Electromechanical brake caliper based on gear and rack structure

Abstract

The utility model relates to the technical field of brake systems, and discloses an electronic mechanical brake caliper based on a gear rack structure, which comprises a motor and a controller sub-assembly, and the inner walls of the motor and the controller sub-assembly are fixedly connected with a planetary reducing mechanism. According to the electronic mechanical brake caliper based on the gear and rack structure, a larger reduction ratio can be provided through three-stage gear speed reduction, then the requirement for the output torque of a motor is reduced, and the motor with a smaller size can be selected; the rack and the piston are integrated, the original hydraulic caliper piston function is reserved, and the end of the rack achieves the anti-backspacing function through toothless design; compared with a crank connecting rod mechanism, the design is simpler, control is easier, the service life can be fully guaranteed through modulus control, and compared with a ball screw, the reliability is higher; the motor is small in axial size, compact in overall structure, large in cavity size, light in weight and beneficial to design of the center of gravity of calipers and arrangement of wheel edges.

Description

Technical Field

[0001] This utility model relates to the field of braking system technology, specifically to an electromechanical brake caliper based on a gear and rack structure. Background Technology

[0002] As consumers place increasing emphasis on vehicle safety, vehicle braking systems are constantly being improved. Compared to hydraulic brake calipers, electromechanical brake calipers offer advantages such as faster response time, lower drag torque, and independent control of braking force at all four wheels, greatly enhancing vehicle handling and comfort. Furthermore, since no brake fluid is involved, they are more environmentally friendly during use.

[0003] At present, although the industry has made some progress in the research of electromechanical brake actuators, most of them are gear set + ball screw type electromechanical brake calipers (publication number CN15773322A), and there are also gear set + crank connecting rod type (publication number CN1757947A) and universal drive + gear rack type (publication number CN116733873A).

[0004] Existing hydraulic brake caliper solutions have the following drawbacks: they involve hydraulic lines, which are prone to leakage; four-wheel brake pressure adjustment requires one-box control of hydraulic pressure, resulting in slow response; and the presence of oil circuits within the brake caliper complicates design and manufacturing.

[0005] The defects of gear set + ball screw type electromechanical brake calipers are: complex braking conditions and large impact loads, which can easily lead to the peeling of ball screw raceways and affect service life; the piston return of electromechanical brake calipers relies on motor control. If the motor control fails during retraction, or if the piston return amount exceeds the expectation due to inertia, the ball screw will reverse excessively. The existing process limit structure is prone to ball screw jamming after repeated impacts, which will lead to brake caliper failure; in addition, the large mass of the ball screw directly affects the center of gravity design of the brake caliper and the noise risk is higher.

[0006] Defects of gear set + crank connecting rod type electromechanical brake caliper: The transmission mechanism is large in size, which makes it difficult to arrange the brake caliper wheel side; the relationship between the speed and displacement of the crank connecting rod mechanism changes in real time with the connecting rod swing angle, which greatly increases the difficulty of the motor to control the clamping force.

[0007] The drawbacks of the universal joint drive + rack and pinion electromechanical brake caliper are: the ball cage structure is complex and costly; the rack pushes the friction plate through the tie rod, and due to the small contact area between the tie rod and the friction plate, the pressure distribution of the friction plate is uneven, resulting in uneven wear of the friction plate, and the poor sealing between the tie rod and the caliper body makes it difficult to waterproof and dustproof; the overall axial dimension is too long, and the wheel edge arrangement is difficult.

[0008] Therefore, we need an electromechanical brake caliper based on a rack and pinion structure. Utility Model Content

[0009] The purpose of this invention is to provide an electromechanical brake caliper based on a gear and rack structure, in order to solve the problems mentioned in the background art, such as the inability of the rack to prevent excessive backlash, large size, heavy weight, and short lifespan.

[0010] To achieve the above objectives, this utility model provides the following technical solution:

[0011] An electromechanical brake caliper based on a gear and rack structure includes a motor and a controller sub-assembly. A planetary reduction mechanism is fixedly connected to the inner wall of the motor and controller sub-assembly. A bevel gear reduction mechanism is provided on one side of the planetary reduction mechanism, and a piston rack mechanism is installed at the bottom of the bevel gear reduction mechanism.

[0012] The planetary reduction mechanism includes a first planetary gear set, and a second planetary gear set is mounted on one side of the first planetary gear set;

[0013] The bevel gear reduction mechanism includes a first bevel gear, a second bevel gear meshing with the outer wall of the first bevel gear, and a second bevel gear bearing installed on the inner wall of the second bevel gear, while the first bevel gear is provided with a first bevel gear bearing on its inner wall.

