Electric Booster Reaction Disk Stiffness for Brake Control
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Solution Overview
Problem
Electric booster-based brake systems without a pedal simulator face challenges in maintaining pedal feel and require high-performance ESC systems for regenerative brake cooperation control, leading to increased manufacturing costs and limited control constraints.
Innovation Solution
A brake apparatus using an electric booster with a reaction disk of specific stiffness, allowing pedal force variations from driver input and electromotive force changes to offset each other, enabling cooperation control through ESC in non-linear piston stroke sections and electric booster control in linear sections, thereby reducing the need for high-performance ESC and minimizing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an electric booster with no pedal simulator is applied to perform brake control, then the braking mechanism is simplified and manufacturing cost is reduced, but the pedal feel is affected due to deformations in the reaction disk
Solution Approach 1:
The patent changes the physical parameter of the reaction disk by specifying its stiffness value (0.05 to 0.15 N/mm³) to minimize deformations. This parameter optimization ensures that the reaction disk maintains sufficient rigidity to provide stable pedal feel while keeping the electric booster design simple and cost-effective without requiring a pedal simulator.
2Measurement precision
If a high-performance ESC system is used for regenerative brake cooperation control, then the control precision is improved, but the manufacturing cost is increased
Solution Approach 1:
The patent segments the brake control into two distinct sections: a non-linear section (0-3 bar pressure range) handled by the ESC system and a linear section (3-10 bar pressure range) handled by the electric booster. This segmentation allows the use of a general, lower-cost ESC system for the non-linear section while relying on the electric booster for precise linear control, thereby reducing overall manufacturing cost without sacrificing control precision.
Solution Approach 2:
The patent applies partial action by having the ESC system handle only the non-linear section of brake control (0-3 bar) rather than the entire range. This partial control approach allows the use of a less expensive ESC system that is sufficient for the non-linear section, while the electric booster handles the remaining linear section requiring higher precision.
3Stability of the object's composition
If the reaction disk stiffness is increased to improve pedal feel, then the pedal stability is improved, but the deformations under pedal stepping force are reduced which affects the offset capability
Solution Approach 1:
The patent identifies and optimizes the reaction disk stiffness parameter within a specific range (0.05 to 0.15 N/mm³) that simultaneously achieves both pedal stability and adequate deformability. This optimized parameter range ensures the reaction disk is stiff enough to provide stable pedal feel but flexible enough to deform under pedal stepping force and electromotive force changes, enabling the offset capability to function properly.
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 maintains consistent pedal feel and reduces manufacturing costs by allowing the use of general ESC systems, while minimizing constraints on regenerative brake cooperation control, ensuring effective brake control without a pedal simulator.
Implementation Method 1
pressurizing a reaction disk using an electromotive force of a motor
Implementation Method 2
deformations in a central portion and an edge portion of a reaction disk by a change in pedal stepping force of a driver and a change in electromotive force of a motor
Data Source
AI summary
A brake apparatus using an electric booster may include: an electric booster connected to a master cylinder and configured to pressure a push rod by pressurizing a reaction disk using an electromotive force of a motor with a pedal stepping force of a driver who steps on a brake pedal, and pressurize a piston of the master cylinder through the push rod; and a control unit configured to compare required brake pressure by the pedal stepping force of the driver and current brake pressure by the motor control to set pressure, and perform cooperation control through an ESC (Electronic Stability Control) and cooperation control through the electric booster.