Stroke Simulator Elastic Member Merging for Brake Feel
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Solution Overview
Problem
Existing stroke simulators with multiple elastic members increase component count, assembly complexity, and weight, potentially compromising brake feeling and increasing costs.
Innovation Solution
A stroke simulator design using a tubular cylinder with a piston and a lid member, featuring a first elastic member and a second elastic member with a protruding portion, where the second elastic member's base portion compresses and deforms to provide reaction force characteristics at different stages of brake operation, reducing the number of components while maintaining brake feeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If three elastic members are provided in the cylinder, then the brake feeling is improved, but the number of components increases and assembly property lowers
Solution Approach 1:
The patent combines the functions of three separate elastic members into a single integrated elastic member with a protruding portion. The base portion and protruding portion work together to provide the reaction force characteristics that previously required three separate components, thereby reducing assembly complexity while maintaining brake feeling.
Solution Approach 2:
The elastic member is segmented into a base portion and a protruding portion, where each segment provides specific reaction force characteristics. The protruding portion provides a first reaction force characteristic at initial stage, while the base portion provides a second reaction force characteristic at later stage, achieving the functional equivalence of three separate members through strategic segmentation.
2Ease of operation
If three elastic members are provided in the cylinder, then the brake feeling is improved, but the cost increases
Solution Approach 1:
By merging three elastic members into one integrated component, the patent reduces manufacturing costs associated with producing, inventorying, and assembling three separate parts. The single elastic member with protruding portion can be manufactured as one piece, eliminating the need for multiple component procurement and assembly operations.
3Force
If a metal spring is used as the elastic member, then the elastic coefficient is high, but the weight and size increase
Solution Approach 1:
The patent applies local quality by creating a protruding portion with specific geometric characteristics that concentrate elastic properties where needed. The protruding portion has a smaller cross-sectional area and different geometry compared to the base portion, allowing high elastic coefficient in the critical initial stage while keeping overall weight low. This localized elastic enhancement avoids the need for a fully dense metal spring throughout the entire component.
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 design achieves reduced component count and weight, simplifies assembly, and enhances brake feeling by utilizing two elastic members to simulate reaction forces at various stages of brake operation, allowing for miniaturization and cost reduction.
Implementation Method 1
the second elastic member includes a base portion arranged in series with the first elastic member, and a protruding portion protruding out from an end face of the base portion on the piston side, and is configured such that, when the piston moves in an axial direction toward the lid member side, the base portion compresses and deforms after the protruding portion abuts against the piston and is compressed and deformed
Data Source
AI summary
The present invention comprises: a piston provided in a cylinder hole; a lid member which closes an opening on the other side of the cylinder hole; and elastic members and which are provided between the piston and the lid member. The elastic members and comprise a first elastic member provided on the piston side of the cylinder hole, and a second elastic member provided on the lid member side of the cylinder hole. The second elastic member has a base portion provided in line with the first elastic member, and a protruding portion protruding from the piston side end surface of the base portion. When the piston has moved in the axial direction to the lid member side, the protruding portion touches the piston, undergoing compressive deformation, and the base portion subsequently undergoes compressive deformation.