Brake Pressure Modulation to Reduce Electric Motor Load
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Solution Overview
Problem
Brake systems for vehicles face inefficiencies in motor loading and energy consumption due to constant brake pressure maintenance, leading to increased mechanical and thermal stress on electric motors.
Innovation Solution
A method and system that modulate brake pressure by initially setting it higher than the setpoint pressure and then gradually reducing it, utilizing a gear unit to convert rotary motor movement into translational piston movement, thereby reducing the torque required and alleviating motor loading through friction losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If constant brake pressure is maintained by continuously actuating the electric motor, then the brake pressure stability is improved, but the motor loading and energy consumption increase
Solution Approach 1:
The patent implements periodic pressure modulation by alternately increasing and decreasing the brake pressure around the setpoint pressure. Instead of continuously maintaining constant pressure, the system periodically varies the pressure, allowing the electric motor to remain stationary during pressure holding phases and only activate during pressure adjustment phases, thereby reducing overall motor energy consumption while maintaining effective brake pressure stability
Solution Approach 2:
The system transitions from a static constant pressure maintenance approach to a dynamic pressure modulation approach. The brake pressure is dynamically adjusted in periodic cycles, with the electric motor dynamically switching between active adjustment modes and idle holding modes, optimizing energy consumption based on real-time pressure requirements
2Manufacturing precision
If the electric motor continuously adjusts the displacement piston to maintain setpoint pressure, then the brake pressure control precision is improved, but the mechanical and thermal stress on the motor increases
Solution Approach 1:
The electric motor operates in periodic cycles of active pressure adjustment followed by idle holding phases. During each cycle, the motor actively adjusts pressure only when deviation from setpoint occurs, then remains stationary during the holding phase. This periodic operation reduces cumulative mechanical stress and thermal buildup, extending motor durability while maintaining precise pressure control through repeated adjustment cycles
Solution Approach 2:
The control unit acts as an intermediary that intelligently manages motor activation. It monitors brake pressure and selectively activates the motor only when pressure adjustment is needed, rather than continuous operation. This intermediary control reduces direct mechanical stress on the motor by eliminating unnecessary activation cycles, thereby improving motor durability while maintaining pressure precision
3Stability of the object's composition
If the displacement piston is continuously actuated to maintain constant pressure, then the pressure stability is improved, but the friction losses in the gear unit increase
Solution Approach 1:
The displacement piston is actuated periodically rather than continuously. During pressure modulation phases, the piston actively adjusts position to change brake pressure. During holding phases, the piston remains stationary, eliminating friction losses that would occur from continuous small adjustments. This periodic actuation maintains pressure stability through deliberate adjustments while minimizing energy-wasting friction during holding periods
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 approach reduces the average torque needed by the electric motor, minimizing mechanical and thermal loading, and allows for periodic hydraulic decoupling to further reduce motor workload, enhancing efficiency and longevity.
Implementation Method 1
the electric motor may be coupled with the displacement piston via a gear unit, which converts a rotary movement of the electric motor into a translatory movement of the displacement piston
Implementation Method 2
During the pressure reduction, friction losses occur in the gear unit that couples the electric motor with the displacement piston. They act counter to the movement of the displacement piston and thus decelerate it.
Data Source
AI summary
A method for operating a brake system. A brake request signal characterizing a brake request is generated by actuating a positioner system of an actuating circuit, and a setpoint brake pressure required in an active circuit is ascertained based on the brake request signal. An actual brake pressure is set in the active circuit according to the setpoint brake pressure using a pressure generation device by moving a displacement piston using an electric motor to actuate a wheel brake coupled with the active circuit. Under the condition that the brake request signal is constant over a predefined period of time, a pressure modulation is carried out, which includes setting the actual brake pressure in the active circuit to a value that is greater than the setpoint brake pressure, and lowering the actual brake pressure by moving the displacement piston using the electric motor until the setpoint brake pressure is reached.