Integrated Brake Master Cylinder Layout for Compact Hydraulic Braking
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Solution Overview
Problem
Conventional hydraulic brake apparatuses have a large size and numerous parts, leading to low production efficiency and high costs due to the independence of the pedal simulator and spare master cylinder.
Innovation Solution
A hydraulic brake apparatus with two pistons and a baffle plate, utilizing elastic components and through holes to create three cavities, allowing for a compact design and controlled oil flow, thereby reducing the number of parts and improving manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pedal simulator and spare master cylinder are designed as independent components, then the braking function is reliable, but the device size becomes large and the number of parts increases
Solution Approach 1:
The patent merges the pedal simulator and spare master cylinder into a single integrated master cylinder assembly. The first piston serves as the spare master cylinder piston while the second piston serves as the pedal simulator piston, both operating within the same housing and sharing common structural elements. This integration reduces the number of separate parts while maintaining the independent functional capabilities of both components, thereby resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The integrated master cylinder assembly performs multiple functions: it serves as both the spare master cylinder (first piston) and pedal simulator (second piston), and also functions as the hydraulic pressure source for the braking system. The single housing accommodates both pistons and provides the cavity structure for hydraulic operation, making the assembly universal and multi-functional, thus reducing part count while maintaining reliability.
2Reliability
If the pedal simulator and spare master cylinder are designed as independent components, then each component can be optimized for its specific function, but the production efficiency decreases due to large size and numerous parts
Solution Approach 1:
By combining the pedal simulator and spare master cylinder into one integrated assembly, the patent reduces the total number of parts that need to be manufactured, assembled, and quality-checked. The single housing and shared structural elements simplify the manufacturing process and assembly operations, thereby improving production efficiency while maintaining the functional optimization of each piston through its dedicated cavity and sealing arrangement.
3Reliability
If independent pedal simulator and spare master cylinder are used, then the hydraulic circuit requires more valves and oil flow control components, but this increases the cost and complexity of the system
Solution Approach 1:
The integrated master cylinder assembly allows the hydraulic circuit to be simplified because the first and second pistons share a common housing and cavity structure. The oil flow between the two pistons can be controlled with fewer valves since they are already positioned adjacent to each other within the same housing, reducing the need for extensive valve apparatus and associated oil circuits that would be required if the components were completely separate.
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 compact design enhances production efficiency and reduces costs while maintaining effective braking functionality by using elastic assemblies and through holes to simulate braking effects and control oil flow.
Implementation Method 1
a first elastic component, a second elastic component, and a third elastic component, disposed in the first sub-cavity, the second sub-cavity, and the second cavity respectively and configured to slide the baffle plate, the first piston, and the second piston
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A hydraulic brake apparatus, a hydraulic brake system, and a vehicle are provided. The hydraulic brake apparatus includes: a housing (1), where the interior of the housing is a cavity structure, and the cavity structure communicates with the outside; a first piston (3), disposed in the cavity structure inside the housing (1), where the first piston (3) and the housing (1) form a first cavity; a baffle plate (6), disposed in the first cavity and dividing the first cavity into a first sub-cavity (702) and a second sub-cavity (703); a second piston (2), disposed in the cavity structure inside the housing (1), where the second piston (2), the first piston (3), and the housing (1) form a second cavity (701); and a first elastic component (402), a second elastic component (403), and a third elastic component (401), disposed in the first sub-cavity (702), the second sub-cavity (703), and the second cavity (701) respectively. The housing (1) includes a first through hole (101) and a second through hole (102). The second piston (2) includes a third through hole (201). The first piston (3) includes a fourth through hole (302) and a fifth through hole (301). Having a small size and including a few parts, the hydraulic brake apparatus can be applied to intelligent vehicles, new energy vehicles, connected vehicles, or autonomous vehicles, thereby improving production efficiency of manufacturers and reducing costs.