Multi-Stage Belt Drive Actuator Package
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Solution Overview
Problem
Existing electric brake systems for vehicles face inefficiencies in load transfer and packaging size due to the need for multiple gears or large gear systems in electro-mechanical actuators, which can lead to increased noise and reduced mechanical efficiency.
Innovation Solution
An electromechanical actuator package featuring a multi-stage belt drive mechanism with a drive pulley machined on the motor rotor shaft, utilizing a series of belts and pulleys to multiply torque and reduce packaging size, while a circuit board is housed within the actuator package to control the motor and manage rotational speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a gear system is used in the electro-mechanical actuator, then torque multiplication is achieved, but device complexity and packaging size increase
Solution Approach 1:
The patent replaces the traditional gear system with a belt drive mechanism. The motor rotor shaft directly drives a drive pulley that is belt-connected to a driven pulley, eliminating the need for multiple gears while achieving the same torque multiplication effect. This substitution reduces mechanical complexity, eliminates gear meshing noise, and simplifies the overall actuator structure.
2Force
If large gears are used for load transfer, then sufficient torque is achieved, but packaging size increases
Solution Approach 1:
The patent changes the mechanical parameters of the drive system by using a belt drive mechanism with optimized pulley ratios. Instead of relying on large gears, the system uses the belt-pulley configuration to achieve the necessary torque multiplication with significantly reduced component sizes, allowing for a more compact actuator package.
3Force
If multiple small gears are used for load transfer, then sufficient torque is achieved, but mechanical efficiency decreases and noise increases
Solution Approach 1:
The patent replaces the multi-gear system with a direct belt drive mechanism that connects the motor rotor shaft to the driven pulley. This eliminates multiple gear meshing stages, reducing mechanical energy loss and improving overall system efficiency. The belt drive also eliminates gear tooth engagement noise, resulting in quieter operation.
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 multi-stage belt drive mechanism enhances mechanical efficiency, reduces noise, and allows for scalable torque output, improving the overall performance and compactness of the brake actuation system.
Implementation Method 1
a multi-stage belt drive mechanism connecting the motor rotor shaft to an actuator output via a plurality of drive belts
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A electromechanical actuator package for actuating a brake assembly may comprise: a motor comprising a motor rotor shaft on which a drive pulley is formed; a multi-stage belt drive mechanism connecting the motor rotor shaft to an actuator output via a plurality of drive belts, the actuator output associated with the brake assembly; a circuit board; and a housing enclosing the motor, the multi-stage belt drive mechanism and the circuit board, wherein the circuit board is positioned between one end of the motor rotor shaft and an inner surface of the housing. The electromechanical actuator package may improve mechanical efficiency as well as reduce the packaging size and mass. Further, the electromechanical actuator package may reduce operational noise.