[0014] The piston rack mechanism includes a transmission gear, the outer wall of which meshes with a rack body, and a piston body is fixedly connected to one side of the rack body, with a piston cap installed on one side of the piston body.

[0015] Preferably, an inner friction plate is provided on one side of the piston rack mechanism, and a brake caliper bracket is fixedly connected to the bottom of the inner friction plate; a brake caliper cylinder is bolted to one side of the motor and controller sub-assembly, and an outer friction plate is provided at the bottom of the brake caliper cylinder; a dust cover is installed on the top of the motor and controller sub-assembly, and a rectangular sealing ring is provided on one side of the dust cover; and a large O-ring is installed on one side of the planetary reduction mechanism.

[0016] Preferably, the first planetary gear set forms a fixed structure with the first bevel gear through the second planetary gear set, and the second planetary gear set is disposed between the first planetary gear set and the first bevel gear.

[0017] Preferably, the first bevel gear forms a rotating structure with the transmission gear through the second bevel gear, and the shape and size of the outer wall of the first bevel gear match the shape and size of the outer wall of the second bevel gear.

[0018] Preferably, the rack body is fixed by a piston body and a piston cap, and the piston body is disposed between the rack body and the piston cap.

[0019] Preferably, the motor and controller sub-assembly forms a movable structure with the brake caliper cylinder and the outer friction plate, and the inner friction plate and the outer friction plate are symmetrically arranged.

[0020] Preferably, the brake caliper cylinder body has two grooves.

[0021] Compared with the prior art, the beneficial effects of this utility model are: this electromechanical brake caliper based on a gear and rack structure,

[0022] 1. Three-stage gear reduction can provide a larger reduction ratio, thereby reducing the requirements for motor output torque and allowing for the selection of a smaller motor;

[0023] 2. The rack and piston are integrated, retaining the original hydraulic caliper piston function. The rack end has an anti-backward function through a toothless design.

[0024] 3. The relationship between the torque and thrust of the gear rack is T=F×R×η. ​​Compared with the crank connecting rod mechanism, it is simpler to design and easier to control. By controlling the module, the service life can be fully guaranteed. Compared with the ball screw, it has higher reliability.

[0025] 4. The motor has a small axial dimension, a compact overall structure, a large cavity volume, and a lighter weight, which is beneficial for caliper center of gravity design and wheel side arrangement. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0027] Figure 2 This is a schematic diagram of the planetary reduction mechanism and the bevel gear reduction mechanism of this utility model;

[0028] Figure 3 This is a schematic diagram of the rack and piston structure of this utility model;

[0029] Figure 4 This is a schematic diagram of the spherical rack structure of this utility model;

[0030] Figure 5 This is a schematic diagram of the brake caliper cylinder structure of this utility model.

[0031] In the diagram: 1. Motor and controller sub-assembly; 2. Planetary reduction mechanism; 201. First planetary gear set; 202. Second planetary gear set; 3. Bevel gear reduction mechanism; 301. First bevel gear; 302. Second bevel gear; 303. First bevel bearing; 304. Second bevel bearing; 4. Piston rack mechanism; 401. Transmission gear; 402. Rack body; 403. Piston body; 404. Piston cap; 5. Inner friction plate; 6. Outer friction plate; 7. Brake caliper cylinder; 8. Brake caliper bracket; 9. Dust cover; 10. Rectangular sealing ring; 11. Large O-ring. Detailed Implementation

[0032] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0033] Please see Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 An electromechanical brake caliper based on a gear and rack structure includes a motor and controller sub-assembly 1, a planetary reduction mechanism 2 fixedly connected to the inner wall of the motor and controller sub-assembly 1, a bevel gear reduction mechanism 3 provided on one side of the planetary reduction mechanism 2, and a piston rack mechanism 4 installed at the bottom of the bevel gear reduction mechanism 3.

[0034] The planetary reduction mechanism 2 includes a first planetary gear set 201, and a second planetary gear set 202 is mounted on one side of the first planetary gear set 201.

[0035] The bevel gear reduction mechanism 3 includes a first bevel gear 301, a second bevel gear 302 meshing with the outer wall of the first bevel gear 301, a second bevel gear bearing 304 installed on the inner wall of the second bevel gear 302, and a first bevel gear bearing 303 provided on the inner wall of the first bevel gear 301.

[0036] The piston rack mechanism 4 includes a transmission gear 401, the outer wall of which meshes with a rack body 402, and a piston body 403 is fixedly connected to one side of the rack body 402, and a piston cap 404 is installed on one side of the piston body 403.

