Electromechanical Brake Actuator With Multi-Stage Torque Drive
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electromechanical brake systems face challenges in efficiently converting electrical energy into mechanical force to effectively apply and release brake pads, particularly in achieving high axial clamping brake force while maintaining mechanical efficiency and reducing packaging size and mass.
Innovation Solution
The proposed electromechanical brake system incorporates a multi-stage drive mechanism comprising a belt drive mechanism and a gear drive mechanism, which operates between a motor shaft and a screw-nut mechanism. This configuration includes a drive pulley and driven pulley connected by a drive belt, and first and second gears engaged to rotate the screw-nut mechanism, thereby multiplying torque and achieving efficient linear motion for brake pad operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a direct-drive mechanism is used to convert electrical energy to mechanical force, then the structure is simple, but the axial clamping brake force is insufficient
Solution Approach 1:
The drive mechanism is segmented into multiple stages: a first-stage belt drive mechanism and a second-stage gear mechanism. The belt drive mechanism includes a drive pulley and driven pulley connected by a belt, while the gear mechanism includes a drive gear and driven gear. This segmentation allows each stage to contribute to torque multiplication, achieving high axial clamping brake force while maintaining a manageable structural complexity through modular design.
2Force
If a multi-stage drive mechanism is used to multiply torque, then the axial clamping brake force increases, but the packaging size and mass increase
Solution Approach 1:
The drive mechanism components are arranged in a nested configuration where the first-stage belt drive mechanism and second-stage gear mechanism are integrated within the same actuator assembly housing. The intermediate shaft serves as a common mounting structure for both the driven pulley and drive gear, allowing compact arrangement that minimizes packaging volume while achieving the required torque multiplication for high axial clamping brake force.
3Force
If a multi-stage drive mechanism is used to multiply torque, then the axial clamping brake force increases, but the packaging volume increases
Solution Approach 1:
The drive mechanism utilizes three-dimensional spatial arrangement to pack the multi-stage components efficiently. The intermediate shaft extends axially to provide mounting surfaces for both pulleys and gears at different radial positions and angular orientations. This dimensional arrangement allows the belt drive and gear mechanism to occupy different spatial zones within the actuator assembly, achieving compact packaging volume while maintaining the torque multiplication necessary for high axial clamping brake force.
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 drive mechanism enhances mechanical efficiency, reduces operational noise, and allows for high axial clamping brake force, while also minimizing packaging size and mass. This configuration effectively addresses the challenges of converting electrical energy into mechanical force for efficient brake operation.
Implementation Method 1
a belt drive mechanism and a gear drive mechanism operably connecting between the motor shaft and the rotatable body of the screw-nut mechanism
Implementation Method 2
a gear drive mechanism operably connecting between the motor shaft and the rotatable body of the screw-nut mechanism
Implementation Method 3
a screw-nut mechanism comprising a rotatable body configured to be rotatable and a translatable body operably coupled with the rotatable body, the translatable body configured to be axially translatable relative to the rotatable body to move a brake pad according to rotation of the rotatable body
Data Source
AI summary
An electromechanical brake system comprises: a screw-nut mechanism comprising a rotatable body and a translatable body configured to be axially translatable relative to the rotatable body to move a brake pad according to rotation of the rotatable body; and an actuator assembly comprising a motor having a motor shaft, and a multiple-stage drive mechanism having belt and gear drive mechanisms and operably connecting between the motor shaft and the rotatable body of the screw-nut mechanism. The belt drive mechanism comprises: a drive belt; a drive pulley provided on the motor shaft; and a driven pulley connected to the drive pulley of the motor shaft via the drive belt, wherein the driven pulley is provided on an intermediate shaft. The gear drive mechanism comprises: a first gear provided on the intermediate shaft; and a second gear rotatably engaged with the first gear to rotate the rotatable body of the screw-nut mechanism.