Double Disc Brake Motor Structure for EV Downhill Braking
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Solution Overview
Problem
Existing electric vehicle motors with single-sided disc brakes experience poor braking performance during long-time downhill periods or rainy days, leading to potential traffic accidents due to inadequate braking at high speeds.
Innovation Solution
An electric vehicle motor with double disc brakes, featuring a first and second disc brake made of aluminum alloy materials, a carbon fiber base layer, a polyimide film reinforced layer, and a ceramic insulating layer, along with increased spoke count from 36-hole to 72-hole, to enhance braking efficiency and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-sided disc brake is used, then the device complexity is reduced, but the braking effectiveness deteriorates during long-time downhill periods or rainy days
Solution Approach 1:
The braking system is segmented into two independent disc brakes positioned at different locations. This segmentation allows each brake to independently contribute to the overall braking force, ensuring reliable braking performance during long-time downhill periods or rainy days when a single brake might be insufficient.
Solution Approach 2:
The braking system transitions from a single-sided configuration to a double-sided configuration, adding a spatial dimension to the braking capability. This dimensional change enables the vehicle to utilize both sides of the wheel for braking, significantly improving braking effectiveness without excessive complexity.
2Temperature
If aluminum alloy materials are used for disc brakes, then heat dissipation performance is improved, but the weight increases
Solution Approach 1:
The material parameters of the disc brake are optimized by selecting aluminum alloy, which has superior thermal conductivity compared to traditional materials. This parameter change enables efficient heat dissipation during braking, preventing brake fade during prolonged use while maintaining reasonable weight through the inherent lightness of aluminum alloys.
Solution Approach 2:
The brake system utilizes composite construction with aluminum alloy disc brakes combined with polyimide film reinforced layers and ceramic insulating materials. This composite approach leverages the heat dissipation advantages of aluminum alloy while using the reinforced layers to compensate for potential weight increases and enhance overall structural performance.
3Strength
If carbon fiber materials with multiple reinforced layers are used for the shell, then structural strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The shell structure employs a composite material system consisting of a carbon fiber base layer combined with polyimide film reinforced layers and ceramic insulating material layers. This composite structure achieves high strength and structural integrity while the modular layering approach facilitates manufacturing by allowing each layer to be applied or bonded separately through established composite manufacturing processes.
Solution Approach 2:
The shell structure is designed with nested layers where the polyimide film reinforced layer is positioned on the carbon fiber base layer, and the ceramic insulating material layer is positioned on the polyimide layer. This nested configuration maximizes structural strength and functional properties while maintaining a compact overall structure that is manageable in manufacturing.
4Reliability
If the number of spokes is increased from 36 to 72, then the fracture risk is reduced, but the device complexity increases
Solution Approach 1:
The wheel structure is segmented into a higher number of individual spoke elements (72 spokes instead of 36). This segmentation distributes the mechanical loads more evenly across multiple elements, reducing the stress on each individual spoke and thereby reducing fracture risk. The increased segmentation also provides redundancy, as the failure of one spoke has less impact on overall wheel integrity.
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 double disc brake configuration improves braking effectiveness, reduces the risk of traffic accidents, and ensures safe operation by dissipating heat, resisting external shocks, and preventing electromagnetic interference, while the increased spoke count reduces fracture risk and enhances cycling safety.
Implementation Method 1
the first disc brake and the second disc brake are both made of aluminum alloy materials since the aluminum alloy materials are excellent in heat dissipation performance and may quickly dissipate heat generated by friction in the braking process
Implementation Method 2
The base layer is made of carbon fiber materials. The materials have the characteristics of high strength and low density, and may provide a firm structure for the whole shell, so that external shocks and pressure may be effectively resisted
Implementation Method 3
The first reinforced layer is made of polyimide films, so that the flexibility and tensile resistance of the shell are further enhanced, and high structural integrity may be kept under different working conditions
Implementation Method 4
The second reinforced layer is made of ceramic insulating materials, so that the motor may be prevented from electromagnetically interfering with other components, and the high temperature resistance of the shell is also promoted
Data Source
AI summary
An electric vehicle motor with double disc brakes is provided, and relates to the field of electric vehicle motors. The electric vehicle motor includes a first disc brake, a motor body, fixed bolts and a second disc brake. A wheel rim is fixedly arranged on an outer surface of the electric vehicle motor. An upper shell is fixedly arranged at an upper end of the wheel rim, and a lower shell is fixedly arranged at a lower end of the wheel rim. The problem of braking may be well solved through double disc brakes, and traffic accidents due to poor braking of the electric vehicle at high speed, in long-time downhill periods or on rainy days may be effectively solved. Moreover, the first disc brake and the second disc brake are both made of aluminum alloy materials.