[0037] Through the above technical solutions, the three-stage gear reduction can provide a larger reduction ratio, thereby reducing the requirements for motor output torque. A smaller motor can be selected. The rack and piston are integrated, retaining the original hydraulic caliper piston function. The toothless design at the end of the rack provides an anti-backward function. The relationship between gear and rack torque and thrust is T=F×R×η. ​​Compared with the crank-connecting rod mechanism, it is simpler to design and easier to control. By controlling the module, the service life can be fully guaranteed. Compared with ball screw, it has higher reliability. The motor has a small axial dimension, a compact overall structure, a large cavity volume, and lighter weight, which is beneficial to the design of the caliper center of gravity and the arrangement of the wheel sides.

[0038] Specifically, an inner friction plate 5 is provided on one side of the piston rack mechanism 4, and a brake caliper bracket 8 is fixedly connected to the bottom of the inner friction plate 5. A brake caliper cylinder 7 is bolted to one side of the motor and controller sub-assembly 1, and an outer friction plate 6 is provided at the bottom of the brake caliper cylinder 7. A dust cover 9 is installed on the top of the motor and controller sub-assembly 1, and a rectangular sealing ring 10 is provided on one side of the dust cover 9. A large O-ring 11 is installed on one side of the planetary reduction mechanism 2.

[0039] Through the above technical solution, the inner friction plate 5 can be pushed to contact the brake disc by the action of the motor. The motor continues to rotate, and the brake caliper cylinder 7 and the brake caliper bracket 8 generate relative movement, forcing the outer friction plate 6 to move backward until it contacts the brake disc and clamps it, thus realizing the braking function. The planetary reduction mechanism 2 is fixed in the housing of the motor and controller sub-assembly 1 by a snap ring and is connected to the brake caliper cylinder 7 by bolts. The large O-ring 11 plays a sealing role.

[0040] Specifically, the first planetary gear set 201 forms a fixed structure with the first bevel gear 301 through the second planetary gear set 202, and the second planetary gear set 202 is disposed between the first planetary gear set 201 and the first bevel gear 301.

[0041] The above technical solution facilitates the rotation of the first planetary gear set 201 by the motor, which in turn drives the first bevel gear 301 on the second planetary gear set 202 to rotate, thus achieving the effect of the first bevel gear 301 rotating.

[0042] Specifically, the first bevel gear 301 forms a rotating structure with the transmission gear 401 through the second bevel gear 302, and the shape and size of the outer wall of the first bevel gear 301 match the shape and size of the outer wall of the second bevel gear 302.

[0043] The above technical solution facilitates the rotation of the first bevel gear 301 while simultaneously driving the second bevel gear 302 to rotate due to meshing, which in turn drives the transmission gear 401 to rotate.

[0044] Specifically, the rack body 402 forms a fixed structure with the piston body 403 and the piston cap 404, and the piston body 403 is disposed between the rack body 402 and the piston cap 404.

[0045] Through the above technical solution, the second bevel gear 302 drives the transmission gear 401 to rotate clockwise, the rack body 402 pushes the piston body 403 forward, and the piston cap 404 pushes the inner friction plate 5 to contact the brake disc, achieving the effect of the inner friction plate 5 rotating. Furthermore, the rack body 402 is designed with a U-shaped structure and a spherical structure at the front end. The piston cap 404, which cooperates with it, has an arc-shaped groove, ensuring that the force transmitted by the rack body 402 is pushed out along the piston axis.

[0046] Specifically, the motor and controller sub-assembly 1 forms a moving structure with the brake caliper cylinder 7 and the outer friction plate 6, and the inner friction plate 5 and the outer friction plate 6 are symmetrically arranged.

[0047] Through the above technical solution, the motor rotates, and the brake caliper cylinder 7 and the brake caliper bracket 8 generate relative movement, which forces the outer friction pad 6 to move backward until it contacts the brake disc and clamps it, thereby realizing the braking function.

[0048] Specifically, the brake caliper cylinder 7 has two grooves.

[0049] Through the above technical solution, grease is applied to each gear set and the brake caliper cylinder 7 to reduce friction and improve efficiency. Two grooves are provided in the brake caliper cylinder 7 to store grease, so as to ensure that there is always sufficient grease between the piston body 403 and the brake caliper cylinder 7.

