Segmented Primary Piston Assembly for Brake Booster Failure
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Solution Overview
Problem
Existing brake systems face challenges in ensuring reliable braking performance when the brake booster actuator device fails, as the driver must apply increased force to compensate for the loss of booster assistance, which can be physically demanding and inefficient.
Innovation Solution
The primary piston assembly allows for the separation and adjustment of primary piston components into segments, enabling the driver to reduce the braking force required by isolating the driver's braking effort to only the first piston component, and using the driver's force to seal the snifting bore and increase brake pressure, even in the absence of a functioning brake booster.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake booster actuator device fails, then the driver must apply increased braking force to compensate, but this increases the physical demand on the driver and reduces braking efficiency
Solution Approach 1:
The primary piston is divided into two separate components: a first primary piston component that the driver directly actuates, and a second primary piston component that is normally actuated by the brake booster. This segmentation allows the driver to maintain braking control even when the brake booster fails, as the driver can directly apply force to the first piston component to seal the snifting bore and build brake pressure.
2Ease of operation
If the primary piston is separated into multiple components, then the driver can reduce braking force by isolating effort to the first piston component, but this increases device complexity
Solution Approach 1:
The second primary piston component is arranged at least partially within a continuous recess of the first primary piston component. This nested arrangement allows both piston components to coexist in a compact configuration, reducing the overall space required and simplifying the assembly structure while still providing the functional benefits of separation.
3Volume of moving object
If the second piston component is arranged within the first piston component, then space is optimized, but the adjustability of both components may be restricted
Solution Approach 1:
The first primary piston component is designed with a continuous recess that provides the second piston component with independent adjustment capability. This local structural feature ensures that the second piston component can be adjusted independently within the recess without being constrained by the position of the first piston component, maintaining full adaptability while optimizing space utilization.
Data Source
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Figure 1B
Figure 1C
AI summary
The invention relates to a primary piston assembly (22, 28) for a master brake cylinder (12) of a vehicle braking system with a first primary piston component (22) having a first piston element (24), to which a driver's braking force (Fb) is transferrable in such manner that a pressure chamber volume of a pressure chamber (10) of a master brake cylinder (12) of the braking system that is fillable with a liquid can be reduced by displacement of the first piston element (24) via the driver's braking force (Fb), wherein the pressure chamber volume that is fillable with a liquid can be further reduced by means of a first braking support force (Fu1) provided by a braking force amplifier actuator device (26), and wherein the primary piston assembly (22, 28) comprises a second primary piston component (28) with a second piston element (30), to which the first braking support force (Fu1) is transferrable in such manner that the pressure chamber volume of the pressure chamber (10) can be reduced by displacement of the second piston element (30) by means of the first braking support force (Fu1). The invention further relates to a production method for a braking unit with at least one master brake cylinder (12) and one braking force amplifier device (48), and a method for operating a braking unit.