Electronic Disc Brake Decelerator Noise Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electronic disc brake systems using motor-on-caliper types face issues with operating noise and durability due to imprecise gear coupling, which degrades the actuator's performance.
Innovation Solution
The electronic disc brake system incorporates a power connection unit with a helical gear and a deceleration gear unit featuring a worm gear and cross-helical gear configuration, supported by C-mounts and ball bearings, to efficiently transmit rotational force while minimizing noise and preventing axis deviation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a plurality of gear devices are used to transmit power from the motor to the actuator, then torque is increased through deceleration, but operating noise and vibration are generated due to imprecise gear coupling
Solution Approach 1:
The patent combines multiple gear functions into a single integrated decelerator assembly where the drive helical gear, driven helical gear, worm gear, and planetary gears work together in one unified structure. This integration reduces the number of separate gear devices and their corresponding couplings, thereby minimizing noise and vibration while maintaining torque multiplication through the combined deceleration stages.
Solution Approach 2:
The patent introduces a precisely manufactured driven helical gear as an intermediary element between the motor's drive helical gear and the worm gear. This intermediate gear stage provides smooth power transmission with precise meshing, reducing冲击 and noise while effectively transmitting torque through the deceleration process.
2Power
If a plurality of gear devices are used to transmit power from the motor to the actuator, then torque is increased through deceleration, but durability is degraded due to imprecise gear coupling
Solution Approach 1:
The patent replaces a simple single-stage gear deceleration system with a multi-stage compound decelerator incorporating helical gears, worm gears, and planetary gears. This sophisticated mechanical system provides more precise torque transmission and distribution, reducing stress concentration on individual gear couplings and improving overall system durability through balanced load distribution.
Solution Approach 2:
The patent employs a planetary gear mechanism that dynamically distributes torque across multiple gear teeth and support points simultaneously. This dynamic load distribution prevents any single gear coupling from bearing excessive stress, thereby enhancing the durability and reliability of the entire power transmission system.
3Object-generated harmful factors
If noise reduction materials are added to the motor housing, then operating noise is reduced, but device complexity and space requirements increase
Solution Approach 1:
The patent converts the potentially harmful noise-generating gear couplings into beneficial quiet-operating components by using helical gear profiles that provide smooth, gradual engagement between teeth. The helical geometry transforms what would be impact-heavy spur gear operations into continuous, quiet meshing, eliminating the need for additional noise reduction materials while actually generating quieter operation from the gears themselves.
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 reduces noise and enhances durability by stabilizing the worm shaft and worm wheel, allowing for a compact, high-torque deceleration mechanism that maintains braking state without additional noise reduction materials.
Implementation Method 1
The power connection unit includes a drive helical gear provided at a rotating shaft of the electric motor and a driven helical gear provided at the first deceleration gear unit and engaged with the drive helical gear to convert a rotation direction. The worm gear may include a worm shaft gear of a worm shaft directly connected to the power connection unit and a worm wheel gear of a worm wheel engaged with the worm shaft
Implementation Method 2
The housing plate includes bearing stoppers which are provided with ball bearings which are configured to rotatably support opposite ends of the worm shaft
Data Source
AI summary
Disclosed is an electronic disc brake. The electronic disc brake includes a disc configured to rotate with vehicle wheels, a caliper housing configured to operate pad plates installed at both sides of the disc, and an actuator having a piston provided inside the caliper housing to come into close contact with the disc, a spindle rotatably installed at the caliper housing to reciprocate the piston, an electric motor configured to rotate the spindle, and a decelerator configured to transmit a rotational force of the electric motor to the spindle, in which the decelerator includes a power connection unit directly connected to the electric motor, and first and second deceleration gear units sequentially connected to the spindle, and the first deceleration gear unit includes a worm gear.