Vehicle Brake Caliper Gear Layout for Stable EMB Packaging
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Solution Overview
Problem
Conventional Electro Mechanical Brake (EMB) systems face issues with size reduction, stability against weight concentration, and vibration due to the structural limitations of ball screws and the additional load from EPB structures.
Innovation Solution
A brake apparatus for a vehicle that includes a caliper body, a driving unit, a piston unit, a transfer gear unit, and a planetary gear unit, where the driving unit, transfer gear unit, and planetary gear unit are directly fixed to the caliper body by an assembly part, reducing the number of parts and weight, and optimizing the placement of the center of gravity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a ball screw is used to secure quick responsiveness and high efficiency of the piston, then the piston responsiveness is improved, but the self-locking function is lost causing random release of braking force
Solution Approach 1:
A self-locking mechanism is introduced as an intermediary component between the ball screw and the piston. This mechanism includes a locking member that engages with the ball screw to prevent its rotation, thereby maintaining the braking force without affecting the quick responsiveness provided by the ball screw structure.
2Reliability
If an EPB structure is added to hold braking state, then the braking stability is improved, but the motor capacity and gear reduction ratio are increased
Solution Approach 1:
The self-locking function is extracted from the EPB structure and implemented as a separate self-locking mechanism. This allows the main motor to be optimized for braking performance without the additional burden of providing self-locking capability, thereby reducing the required motor capacity and gear reduction ratio.
3Ease of operation
If ECU and actuator are mounted on caliper, then the braking control is improved, but the caliper weight increases causing vibration and vulnerability
Solution Approach 1:
The ECU and actuator are relocated from the caliper to the vehicle body or other suitable locations. This dimensional redistribution of components reduces the caliper weight and its concentration, thereby minimizing vibration and vulnerability while maintaining effective braking control through optimized signal transmission and actuation.
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 solution reduces the overall size of the brake apparatus, enhances stability by minimizing weight concentration and vibration, and optimizes the reduction ratio of the planetary gear unit, leading to a more compact and efficient brake system.
Implementation Method 1
a planetary gear unit fixed to the caliper body, and moves the piston unit forward and backward in connection with a rotation of the transfer gear unit
Data Source
AI summary
A brake apparatus for a vehicle may include: a caliper body fixed to a vehicle body, a driving unit fixed to the caliper body, and configured to generate a rotational force, a piston unit movably installed in the caliper body, and configured to press or release a brake pad according to a moving direction thereof, a transfer gear unit connected to the driving unit, and rotated by the rotational force received from the driving unit, and a planetary gear unit fixed to the caliper body, and configured to move the piston unit forward and backward in connection with the rotation of the transfer gear unit.