Separated Pedal Simulator Layout for Flexible Brake Installation
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Solution Overview
Problem
Existing pedal simulators are integrated with electric boosters, limiting installation freedom and causing noise and impact issues due to their large volume and heavy weight.
Innovation Solution
A pedal simulator design that separates from the electric control system, featuring a cylinder body, movable piston, guide bushing, damper, push rod, and return means, allowing for improved installation flexibility and reduced noise and impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pedal simulator is integrated with the electric booster, then the braking performance can be created, but the volume and weight of the electric booster increase, limiting installation freedom and requiring high firewall rigidity
Solution Approach 1:
The pedal simulator is separated from the electric booster into an independent component. The simulator includes a cylinder body, piston, guide bushing, and return means that can be independently installed on the firewall, while the electric booster remains a separate unit. This segmentation allows each component to be optimized independently and installed in different locations.
Solution Approach 2:
The simulator function is extracted from the electric booster structure. The simulator is now a standalone device that can be mounted separately on the firewall, removing the constraint that required the electric booster to accommodate simulator components, thereby reducing the electric booster's volume and weight.
2Reliability
If the pedal simulator is integrated with the electric booster, then the braking performance can be created, but the weight of the electric booster increases, requiring high firewall rigidity
Solution Approach 1:
The simulator is segmented from the electric booster into a separate weight-bearing component mounted on the firewall. This allows the electric booster's weight to be reduced while the firewall structure supports the simulator's weight independently.
Solution Approach 2:
The simulator's weight is extracted from the electric booster assembly and transferred to the firewall mounting structure. The simulator includes its own housing and mounting features that interface directly with the firewall, separating the weight burden from the electric booster.
3Adaptability or versatility
If the pedal simulator is separated from the electric control system, then installation freedom is improved and noise and impact are reduced, but the device complexity increases
Solution Approach 1:
The simulator is designed as a modular segmented unit with standardized mounting interfaces on the firewall. This segmentation enables flexible installation in various locations while maintaining relatively simple individual component designs that don't require complex integration with the electric booster.
4Volume of moving object
If the pedal simulator is separated from the electric control system, then installation freedom is improved, but the device complexity increases
Solution Approach 1:
Both the simulator and electric booster are segmented into independent units with simplified individual designs. The simulator contains only the necessary components (cylinder body, piston, guide bushing, return means) for its specific function, while the electric booster focuses solely on its motor and control functions, reducing overall system complexity despite the separation.
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 pedal simulator enhances installation freedom, reduces noise and impact, and allows for various braking performance configurations without altering the electric booster's shape or size.
Implementation Method 1
a guide bushing provided at one side of the cylinder body and configured to reduce friction between the cylinder body and the piston
Implementation Method 2
a damper provided in the cylinder body and configured to transfer pedal feel to an electric booster by means of a pressure applied from the piston
Implementation Method 3
a return means provided while covering one side of the guide bushing and a part of the push rod and configured to provide a restoring force for moving rearward the push rod that has moved forward
Data Source
AI summary
A pedal simulator including a cylinder body featuring an open side and a closed side, a piston for pedal operation, a guide bushing to reduce friction, a damper for pedal feel transfer to an electric booster, a push rod connecting the pedal and piston, and a return means for restoring the push rod's position after moving forward.