Single Piston Brake Master Cylinder Stroke Reduction
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Solution Overview
Problem
Conventional brake apply master cylinders with two pistons and an intervening spring require longer piston strokes and more complex seal arrangements, which can lead to inefficiencies and increased complexity in brake system operation.
Innovation Solution
A brake apply master cylinder design featuring a single brake apply piston and an optional pressure equalization piston, which reduces chamber volumes and simplifies the piston stroke mechanism, potentially reducing the total piston stroke and enhancing operational efficiency by using a single piston to divide the bore into primary and secondary fluid chambers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single brake apply piston is used to divide the bore into primary and secondary fluid chambers, then the total piston stroke is reduced and seal arrangement is simplified, but the pressure equalization between chambers becomes more challenging
Solution Approach 1:
A pressure equalization piston is introduced as an intermediary component between the primary and secondary fluid chambers. This pressure equalization piston communicates with both chambers and ensures pressure balance, resolving the reliability concern while maintaining the simplicity of the single brake apply piston design
Solution Approach 2:
The single brake apply piston is segmented into distinct sections (primary piston section and secondary piston section) that independently control the primary and secondary fluid chambers. This segmentation allows each section to function independently while maintaining overall system simplicity and reducing total stroke requirements
2Length of moving object
If a single brake apply piston with pressure equalization piston is used, then the total piston stroke is reduced, but the manufacturing complexity of the piston assembly increases
Solution Approach 1:
The piston assembly is divided into separate, manufacturable sections (primary piston section, secondary piston section, and pressure equalization piston) that can be manufactured independently using standard machining processes, then assembled together. This segmentation reduces the total stroke length while maintaining ease of manufacture through modular construction
3Reliability
If conventional two-piston design is used, then pressure equalization is achieved, but the seal arrangement becomes more complex and piston stroke increases
Solution Approach 1:
The functions of two separate pistons are merged into a single brake apply piston with integrated primary and secondary sections. The pressure equalization piston serves as a common interface for both chambers, reducing the number of seals required while maintaining pressure equalization reliability
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 single piston design reduces the total piston stroke and simplifies the seal arrangement, enhancing operational efficiency and potentially reducing the complexity of brake system operation compared to conventional systems.
Implementation Method 1
Longitudinal forward movement of the single brake apply piston reduces the first and second chamber volumes, compressing the brake fluid in the primary brake circuit and secondary brake circuit
Implementation Method 2
The pressure equalization piston has a first end in fluid communication with the primary fluid chamber and a second end in fluid communication with the secondary fluid chamber
Implementation Method 3
The return spring assembly is positioned in the bore and extends from the closed front end to a return-spring seat of the single brake apply piston
Data Source
AI summary
A brake apply master cylinder includes a body and a piston assembly. The body includes a bore. The bore has a longitudinal axis, a closed front end, a primary fluid outlet fluidly connectable to a primary brake circuit, and a secondary fluid outlet fluidly connectable to a secondary brake circuit. The piston assembly includes a single brake apply piston positioned in the bore. The piston assembly fluidly divides the bore into a primary fluid chamber in fluid communication with the primary fluid outlet and a secondary fluid chamber in fluid communication with the secondary fluid outlet. Another brake apply master cylinder includes a body, a piston assembly, and a return spring assembly. The return spring assembly is positioned in the bore of the body and extends from the closed front end of the bore to a return-spring seat of a single brake apply piston of the piston assembly.