Pedal Brake Assembly With Independent Electric Boost and Manual Braking
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Solution Overview
Problem
Existing brake systems for electric and hybrid vehicles face challenges in seamlessly integrating regenerative braking with driver input, especially in vehicles without engine vacuum, leading to increased complexity and space consumption, and fail to efficiently support autonomous driving levels by maintaining manual brake function and reducing manufacturing costs.
Innovation Solution
A pedal brake assembly with a single master cylinder block that combines electric boost and pedal brake functionality, featuring a push rod and actuator system with a plunger mechanism for independent movement of brake pistons, allowing for seamless interaction with Electronic Stability Control (ESC) and supporting various autonomy levels through novel brake pressure return paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electric boost and pedal brake functionality are combined in a single master cylinder block, then device complexity is reduced and manufacturing cost decreases, but the system must maintain independent movement capability of brake pistons for both manual and autonomous modes
Solution Approach 1:
The brake piston assembly is segmented into multiple independent pistons (first brake piston and second brake piston) that can move independently within the single master cylinder block. Each piston has its own movement path and can be actuated separately, allowing the system to maintain versatility for both manual and autonomous braking modes while using a unified structural platform that reduces overall complexity.
Solution Approach 2:
The single master cylinder block is designed to perform multiple functions: it supports both manual brake application through the push rod and automatic brake application through the actuator. The block accommodates both first and second brake pistons that can operate independently, enabling the same structural component to serve both traditional hydraulic braking and autonomous emergency braking functions, thereby reducing device complexity while maintaining adaptability.
2Adaptability or versatility
If a push rod and actuator system with plunger mechanism is used, then seamless interaction with ESC and autonomous driving is enabled, but manufacturing precision requirements increase
Solution Approach 1:
The plunger mechanism serves as an intermediary component between the actuator and the brake pistons. The plunger receives actuation force from the actuator and translates it into controlled movement of the brake pistons. This intermediary mechanism allows for precise control and adjustment of piston movement, enabling seamless interaction with ESC and autonomous driving systems while providing a buffer that can accommodate reasonable manufacturing tolerances through its own adjustment capabilities.
Solution Approach 2:
The push rod and actuator system is designed with dynamic adjustment capabilities. The actuator can independently control the movement of brake pistons based on real-time driving conditions and ESC requirements. The system transitions smoothly between manual and autonomous modes, with the actuator adjusting its engagement and force application dynamically. This dynamic control approach enables versatile brake control interaction while allowing for practical manufacturing precision through adaptive control algorithms.
3Adaptability or versatility
If electric boost is provided without engine vacuum, then hybrid and electric vehicle compatibility is improved, but the system length may increase consuming space under the vehicle hood
Solution Approach 1:
The electric boost system is merged with the traditional hydraulic brake system into a single integrated master cylinder assembly. The electric actuator is positioned within the same housing that contains the brake pistons and hydraulic chambers. This merging eliminates the need for separate vacuum booster components, allowing the system to accommodate hybrid and electric vehicle platforms without engine vacuum while maintaining a compact overall length that fits within standard vehicle hood spaces.
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 reduces manufacturing costs, provides a seamless interaction between pedal braking and advanced vehicle braking, and satisfies at least level 2 of vehicle autonomy, enabling efficient regenerative braking blending and independent operation in different modes, including autonomous and manual modes, while maintaining the manual brake function without extending the system's length.
Implementation Method 1
An actuator couples to the at least one brake piston for driving the at least one brake piston axially along the center axis between an opened position and a compressed position
Implementation Method 2
A push rod extends along the center axis between a first end and a second end for moving the at least one brake piston in the bore
Implementation Method 3
a push rod actuated master cylinder which generates a hydraulic pressure that is transmitted through brake lines to actuate hydraulic brakes
Data Source
AI summary
A pedal brake assembly comprises a master cylinder block defining a bore extending along a center axis. At least one brake piston is slidably disposed in the bore. A push rod, having a body portion and an end portion, extends between a first end and a second end. The second end is coupled to a brake pedal. A housing defines a channel for receiving the push rod. An actuator couples to the at least one brake piston. The body portion is slidably disposed in the channel. The end portion is in an abutment relationship with the housing and defines a hole extending from the first end to the body portion. A plunger is slidably disposed in the end portion for engaging the at least one brake piston whereby the push rod and the actuator are independently movable along the center axis.