Deformable Actuator for Brake Booster Impact Protection
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Solution Overview
Problem
In hybrid vehicles, the large gearbox housing and electric brake booster system can cause undesirable deformations of the bulkhead and displacement of the brake pedal and steering column during a frontal impact due to a direct force connection, leading to potential safety hazards.
Innovation Solution
A brake booster device with a deformable actuator formed by pivot elements and a displacement element, mounted on a vehicle component, which pivots to apply a force to the brake booster in the Z direction, altering its position and moving it out of the direct force path from the gearbox housing, thereby reducing deformation and displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a direct force connection between the gearbox housing and the brake booster system is produced during a frontal impact, then the packaging of the gearbox housing and the electric brake booster system is achieved, but this leads to undesirable deformations of the bulkhead, displacement of the brake pedal, and deformations of the dashboard carrier
Solution Approach 1:
The actuator serves as an intermediary element between the gearbox housing and the brake booster. It includes a first element connected to the gearbox housing, a second element connected to the brake booster, and a deformable connecting element joining these two elements. This mediator absorbs and redistributes impact forces, preventing direct force transmission that causes bulkhead deformation while maintaining the packaged arrangement of components.
2Device complexity
If a direct force connection between the gearbox housing and the brake booster system is produced, then the structural connection is simplified, but this causes displacement of the brake pedal and steering column
Solution Approach 1:
The actuator with its deformable connecting element acts as a mediator that decouples the direct force connection between the gearbox housing and brake booster. This intermediary structure allows controlled deformation under impact forces, preventing the transmission of destabilizing forces to the brake pedal and steering column while maintaining normal operational connectivity.
Solution Approach 2:
The connecting element of the actuator is designed to be deformable, allowing it to dynamically adapt its stiffness and geometry in response to applied forces. During normal operation, it maintains a rigid connection for structural stability, but during impact, it deforms to absorb energy and prevent force transmission that would displace the brake pedal and steering column.
3Object-affected harmful factors
If the brake booster is completely detached from the fastening points, then the force path is interrupted, but this causes loss of functional connection and control
Solution Approach 1:
The actuator serves as a controlled intermediary between the gearbox housing and brake booster, replacing complete detachment with a managed connection. The deformable connecting element allows the actuator to move and absorb impact forces, interrupting the harmful force path, while maintaining the functional connection necessary for normal brake operation and control.
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 solution effectively reduces bulkhead deformation and minimizes brake pedal and steering column displacement during a frontal impact, enhancing occupant safety by interrupting the direct force path between the gearbox housing and brake booster, allowing controlled movement of the brake booster without complete detachment of fastening points.
Implementation Method 1
The two pivot elements are mounted at a spacing from one another on a vehicle component such that they are pivotable about respective rotary axes extending in a Y direction
Implementation Method 2
A deformable actuator which is formed by at least two pivot elements and a displacement element
Data Source
AI summary
An exemplary brake booster device includes, among other things, a brake booster mounted on a vehicle component, and an actuator that, in response to a force applied to the actuator by a gearbox housing, pivots to move the brake booster upward. The actuator includes at least two pivot elements spaced from each other, and a displacement mounted in a jointed manner between the at least two pivot elements.