Hydraulic Brake Booster Structure for Adjustable Boosting Ratio
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Solution Overview
Problem
Conventional brake boosters in hydraulic braking systems are difficult and costly to modify for varying the boosting ratio, which is a requirement in agricultural vehicles due to optimization needs and evolving regulations.
Innovation Solution
The hydraulic braking device includes a brake booster with a control piston and a bushing or thrust portion, allowing the effective cross-sectional area to be easily modified by replacing the bushing or control piston, along with associated gaskets and washers, to adjust the boosting ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the conventional brake booster design is used, then the braking function is performed effectively, but the boosting ratio cannot be easily modified when different ratios are required
Solution Approach 1:
The control piston is divided into multiple independent components: a body portion, a plunger, and a disc. This segmentation allows the disc to be replaced independently to change the effective cross-sectional area, enabling easy adjustment of the boosting ratio without replacing the entire control piston assembly
Solution Approach 2:
The control piston body and plunger are designed as universal components that can work with different disc variations. This multi-functionality allows a single base assembly to support multiple boosting ratios by simply changing the disc component, reducing overall system complexity and cost
2Adaptability or versatility
If the control piston is replaced with another one having a different cross-sectional area, then the boosting ratio changes, but other components especially the plunger sliding on the control piston must also be replaced
Solution Approach 1:
The control piston is segmented into a reusable body/plunger assembly and a replaceable disc component. Only the disc needs to be replaced to achieve different cross-sectional areas, significantly reducing the number of components that must be replaced compared to replacing the entire control piston
Solution Approach 2:
The disc is nested within the control piston structure, allowing it to be independently removed and replaced while retaining the outer housing and plunger components. This nested design enables partial replacement rather than complete assembly replacement
3Adaptability or versatility
If the plunger sliding on the control piston is replaced, then the boosting ratio can be modified, but this solution involves remarkable costs to be practiced
Solution Approach 1:
The design segments the cost-bearing components from the replaceable components. The expensive plunger and body are retained, while only the relatively inexpensive disc is replaced to achieve the desired boosting ratio modification, significantly reducing modification costs
Solution Approach 2:
The disc is designed as a low-cost, easily replaceable component compared to the plunger and body. By making the disc the sacrificial/replaceable element, the system enables cost-effective boosting ratio adjustments without investing in expensive custom plungers or bodies
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 enables easy and cost-effective adjustment of the boosting ratio without replacing the entire control piston or plunger, enhancing customization and compliance with changing regulations.
Implementation Method 1
a control piston (also called spool) connected to a brake pedal. The control piston is adapted to drive a brake booster allowing to exert a pressure onto a piston of the master cylinder so that this piston generates, within a chamber of the master cylinder, a control pressure
Implementation Method 2
the pressure difference (delta pressure) between the two chambers exerts onto the brake booster piston a thrust which adds to the thrust exerted by the pedal, thereby making the pedal move towards the chamber of the master cylinder, thus amplifying the force
Data Source
AI summary
A hydraulic braking device comprising a master cylinder and a brake booster. The braking device comprises a control piston driven by actuating a brake pedal and mounted so as to be tightly slidable in a plunger of a piston of the brake booster. The control piston comprises a first end portion having a certain cross-sectional area and being arranged to cooperate with a gasket so as to establish, during braking, a modulated communication between the first chamber of the brake booster and a discharge chamber of the master cylinder. The braking device has an effective cross-sectional area counter-acting a pressure existing in a region comprised between a master cylinder piston and the control piston. Such area is different from the cross-sectional area of the first end portion of the control piston.