteristic is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The invention achieves different stiffness characteristics by systematically varying key parameters of the disk springs - primarily thickness and shape - across the three springs. The first disk spring has specific thickness and shape parameters for high stiffness, the second has intermediate parameters, and the third has parameters optimized for lower stiffness. These parameter variations are designed to create distinct stiffness regions that collectively form the progressive brake actuation curve.
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 provides a cost-effective and space-efficient driver brake force simulator that replicates a standard brake actuation feel, simplifies integration into hydraulic systems, and enhances driver comfort by offering a progressive simulation characteristic curve, while maintaining negligible counterforce during brake application.
Implementation Method 1
multiple disk springs with varying spring stiffness characteristic curves
Implementation Method 2
at least one coil spring as the at least one further spring
Data Source
AI summary
A driver brake force simulator is provided for a braking system of a vehicle, including at least one spring, and a displaceable piston which delimits a pressure chamber formed in the driver brake force simulator and which is movable from its starting position, against an elastic force of the at least one spring, by a predefined maximum displacement travel in a first direction in such a way that a volume of the pressure chamber which is fillable with brake fluid is increasable. The driver brake force simulator includes at least multiple disk springs as the at least one spring. Moreover, a manufacturing method is provided for a driver brake force simulator for a braking system of a vehicle by supporting a displaceable piston of the driver brake force simulator with the aid of at least one spring. The displaceable piston is supported by at least multiple disk springs as the at least one spring.