Pedal Travel Simulator Spring Ring Stroke Limiting
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Solution Overview
Problem
Existing pedal travel simulators for hydraulic vehicle power braking systems lack effective mechanisms to limit piston stroke and manage spring tensioning, leading to inefficiencies in brake fluid displacement and actuation force simulation.
Innovation Solution
A pedal travel simulator design featuring a cup-shaped cover with a helical compression spring and a spring ring that limits piston stroke, along with a fitting to hold the spring elements, allowing pre-assembly and simplifying assembly, and utilizing a second spring element for simulating the 'jump-in' actuation force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If no piston stop is provided, then the piston can move freely in the cylinder, but the cover is subjected to excessive piston force due to brake pressure and the spring element is overly tensioned
Solution Approach 1:
The piston stop function is extracted as a separate component (spring ring) from the cover structure, allowing the cover to focus on its primary function of containing the spring element while the spring ring specifically handles the piston stroke limitation and force management
Solution Approach 2:
The spring ring acts as an intermediary component between the piston and the cover, mediating the interaction by limiting piston stroke and thereby controlling the force transmitted to the cover and the tension on the spring element
2Manufacturing precision
If the first spring element acts on the piston over its entire stroke, then continuous force is applied, but the spring element cannot be properly tensioned and the actuation force simulation is inaccurate
Solution Approach 1:
The spring element's engagement is segmented into two phases: initially held in a tensioned state by the fitting during assembly, then released to act on the piston only after the piston reaches a certain position in its stroke, achieving both proper tensioning and accurate force simulation
Solution Approach 2:
The spring element is pre-tensioned during assembly by the fitting before the piston begins its stroke, ensuring the spring is properly prepared to provide accurate actuation force simulation when the piston reaches the appropriate position
3Ease of manufacture
If the cover, fitting, and spring element are assembled separately, then each component can be manufactured independently, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The cover, fitting, and spring element are merged into a pre-assembled unit that is manufactured and tested as an integrated component set, then installed as a single unit in the pedal travel simulator, combining the benefits of independent manufacturing with simplified final assembly
Solution Approach 2:
The fitting and spring element are preliminarily assembled with the cover in a pre-assembly step before installation into the complete pedal travel simulator, allowing for quality control and proper positioning to be established early in the manufacturing process
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 limits piston stroke, manages spring tension, and enhances the simulation of actuation forces, improving the efficiency of brake fluid displacement and actuation in hydraulic vehicle power braking systems.
Implementation Method 1
A first spring element (8) that acts on the piston (4) to move it into the cylinder (3) is situated in the cover (5)
Implementation Method 2
a spring ring (19) that is inserted into a circumferential groove between the piston (4) and the cover (5) and that protrudes inwardly from the groove, so that the spring ring (19) forms a piston stop that limits the stroke of the piston (4) in the direction of the cover (5)
Implementation Method 3
when actuated it displaces brake fluid into the pedal travel simulator (1), which communicates with the master brake cylinder during the power braking
Data Source
AI summary
A stroke of a piston of a pedal travel simulator is limited via a spring ring that is inserted into a circumferential groove in a cylinder of the pedal travel simulator. The spring ring relieves the load on a cover of the pedal travel simulator that closes the cylinder of the pedal travel simulator.