Eddy Current Wheel Brake With Variable Ratio Torque Control
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Solution Overview
Problem
Existing brake systems in heavy-duty vehicles face issues with brake fading due to heat buildup and limited endurance braking capabilities, especially when using friction brakes and electric machines, necessitating additional components or over-dimensioning the electrical energy system.
Innovation Solution
A wheel brake arrangement incorporating an eddy current wheel brake with a transmission arrangement featuring a ratio varying mechanism to maintain optimal rotational speed within a predetermined range, utilizing electric power from the vehicle's source during braking, and integrating with an energy storage system to enhance braking efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If friction brakes are used for prolonged periods, then braking torque is generated effectively, but brake fading occurs due to heat buildup
Solution Approach 1:
The patent replaces the traditional mechanical friction brake system with an eddy current brake system that uses electromagnetic fields to generate braking force. The eddy current brake employs a magnetic field interacting with conductive material to produce braking torque without mechanical contact, thereby eliminating heat buildup and brake fading while maintaining effective braking power.
2Loss of energy
If electric machine is used for regenerative braking, then energy efficiency increases, but endurance braking capability is limited by ESS and brake resistor capacity
Solution Approach 1:
The patent introduces an eddy current brake as an intermediary braking system that bridges the gap between regenerative braking and traditional friction brakes. The eddy current brake can absorb excess energy during prolonged braking events when the ESS and brake resistor reach their capacity limits, enabling continuous endurance braking without requiring over-dimensioning of the electrical energy system.
Solution Approach 2:
The patent changes the operational parameters of the braking system by introducing a variable ratio transmission arrangement that dynamically adjusts the rotational speed ratio between the eddy current brake and the wheel. This allows the system to optimize braking torque distribution and maintain effective braking capability across varying vehicle speeds and braking intensities, extending endurance braking capability.
3Reliability
If additional braking means are installed to support endurance braking, then braking capability is improved, but device complexity increases
Solution Approach 1:
The patent makes the eddy current brake a multi-functional component that serves multiple purposes: it provides primary braking torque, enables regenerative braking by absorbing excess energy, and extends endurance braking capability. By integrating these functions into a single system with variable ratio control, the patent avoids the need for multiple separate braking systems, thereby improving endurance braking capability without proportionally increasing device complexity.
4Power
If friction brakes are used intensively, then braking torque is generated, but maintenance requirements increase due to wear
Solution Approach 1:
The patent replaces the mechanical friction brake system with an eddy current brake system that uses electromagnetic fields to generate braking force. The eddy current brake employs a magnetic field interacting with conductive material to produce braking torque without mechanical contact, thereby eliminating wear and significantly reducing maintenance requirements while maintaining effective braking power.
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 provides optimized braking capability, reduces maintenance needs, enables anti-lock braking, and amplifies torque without friction elements, ensuring efficient energy dissipation and seamless operation across varying vehicle speeds.
Implementation Method 1
The electric machine may then act as a generator which converts the kinetic energy from the vehicle into electrical energy
Implementation Method 2
an eddy current wheel brake configured to receive electric power from a source of electric power of the vehicle during braking
Data Source
Figure 1~2
Figure 3a
Figure 3b
AI summary
The present invention relates to a wheel brake arrangement for a vehicle, the wheel brake arrangement comprising an eddy current wheel brake configured to receive electric power from a source of electric power of the vehicle during braking, and a transmission arrangement comprising a first shaft connected to the eddy current wheel brake, and a second shaft connectable to a wheel of the vehicle, wherein the transmission arrangement comprises a ratio varying arrangement, the ratio varying arrangement being configured to, for any rotational speed below a predetermined threshold speed of the second shaft during braking, control a rotational speed of the first shaft to be maintained within a predetermined rotational speed range.