Converter-Actuated Brake Assembly for Compact E-Axle Packaging

The patent transforms the conventional linear actuation mechanism into a rotational actuation system. The converter unit converts rotational motion into the linear motion required for brake pad actuation, fundamentally changing the dimension of motion from translational to rotational. This dimensional change allows for a more compact overall structure while maintaining the necessary braking force application.

The patent replaces the traditional pneumatic actuator system with a mechanical converter system that uses rotational motion. Instead of relying on pneumatic pressure to directly extend a piston in a linear fashion, the system uses a converter unit with cam surfaces or inclined planes that transform rotational input into the required linear displacement of brake pads, reducing the space needed for pneumatic components.

The converter unit serves multiple functions: it converts rotational motion to linear motion, provides mechanical advantage through its cam or inclined plane surfaces, and acts as a compact actuation mechanism that integrates several functions into a single component. This multi-functionality reduces the need for separate components, thereby reducing overall space while managing complexity.

The brake assembly is divided into distinct functional modules: the converter unit for motion transformation, the brake caliper for force application, and the brake pads for friction. This segmentation allows each component to be optimized independently for space efficiency while maintaining overall system performance.