Brake Caliper Locking Mechanism for Emergency Disc Release
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Solution Overview
Problem
Existing EMB systems lack a mechanism to release residual clamping force between the brake pad and brake disc when the main motor or control circuit fails, leading to excessive drag force on wheels and unsafe vehicle operation, which is a barrier for achieving L3 and higher levels of autonomous driving.
Innovation Solution
A brake caliper with an actuator and locking mechanism, featuring a second motor and transmission mechanism with self-locking function, including a semi-enclosed gear and worm rod, to actively release the brake disc and prevent continuous wheel locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a locking mechanism is added to achieve parking function, then the parking function is improved, but the device complexity increases and the mechanism cannot release residual clamping force
Solution Approach 1:
The locking mechanism is designed to perform multiple functions: it provides parking locking through the second motor and transmission mechanism, and simultaneously serves as an emergency release mechanism when the first motor fails. The self-locking transmission mechanism engages with the first transmission mechanism to either lock or release the brake disc, making the system multi-functional without requiring separate dedicated mechanisms for each function.
2Productivity
If the first transmission mechanism is used for braking, then the braking function is achieved, but the residual clamping force cannot be released when motor failure occurs
Solution Approach 1:
The self-locking transmission mechanism acts as an intermediary between the second motor and the first transmission mechanism. When the first motor fails, the second motor drives the self-locking transmission mechanism, which then engages with the first transmission mechanism to release the residual clamping force on the brake disc, serving as a mediator that enables emergency release without directly replacing the primary braking system.
Solution Approach 2:
The system incorporates a backup locking and release mechanism that activates beforehand when failure is detected. The second motor and self-locking transmission mechanism are pre-positioned to engage with the first transmission mechanism, providing a safety cushion that prevents the brake disc from remaining locked due to motor failure, thereby ensuring reliability before critical failure occurs.
3Reliability
If a second motor and self-locking transmission mechanism are added for emergency release, then the reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The second transmission mechanism is merged with the first transmission mechanism through the self-locking engagement of convex teeth with transmission gears. This integration allows the emergency release system to share structural elements with the primary braking system, reducing the need for completely separate components and simplifying manufacturing while maintaining reliability.
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
Ensures reliable locking and timely release of the brake disc, allowing safe vehicle operation even when the main motor or control circuit fails, meeting the requirements for L3 and higher levels of autonomous driving.
Implementation Method 1
The second transmission mechanism includes a worm rod connected with the second motor. The worm rod is meshed with the power output part.
Implementation Method 2
An elastic element for applying an elastic effect to the limiting pin is disposed in the mounting hole.
Data Source
AI summary
A brake caliper includes an actuator and a locking mechanism. The actuator includes a first motor and a first transmission mechanism. The locking mechanism includes a second motor and a second transmission mechanism which is connected with the second motor and has a self-locking function. A power output part of the second transmission mechanism is meshed with a transmission gear on a power transmission path of the first transmission mechanism in a locked state. The brake caliper has a locking function and can release the brake disc in time when the first motor and its control fail, thereby preventing continuous locking of the wheels during the driving process of the vehicle.