Drive Axle Locking Actuator for Redundant EV Braking
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Solution Overview
Problem
Electric vehicles with single-speed transmission often lack redundancy in their brake systems, as they may not have a parking lock or locking pawl, which is crucial for ensuring braking performance and safety, especially in automated driving scenarios.
Innovation Solution
A controllable actuator device connected to the drive axle of an electric vehicle, controlled by the vehicle's onboard electronics, which eliminates the need for a separate control system and bus connection, utilizing a locking pawl or electric motor to create a braking or locking effect, thereby providing redundancy and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate control system and bus connection (e.g., CAN bus) are provided for the actuator device, then the actuator can be controlled independently, but the device complexity and costs increase
Solution Approach 1:
The patent merges the control function of the actuator device with the existing vehicle control unit. The control unit that already manages the service brake system is extended to also control the actuator device, eliminating the need for a separate control system and bus connection. This integration maintains independent control capability while reducing overall system complexity.
Solution Approach 2:
The control unit is designed to perform multiple functions: it controls both the service brake system and the actuator device. This multi-functional approach allows a single control unit to manage different braking components without requiring dedicated control hardware for each component, thereby reducing device complexity while maintaining operational independence.
2Reliability
If a locking pawl or redundant brake component is added to electric vehicles with single-speed transmission, then braking redundancy is achieved, but the device complexity increases
Solution Approach 1:
The actuator device is segmented into distinct functional components: a first actuator for engaging the locking pawl and a second actuator for releasing it. This segmentation allows the redundant braking function to be added as a modular component rather than integrating it into the existing brake system structure, thereby achieving reliability without significantly increasing overall device complexity.
Solution Approach 2:
The locking pawl acts as an intermediary mechanical component between the electric motor and the drive axle. It provides a simple, reliable mechanical locking mechanism that adds redundancy to the braking system without requiring complex electronic control or integration with the existing hydraulic brake system, thus improving reliability while minimizing structural complexity.
3Ease of operation
If additional hardware and software are provided for controlling the actuator device, then precise control is achieved, but the costs increase
Solution Approach 1:
The actuator device utilizes the existing control unit and communication infrastructure of the vehicle to achieve precise control. The control unit already has the computational resources and communication protocols necessary to control the actuator, eliminating the need for additional control hardware and software. This self-service approach allows precise control to be achieved without increasing manufacturing costs.
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 enables a cost-effective, robust, and redundant brake system that can be controlled directly by the vehicle's existing control devices, ensuring reliable braking and holding mechanisms without the need for additional hardware or software, suitable for highly automated vehicles.
Implementation Method 1
the actuator device includes an electric motor for actuating the locking pawl
Implementation Method 2
a clamp by means of which a frictional connection to the drive axle can be established
Data Source
AI summary
A controllable actuator unit (1) having an electronic connecting device (AN). The actuator device (1) is connectable to a drive axle of an electrically operated vehicle (2), such that a braking or locking effect for a rotary movement of the drive axle can be produced. The actuator device (1) is controllable by a control device (SE) via the electronic connecting device (AN).