Brake Caliper Control Housing for BCU Heat and Stress Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The integration of the Brake Control Unit (BCU) within the brake caliper poses challenges due to high overheating, mechanical stresses, and limited space, which can affect the operation and reliability of the brake system.
Innovation Solution
The design incorporates a control housing with an electric motor and BCU, where the electric motor is housed within the transmission housing, reducing overall dimensions and optimizing thermal management through the use of materials with varying thermal conductivities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the BCU is integrated inside the brake caliper, then the management of the brake caliper is simplified and electromagnetic radiation is confined, but the brake caliper is subjected to high overheating and mechanical stresses that affect the BCU operation
Solution Approach 1:
The brake caliper is divided into two distinct housing sections: a transmission housing for mechanical components and a control housing for electronic components (BCU and electric motor). This segmentation isolates the temperature-sensitive BCU from the high-temperature braking zone while maintaining overall system integration.
Solution Approach 2:
A thermal barrier is introduced between the transmission housing and control housing to prevent heat transfer from the braking zone to the BCU. This intermediary structure protects the electronic components from thermal damage while allowing the system to maintain compact integration.
2Object-affected harmful factors
If the BCU is integrated inside the brake caliper, then electromagnetic radiation is confined to the caliper assembly, but the brake caliper volume is limited making it difficult to accommodate the BCU electronic boards
Solution Approach 1:
The control housing is designed to extend in the axial direction of the brake caliper, utilizing the limited space efficiently. The electronic boards are arranged to fit within this extended housing without increasing the radial dimensions, thus accommodating the BCU within the constrained wheel space.
3Length of stationary object
If the electric motor is housed within the transmission housing, then the overall dimensions of the brake caliper are reduced, but the thermal management becomes more challenging
Solution Approach 1:
The housing is segmented into transmission and control sections with distinct thermal characteristics. The transmission housing contains the electric motor and mechanical components, while the control housing contains the temperature-sensitive BCU. This segmentation allows different thermal management strategies for each section.
Solution Approach 2:
A thermal barrier is positioned between the transmission housing and control housing to prevent heat transfer from the electric motor and braking zone to the BCU. This intermediary structure enables compact integration while maintaining thermal isolation for reliable electronic component 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
This configuration reduces mechanical stresses and thermal loads on the BCU, enhances the integration of electric/electronic components within the brake caliper, and minimizes the system's overall dimensions while maintaining effective braking performance.
Implementation Method 1
a brake control unit, housed within a control housing, and configured to control the electric motor
Implementation Method 2
optimizing thermal management through the use of materials with varying thermal conductivities
Data Source
AI summary
A brake caliper has a caliper body having two side walls delimiting a disc space for accommodating a portion of a brake disc, a connection structure extending straddling the disc space and connecting the side walls to each other, and a pad housing for accommodating at least one pad. A transmission housing is connected to the caliper body so that a front wall of the transmission housing faces the disc space. Thrust members bias the pads against the brake disc along an actuation axis. A control housing supports and houses an electric motor having a drive shaft. and configured to generate and transfer mechanical power to the thrust members. A brake control unit controls the electric motor. The drive shaft protrudes from a front side of the electric motor facing the caliper body. The brake control unit has an electronic board extending in a transverse direction with respect to the actuation axis.