Brake Controller Compact Design via Motor Case Integration
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Solution Overview
Problem
Brake controllers face challenges in minimizing their size while maintaining high reliability and efficiency, particularly in accommodating both hydraulic pressure control mechanisms and motor control units within a compact space.
Innovation Solution
The design integrates a motor control unit with a cooling metal case that is aligned with the hydraulic pressure control mechanism, utilizing the space efficiently by forming cooling fins and positioning the motor control unit to optimize cooling and reduce volume, while also ensuring easy assembly and protection from mechanical damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a motor control unit and hydraulic pressure control mechanism are integrated in a brake controller, then high reliability and efficient space utilization are achieved, but the device size increases
Solution Approach 1:
The motor control unit is integrated with the hydraulic pressure control mechanism by fixing the motor control unit's case to the housing of the hydraulic pressure control mechanism. This merging of two separate control units into a single integrated assembly achieves high reliability through unified structure while efficiently utilizing the available space, thereby avoiding a significant increase in overall device size.
Solution Approach 2:
The housing of the hydraulic pressure control mechanism serves multiple functions: it contains the hydraulic components (master cylinder, moving mechanism) and simultaneously acts as a mounting structure for the motor control unit. This multi-functionality allows the brake controller to accommodate both control systems without requiring additional external housing, thus maintaining compact dimensions while ensuring reliable operation.
2Volume of stationary object
If the motor control unit is integrated with the hydraulic pressure control mechanism, then space utilization is improved, but assembly complexity increases
Solution Approach 1:
The brake controller is divided into two main segments: the hydraulic pressure control mechanism (containing master cylinder and moving mechanism) and the motor control unit. By fixing these two segments together rather than integrating all components into a single monolithic structure, the design achieves compact volume while keeping assembly complexity manageable through modular construction.
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 effectively inhibits the growth in size of brake controllers, enhances cooling efficiency, improves productivity and reliability, and simplifies the assembly and maintenance processes by utilizing space efficiently and protecting critical components.
Implementation Method 1
a motor control unit with a cooling metal case
Implementation Method 2
forming cooling fins
Data Source
AI summary
Provided is a brake controller which can be made smaller. The brake controller (100) has a hydraulic control mechanism (150), which comprises a master cylinder (250) which generates a hydraulic fluid pressure on the basis of an input piston (182) and a control piston (190) that move when a braking operation is performed, motors (290, 296), and a moving mechanism (200) which moves the aforementioned control piston as the aforementioned motors turn, and a motor control unit (300) for regulating the turning of the aforementioned motors. The brake controller is characterized in that the aforementioned motor control unit (300) has a metal case (302) with a built-in control circuit, the aforementioned metal case (302) is affixed to the housing (160) of the aforementioned moving mechanism (200), one end of the aforementioned case (302) is placed at approximately the same position as an end of the aforementioned moving mechanism (200) in the axial direction of the aforementioned input piston (182), and the other end of the aforementioned case (302) is placed at approximately the same position as an end of the aforementioned master cylinder (250).