Decentralized Electrohydraulic Brake Unit With Active Pad Retraction
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Solution Overview
Problem
Centralized electrohydraulic brake systems face challenges in efficiency and wear reduction, particularly as vehicle electrification necessitates more decentralized brake configurations that avoid hydraulic line requirements and minimize energy loss and noise.
Innovation Solution
A decentralized electrohydraulic brake unit featuring a brake caliper and piston connected via an elastic means, allowing for direct separation of the brake piston from the brake disc after braking, with a pressure chamber and sensor for precise pressure regulation, and using a smaller motor and plastic materials to reduce weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a centralized electrohydraulic brake system is used, then cost-effectiveness and convenience are improved, but efficiency and wear reduction are worsened
Solution Approach 1:
The brake system is divided into decentralized brake units at each wheel, with each unit having its own drive device and hydraulic system. This segmentation eliminates the need for long hydraulic lines and enables independent brake pressure generation at each wheel, reducing energy loss while maintaining cost-effectiveness through modular architecture
2Loss of energy
If a decentralized brake system is implemented, then energy loss is reduced, but hydraulic line requirements increase complexity
Solution Approach 1:
The hydraulic line network is extracted and eliminated from the system. Each decentralized brake unit generates its own brake pressure locally through an integrated drive device and brake caliper piston, completely removing the need for hydraulic lines connecting the brake units to the vehicle body
3Speed
If the brake piston remains in contact with the brake disc after braking, then braking readiness is improved, but wear and energy loss increase
Solution Approach 1:
The elastic means is pre-configured to automatically retract the brake piston from the brake disc immediately after braking operation. This preliminary retraction action prevents prolonged contact between brake pads and disc, eliminating wear and energy loss while maintaining braking readiness through rapid re-engagement capability
Solution Approach 2:
The elastic means provides self-service by automatically retracting the brake piston without requiring external actuation. The elastic element stores energy during braking and releases it after braking to separate the brake piston from the disc, creating a self-regulating system that prevents wear and energy loss
4Force
If a larger motor is used to move the brake caliper piston, then braking force is improved, but weight on the unsprung wheel increases
Solution Approach 1:
The system transitions from direct motor-to-brake-piston coupling to a two-stage hydraulic transmission system. The motor moves the brake caliper piston which then generates hydraulic pressure to move the larger brake piston, effectively transmitting force through a different dimensional pathway that allows smaller motor size while maintaining high braking force
5Manufacturing precision
If tighter tolerances are applied to brake components, then manufacturing precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The system changes the operational parameters by using hydraulic pressure transmission to amplify force. This allows the use of larger brake piston diameter with relaxed tolerances, as the hydraulic system compensates for minor dimensional variations, reducing manufacturing cost and complexity while maintaining effective braking performance
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 solution eliminates brake pad wear, reduces energy loss, enhances ride comfort, and minimizes noise by enabling precise brake pressure control and using lighter, less expensive components, while maintaining high braking force.
Implementation Method 1
The brake caliper piston and the brake piston are connected to one another via an elastic means (i.e., an elastic element), via which the brake piston can actively be retracted after a braking operation
Implementation Method 2
the elastic means is a spring
Implementation Method 3
a brake caliper piston which can be moved axially in the brake caliper via a drive device and via which hydraulic pressure can be applied to a brake piston
Implementation Method 4
a brake pad disposed on the brake piston can be placed against a brake disc to brake the wheel
Data Source
AI summary
A decentralized electrohydraulic brake unit for braking a wheel of a motor vehicle. The brake unit includes a brake caliper and a brake caliper piston which can be moved axially in the brake caliper via a drive device and via which hydraulic pressure can be applied to a brake piston. A brake pad is disposed on the brake piston. The brake caliper piston and the brake piston are connected to one another via an elastic element, via which the brake piston can actively be retracted after a braking operation.