Integrated BBW Actuator Unit for Compact Braking and Parking
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Solution Overview
Problem
Existing electro-mechanical brake systems (EMBs) face issues such as large axial mounting space, inability to realize parking functions due to lack of integration, complex system structures, high costs, and motor overheating due to high energy consumption and heat generation.
Innovation Solution
A brake-by-wire (BBW) electronic control actuator unit is introduced, which integrates a permanent magnet brushless direct-current motor (PMBDCM) and speed-reducing torque-increasing gear sets directly to the brake caliper, eliminating hydraulic systems and enabling all-electric operation for braking. This design includes a parking locking electromagnetic assembly for integrated parking functionality and a compact structure for reduced size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a motor with high designed power is used to drive both braking and parking braking in EMB, then the braking performance is improved, but the size and weight of the motor increase, causing high energy consumption and high heat productivity
Solution Approach 1:
The patent divides the braking system into two independent actuators: a first actuator for service braking and a second actuator for parking braking. This segmentation allows each actuator to be optimized for its specific function, with the parking brake actuator being smaller and lighter since it only needs to provide holding force, not continuous braking power.
Solution Approach 2:
The patent integrates the parking brake mechanism into the brake caliper assembly, merging the parking brake actuator with the service brake caliper. This combination eliminates the need for a separate parking brake mechanism and reduces overall system complexity while achieving space savings.
2Power
If a motor with high designed power is used to drive both braking and parking braking in EMB, then the braking performance is improved, but energy consumption increases
Solution Approach 1:
The patent segments the braking function into service braking and parking braking, allowing the parking brake actuator to be smaller and consume less energy since it only needs to provide holding force rather than continuous braking power.
Solution Approach 2:
The parking brake operates periodically (when parking is needed) rather than continuously, and uses a smaller actuator that consumes minimal energy during these periodic operations, compared to a high-power motor running continuously for both functions.
3Power
If a motor with high designed power is used to drive both braking and parking braking in EMB, then the braking performance is improved, but heat productivity increases, causing motor overheating and potential demagnetization
Solution Approach 1:
The patent separates the high-power service braking function from the low-power parking braking function into different actuators. The parking brake actuator generates minimal heat since it only provides holding force, preventing the overheating and demagnetization issues that would occur with a continuously high-power motor.
Solution Approach 2:
The parking brake operates periodically rather than continuously, allowing heat dissipation between operations. The smaller actuator size and intermittent operation prevent heat accumulation that would lead to motor overheating and demagnetization.
4Ease of operation
If the parking brake structure is composed of a ratchet mechanism and a lever mechanism restored by a spring, then the parking function is achieved, but the structure becomes complex and the service life is reduced
Solution Approach 1:
The patent replaces the mechanical ratchet and lever mechanism with an electromagnetic actuator that uses electromagnetic force to engage and disengage the parking brake. This substitution eliminates complex mechanical components, reduces the number of parts, and improves reliability while maintaining the parking function.
5Ease of operation
If the parking brake structure is composed of a ratchet mechanism and a lever mechanism restored by a spring, then the parking function is achieved, but the service life of the mechanism is reduced
Solution Approach 1:
The patent replaces the mechanical ratchet and lever mechanism with an electromagnetic actuator, eliminating wear-prone mechanical components. The electromagnetic system has no moving parts that experience friction or wear, significantly extending the service life of the parking brake mechanism.
6Ease of manufacture
If the EMB actuator unit uses a two-point fixation manner, then the mounting is simplified, but the system reliability cannot be met
Solution Approach 1:
The patent integrates the parking brake mechanism directly into the brake caliper assembly, merging two previously separate components. This integration creates a more compact unit with fewer mounting points needed while improving reliability through reduced connection interfaces and better structural coherence.
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 BBW electronic control actuator unit achieves a high integration level, compact structure, and efficient heat dissipation, resulting in improved braking performance, reduced energy consumption, and extended motor service life, while also simplifying the system and reducing costs.
Implementation Method 1
a permanent magnet brushless direct-current motor (PMBDCM) and speed-reducing torque-increasing gear sets integrated in the machine body, where the PMBDCM includes a stator assembly and a rotor assembly
Implementation Method 2
The locking latch is provided in the locking mounting housing vertically and slidably
Data Source
AI summary
The provided are a brake-by-wire (BBW) electronic control actuator unit and a use thereof. The BBW electronic control actuator unit includes a machine body, as well as a permanent magnet brushless direct-current motor (PMBDCM) and speed-reducing torque-increasing gear sets integrated in the machine body, where the PMBDCM includes a stator assembly and a rotor assembly; the rotor assembly is connected to one end of a motor shaft; the other end of the motor shaft is connected to an input end of each of the speed-reducing torque-increasing gear sets; an output end of the speed-reducing torque-increasing gear set is connected to an output shaft; and the output shaft extends out of the machine body. According to the BBW electronic control actuator unit and the use thereof, by assembling the PMBDCM and the speed-reducing torque-increasing gear set, there are advantages of a high mounting accuracy, and a compact structure.