Brake Cooling Duct Shutter with Fail-Safe Actuation
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Solution Overview
Problem
Existing cooling duct systems for road vehicle brakes often compromise aerodynamics due to air intakes, and there is a risk of inadequate cooling in case of malfunctioning actuating devices controlling the shutters.
Innovation Solution
A road vehicle cooling duct system with rotationally fitted shutters that are mechanically and electrically controlled to maintain an open position by default, using an elastic element and a direct current motor with a worm screw reduction gear, and a locking device to ensure the shutters remain closed when not needed, preventing foreign objects from entering and maintaining safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air intakes are provided for brake cooling ducts, then brake cooling is improved, but aerodynamic penetration coefficient deteriorates
Solution Approach 1:
The shutter is made mobile to dynamically adjust the air intake opening based on braking conditions. It can move between a closed position (reducing aerodynamic drag) and an open position (increasing cooling air flow), allowing the system to adapt to varying operational requirements and resolve the contradiction between cooling performance and aerodynamic efficiency.
2Object-generated harmful factors
If a shutter is added to control air intake, then aerodynamic penetration is improved when closed, but device complexity increases
Solution Approach 1:
The system utilizes the vehicle's existing air conditioning compressor and its integrated shutter control mechanism to serve the dual purpose of cabin climate control and brake cooling management. The air conditioning shutter, when opened, also allows air to enter the brake cooling duct, eliminating the need for a separate dedicated shutter mechanism and reducing overall device complexity.
3Object-generated harmful factors
If the shutter is controlled to close normally, then aerodynamic performance is improved, but reliability of brake cooling deteriorates in case of malfunction
Solution Approach 1:
The system incorporates a fail-safe design where the air conditioning shutter is positioned such that if it fails to open or becomes stuck, air flow can still reach the brake cooling duct through the air conditioning intake path. This prior arrangement ensures that even in case of shutter malfunction, the brake cooling function remains partially or fully operational, cushioning against the potential failure mode.
4Device complexity
If the air conditioning shutter is used for brake cooling, then device complexity is reduced, but the shutter may not open reliably for cooling purposes
Solution Approach 1:
The control unit receives feedback from braking condition sensors and actively controls the air conditioning shutter opening based on real-time operational data. When braking is detected or brake temperature exceeds thresholds, the control unit commands the shutter to open, ensuring reliable activation for cooling purposes despite the shutter's primary design for climate control. This active feedback control compensates for the shutter's dual-purpose nature.
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 system ensures maximum brake cooling while minimizing aerodynamic drag and power consumption, maintaining safety even in actuator failures by defaulting to an open position and using mechanical irreversibility to prevent unwanted opening.
Implementation Method 1
applying an opening force in the absence of other external interventions
Implementation Method 2
a direct current motor with a worm screw reduction gear
Implementation Method 3
worm screw reduction gear which transforms a rotation of the direct current motor with a high torque into a rotation of the main shaft with a lower torque
Implementation Method 4
convey the cooling air towards the brakes themselves
Data Source
Figure 1
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AI summary
A road vehicle (1) provided with a cooling duct (16) for the cooling of a brake (13); the cooling duct (16) has: an air intake (17) arranged at the inlet of the cooling duct (16); a shutter (19), which is mobile, so as to move between a closing position, in which the shutter (19) closes the air intake (17), and an opening position, in which the shutter (19) leaves the air intake (17) unobstructed; and an electric actuating device (21), which controls the movement of the shutter (19) and, therefore, moves the shutter (19) between the closing position and the opening position and is mechanically configured to be normally open and, therefore, in the absence of a power supply, to push the shutter (19) towards the opening position.