Brake Pedal Simulator Using Magnetorheological Fluid Tuning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Modern brake-by-wire motor vehicle brake systems require customizable force-travel profiles for different vehicle applications, but existing simulator units are complex, costly, and inefficient, with limitations in precision and adaptability.
Innovation Solution
A simulator unit with a reciprocating piston that displaces magnetorheological fluid between two chambers, using an electrically controllable electromagnetic field to adjust viscosity and generate customizable force-displacement characteristics, allowing for precise calibration and different brake profiles without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complex interaction of components is used to reproduce specific force-travel profiles, then the precision of force-displacement characteristics is improved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent applies parameter changes by utilizing magnetorheological fluid whose viscosity can be dynamically adjusted through magnetic field strength. By changing the magnetic field parameters (coil current, magnetic flux density), the simulator can reproduce different force-travel profiles without modifying the physical structure. This allows precise customization of brake pedal characteristics for different vehicle applications using a single universal simulator unit.
Solution Approach 2:
The invention achieves universality by designing a single simulator unit that can serve multiple customer-specific applications. The magnetorheological fluid's variable viscosity property enables the same hardware to reproduce various force-displacement characteristics required by different vehicle manufacturers, eliminating the need for custom-developed components for each application.
2Adaptability or versatility
If custom components are developed and manufactured for each customer's unique brake pedal characteristics, then the adaptability to different applications is improved, but the development effort and production cost increase
Solution Approach 1:
The patent enables adaptability through parameter changes in the magnetorheological fluid's viscosity by adjusting magnetic field strength. This allows the same simulator unit to be adapted to different customer requirements by simply changing electrical parameters (coil current, magnetic flux density) rather than developing custom mechanical components for each application.
Solution Approach 2:
The invention replaces complex mechanical component interactions with an electromagnetic field-based system. Instead of using mechanically adjustable components to achieve different force-travel profiles, the patent uses an electromagnetic coil to control the magnetorheological fluid's viscosity, substituting mechanical complexity with electrical control.
3Manufacturing precision
If magnetorheological fluid is influenced by potential difference between electrically energized piston head and bore, then the viscosity control is achieved, but the electrical insulation complexity and material selection limitations increase
Solution Approach 1:
The patent replaces the electrical insulation problem by substituting the electrical field generation method. Instead of creating a potential difference between the piston head and bore (which requires complex insulation), the invention uses an electromagnetic coil that generates a magnetic field through the magnetorheological fluid without requiring direct electrical contact or complex insulation arrangements.
4Manufacturing precision
If a coil is arranged around the chamber to generate magnetic field, then the magnetorheological fluid influence is achieved, but the simulator positioning is limited to immediate vicinity of foot pedal
Solution Approach 1:
The patent improves positioning flexibility by using an electromagnetic coil system that can be integrated into the simulator unit itself. The coil generates a magnetic field that acts on the magnetorheological fluid within the piston chamber, allowing the simulator to be positioned more flexibly without requiring the coil to be externally arranged around the chamber, thereby reducing spatial constraints.
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
Enables cost-effective and precise implementation of various force-travel profiles, simplifying development and manufacturing by using software to adjust viscosity and field strength, ensuring consistent performance across different vehicle applications.
Implementation Method 1
at least one reciprocating piston (4) which is axially displaceable in a piston bore (3) and which displaces a magnetorheological fluid (6) from a first chamber (8) into a second chamber (9) along its stroke via a hydraulic connection (7)
Implementation Method 2
the simulator unit has at least one electrically controllable field generator, which is preferably designed as an electromagnetic coil or at least comprises such a coil
Data Source
Figure 1~3b
Figure 4~9
AI summary
The invention relates to a braking device (1) for a vehicle braking system, in particular a brake-by-wire motor vehicle braking system, comprising at least one simulator unit (2) for separately generating a counterforce (Fg) acting on an actuating element (14) operated by a driver against an actuating force (Fb). In order to realize different force-displacement characteristics of the simulator unit particularly effectively and cost-efficiently, it is proposed according to the invention that the simulator unit (2) comprises at least one reciprocating piston (4) that is axially displaceable, at least partially, in a piston bore (3), and which, along its stroke (5), displaces a magnetorheological fluid (6) from a first chamber (8) into a second chamber (9) via a hydraulic connection (7).