[0050] Working principle: When using this gear and rack-based electromechanical brake caliper, firstly, when the driver presses the brake pedal, the motor and controller receive a CAN signal and start driving the motor. One side of the motor spindle drives the first planetary gear set 201 and the second planetary gear set 202, which in turn causes the first bevel gear 301 to rotate counterclockwise. The second bevel gear 302 then drives the transmission gear 401 to rotate clockwise. The rack body 402 pushes the piston body 403 forward, and the piston cap 404 pushes the inner friction plate 5 to contact the brake disc. The motor continues to rotate, and the brake caliper cylinder 7 and the brake caliper bracket 8 generate relative movement, forcing the outer friction plate 6 to move backward until it contacts the brake disc and clamps it, thus realizing the braking function.

[0051] When the driver releases the brake pedal, the motor rotates clockwise. According to the above logic, the rack body 402 drives the piston body 403 to move backward. The brake is released. The front end of the rack body 402 has no toothed structure. After it moves backward to a certain extent, the transmission gear 401 cannot rotate, which can play the role of preventing excessive retraction. This completes all the work.

[0052] The disc clearance of this EMB braking system is designed to be 0.2-3 mm on one side. To prevent the disc clearance from increasing after the friction pads wear, the motor receives a quality control signal from the controller each time it is powered on to verify the disc clearance. When wear occurs on the friction pads, the motor rotates forward a certain number of times to clamp the brake disc with the friction pads. The contact state of the discs can be detected by the change in current. After the friction pads clamp the brake disc, the controller drives the motor to reverse a fixed number of times. This number of times can be calculated from the rack stroke and the reduction ratio of the reduction system, thus maintaining the disc clearance value at 0.2-3 mm on one side. Any content not described in detail in this specification is prior art known to those skilled in the art.

[0053] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit defined by the appended claims and their equivalents.

Claims

1. An electromechanical brake caliper based on a rack and pinion structure, comprising a motor and controller subassembly (1), characterized in that: The inner wall of the motor and controller subassembly (1) is fixedly connected with a planetary reduction mechanism (2), one side of the planetary reduction mechanism (2) is provided with a bevel gear reduction mechanism (3), and the bottom of the bevel gear reduction mechanism (3) is provided with a piston rack mechanism (4). The planetary reduction mechanism (2) comprises a first planetary gear set (201), and one side of the first planetary gear set (201) is provided with a second planetary gear set (202). The bevel gear reduction mechanism (3) comprises a first bevel gear (301), the outer wall of the first bevel gear (301) is engaged with a second bevel gear (302), the inner wall of the second bevel gear (302) is provided with a second bevel gear bearing (304), and the inner wall of the first bevel gear (301) is provided with a first bevel gear bearing (303). The piston rack mechanism (4) comprises a transmission gear (401), the outer wall of the transmission gear (401) is engaged with a rack body (402), one side of the rack body (402) is fixedly connected with a piston body (403), and one side of the piston body (403) is provided with a piston cap (404).

2. The electronic mechanical brake caliper based on the rack and pinion structure according to claim 1, characterized in that: One side of the piston rack mechanism (4) is provided with an inner friction plate (5), the bottom of the inner friction plate (5) is fixedly connected with a brake caliper support (8), one side of the motor and controller subassembly (1) is bolted with a brake caliper cylinder body (7), the bottom of the brake caliper cylinder body (7) is provided with an outer friction plate (6), the top of the motor and controller subassembly (1) is provided with a dust cover (9), one side of the dust cover (9) is provided with a rectangular sealing ring (10), and one side of the planetary reduction mechanism (2) is provided with a large O-ring (11).

3. The electronic mechanical brake caliper based on the rack and pinion structure according to claim 1, characterized in that: The first planetary gear set (201) and the first bevel gear (301) constitute a fixed structure through the second planetary gear set (202), and the second planetary gear set (202) is arranged between the first planetary gear set (201) and the first bevel gear (301).

4. The electronic mechanical brake caliper based on the rack and pinion structure according to claim 1, characterized in that: The first bevel gear (301) and the transmission gear (401) constitute a rotating structure through the second bevel gear (302), and the shape and size of the outer wall of the first bevel gear (301) are matched with the shape and size of the outer wall of the second bevel gear (302).

5. The electronic mechanical brake caliper based on the rack and pinion structure according to claim 1, characterized in that: The rack body (402) and the piston cap (404) constitute a fixed structure through the piston body (403), and the piston body (403) is arranged between the rack body (402) and the piston cap (404).

6. The electronic mechanical brake caliper based on the rack and pinion structure according to claim 1, characterized in that: The motor and controller subassembly (1) and the outer friction plate (6) constitute a moving structure through the brake caliper cylinder body (7), and the inner friction plate (5) and the outer friction plate (6) are symmetrically arranged.

7. The electronic mechanical brake caliper based on the rack and pinion structure according to claim 2, characterized in that: The brake caliper cylinder body (7) is provided with two grooves.

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