Tandem Master Cylinder Layout With Integrated Pedal Feel Balancing
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Solution Overview
Problem
Conventional brake systems require separate pedal feel simulators and additional valves, which complicate the design and functionality, especially in emergency and test modes, where efficient pressure equalization and fluid management are critical.
Innovation Solution
A tandem master cylinder arrangement with a floating piston and an elastic pedal feel element, which integrates the pedal simulator function, allows for pressure equalization between chambers without direct hydraulic connection, and includes ventilation channels and valves for emergency and test modes, reducing the need for extra components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional brake system uses a separate pedal feel simulator and additional valves, then the pedal feel can be simulated, but the device complexity increases
Solution Approach 1:
The patent combines the pedal feel simulator function directly into the master cylinder assembly by integrating an elastic element between the first and second master pistons. This eliminates the need for a separate pedal feel simulator and additional valves, reducing component count while maintaining the pedal feel simulation function.
Solution Approach 2:
The master cylinder assembly is designed to perform multiple functions: it serves as both the hydraulic pressure generation device and the pedal feel simulator. The elastic element between the pistons provides both structural separation and pedal feel simulation, making the system more compact and less complex.
2Force
If the second master piston is locked in normal operating mode, then the pedal feel element can generate pedal force, but pressure equalization between chambers becomes difficult in emergency mode
Solution Approach 1:
The second master piston is designed to be movable rather than locked, allowing it to dynamically adjust its position. In normal operating mode, the piston remains relatively stable to allow pedal force generation. In emergency mode, the piston can move freely to enable pressure equalization between chambers through the balancing path, providing adaptability to different operating conditions.
Solution Approach 2:
A balancing piston is introduced as an intermediary element between the first and second master chambers. This balancing piston can move along a balancing path to equalize pressures between chambers in emergency mode, while not interfering with the normal operation of the pedal feel element in standard operating conditions.
3Ease of manufacture
If ventilation channels are provided in the piston wall, then fluid management is improved, but the manufacturing complexity increases
Solution Approach 1:
The piston structure is designed with multi-functionality: the piston wall serves both as a structural separator between chambers and as a conduit for ventilation channels. The balancing piston also serves dual purposes of pressure equalization and fluid management through its positioning on the balancing path, reducing the need for separate complex fluid management components.
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 provides a compact, efficient brake system that mimics conventional pedal feel in normal mode, ensures emergency mode functionality, and minimizes the number of valves required for testing, enhancing reliability and simplicity.
Implementation Method 1
the elastic pedal feel element can mimic the pedal force of a brake pedal of a conventional braking system during a braking action. Thus, the elastic pedal feel element can function as a pedal simulator and the driver experiences a counterforce when the brake pedal is operated
Implementation Method 2
the balancing piston separating the balancing chamber from the second master chamber and the balancing chamber being hydraulically connected to the first master chamber via a balancing path for balancing a first hydraulic pressure in the first master chamber and a second hydraulic pressure in the second master chamber
Data Source
AI summary
The present invention relates to a master cylinder arrangement for a brake system, comprising a tandem master cylinder including a master cylinder housing, a first master piston movably arranged in the master cylinder housing, a second master piston movably arranged in the master cylinder housing, a balancing piston movably arranged in the second master piston, and an elastic pedal feel element. The invention further relates to a hydraulic system for a brake system as well as a brake system.