Decoupled Brake Booster With Segmented Chambers
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Solution Overview
Problem
Existing braking systems with hydraulic brake boosters integrated in series with the master cylinder are bulky and complex, making them difficult to integrate into vehicle engine compartments and lacking effective emergency operation mechanisms in case of high pressure unit malfunction.
Innovation Solution
A braking system with a decoupled hydraulic brake booster and master cylinder, featuring a boost chamber supplied by a high-pressure unit, an actuator chamber connected to the brake pedal, and a controlled hydraulic link between the two, allowing for emergency operation through a simulator chamber and mechanical push rod mechanism, eliminating the need for additional pistons and enabling automatic pressurization without driver intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic brake booster is integrated in series with the master cylinder, then braking assistance is provided, but the system becomes bulky and complex
Solution Approach 1:
The brake booster is segmented into two independent chambers: a boost chamber for normal braking assistance and an actuator chamber for emergency operation. This segmentation allows each chamber to perform its specific function independently, simplifying the overall system design while maintaining comprehensive braking assistance capabilities.
Solution Approach 2:
The single brake booster body serves multiple functions: it provides braking assistance during normal operation through the boost chamber, and enables emergency braking through the actuator chamber. This multi-functionality eliminates the need for separate emergency braking mechanisms, reducing system complexity.
2Reliability
If a hydraulic brake booster is integrated in series with the master cylinder, then braking assistance is provided, but the system occupies excessive space
Solution Approach 1:
The boost chamber and actuator chamber are merged into a single brake booster body, sharing common structural elements and fluid passages. This consolidation reduces the overall volume required compared to having separate boosters for normal and emergency braking functions.
Solution Approach 2:
The actuator piston and its chamber are nested within the same housing as the boost chamber, with both chambers sharing the brake booster body structure. This nested arrangement maximizes space utilization and minimizes the external dimensions of the braking system.
3Extent of automation
If the master cylinder is decoupled from the brake pedal, then automated braking control is enabled, but emergency operation capability is lost
Solution Approach 1:
The actuator chamber is pre-filled with brake fluid and the actuator piston is positioned in advance, ready to provide emergency braking assistance. When the high-pressure unit fails, the system automatically activates the actuator chamber without requiring driver intervention, ensuring emergency operation capability is maintained.
Solution Approach 2:
The system incorporates automatic detection of high-pressure unit malfunction through the hydraulic linkage between chambers. When failure is detected, the control system automatically switches to emergency operation mode by activating the actuator chamber, providing feedback-based automated response to maintain reliability.
4Reliability
If additional pistons are added to the brake booster for pressurization, then emergency operation is improved, but device complexity increases
Solution Approach 1:
The actuator piston serves dual functions: it provides emergency braking assistance by pressurizing the master cylinder, and it also acts as the primary actuator for normal braking when the high-pressure unit is unavailable. This multi-functionality eliminates the need for additional dedicated emergency pistons.
Solution Approach 2:
The actuator chamber uses the brake fluid already present in the system and the mechanical advantage of the brake pedal linkage to generate emergency braking pressure without requiring additional pressurization mechanisms or extra pistons. The system serves itself using existing components.
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
The system achieves a simpler design with reduced bulk, enabling efficient integration into vehicles and providing reliable emergency braking operations by automatically pressurizing the master cylinder and boosting brake pedal force, even in the event of high pressure unit failure or hydraulic leakage.
Implementation Method 1
a high pressure unit (300), supplying brake fluid under high pressure on command to the boost chamber (206) in order to act on the piston (110) of the master cylinder (100)
Implementation Method 2
an actuator piston (220) connected to the control rod (230) of the brake pedal... the piston (110) of the master cylinder carries a push rod (130) fixed in movement to the piston and protruding into the actuator chamber... the actuator piston is able to push directly the push rod associated with the master cylinder
Implementation Method 3
a controlled hydraulic link between the boost chamber (206) and the actuator chamber (209)... in the event of malfunction of the high pressure unit, it is possible to provide emergency operation, firstly by placing the actuator chamber in communication with the boost chamber to force fluid from the actuator chamber back to the boost chamber
Implementation Method 4
a brake booster formed by a simulator chamber defined by a piston pushed back by at least one spring
Data Source
AI summary
Braking system with master cylinder (100), decoupled from the brake pedal and hydraulic brake booster (200), comprisinga boost chamber (206) in which the rear of the piston (110) of the master cylinder (100) is inserted, supplied in a controlled manner by a high-pressure unit (300), supplying brake fluid under high pressure on command to the boost chamber in order to act on the piston (110) of the master cylinder (100), andan actuator chamber (209) receiving an actuator piston (220) connected to the control rod (230) of the brake pedal.A controlled hydraulic link (320, 321) connects the boost chamber (206) and the actuator chamber (209) and a further controlled hydraulic link (310, 311) connects the actuator chamber (209) to the chamber of a brake simulator (270).