Integrated E-Axle Brake Disc Layout for Compact Emergency Braking
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Solution Overview
Problem
Existing electric axle drive units in vehicles require additional mechanical brake systems for emergency braking, which occupy significant installation space and are not compactly designed.
Innovation Solution
An integrated electric axle drive unit with a brake device that includes a stator and rotor coupled to a wheel hub, featuring a brake module with axially movable brake disc elements and a hydraulically actuated multi-piston brake system, allowing for a compact and easy-to-assemble design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate conventional mechanical brake system is installed for emergency braking, then braking reliability is improved, but installation space is increased
Solution Approach 1:
The patent combines the electric motor and brake device into a single integrated axle drive unit. The brake device is received within the housing of the electric motor, merging two previously separate systems into one compact unit. This integration allows the brake system to share space with the motor components, thereby reducing overall installation space while maintaining independent braking capability for reliability.
Solution Approach 2:
The brake device is nested within the housing structure of the electric motor. Specifically, the brake components are arranged within the available space inside the motor housing, effectively utilizing the existing structural envelope. This nesting approach allows the brake system to occupy space that would otherwise be unused or underutilized in the motor housing, achieving space reduction without compromising braking function.
2Device complexity
If brake components are made axially movable for compact design, then device complexity is reduced, but manufacturing precision is worsened
Solution Approach 1:
The brake disc element is designed to be axially movable relative to its support part, transitioning between a retracted position (normal operation) and an extended position (braking engagement). This dynamic capability allows the brake system to achieve compact dimensions during non-braking phases while maintaining the necessary braking geometry when activated. The axial movement is controlled through the actuation unit, which manages the engagement and disengagement of brake components.
Solution Approach 2:
The actuation unit employs hydraulic or pneumatic pressure to control the axial movement of brake components. Pressure actuators apply controlled forces to move the brake disc element axially, enabling precise engagement and disengagement. This approach replaces complex mechanical linkage systems with fluid-powered actuation, simplifying the overall structure while providing reliable control over the movable brake components.
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 solution enables a compact and powerful braking system that reduces installation space requirements while maintaining effective braking performance, allowing for efficient heat dissipation and easy assembly.
Implementation Method 1
a second brake component that is arranged and designed to be frictionally connected with the first brake component
Implementation Method 2
If the actuation unit is implemented as a hydraulically actuated actuation unit, this is realized in a particularly powerful manner
Data Source
AI summary
An electric axle drive unit for a motor vehicle, having an electric motor with a stator that is fixedly received in a housing, and a rotor that is rotatably mounted relative to the stator and rotationally coupled or coupleable to a wheel hub. A brake device is operatively connected to the wheel hub. The brake device has a first brake component fixedly supported on the housing, a second brake component rotationally fixed to the wheel hub that is frictionally connectable to the first brake component, and an actuation unit that applies a braking force that interconnects the brake components. One of the brake components has a brake disc element rotationally fixed to a support part and is displaceably received in the axial direction of a rotational axis of the wheel hub relative to the support part.